CN117330576A

CN117330576A - Poor welding detection equipment and method for junction box bus bar

Info

Publication number: CN117330576A
Application number: CN202311434682.2A
Authority: CN
Inventors: 霍哲; 李宗斌
Original assignee: Rongyun Optoelectronic Technology Suzhou Co ltd
Current assignee: Rongyun Optoelectronic Technology Suzhou Co ltd
Priority date: 2023-11-01
Filing date: 2023-11-01
Publication date: 2024-01-02
Anticipated expiration: 2043-11-01
Also published as: CN117330576B

Abstract

The invention provides a device and a method for detecting poor welding of a bus bar of a junction box, wherein the method comprises the following steps: transferring the battery assembly with the junction box to a first detection position, and acquiring an image of the welding spot position of the bus bar of the junction box at the first detection position to be a first image; after the first image is acquired, the junction box is transferred to a poking position, and poking force with a preset size is applied to a bus bar in the junction box at the poking position; after the bus bar is stirred, acquiring an image of the welding point position of the bus bar of the junction box again to be a second image; and judging whether the welding of the bus bar in the junction box is bad or not by comparing the difference between the second image and the first image. According to the invention, external intervention is applied to the bus bar, and the poor welding condition of the false welding and the poor welding can be accurately obtained through visual comparison, so that the poor welding detection precision of the bus bar of the junction box is improved, the omission rate is low, and the manufacturing reject ratio of the battery assembly is further reduced.

Description

Poor welding detection equipment and method for junction box bus bar

Technical Field

The invention relates to the technical field of visual detection of cold joint, in particular to equipment and a method for detecting poor welding of a junction box bus bar.

Background

In the production process of the solar cell module, the bus bar is welded on the junction box through soldering or laser welding, so that the welding spots of the bus bar are required to be ensured to be firm and reliable, and the virtual welding is not required. In order to ensure the final welding quality of the bus bar and the junction box, at present, three groups of visual inspection cameras are directly erected behind the junction box welding equipment in the related art, whether the poor solar cell module is subjected to cold welding or not is observed through the appearance of the drawing, and if the situation of cold welding is detected, the poor solar cell module is marked and repaired. However, in the related art, the detection of the cold joint is only performed by observing the appearance of the drawing (the consistency of the two-dimensional image is determined, and the comparison with the reference image is required), so that some components which are not cold joint but are not welded firmly enough (for example, the welding points have cracks, holes and the like, and the welding is not firm), so that the manufacturing reject ratio of the battery component is high.

Disclosure of Invention

The device and the method for detecting the poor welding of the bus bar of the junction box can at least partially solve the problems.

The invention aims to provide a method for detecting poor welding of a bus bar of a junction box, which comprises the following steps:

Transferring the battery assembly with the junction box to a first detection position, and acquiring an image of a bus bar welding spot position of the junction box at the first detection position to be a first image;

after the first image is acquired, transferring the junction box to a poking position, and applying poking force with a preset magnitude to the bus bar in the junction box at the poking position;

after the bus bar is stirred, acquiring an image of the welding point position of the bus bar of the junction box again to be a second image;

and judging whether the welding of the bus bar in the junction box is bad or not by comparing the difference between the second image and the first image.

In some embodiments, the first image includes a first two-dimensional image and a first three-dimensional image, and the second image includes a second two-dimensional image and a second three-dimensional image, wherein the first two-dimensional image and the second two-dimensional image are both obtained when the junction box is in a stationary state, the first three-dimensional image is obtained during a transition of the junction box from the first detection position to the toggle position, and the second three-dimensional image is obtained during a transition of the junction box again after the toggle position is toggled.

In some embodiments, determining whether the welding of the bus bar within the junction box is poor by comparing the difference of the second image and the first image specifically includes:

and comparing the three-dimensional contour data acquired by the second three-dimensional image with the three-dimensional contour data acquired by the first three-dimensional image, judging that the welding is good if the two three-dimensional contour data are the same, and judging that the welding is bad if the two three-dimensional contour data are different.

In some embodiments, the detection method further comprises the steps of:

and acquiring the height dimension of the welding spot of the bus bar through the first three-dimensional image, and outputting prompt information when the height dimension of the welding spot is not in a set range.

In some embodiments of the present invention, in some embodiments,

before transferring the battery assembly to the first inspection station, positioning the battery assembly is also included.

In some embodiments, prior to dialing the bus bar, the step of clamping the terminal block is further included.

In some embodiments, the step of clamping the junction box comprises:

controlling the two groups of clamping assemblies to descend by a first preset height so that the two groups of pressure head assemblies are respectively positioned on two opposite sides of the junction box;

controlling the expansion rod of the first expansion driving assembly to extend out so that each pressure head is flexibly pressed on the outer side wall of the junction box under the action of the corresponding third elastic piece;

The telescopic rod of the second telescopic driving assembly is controlled to extend to form pressing and holding of the locking pins on the sliding shafts, so that the locking pins are clamped and positioned between the mounting base and the end face of the telescopic rod of the second telescopic driving assembly.

In some embodiments, the step of clamping the junction box further comprises:

when the clamping of the junction box needs to be released, controlling the telescopic rod of the second telescopic driving assembly to retract;

and then, controlling the telescopic rods of the first telescopic driving assemblies to retract so as to enable each pressure head assembly to return to the release position from the holding position.

The invention also provides a device for detecting poor welding of the junction box bus bar, which is used for executing the method for detecting poor welding of the junction box bus bar.

In some embodiments, the detection apparatus includes a robotic paddle module and a junction box clamp.

The invention relates to a junction box bus bar welding failure detection device and a detection method thereof, wherein:

the invention can accurately obtain the poor welding condition of the virtual welding and the weak welding through visual contrast, thereby improving the detection precision of the poor welding of the bus bar of the junction box, reducing the omission rate and further reducing the manufacturing reject ratio of the battery component, namely improving the quality of the battery component.

Drawings

Fig. 1 is a schematic view showing the general structure of the junction box busbar poor welding detection apparatus of the present invention at a view angle.

Fig. 2 is a schematic view showing a state in which the junction box bus bar poor welding detection apparatus of fig. 1 has a battery pack thereon.

Fig. 3 is a schematic view of the general structure of the junction box busbar poor welding detection apparatus of the present invention at another view angle.

Fig. 4 is a schematic diagram showing the relative positional relationship among the battery assembly transfer module, the lifting and carrying module, and the positioning module in fig. 1.

Fig. 5 is a schematic perspective view of the manipulator pulling module in fig. 1.

Fig. 6 is a front view (partially cut-away) of fig. 5.

Fig. 7 is a right side view (partially cut-away) of fig. 5.

Fig. 8 is a schematic perspective view of a single clamping assembly in the terminal block clamp of fig. 1.

Fig. 9 is a top view of the clamping assembly of fig. 8.

Fig. 10 is a partial cross-sectional view of the clamp assembly of fig. 9.

Fig. 11 is a schematic perspective view of an assembled manipulator pulling module and a terminal box clamp according to an embodiment of the invention.

FIG. 12 is a front view of FIG. 11;

FIG. 13 is a schematic illustration of the positional relationship between an ideal weld and a ramped weld with a pick;

fig. 14 is a schematic step diagram of a method for detecting defective welding of a bus bar of a junction box according to the present invention.

In the figure:

100. a component feed transfer module; 200. jacking and carrying modules; 210. a carrier; 220. a lifting driving member; 300. a positioning module; 400. a first camera module; 500. a second camera module;

600. a manipulator pulling module; 611. a first mount; 6111. a first limit structure; 6112. a first bolt; 6113. a limit groove; 6114. a second bolt; 6121. a poking head; 6122. a connecting body; 613. a first elastic member; 614. a first sensor; 615. a first sensing member; 616. a vertical slide rail; 621. a second mounting base; 622. a horizontal slide rail; 623. a second elastic member; 624. a limit flange; 625. a second sensor; 626. a second sensing member; 627. a second cushion block;

700. a junction box clamp; 710. a mounting base; 720. a pressing member; 721. a pressure head; 722. a sliding shaft; 7221. a third blind hole; 7222. a connection groove; 723. a locking pin; 724. pressing and holding the sliding rail; 740. a first telescoping drive assembly; 741. a T-joint; 750. a second telescoping drive assembly; 751. a first locking head; 752. a second locking head; 760. a lifting driving member;

800. a component discharging and transmitting module; 900. a battery assembly; 901. a junction box; 1000. and a controller.

Detailed Description

Example embodiments will now be described more fully with reference to the accompanying drawings. However, the exemplary embodiments can be embodied in many forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the example embodiments to those skilled in the art. In the drawings, the thickness of regions and layers are exaggerated for clarity. The same reference numerals in the drawings denote the same or similar structures, and thus detailed descriptions thereof will be omitted.

The described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the inventive aspects may be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

The embodiments described in the following examples are examples of the junction box bus bar defective welding detection apparatus and the detection method of the present invention, but the scope of the present invention is not limited thereto. All other embodiments, which can be made by those skilled in the art without the inventive effort, are intended to be encompassed within the scope of the present invention.

Referring to fig. 1 to 14 in combination, according to an embodiment of the present invention, there is provided a junction box bus bar poor welding detection apparatus including:

the battery pack transmission module is used for adjusting the position of the battery pack 900 with the junction box 901 positioned on the battery pack transmission module so as to realize the transfer of the battery pack 900 between different operation stations, and the battery pack transmission module can be a material transmission belt and can be a mechanical arm, a mechanical arm and the like capable of changing and adjusting the position of an object;

the manipulator poking module 600 is arranged adjacent to the battery pack transmission module and is used for poking the bus bar in the junction box 901 at the poking position, and it can be understood that the manipulator poking module 600 can apply poking force with a preset magnitude on the bus bar, when the virtual welding or the welding between the bus bar and the junction box 901 is weak, the position is changed under the poking force, and when the bus bar and the junction box 901 have better welding quality, the poking force is insufficient to change the position of the bus bar;

the first camera module 400 is located at the first detection position, and is configured to obtain a first image of the bus bar in the junction box 901 before being stirred by the manipulator stirring module 600, that is, the first image includes a state of the junction box 901 and the bus bar after being welded in the previous process, and at least a state of the bus bar before being stirred should be explicitly displayed in the first image;

The second camera module 500 is located at a second detection position, and is configured to obtain a second image of the bus bar in the junction box 901 after being stirred by the manipulator stirring module 600, that is, the second image includes a state of the bus bar after the bus bar is stirred by the manipulator stirring module 600;

the judging module is configured to judge whether the welding of the bus bar in the junction box 901 is bad by comparing the difference between the second image and the first image, and the judging module may be a controller 1000 (e.g. an industrial personal computer) configured in a matching manner, or may be configured separately as a component independent of the detecting device of the present invention.

In the technical scheme, the manipulator poking module 600 is adopted to apply poking force with a preset size to the bus bar in the junction box 901 welded with the bus bar, and the first camera module 400 and the second camera module 500 are adopted to respectively acquire images before and after the bus bar is poked for comparison.

The first camera module 400 and the second camera module 500 may, for example, only include 2D cameras, that is, only acquire the image contrast of the bus bar before and after being stirred by the two-dimensional image acquisition method, so as to accurately detect the welding failure phenomena such as cold welding and welding insecurity. Of course, the first camera module 400 and the second camera module 500 may also include only 3D cameras, respectively, so as to obtain corresponding three-dimensional images.

In a preferred embodiment, the first camera module 400 includes a first 2D camera and a first 3D camera, with reference to the transmission direction of the battery assembly 900, the first 2D camera is located upstream of the first 3D camera, and the first 2D camera and the first 3D camera are respectively used for acquiring a first two-dimensional image and a first three-dimensional image of the junction box 901 at the first detection position; and/or, the second camera module 500 includes a second 2D camera and a second 3D camera, and the second 2D camera is located upstream of the second 3D camera with respect to the transmission direction of the battery assembly 900, and the second 2D camera and the second 3D camera are respectively used for acquiring a second two-dimensional image and a second three-dimensional image of the junction box 901 at the second detection position. That is, in this preferred embodiment, the first camera module 400 and the second camera module 500 respectively include a 2D camera and a 3D camera, wherein the 3D camera obtains an accurate three-dimensional image of the bus bar and the welding spot thereof during the movement of the bus bar within the field of view (i.e. during the transmission), so as to more accurately identify whether the welding spot has a welding defect (such as a crack, an air hole, etc.), further improve the accuracy of visually identifying the welding defect, and the 2D camera can accurately obtain the position of the junction box 901 within the field of view, which can ensure that the junction box 901 can be more accurately conveyed to the corresponding operation station (such as a toggle position, a first detection position, etc.), and the obtained two-dimensional image is also beneficial to forming a more accurate three-dimensional image.

In a specific embodiment, the method for determining whether the welding of the bus bar in the junction box 901 is defective by comparing the difference of the second image and the first image specifically includes: the second image is a second three-dimensional image, the first image is a first three-dimensional image, the second three-dimensional image is compared with three-dimensional contour data acquired by the first three-dimensional image, if the second three-dimensional image and the first three-dimensional image are the same, the welding is judged to be good, and if the second three-dimensional image and the first three-dimensional image are different, the welding is judged to be bad. According to the technical scheme, the judgment of poor welding is realized through the consistency of the three-dimensional outline data of the welding spots in the two obtained three-dimensional images, and the method is simple, quick and accurate.

In another preferred embodiment, the judging module is further configured to obtain a height dimension of a welding point of the bus bar through the first three-dimensional image, and output a prompt message when the height dimension of the welding point is not within the set range. According to the technical scheme, the height dimension of the welding spot of the bus bar can be accurately obtained through the first three-dimensional image, when the height dimension is smaller than the set range or larger than the set range, the fact that the welding parameter or the welding process of the previous procedure has larger deviation is indicated, and at the moment, the output prompt information is fed back to related personnel so as to timely correct and perfect the welding parameter or the welding process of the previous procedure, namely the invention has the functions of outputting the 3D image of the welding spot and data, quantifying the height dimension of the welding spot, and providing data support for the statistical welding process and yield of the production line.

In some embodiments, the junction box busbar poor welding detection apparatus further includes: the positioning module 300 is disposed adjacent to the battery assembly transmission module, so as to position the battery assembly 900 on the battery assembly transmission module, that is, the battery assembly is positioned at a relatively accurate position before the first camera module 400 acquires the image of the junction box 901, so as to ensure that the positions of the junction box 901 before and after photographing are consistent as much as possible. The positioning module 300 includes, for example, an approaching roller with a certain flexibility and a telescopic driving component (such as an air cylinder) capable of driving the approaching roller to move transversely, and the position of the battery assembly 900 contacting with the approaching roller is adjusted by the retracting action of the telescopic driving component, which is a more conventional assembly in the industry and will not be described herein.

In some embodiments, the junction box busbar poor welding detection apparatus further includes: the jacking carrying module 200 is arranged in parallel with the battery assembly transmission module and is positioned below the battery assembly 900 to jack up the battery assembly 900 to a first detection position, the junction box 901 can be sequentially transmitted to a poking position and a second detection position from the first detection position along the transmission direction of the battery assembly transmission module, the battery assembly 900 can fall back to the battery assembly transmission module after the battery assembly 900 is detected, and the transmission speed precision of the jacking carrying module 200 is higher than that of the battery assembly transmission module. It should be noted that the toggle position and the second detection position may be the same position in the practical application process, and may be two positions located upstream and downstream in the transmission direction of the battery assembly 900. In this technical scheme, through jacking transport module 200 with battery pack 900 by battery pack transmission module lift-up and can with battery pack 900 transmit to first detection position, stir position and second detection position in proper order, can guarantee the transmission speed precision of battery pack 900 with lower production line manufacturing cost, and then guarantee the aforesaid first camera module 400 and the accuracy of making a video recording of second camera module 500. Generally, in order to ensure the accuracy of image capturing, the lifting and carrying module 200 has a lower transmission speed but a higher accuracy, and is therefore only used to adjust the position of the battery assembly 900 between the first detection position, the toggle position and the second detection position, and the battery assembly transmission module is responsible for feeding and discharging the battery assembly 900, which can have a higher transmission speed to improve the productivity, and the accuracy of the transmission speed is not required to be too high. The jacking and transporting module 200 can adopt a jacking and transplanting assembly which is conventional in the industry, and the speed and the precision of the jacking and transporting module can meet the production line requirements.

In a preferred embodiment, the battery assembly transfer module includes an assembly feed transfer module 100 and an assembly discharge transfer module 800, and the jacking handling module 200 is capable of jacking and transferring the battery assembly 900 on the assembly feed transfer module 100 back onto the assembly discharge transfer module 800. In this technical scheme, battery pack transmission module comprises two sections around subassembly feeding transmission module 100 and the subassembly ejection of compact transmission module 800, and jacking transport module 200 then is in the position that both adjoined, and two sections can control feeding and ejection of compact respectively around adopting, and the independent control of feeding and ejection of compact can also satisfy production beat when reducing the operation energy consumption, improves production efficiency. Referring to fig. 4, the feeding and discharging transmission modules 100 and 800 are approximately mirror-image distribution, each transmission module is divided into three belts, i.e. left, middle and right, and the three belts are driven by a motor to run synchronously, and the jacking and carrying modules 200 are two sets and are symmetrically arranged in the middle of the belts.

The lifting and carrying module 200 comprises a carrier 210 and a lifting driving member 220 positioned below the carrier 210, wherein a vacuum chuck (not shown and not marked in the figure) is arranged on the carrier 210, the lifting cylinder 220 can control the carrier 210 to lift, and the vacuum chuck arranged on the carrier 210 can adsorb the battery assembly 900 on the carrier 210, so that the battery assembly 900 is prevented from displacement during carrying.

In some embodiments, the battery assembly 900 has a plurality of junction boxes 901, where the junction boxes 901 are sequentially spaced along the transmission direction of the battery assembly 900, and the adjacent two junction boxes 901 are spaced apart by L, and the first detecting position and the toggle position are spaced apart by L, where the second detecting position and the toggle position are preferably the same in horizontal position, as shown in fig. 2, and in a specific embodiment, there are three junction boxes 901 on the battery assembly 900. In the technical scheme, the spacing of the stations is equal to the spacing of the junction boxes, so that the stations can operate in parallel, for example, when the former junction box is in the poking position for poking, the latter junction box is just in the first detection position for acquiring the first image, the detection time consumption of a single component can be obviously reduced, and the productivity is improved.

As described above, when the bus bar welding defect is detected, a specific force is required to stir the bus bar in the junction box, and the junction box is required to be clamped by the clamp in the stirring process because the junction box is in a semi-fixed state at the detection station, otherwise, the junction box position can be moved, and the bus bar belt can also generate stress due to pulling. The position accuracy of the junction box itself on the assembly is also poor, with a deviation of 2-3mm in the horizontal plane X and Y directions, and with a certain angle. At present, the current anchor clamps are many through the direct centre gripping of corresponding object of power such as cylinder, motor, when it was applied to the centre gripping terminal box, can install anchor clamps on correction platform, fix a position the terminal box through the vision, and the anchor clamps position is corrected to the rethread correction platform, carries out the centre gripping to the terminal box, but the terminal box anchor clamps that adopt this kind of structure have following problem at least: (1) The clamping correction of the clamp can not completely correct the position of the upper junction box, and slight displacement and stress of the junction box can be caused after the clamping due to the visual positioning error of the junction box; (2) From the movement of materials to the visual photographing calculation and the coordinate giving, the correction mechanism takes a long time to correct, and the productivity is affected.

Referring to fig. 8 to 12 in combination, in some embodiments, the junction box busbar poor welding detection apparatus further includes: the terminal block clamp 700 is used for flexibly pressing opposite sides of the terminal block 901 before the manipulator pulling module 600 pulls the bus bar so as to clamp the opposite sides of the terminal block 901 to fix the position of the terminal block 901.

In this technical scheme, terminal box anchor clamps 700 flexible pressurization centre gripping in terminal box 901's opposite both sides form the location to terminal box 901, can not lead to terminal box 901 position to the theoretical center removal of rigid clamp because of rigid centre gripping at the in-process terminal box 901's of centre gripping terminal box 901 position, can not destroy the connection between terminal box 901 and the glass board of battery pack 900, still need not to stir in the correlation technique simultaneously and carry out the position correction to terminal box 901 between the busbar in the terminal box 901 to can improve production efficiency, and then promote the line productivity.

In one particular embodiment, referring to fig. 11 and 12 in combination, the terminal block clamp 700 includes two oppositely disposed clamp assemblies (not referenced), and, in particular, referring to fig. 8, the clamp assemblies include: the installation base 710 and two sets of pressure head assemblies (not labeled in the drawing) arranged in parallel and at intervals, the pressure head assemblies comprise a pressure holding piece 720, the pressure holding piece 720 and the installation base 710 are connected in a sliding manner (specifically, for example, the pressure holding slide rail 724 and the installation base 710 are respectively connected in a sliding manner), one end of the pressure holding piece 720 is a pressure head 721, a third elastic piece, such as a metal spiral spring, is clamped between the other end of the pressure holding piece 720 and the installation base 710, and has a certain flexibility and rigidity, wherein the flexibility is favorable for the pressure head 721 to apply pressure to the flexibility of the side wall of the junction box 901, and the rigidity is favorable for keeping the position of the junction box 901 unchanged when the stirring force is relatively small.

In this technical scheme, two sets of pressure head subassemblies that interval is parallel can independently flexible pressure application respectively on the same lateral wall of terminal box 901, prevents to the position variation that the single-point application of force leads to of terminal box 901, can also realize simultaneously the location centre gripping to terminal box 901 under the condition that the hookup location of permission terminal box 901 and glass board has the error. In a specific application, the pressure heads 721 of the two pressure head assemblies of the two opposite clamping assemblies are respectively and coaxially arranged at last, so as to prevent the clamping from generating torque to the junction box 901.

Referring specifically to fig. 10, in some embodiments, the pressing member 720 includes a sliding shaft 722, the pressing head 721 is connected to a first end of the sliding shaft 722, a second end of the sliding shaft 722 is formed with a third blind hole 7221, a portion of the third elastic member is accommodated in the third blind hole 7221, and a remaining portion of the third elastic member is in the third blind hole 7221 and abuts against the mounting base 710. In this technical scheme, construct third blind hole 7221 at the second end of sliding shaft 722 and make the one end of third elastic component can be held in this blind hole, and then guaranteed that sliding shaft 722 is more smooth and easy by the process that the third elastic component slided out after the application of force, namely forms the guide to the deformation direction of third elastic component, and the position of in-process third elastic component is more reliable stable.

Referring to fig. 8, in some embodiments, the junction box clamp 700 further comprises: the first telescopic driving assembly 740, the first telescopic driving assembly 740 is used for driving the two pressure head assemblies to return to the releasing position separated from the junction box 901 from the pressing position for pressing the junction box 901, and the first telescopic driving assembly 740 can specifically adopt a telescopic cylinder. Referring to fig. 9, in this solution, by switching the axial positions of the two ram assemblies driven by the extension and retraction of the first telescopic driving assembly 740, specifically, when the first telescopic driving assembly 740 is retracted, it will drive the third elastic member to retract, at this time, the ram assembly is located away from the junction box 901 and is in the release position, and when the first telescopic driving assembly 740 is extended, the ram assembly slides towards the junction box 901 side under the resilience force of the third elastic member and is then in the holding position.

With continued reference to fig. 9, in a preferred embodiment, the end of the telescopic rod of the first telescopic driving assembly 740 has a T-shaped joint 741, the two ram assemblies respectively have side walls opposite to each other of the sliding shaft 722 formed with connection grooves 7222, two protruding portions of the T-shaped joint 741 are respectively accommodated in the connection grooves 7222, and the length of the connection grooves 7222 in the sliding direction of the sliding shaft 722 is not less than the maximum deformation amount of the third elastic member, so as to ensure that the third elastic member can efficiently apply force to each ram 721 when the first telescopic driving assembly 740 is in the extended state. In this technical solution, the T-shaped joint is simultaneously overlapped with the connecting grooves 7222 of the two sliding shafts 722, so that the position switching of the two ram assemblies can be simultaneously realized by adopting one first telescopic driving assembly 740, and the structural design and control are simplified.

In some embodiments, the junction box clamp 700 further comprises: the second telescopic driving assembly 750, the second telescopic driving assembly 750 is used for locking the axial position of each sliding shaft 722 when each pressure head assembly is in the holding position, and the second telescopic driving assembly 750 can be specifically realized by adopting a telescopic cylinder. In this technical scheme, can lock the pressure head subassembly that is in the pressure and hold the position through second flexible drive assembly 750 in order to prevent the terminal box 901 position change that the rigidity of third elastic component is too little brought when stirring the busbar.

As a specific embodiment, referring to fig. 10, each sliding shaft 722 has a through hole perpendicular to the sliding direction thereof, and a locking pin 723 is slidably inserted in the through hole, and when each pressing head assembly is at the releasing position, the axes of each locking pin 723 of each sliding shaft 722 and the telescopic rod of the second telescopic driving assembly 750 are parallel and can form interference in the axial direction, so that when the pressing head assembly is at the pressing position, that is, each pressing head assembly on two opposite sides of the junction box 901 is pressed in place, the second telescopic driving assembly 750 is controlled to extend, so that the extrusion of each locking pin 723 can be realized, and the axial position of each sliding shaft 722 can be ensured to be fixed when the bus bar is stirred. In the technical scheme, the second telescopic driving assembly 750 and each locking pin 723 are adopted to form axial abutting and pressing so as to realize axial positioning of each sliding shaft 722, and the structure and the control are simple.

As further shown in fig. 10, a second locking head 752 is provided at a position of the mounting base 710 corresponding to an end surface of the locking pin 723, and an end of the telescopic rod of the second telescopic driving assembly 750 is connected with a first locking head 751, and the first locking head 751 and the second locking head 752 may be formed with respective anti-slip structures (e.g., stripe patterns) on the end surfaces of the end surfaces facing the locking pin 723, respectively, so as to be able to increase friction force with the locking pin 723 when locking the ram assembly, ensuring effective locking.

In a preferred embodiment, the locking pins 723 have a clearance with the through holes in which they are assembled, i.e., the hole diameter of the through holes is slightly larger than the outer diameter of the locking pins 723, so that effective positioning can be achieved when the axial centers of the two locking pins 723 are not coaxial due to the front-rear flatness inconsistency of one side wall of the junction box 901, and the aforementioned clearance should not be excessively large.

In some embodiments, the junction box clamp 700 further comprises: the lifting driving member 760 is configured to drive the clamping assembly to lift, and the lifting driving member 760 may specifically be an air cylinder, specifically, when the junction box clamp 700 is required to clamp the junction box 901 for positioning, the lifting driving member 760 is first controlled to descend to a suitable height, and then the first telescopic driving assembly 740 and the second telescopic driving assembly 750 are controlled to act to finally clamp and position the junction box 901.

According to an embodiment of the present invention, there is also provided a control method of the above-described junction box clamp, including the steps of:

controlling the two sets of clamping assemblies to descend by a first preset height (specifically controlling the lifting drive 760 to descend) so that the two sets of ram assemblies are respectively positioned on two opposite sides of the junction box 901;

controlling the extension of the telescopic rod of the first telescopic driving assembly 740 to enable each pressure head 721 to be flexibly pressed on the outer side wall of the junction box 901 under the action of the corresponding third elastic piece;

the extension of the telescopic rod of the second telescopic drive assembly 750 is controlled to form a press-holding of the locking pin 723 on each sliding shaft 722 such that the locking pin 723 is clamped and positioned between the mounting base 710 and the end face of the telescopic rod of the second telescopic drive assembly 750.

In this technical scheme, through the flexible axial position that presses location terminal box 901 of pressure head subassembly back control second flexible drive assembly 750 locking sliding shaft 722 again, the in-process terminal box 901's of centre gripping terminal box 901 position can not lead to terminal box 901 position to the theoretical center removal of rigid clamp because of the rigidity centre gripping, can not destroy the connection between the glass board of terminal box 901 and battery pack 900, still need not simultaneously in the correlation technique and stir the terminal box 901 and carry out the position correction between the busbar in the terminal box 901 to can improve production efficiency, and then promote the line productivity.

The control method of the terminal box clamp further comprises the following steps: when the clamping of the junction box 901 needs to be released, the telescopic rod of the second telescopic driving assembly 750 is controlled to retract; then, the telescopic rod of the first telescopic driving assembly 740 is controlled to retract so that each ram assembly returns from the holding position to the releasing position, and thus the position adjustment switching of the junction box 901 is not affected.

In terms of stirring the bus bars, the shapes and the sizes of welding spots of the junction box 901 are different, and the heights of the junction box are also changed in millimeter level. At present, most of the existing modes are to fix a poking head on a Z axis (namely vertical), set a designated descending distance, enable the poking head to descend to a designated position, drive the poking head to displace on an X-Y plane (namely horizontal plane) through a horizontal axis, so that the poking head can mechanically poke the bus bar, but the implementation mode has the following problems: (1) The lower detection height of the poking head is a fixed value, and the workpiece is damaged by the poking head due to the fact that the workpiece is too high, and the welding spot cannot be poked by the poking head due to the fact that the workpiece is too low; (2) The force of dialling is decided by the thrust of drive shaft, and it is too big to the fixed knot structure impact, can lead to the destruction of structure.

Accordingly, the present invention also provides a manipulator assembly 600 comprising: the vertical pushing component (not indexed in the figure) and the horizontal stirring component (not indexed in the figure), the horizontal stirring component can apply force to the vertical pushing component to generate movement or movement trend along the horizontal direction, wherein the vertical pushing component comprises a first mounting seat 611 and a stirring piece (not indexed in the figure) which can be connected onto the first mounting seat 611 in a sliding manner along the vertical direction (specifically, for example, through a vertical sliding rail 616), the first mounting seat 611 is provided with a first limiting structure 6111, the first limiting structure 6111 can limit the vertical displacement of the stirring piece, and a first elastic piece 613 is clamped between the first limiting structure 6111 and the stirring piece.

In this technical scheme, through the centre gripping setting first elastic component 613 between first limit structure 6111 and stirring the piece, when the work piece of control vertical pushing down subassembly decline contact below is the busbar in the terminal box 901, can be with flexible mode and work piece contact, also realized stirring the buffering contact of piece and work piece promptly, effectively prevent stirring the impact damage of piece down (i.e. decline) in-process to the work piece, and effectively prevent to stir the fixed height of first lower probe among the prior art and the work piece actual height when the phenomenon that leads to crush the work piece or can not effectively contact and then dial the solder joint to take place.

Referring specifically to fig. 7, the top end of the toggle member is provided with a T-shaped head, the first limit structure 6111 is provided with a T-shaped groove, the T-shaped head is vertically movably located in the T-shaped groove, it can be understood that, with the orientation shown in fig. 7 as a reference, the bottom wall of the T-shaped groove (i.e., the top wall of the T-shaped groove) forms a vertical position limit for the T-shaped head.

Specifically, the maximum vertical distance between the top surface of the T-shaped head and the bottom surface of the T-shaped groove (namely the bottom wall of the groove) is b, and b is smaller than the height a of the slope-shaped welding point of the bus bar in the junction box 901, so that when the welding point is provided with a slope, the stirring piece is prevented from being separated from the welding point due to overlarge vertical component force caused by the existence of the slope in the stirring force applying process, and the phenomenon of effectively stirring the welding point is not realized. Referring to fig. 13 specifically, the state of an ideal welding spot and a welding spot with a slope is shown in the drawing, for the ideal welding spot, when the stirring member is pressed down to a target position along the Z direction (i.e. vertically) in the drawing and then the stirring force in the X direction (i.e. horizontally) is applied, because the welding is not guided by the slope, no upward reaction force exists on the welding spot at this time, therefore, the possibility that the stirring member is separated from the welding spot is also not existed, the stirring force reaches a preset value, and then whether the welding is bad can be further judged, and for the welding spot with a slope, in the same operation process, a vertical upward component exists due to the existence of the slope, the stirring member moves upward when the component is larger than the sum of the elastic force of the first elastic member 613 and the whole dead weight of the stirring member, and if the upper limit of the movement of the stirring member is not limited, for example, the stirring member can move to the height c in fig. 13, and the stirring member cannot realize effective stirring of the welding spot, therefore, the invention limits the upward stirring member to the b value, and the ineffective stirring phenomenon can be effectively prevented.

In some embodiments of the present invention, in some embodiments,

the top end face of the T-shaped head of the toggle member is provided with a first blind hole (not indexed in the figure), the first elastic member 613 is accommodated in the first blind hole and is coaxial with the first blind hole, a first cushion block (not shown in the figure) is slidably connected in an orifice of the first blind hole, a first bolt 6112 is in threaded connection with the first limiting structure 6111, the head of the first bolt 6112 is abutted to the top surface of the first cushion block, namely, the first cushion block is positioned between the head of the first bolt 6112 and the first elastic member 613, so that effective and stable transmission of force between the first bolt 6112 and the first elastic member 613 is ensured, and the first elastic member 613 can be a metal coil spring. In this technical solution, the first bolt 6112 can form different pre-pressures on the first elastic member 613 by the screwing length, so that the toggle member of the present invention can adapt to buffering and abutting against more workpieces with different specifications.

In a preferred embodiment, the stirring member specifically includes a stirring head 6121 and a connecting body 6122, wherein the stirring head 6121 is detachably connected to the bottom end of the connecting body 6122, and the aforementioned first blind hole is configured at the top end of the connecting body 6122.

Referring specifically to fig. 6, in some embodiments, a first sensor 614 is disposed on the first mounting seat 611, a first sensing element 615 that is matched with the first sensor 614 is detachably connected to the toggle element, in a specific embodiment, the first sensor 614 is a U-shaped photoelectric correlation sensor, the first sensing element 615 is a metal sheet that can lift along with the lifting of the toggle element, and after the first sensor 614 is matched with the first sensing element 615, the first sensor 614 is triggered to send a corresponding toggle element to collide with a workpiece after the first sensing element 615 is in a sensing area of the first sensor 614, and then the corresponding toggle element can be fed back to a corresponding control component (for example, can be integrated in the controller 1000) to control the horizontal toggle assembly of the present invention to generate a toggle action.

Referring to fig. 5 and 6 in combination, the horizontal toggle assembly includes a second mounting seat 621, the first mounting seat 611 is slidably connected to the second mounting seat 621 through a horizontal sliding rail 622, the second mounting seat 621 has a second limiting structure (not labeled in the drawing), the second limiting structure can limit the horizontal displacement of the first mounting seat 611, and a second elastic member 623 is sandwiched between the second limiting structure and the first mounting seat 611. In this technical solution, the second elastic element 623 is disposed between the second limiting structure and the first mounting seat 611, so as to realize flexible buffer application of the toggle force to the welding spot position, and prevent impact damage caused by rigid force application to the welding spot or the workpiece.

In some embodiments of the present invention, in some embodiments,

the first mounting seat 611 is formed with a limit groove 6113, the second mounting plate 621 is formed with a second blind hole (not labeled in the figure), the second elastic element 623 is accommodated in the second blind hole and is coaxial with the second blind hole, the orifice of the second blind hole is formed with a limit flange 624, the limit flange 624 is accommodated in the limit groove 6113, and the second elastic element 623 can also be a metal coil spring. The limiting flange 624 is disposed in the limiting groove 6113 to limit the horizontal movement of the first mounting seat 611 and the components (including the toggle member) thereon, and in a preferred embodiment, the limiting groove 6113 is a waist hole with a long axis in a vertical direction. Further, a second cushion block 627 is slidably connected in the hole of the second blind hole, a second bolt 6114 is connected to the groove wall of the limit groove 6113 in a threaded manner, the head of the second bolt 6114 is abutted to the second cushion block 627, and the pre-pressure on the second elastic component 623 can be changed by adjusting the screwing length of the second bolt 6114.

In a preferred embodiment, the second sensor 625 is disposed on the second mounting seat 621, and the second sensing member 626 matched with the second sensor 625 is detachably connected to the first mounting seat 611, where the second sensor 625 may be of the same type as the first sensor 614, and the position adjustment of the second sensing member 626 can adjust the pulling force to adapt to different workpieces and pulling conditions.

According to an embodiment of the present invention, referring to fig. 14, there is also provided a method for detecting a welding failure of a junction box bus bar, including the steps of:

transferring the battery assembly 900 having the junction box 901 to a first detection position (for example, using the battery assembly transfer module or the jacking and transporting module 200 above), and acquiring an image of the bus bar welding spot position of the junction box 901 at the first detection position as a first image;

after the first image is acquired, the junction box 901 is transferred to a poking position (for example, the battery assembly transmission module or the jacking and carrying module 200 is adopted), and poking force with a preset magnitude is applied to bus bars in the junction box 901 at the poking position;

after the bus bar is shifted, an image of the bus bar welding spot position of the junction box 901 is acquired again as a second image;

Whether the welding of the bus bar in the junction box 901 is defective is judged by comparing the difference of the second image and the first image.

In the technical scheme, the poking force with the preset size is applied to the bus bar in the junction box 901 where the bus bar is welded, and images before and after poking the bus bar are respectively acquired for comparison.

The application mode of the aforementioned pulling force may be varied, and for example, the "pulling" effect may be generated by utilizing the change of physical quantities such as the airflow impact, the photosensitivity (for photosensitive materials), the sonic energy (for example, ultrasonic vibration), etc., and as a preferred implementation mode, the manipulator pulling module 600 described in the present invention may be also used.

The first image and the second image may be obtained in various ways, for example, components capable of obtaining stable reference information data for comparison, such as spectra, and the corresponding first image and the second image are both spectrograms, and as a preferred embodiment, the first image and the second image are both visual images, that is, are obtained by the first camera module 400 and the second camera module 500, respectively.

In some embodiments, the first image includes a first two-dimensional image and a first three-dimensional image, and the second image includes a second two-dimensional image and a second three-dimensional image, wherein the first two-dimensional image and the second two-dimensional image are both obtained when the junction box 901 is in a static state, the first three-dimensional image is obtained during a transition of the junction box 901 from the first detection position to the toggle position, and the second three-dimensional image is obtained during a transition of the junction box 901 after the toggle position is toggled. In the preferred embodiment, an accurate three-dimensional image of the bus bar and the welding spot thereof is acquired in the moving process (namely in the transmission process) of the bus bar within the visual field of the camera, so that whether welding defects (such as cracks and air holes) exist in the welding spot can be more accurately identified, and the accuracy of visually identifying the welding defects is further improved.

In some embodiments, determining whether the welding of the bus bar within the junction box 901 is poor by comparing the difference of the second image and the first image specifically includes: and comparing the three-dimensional contour data acquired through the second three-dimensional image and the first three-dimensional image, judging that the welding is good if the two three-dimensional images are the same, and judging that the welding is bad if the two three-dimensional images are different. And the judgment of poor welding is realized by the consistency of the three-dimensional outline data of the welding spots in the two obtained three-dimensional images, so that the method is simple, quick and accurate.

In some embodiments, the junction box busbar poor welding detection method further includes the steps of:

and acquiring the height dimension of the welding spot of the bus bar through the first three-dimensional image, and outputting prompt information when the height dimension of the welding spot is not in a set range. According to the technical scheme, the height dimension of the welding spot of the bus bar can be accurately obtained through the first three-dimensional image, when the height dimension is smaller than the set range or larger than the set range, the fact that the welding parameter or the welding process of the previous procedure has larger deviation is indicated, and at the moment, the output prompt information is fed back to related personnel so as to timely correct and perfect the welding parameter or the welding process of the previous procedure, namely the invention has the functions of outputting the 3D image of the welding spot and data, quantifying the height dimension of the welding spot, and providing data support for the statistical welding process and yield of the production line.

In some embodiments of the present invention, in some embodiments,

before transferring the battery assembly 900 to the first detection position, positioning the battery assembly 900, that is, positioning the battery assembly in a relatively accurate position before the first camera module 400 acquires the image of the junction box 901, so as to ensure that the positions of the junction box 901 before and after photographing are consistent as much as possible.

In some embodiments, the step of clamping the junction box 901 is further included before the bus bar is shifted, specifically implemented by using the junction box clamp 700, so as to ensure that the position of the junction box 901 is stable and unchanged in the subsequent shifting process, and prevent the junction box 901 from being separated from the glass plate of the battery assembly 900.

In some embodiments, the step of clamping junction box 901 comprises: controlling the two groups of clamping assemblies to descend by a first preset height so that the two groups of pressure head assemblies are respectively positioned on two opposite sides of the junction box 901; controlling the extension of the telescopic rod of the first telescopic driving assembly 740 to enable each pressure head 721 to be flexibly pressed on the outer side wall of the junction box 901 under the action of the corresponding third elastic piece; the extension of the telescopic rod of the second telescopic drive assembly 750 is controlled to form a press-holding of the locking pin 723 on each sliding shaft 722 such that the locking pin 723 is clamped and positioned between the mounting base 710 and the end face of the telescopic rod of the second telescopic drive assembly 750.

In some embodiments, the step of clamping junction box 901 further comprises: when the clamping of the junction box 901 needs to be released, the telescopic rod of the second telescopic driving assembly 750 is controlled to retract; thereafter, the telescoping rod of the first telescoping drive assembly 740 is controlled to retract to return each ram assembly from the hold-down position to the release position.

The above is only a preferred embodiment of the present invention, and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. The method for detecting the poor welding of the bus bar of the junction box is characterized by comprising the following steps of:

transferring a battery assembly (900) with a junction box (901) to a first detection position, and acquiring an image of a bus bar welding spot position of the junction box (901) at the first detection position as a first image;

after the first image is acquired, transferring the junction box (901) to a poking position, and applying poking force with preset magnitude to the bus bar in the junction box (901) at the poking position;

After the bus bar is shifted, acquiring an image of a bus bar welding spot position of the junction box (901) again to be a second image;

and judging whether the welding of the bus bar in the junction box (901) is bad or not by comparing the difference between the second image and the first image.

2. The detection method according to claim 1, wherein the first image comprises a first two-dimensional image and a first three-dimensional image, and the second image comprises a second two-dimensional image and a second three-dimensional image, wherein the first two-dimensional image and the second two-dimensional image are both obtained when the junction box (901) is in a stationary state, the first three-dimensional image is obtained during a transition of the junction box (901) from the first detection position to the toggle position, and the second three-dimensional image is obtained during a transition of the junction box (901) again after the toggle position is toggled.

3. The detection method according to claim 2, wherein determining whether welding of the bus bar in the junction box (901) is defective or not by comparing the difference of the second image and the first image specifically includes:

4. A method of detecting according to claim 3, further comprising the steps of:

5. The method according to claim 1, wherein,

before transferring the battery assembly (900) to the first detection position, further comprising locating a position of the battery assembly (900).

6. The method of detecting according to claim 1, further comprising the step of clamping the junction box (901) before the bus bar is toggled.

7. The method according to claim 6, wherein the step of holding the junction box (901) includes:

controlling the two groups of clamping assemblies to descend by a first preset height so that the two groups of pressure head assemblies are respectively positioned on two opposite sides of the junction box (901);

controlling the expansion rod of the first expansion driving assembly (740) to extend out so that each pressure head (721) is flexibly pressed on the outer side wall of the junction box (901) under the action of the corresponding third elastic piece;

the extension of the telescopic rod of the second telescopic driving assembly (750) is controlled to form the pressing of a locking pin (723) on each sliding shaft (722) so that the locking pin (723) is clamped and positioned between the mounting base (710) and the end face of the telescopic rod of the second telescopic driving assembly (750).

8. The method according to claim 7, wherein the step of holding the junction box (901) further comprises:

when the clamping of the junction box (901) needs to be released, controlling the telescopic rod of the second telescopic driving assembly (750) to retract;

thereafter, the telescoping rod of the first telescoping drive assembly (740) is controlled to retract to return each ram assembly from the hold-down position to the release position.

9. A junction-box bus-bar-poor-welding detecting apparatus, characterized by being configured to perform the junction-box bus-bar-poor-welding detecting method according to any one of claims 1 to 8.

10. The junction-box busbar poor welding detection apparatus of claim 9, including a robot poking module (600) and a junction-box clamp (700).