CN112091348A - Novel wave soldering process method for solar photovoltaic junction box - Google Patents
Novel wave soldering process method for solar photovoltaic junction box Download PDFInfo
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- CN112091348A CN112091348A CN202010895769.XA CN202010895769A CN112091348A CN 112091348 A CN112091348 A CN 112091348A CN 202010895769 A CN202010895769 A CN 202010895769A CN 112091348 A CN112091348 A CN 112091348A
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- soldering
- wave soldering
- junction box
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- solar photovoltaic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/08—Soldering by means of dipping in molten solder
- B23K1/085—Wave soldering
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/20—Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/20—Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
- B23K1/203—Fluxing, i.e. applying flux onto surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/06—Solder feeding devices; Solder melting pans
- B23K3/0646—Solder baths
- B23K3/0653—Solder baths with wave generating means, e.g. nozzles, jets, fountains
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/06—Solder feeding devices; Solder melting pans
- B23K3/0646—Solder baths
- B23K3/0669—Solder baths with dipping means
- B23K3/0676—Conveyors therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/08—Auxiliary devices therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/08—Auxiliary devices therefor
- B23K3/087—Soldering or brazing jigs, fixtures or clamping means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/36—Electric or electronic devices
- B23K2101/42—Printed circuits
Abstract
A novel wave soldering process method for a solar photovoltaic junction box comprises the solar photovoltaic junction box, a modular diode, a wave soldering carrier, a wave soldering operation system, soldering flux and a soldering tin bar, wherein the wave soldering operation system comprises a feeding hole, a discharging hole, an inclined conveying belt, a soldering flux spraying device, a preheating area, a welding area, a cooling area, a soldering flux groove, a feeding sensor, a discharging sensor, a counter, a PLC (programmable logic controller) and a control computer; the method comprises the following steps: adding consumables into the corresponding material cylinder; then the modularized diode is placed in a wave soldering carrier; then placing the same on an inclined conveying belt; then the system runs, and the carrier passing through wave soldering sequentially passes through a preheating zone, a welding zone and a cooling zone and finally runs to a discharge port; taking down the over-wave soldering carrier from the discharge port, and taking out the modular diode from the over-wave soldering carrier; and then the solar photovoltaic junction box is arranged in the solar photovoltaic junction box. The invention reduces the labor cost, has lower cost of using auxiliary materials and improves the production efficiency.
Description
Technical Field
The invention relates to the field of electronic manufacturing and welding processes, in particular to a novel wave soldering process method for a solar photovoltaic junction box.
Background
The solar photovoltaic junction box is a connecting device between a solar cell array formed by solar cell modules and the solar charging control device, and is mainly used for connecting and protecting the solar photovoltaic modules, connecting electric power generated by the solar cells with an external circuit and conducting current generated by the photovoltaic modules.
At present, the solar photovoltaic junction box product has various welding processing methods, such as traditional manual tin adding welding forming, automatic tin soldering equipment welding forming, tin point welding on a product welding point through tin point equipment and then through reflow furnace welding forming, tin paste printing on the product welding point through manufacturing a special steel mesh and through reflow furnace welding forming and the like, wherein the tin point adding reflow welding processing efficiency is highest.
However, the solder dispensing and reflow soldering process also requires a lot of manpower and a lot of equipment (people are required to take carriers, place products and package boxes), and lead or lead-free solder paste is used, and the content of the soldering flux accounts for about 10 ± 2% in order to improve the soldering state of the active box of the solder paste. Because the solder joint of the junction box product is large and the required tin amount is large, the components of the soldering flux can not be completely volatilized after reflow soldering, so that a large amount of soldering flux is remained on the product and even flows into the back of the product, the residual soldering flux has high viscosity and is difficult to take, and the operation of the subsequent process is greatly influenced. And because the fluidity of the solder paste is stronger, the solder paste forms a large amount of solder paste in a diffusion state around the welding spot and also exists in the non-welding part, and finally, the quality control can only give way to receive.
Therefore, the technology needs to be improved, and a novel welding process method for the solar photovoltaic junction box, which can reduce the labor input and the production cost, is designed.
Disclosure of Invention
The invention aims to solve the technical problem of providing a novel wave soldering process method of a solar photovoltaic junction box, which has high production efficiency and controllable production cost and aims at solving the problems in the prior art.
The technical scheme adopted by the invention for solving the technical problems is as follows: a novel wave soldering process method for a solar photovoltaic junction box comprises the solar photovoltaic junction box, a modular diode, a wave soldering carrier, a wave soldering operation system, soldering flux and a soldering tin bar, wherein the wave soldering operation system comprises a feeding hole, a discharging hole, an inclined conveying belt, a soldering flux spraying device, a preheating area, a welding area, a cooling area, a soldering flux groove, a feeding sensor, a discharging sensor, a counter, a PLC (programmable logic controller) and a control computer;
the inclined conveyor belt is arranged between the feeding hole and the discharging hole, the welding flux spraying device is provided with a welding flux charging barrel for storing welding flux, the preheating area comprises a preheater arranged below the inclined conveyor belt, the welding area comprises a jet flow pipe and a tin cylinder for containing liquid tin, the tin cylinder is positioned at the bottom end of the jet flow pipe, the welding flux groove is arranged below the inclined conveyor belt, the feeding sensor is positioned on one side of the feeding hole, and the discharging sensor and the counter are positioned on one side of the discharging hole; the method comprises the following steps:
step 1: adding soldering flux into the soldering flux charging barrel, and adding the soldering tin bar into the tin cylinder;
step 2: placing the modular diode in a wave soldering carrier;
and step 3: placing the over-wave soldering carrier on an inclined conveying belt at a feed inlet;
and 4, step 4: the wave-soldering operation system operates, the inclined conveyor belt drives the wave-soldering carrier to sequentially pass through the preheating area, the welding area and the cooling area, and finally the wave-soldering carrier operates to the discharge port;
and 5: taking the over-wave soldering carrier down from the discharge port, and taking the modular diode out of the over-wave soldering carrier;
step 6: and installing the modularized diode in the solar photovoltaic junction box.
And 7: inspection and electrical testing.
Further, in the step 2, the modularized diodes are placed in the wave soldering carrier, and the automatic placement can be performed by using a manipulator.
Further, the conveying speed of the inclined conveyor belt is 1000-1500mm/s, and the inclination of the inclined conveyor belt is 6-10 degrees.
Further, the density of the soldering flux is 0.82-0.86g/cm3And the spraying flow rate of the welding flux spraying device is 15-25 ml/min.
Furthermore, the tin soldering bar adopts a lead tin soldering bar, and the temperature of the tin cylinder is 240 +/-3 ℃.
Furthermore, the solder bar adopts a lead-free solder bar, and the temperature of the tin cylinder is 260 +/-3 ℃.
Further, the temperature of the preheating zone is 100-130 ℃, and the temperature rising slope is 1-3 ℃/S.
Furthermore, the welding time of the over-wave welding point on the tin cylinder is 2-4S, and the height of the wave crest is 8 +/-1 MM.
Compared with the prior art, the novel wave soldering process method of the solar photovoltaic junction box has the following beneficial effects: wave soldering is the soldering process in which the soldering surface of a plug-in board is directly contacted with high-temperature liquid tin to achieve the purpose of soldering, the high-temperature liquid tin keeps an inclined surface, and the liquid tin forms a wave-like phenomenon by a special device, so the wave soldering is called as wave soldering, and the main material of the wave soldering is a soldering tin bar. Compared with a spot soldering and reflow soldering method, the method has the advantages that one third of manpower is reduced by using wave soldering, the input cost of equipment is greatly reduced, one third of cost investment of auxiliary material soldering strips used for wave soldering is saved relative to soldering paste, the price cost of the auxiliary material soldering strips used for wave soldering is much lower than that of the auxiliary material soldering strips used for reflow soldering, the production efficiency is improved by more than 50%, and the method has good popularization and application values.
Drawings
Fig. 1 is a process flow diagram of a novel wave soldering process method of a solar photovoltaic junction box.
Fig. 2 is a reference diagram of a wave soldering operation system of the novel wave soldering process method of the solar photovoltaic junction box.
FIG. 3 is a wave soldering curve reference diagram of the novel wave soldering process of the solar photovoltaic junction box.
Detailed Description
The invention is described in further detail below with reference to the accompanying examples.
As shown in fig. 1 to 2, the novel wave soldering process method for the solar photovoltaic junction box comprises the solar photovoltaic junction box, a modular diode to be soldered, a wave soldering carrier, a wave soldering operation system, soldering flux and a soldering tin bar, wherein the wave soldering operation system comprises a feeding hole, a discharging hole, an inclined conveying belt, a soldering flux spraying device, a preheating area, a welding area, a cooling area, a soldering flux groove, a feeding sensor, a discharging sensor, a counter, a PLC (programmable logic controller) and a control computer. The over-wave soldering carrier shields the non-soldering part of the product and only keeps the structure of the soldering point part of the product.
The setting of slope conveyer belt is between feed inlet and discharge gate, and the flux spraying device is provided with the scaling powder feed cylinder that is used for saving the scaling powder, and the preheating zone is including setting up the pre-heater in the slope conveyer belt below, and the preheating after the spraying of pre-heater scaling powder can promote PCB's temperature gradually and make the scaling powder activation, and the thermal shock that produces when this process can also reduce the built-up member and get into the crest. It may also be used to evaporate any moisture that may be absorbed or the carrier solvent that dilutes the flux. The welding area includes the spout pipe and is used for holding the tin jar of liquid tin, and the tin jar is located the bottom of spout pipe, with the welding tin bar melting after with liquid tin blowout through the spout pipe, form the tin wave, realize the welding to modular diode welding point. The welding flux groove sets up in the slope conveyer belt below for retrieve the thing that drops such as welding slag, feeding sensor is located feed inlet one side, and ejection of compact sensor, counter are located discharge gate one side. The PLC controller and the control computer are electrically connected with each other, so that a user can operate on the control computer to adjust parameters in time.
The wave soldering process route is as follows:
step 1: adding soldering flux into the soldering flux charging barrel, and adding the soldering tin bar into the tin cylinder;
step 2: placing the modular diode in a wave soldering carrier;
and step 3: placing the over-wave soldering carrier on an inclined conveying belt at a feed inlet;
and 4, step 4: the wave-soldering operation system operates, the inclined conveyor belt drives the wave-soldering carrier to sequentially pass through the preheating area, the welding area and the cooling area, and finally the wave-soldering carrier operates to the discharge port;
and 5: taking the over-wave soldering carrier down from the discharge port, and taking the modular diode out of the over-wave soldering carrier;
step 6: and installing the modularized diode in the solar photovoltaic junction box.
In addition, in the step 2, the wiring box circuit board can be placed in the wave soldering carrier manually, and preferably, the wiring box circuit board can be placed automatically by mechanical equipment, such as a manipulator.
In addition, step 7 can be optionally added, wherein step 7 is inspection and electrical test to ensure the quality of the product.
Fig. 3 is a wave-soldering curve reference diagram, but the second wave peak is not used for wave soldering of the solar photovoltaic junction box product. The wave soldering process has full soldering point without diffusion and fluxing agent residue, and completely meets the quality requirement. The key parameters are set as follows:
1. the speed of conveyance (1000-1500 mm/s);
2. the density D of the soldering flux is controlled to be 0.82-0.86g/cm3And the spraying amount of the soldering flux is controlled (the spraying pressure is controlled to be 0.15-0.25 Mpa, and the spraying flow rate is controlled to be 15-25 ml/min);
3. the temperature of the wave soldering tin cylinder (lead: 240 +/-3 ℃, lead-free: 260 +/-3 ℃);
4. preheating temperature is controlled at 100-130 ℃, and temperature rising slope is controlled at 1-3 ℃/S;
5. wave soldering time range: 2-4S;
6. the height of the wave crest is controlled to be 8 +/-1 MM;
7. controlling the transportation traction angle of wave soldering at 6-10 degrees;
therefore, in this embodiment, the conveying speed of the inclined conveyor belt is 1000 to 1500mm/s, and the density of the flux is 0.82 to 0.86g/cm3The spraying flow of the welding flux spraying device is 15-25 ml/min;
when the solder bar is a lead solder bar, the temperature of the tin cylinder is 240 +/-3 ℃;
when the soldering tin bar is a lead-free soldering tin bar, the temperature of the tin cylinder is 260 +/-3 ℃;
the temperature of the preheating zone is 100-130 ℃, the temperature rising slope is 1-3 ℃/S, namely, the temperature of the modular diode rises 1-3 ℃ per second in the preheating zone, and the damage of thermal shock to elements is prevented.
The welding time of the wave-soldering welding point in the tin cylinder is 2-4S, and the height of the wave is 8 +/-1 MM;
the slope of the inclined conveyor belt is 6-10 degrees.
In addition, it is noted that the above parameters are optimized for the respective devices, including the respective excipients, and these parameters are not constant, but can be further optimized and changed.
Compared with a spot-tin and reflux welding method, the novel wave soldering process method for the solar photovoltaic junction box reduces one third of manpower by using wave soldering, greatly reduces the input cost of equipment, saves one third of the cost investment of auxiliary material soldering tin bars used for wave soldering relative to soldering paste, and improves the production efficiency by more than 50%.
Finally, it should be noted that: the above examples are merely illustrative of the technical solutions of the present invention, and not limitative thereof; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Claims (9)
1. A novel wave soldering process method for a solar photovoltaic junction box comprises the solar photovoltaic junction box, a modular diode, a wave soldering carrier, a wave soldering operation system, soldering flux and a soldering tin bar, wherein the wave soldering operation system comprises a feeding hole, a discharging hole, an inclined conveying belt, a soldering flux spraying device, a preheating area, a welding area, a cooling area, a soldering flux groove, a feeding sensor, a discharging sensor, a counter, a PLC (programmable logic controller) and a control computer;
the inclined conveyor belt is arranged between the feeding hole and the discharging hole, the welding flux spraying device is provided with a welding flux charging barrel for storing welding flux, the preheating area comprises a preheater arranged below the inclined conveyor belt, the welding area comprises a jet flow pipe and a tin cylinder for containing liquid tin, the tin cylinder is positioned at the bottom end of the jet flow pipe, the welding flux groove is arranged below the inclined conveyor belt, the feeding sensor is positioned on one side of the feeding hole, and the discharging sensor and the counter are positioned on one side of the discharging hole; the method is characterized by comprising the following steps:
step 1: adding soldering flux into the soldering flux charging barrel, and adding the soldering tin bar into the tin cylinder;
step 2: placing the modular diode in a wave soldering carrier;
and step 3: placing the over-wave soldering carrier on an inclined conveying belt at a feed inlet;
and 4, step 4: the wave-soldering operation system operates, the inclined conveyor belt drives the wave-soldering carrier to sequentially pass through the preheating area, the welding area and the cooling area, and finally the wave-soldering carrier operates to the discharge port;
and 5: taking the over-wave soldering carrier down from the discharge port, and taking the modular diode out of the over-wave soldering carrier;
step 6: and installing the modularized diode in the solar photovoltaic junction box.
2. The novel wave soldering process method for the solar photovoltaic junction box as claimed in claim 1, wherein in the step 2, the modularized diodes are placed in the wave soldering carrier and can be automatically placed by a manipulator.
3. The novel wave soldering process method for the solar photovoltaic junction box as claimed in claim 1, wherein step 6 is followed by step 7, and the step 7 is an inspection and electrical test.
4. The novel wave soldering process method for the solar photovoltaic junction box according to claim 1, wherein the conveying speed of the inclined conveyor belt is 1000-1500mm/s, and the inclination of the inclined conveyor belt is 6-10 degrees.
5. The novel wave soldering process method of the solar photovoltaic junction box as claimed in claim 1, wherein the density of the soldering flux is 0.82-0.86g/cm3And the spraying flow rate of the welding flux spraying device is 15-25 ml/min.
6. The novel wave soldering process method of the solar photovoltaic junction box as claimed in claim 1, wherein a lead soldering tin bar is adopted as the soldering tin bar, and the temperature of the tin cylinder is 240 +/-3 ℃.
7. The novel wave soldering process method of the solar photovoltaic junction box as claimed in claim 1, wherein the solder bars are lead-free solder bars, and the temperature of the tin cylinder is 260 +/-3 ℃.
8. The novel wave soldering process method of the solar photovoltaic junction box as claimed in claim 1, wherein the temperature of the preheating zone is 100-130 ℃, and the temperature rise slope is 1-3 ℃/S.
9. The novel wave soldering process method of the solar photovoltaic junction box as claimed in claim 1, wherein the heating time of the over-wave soldering carrier in the soldering area is 2-4S, and the height of the wave is 8 +/-1 MM.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010895769.XA CN112091348A (en) | 2020-08-31 | 2020-08-31 | Novel wave soldering process method for solar photovoltaic junction box |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010895769.XA CN112091348A (en) | 2020-08-31 | 2020-08-31 | Novel wave soldering process method for solar photovoltaic junction box |
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| CN112091348A true CN112091348A (en) | 2020-12-18 |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114378390A (en) * | 2022-01-24 | 2022-04-22 | 周锦华 | Electronic assembly welding method for automatically raising wave soldering of components |
| CN116618778A (en) * | 2023-05-05 | 2023-08-22 | 广东剑鑫科技股份有限公司 | Welding process of efficient soldering flux |
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| CN205519979U (en) * | 2016-04-12 | 2016-08-31 | 昆山升菖电子有限公司 | Tin stove is crossed to energy -concerving and environment -protective type wave -soldering |
| CN105934108A (en) * | 2016-06-28 | 2016-09-07 | 华高科技（苏州）有限公司 | Efficient high-precision wave crest welding process |
| CN109365942A (en) * | 2018-12-29 | 2019-02-22 | 广西贵港市华远电子科技有限公司 | Automatic tin solder and its control method |
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| DE102008020383A1 (en) * | 2008-04-23 | 2009-10-29 | Seho Systemtechnik Gmbh | Method for attaching solar cell to conducting film to produce solar cell module, involves soldering contact points, where melted solder passes through clearance holes from bottom and connects conducting film and solar cells with one another |
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| CN114378390A (en) * | 2022-01-24 | 2022-04-22 | 周锦华 | Electronic assembly welding method for automatically raising wave soldering of components |
| CN116618778A (en) * | 2023-05-05 | 2023-08-22 | 广东剑鑫科技股份有限公司 | Welding process of efficient soldering flux |
| CN116618778B (en) * | 2023-05-05 | 2023-12-05 | 广东剑鑫科技股份有限公司 | Welding process of efficient soldering flux |
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Application publication date: 20201218 |
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