DE202010014971U1 - Device for bending a connection contact of a photovoltaic module - Google Patents

Abstract

Device for bending a connection contact (2) of a photovoltaic module (3) from an initial position into a defined end position, comprising at least one automatically movable bending jaw (5), which in a desired position on a segment of the connection contact (2) projecting beyond the photovoltaic module (3) is position fixable, being bent by performing a pivotal or linear movement of the bending jaw (5) of this voltage applied to the terminal contact (2) in the end position.

Description

The invention relates to a device for bending a connection contact of a photovoltaic module.

Photovoltaic modules of any configuration generally include terminal contacts, also called busbars or ribbons, which consist in particular of copper flat strips. Such connection contacts are used for electrical contacting of a photovoltaic module for forwarding the photonically generated currents. For this purpose, the connection contacts with electrical connection means of an electrical junction box, also called junction box, conductively connected.

A major problem in the production of photovoltaic modules is that the projecting over an interface terminal contacts must be introduced during the manufacturing process in different end positions. In a first such end position, the terminals are flat on the photovoltaic module. To bring flat from the photovoltaic module terminal contacts in this position, they must first pass through encapsulation material such. As an EVA film, and optionally glass or other substrates are bent up. Subsequently and before a lamination process, the through-routed connection contacts are flat-bent into a defined position on the interface. In a third end position, the connection contacts of the photovoltaic module can in particular protrude vertically, in order then to be contacted with the connection means of a junction box. In this case, originally flat on the photovoltaic module resting terminal contacts must be bent in the appropriate end position.

The bending and flat bending of the terminal contacts of a photovoltaic module is still predominantly manually. Since the terminal contacts have a very low material thickness, typically in the order of 100 to 400 .mu.m, it is extremely time-consuming and difficult to manually bend the terminal contacts in a defined manner. Furthermore, it is only limited possible to bring the terminal contacts exactly and reproducibly in their final position. After all, there is a great danger of damaging the terminals during bending.

The invention has for its object to enable the most cost-effective and reproducible production of photovoltaic modules.

To solve this problem, the features of claim 1 are provided. Advantageous embodiments and expedient developments of the invention are described in the subclaims.

The device according to the invention serves to bend a connection contact of a photovoltaic module from an initial position into a defined end position. The device comprises at least one automatically movable bending jaws. This can be fixed in position in a desired position on a segment of the connection contact protruding beyond the photovoltaic module. By performing a pivotal or linear movement of the bending jaw of this fitting terminal contact is bent into the final position.

The device according to the invention can be used both for bending and for flat bending of connection contacts in photovoltaic modules of all kinds.

A significant advantage is that with the device according to the invention a completely automated bending of connection contacts is made possible. Elaborate manual machining operations are thus eliminated. Furthermore, it is advantageous that with the device according to the invention, the connection contacts can be accurately and reproducibly introduced into their final position by means of the bending processes carried out automatically, that is, a high processing quality is obtained. This applies in particular to terminal contacts with material thicknesses in the order of about 100 microns to 400 microns.

In a particularly advantageous embodiment of the invention, a vacuum generating unit is associated with the bending jaws, by means of which a vacuum can be generated in the bending jaws, by means of which a connection contact can be fixed in position on the bending jaws.

Due to the vacuum generated in the vacuum generating unit, the connection contact to be bent can be securely fixed in position and precisely positioned on the bending jaw, without any danger of damage to the connection contact. The vacuum is generated in a targeted manner after bringing the bending bit to the connection contact before carrying out the bending process, so that then the connection contact is securely fixed to the bending jaw during the entire bending process. As a result, the bending process can be performed safely and reproducibly.

Particularly advantageously, the vacuum generating unit is associated with a control unit, by means of which the generated vacuum is controlled and based on which the orientation of the bending jaw to the terminal contact is controlled.

In this way, possible misalignments of the bending jaw relative to the connection contact can be detected and corrected in good time.

The device according to the invention advantageously has different modules for flat bending and bending of connection contacts.

In a first module, a bending jaw and an automatically movable bending mandrel are provided for flat bending of a terminal contact projecting from the photovoltaic module into an end position resting on the photovoltaic module. The tip of the mandrel can be applied to the terminal contact, whereby the bending line is defined for flat bending of the terminal.

In this case, advantageously, the bending mandrel as well as the bending jaws by means of an actuator adjustable.

Due to the positioning of the bending mandrel, the bending line, along which the connection contact is bent from an initial position protruding from the photovoltaic module onto the photovoltaic module, can be specified in a simple manner. The bending of the terminal itself is then carried out by the pivoting or linear operation of the Biegebackens, so that exactly bends the adjacent terminal contact, so that the terminal contact rests tightly against the photovoltaic module.

The vacuum generated by the vacuum generating unit reliably secures the terminal contact on the bending jaws and that both when it comes to different material thicknesses and lengths of the connection contacts. This means that in any case the vacuum generating unit is sufficient as a position fixing means for securing the connection contact at the bending jaws during the flat bending, since the bending jaws presses from above onto the connection contact.

In a device for bending a resting on the photovoltaic module terminal in a protruding from the photovoltaic module end position a bending jaws and a pressing jaws are provided, wherein by means of the terminal contact fixed position Biegebackens bending takes place and by means of the pressing jaw shaping of the terminal through which the terminal contact stiffened is and is held in an end position.

The shaping achieved by means of the press jaw and the stiffening of the connection contact caused thereby ensures that the terminal contact protruding from the photovoltaic module in the end position remains safely in this end position without additional aids and can thus be electrically connected to connection means of a junction box.

Even when bending a connection contact the bending process is carried out by means of the bending jaw. For this purpose, the bending jaws is first guided from above onto the connection contact and then fixed in position at the connection contact by means of the vacuum generated in the vacuum generation unit. Then, the pivotal or linear movement of the bending jaw takes place, through which the connection contact is bent. The bending jaws pulls on the connection contact. For connection contacts with material thicknesses in the order of 100 microns to 400 microns, the vacuum generated in relation to the length of material to hold the connection contact securely to this during the pivotal or linear movement of the bending jaw. For connection contacts with higher material thicknesses, the vacuum may not be sufficient for complete positional fixation of the connection contact. In this application, superscripting is supported by an actor.

For example, the pressing jaws then have a ramp, by means of which, during bending, the installation of the connection contact at the bending jaw is supported.

The supportive effect of the ramp of the press-jaw thus undesirable detachment of the terminal contact is avoided by the bending jaws during the bending process.

The modules of the device according to the invention, which serve on the one hand for bending and on the other for flat bending of connection contacts, each have a bending jaws. The bending jaws of the various modules can in principle be identical, but are preferably designed differently.

The invention will be explained below with reference to the drawings. Show it:

1 : First exemplary embodiment of a module for flat bending of connection contacts.

2 : Positions of a bending jaw and bending mandrel of the module according to 1 in a first phase of a bending process.

3 : Arrangement according to 2 in a second phase of the bending process.

4 : First embodiment of a module for bending connection contacts.

5 : Positions of a bending jaw of the module according to 4 in a first phase of the bending process.

6 : Positions of the bending jaw and a pressing jaw of the module according to 4 in a second phase of the bending process.

7 : Cross-sectional view of the press jaw in accordance with 6 ,

8th : Cross-sectional view of one with the pressing jaws according to 7 shaped connection contact.

9 : Second exemplary embodiment of a module for flat bending of connection contacts.

10 Second embodiment of a module for bending terminal contacts.

1 shows a first module 1 a device for bending terminal contacts 2 a photovoltaic module 3 , The photovoltaic module 3 can be designed in different variants. The provided connection contacts 2 , so-called busbars or ribbons, consist for. B. from copper flat strips. The connection contacts 2 are in terminal contact bushings 4 in the photovoltaic module 3 stored, wherein in the embodiment of 1 the upper segments of the connection contacts 2 vertically above the flat top of the photovoltaic module 3 protrude. The connection contacts 2 are generally used for electrical contact with electrical outlets, not shown, by means of which an electrical connection for forwarding the photonically generated currents is produced.

During the manufacturing process of the photovoltaic module 3 it is necessary that over the top of the photovoltaic module 3 protruding contacts 2 To bend flat, that is to bend so that it is flat on the top of the photovoltaic module 3 rest. This is the purpose of the module 1 according to 1 ,

The module 1 forms a machining head, with a drive unit, not shown, relative to the photovoltaic module 3 can be moved and can also be rotated about a vertically oriented axis of rotation D, so that the machining head relative to the connection contacts to be bent 2 can be positioned.

The module 1 has a bending jaws for performing flat bending processes 5 on, which is movable by means of a drive, not shown. The bending jaws 5 is on a swivel arm 6 stored, in turn, on a slider 7 is stored and along a rail-shaped forced operation 8th is movable. Instead of the Schenkarms can also be a linear arm, which performs a linear movement, may be provided. Furthermore, the module comprises 1 a bending mandrel 9 by means of a drive along the forced operation 8th is movable. The bending mandrel 9 is on a bracket 10 and another slider 11 attached and protrudes horizontally from this.

The with the module 1 performed flat bending a connection contact 2 is in the schematic representations of 2 and 3 illustrated. Before the beginning of the bending process, the connection contact is located 2 perpendicular from the top of the photovoltaic module 3 ( 2 ). Here is the connection contact 2 in the connection contact bushing 4 guided so that it does not touch its edge. With the module 1 a defined flat bending of the connection contact takes place 2 such that even after the flat bending of the terminal 2 this the edge of the terminal contact bushing 4 not touched.

For this purpose, first the bending mandrel 9 to the connection contact 2 introduced so that the tip of the bending beak 5 at a predetermined location of the terminal 2 is present ( 2 ). This defines the bend line along which the connection contact 2 is bent flat. To bend the Biegebacken 5 to the connection contact 2 introduced. The bending jaws 5 is then at the terminal contact 2 fixed in position. For this purpose, the module 1 a vacuum generating unit, not shown, with the in the bending jaws 5 a vacuum is generated. After the bending jaws 5 as in 2 in its nominal position on the connection contact 2 is fixed in position, this is pivoted to carry out the bending operation. The swing direction is in 2 illustrated with an arrow. 3 shows the arrangement according to 2 after the bending process. The connection contact 2 lies flat on the bending jaws 5 on, in turn, on the photovoltaic module 3 rests. After the bending process, the bending jaws 5 removed, so that then the connection contact 2 at a small constant distance to the top of the photovoltaic module 3 runs. The distance of the flattened terminal contact can be ensured by means of an actuator-mounted pad. The controlled flat bending in this end position deformations of the connection contact 2 avoided.

The vacuum generating unit is assigned a control unit by means of which the generated vacuum is controlled. By registering deviations of the vacuum from a set value after placing the bending jaw 5 on the connection contact 2 may cause incorrect alignments of the bending jaw 5 relative to the connection contact 2 be recognized.

4 shows a module 1' the device according to the invention for bending of connection contacts 2 , In 4 are two in terminal contact bushings 4 guided, flat on the top of the photovoltaic module 3 Overlying connection contacts 2 represented by means of the module 1' can be bent.

The module 1' has the same name as the module 1 according to 1 a movable and about a rotation axis D rotatable machining head. Furthermore, the module has 1' a bending jaw 5 on, constructively from the Biegebacken 5 of the module 1 can differentiate. Analogous to the module 1 according to 1 is the Biegebacken 5 of the module 1' on a swivel arm 6 stored, the one hand on a slider 7 is stored and along a rail-shaped forced operation 8th is movable. Unlike the module 1 according to 1 assigns the module 1' according to 4 no bending mandrel 9 but one on the slide 11 stored and actuated movable jaws 12 on. Furthermore, the module has 1' a vacuum generating unit for generating a vacuum in the bending jaws 5 and one of these associated control unit.

The with the module 1 according to 4 performed bending a terminal contact 2 is in the 5 and 6 shown. How out 5 can be seen, this is first the bending jaws 5 from the top of the flat on the photovoltaic module 3 lying connection contact 2 placed. In this nominal position of the bending jaws 5 at the connection contact 2 fixed in position by means of the vacuum generated in the vacuum generating unit. Subsequently, the bending jaws 5 pivoted, the pivoting direction with the arrow in 5 is marked. 6 shows the connection contact 2 after the bending process. The connection contact 2 then stands vertically upwards from the top of the photovoltaic module 3 in front. In this position, the pressing jaws 12 to the connection contact 2 moved up so that the connection contact 2 between bending jaws 5 and pressing jaws 12 is pressed. With the press baking 12 there is a deformation of the connection contact 2 and thereby a stiffening of the terminal 2 , For this purpose, the pressing jaws 12 the in 7 illustrated cross section on. The front of the press jaws 12 connected to the connection contact 2 is introduced, has two successive wedge-shaped faces. For firm pressing of the connection contact 2 with the press baking 12 becomes the connection contact 2 a corresponding angled structure imprinted as 8th shows. This is the connection contact 2 stiffened and becomes stable in the 6 held end position held. This is an essential condition that then the connection contact 2 can be contacted with electrical connection means of a junction box.

For connection contacts 2 with material thicknesses in the range of about 100 .mu.m to 400 .mu.m, the vacuum generated in the vacuum generating unit in relation to the material length is sufficient to make the connection contact 2 during the entire bending process at the Biegebacken 5 to keep. For connection contacts 2 with higher material thicknesses, the adhesive force caused by the vacuum may not be sufficient to the terminal contact 2 sure to fix. In this application, superscripting is supported by an actor. In this case, the press jaws 12 z. B. a ramp-shaped element, which in the bending under the terminal contact 2 is pushed and thereby the connection contact 2 further fixed in position.

9 shows a second embodiment of a module 1 a device for bending terminal contacts 2 a photovoltaic module 3 , Analogous to the embodiment according to 1 forms the module 1 according to 9 a machining head, which can be moved with a drive unit relative to the photovoltaic module and rotated about a vertical axis of rotation D, so that the machining head relative to the terminal contacts to be bent 2 can be positioned.

The module 1 has for performing flat bending processes bending slide 5a on that in a frame 13 of the machining head are stored. By drives in the form of pneumatic cylinders 14 can the bending pushers 5a Perform linear movements. For flat bending of connection contacts 2 are on brackets 15 the bending pusher 5a roll 16 rotatably mounted. Analogous to the arrangement according to 1 are the connection contacts 2 in connection contact bushings 4 stored and are perpendicular from the top of the photovoltaic module 3 out. For flat bending of the connection contacts 2 become the previously positioned rolls 16 via the connection contacts 2 guided. By means of another pneumatic cylinder 14a becomes the necessary contact pressure of the rollers 16 against the photovoltaic module 3 generated. Analogous to the embodiment according to FIG 1 are bending thorns 9 containing bending mandril mounts 9a provided by means of which the bending lines for the connection contacts 2 To be defined. The bending mandril mounts 9a are with the Biegeschiebern 5a displaceable. The bending mandril mounts 9a are plate-shaped in the present case.

10 shows a further embodiment of a module 1' for bending connection contacts 2 , The module 1' according to 10 has analogous to the module according to 4 a movable and one about a rotation axis D rotatable machining head.

The machining head has bending jaws 5 on, on a frame part 17 are stored and are linearly movable on this by means of pneumatic drives. At each bending beam are on holding elements 18 ramps 19 stored. For bending the connection contacts 2 become the ramps 19 under the respective connection contacts 2 pushed. Then the connection contacts 2 by movements of the ramps 19 bent.

LIST OF REFERENCE NUMBERS

1

module

1'

module

2

connection contact

3

photovoltaic module

4

Connection via hole

5

bending jaws

5a

bending slider

6

swivel arm

7

pusher

8th

forced control

9

mandrel

9a

Mandrel-counter bracket

10

bracket

11

pusher

12

pressing jaws

13

frame

14

pneumatic cylinder

14a

pneumatic cylinder

15

bracket

16

roller

17

frame part

18

retaining element

19

ramp

Claims (10)

Device for bending a terminal ( 2 ) of a photovoltaic module ( 3 ) from an initial position to a defined end position, comprising at least one automatically movable bending jaws ( 5 ), which in a desired position at one via the photovoltaic module ( 3 ) protruding segment of the terminal ( 2 ) is position fixable, wherein by performing a pivotal or linear movement of the bending jaw ( 5 ) the terminal contact ( 2 ) is bent into the end position. Apparatus according to claim 1, characterized in that the bending jaws ( 5 ) is adjustable by means of an actuator. Apparatus according to claim 2, characterized in that the bending jaws ( 5 ) on a swivel arm ( 6 ) or linear arm is mounted along a positive guide ( 8th ) is movable. Device according to one of claims 1 to 3, characterized in that the bending jaws ( 5 ) is associated with a vacuum generating unit, by means of which in the bending jaws ( 5 ) a vacuum can be generated, by means of which a connection contact ( 2 ) at the Biegebacken ( 5 ) is position fixable. Apparatus according to claim 4, characterized in that the vacuum generating unit is associated with a control unit, by means of which the generated vacuum is controlled and based on which the orientation of the Biegebackens ( 5 ) to the connection contact ( 2 ) is controlled. Device according to one of claims 1 to 5, characterized in that in a bending jaws ( 5 ) for flat bending one of the photovoltaic module ( 3 ) protruding contact ( 2 ) into one on the photovoltaic module ( 3 ) resting end position an automatically movable mandrel ( 9 ) is provided whose tip to the terminal contact ( 2 ) can be applied, whereby the bending line for flat bending of the terminal ( 2 ) is defined. Apparatus according to claim 6, characterized in that the bending mandrel ( 9 ) is adjustable by means of an actuator. Device according to one of claims 1 to 7, characterized in that a bending jaws ( 5 ) for bending one on the photovoltaic module ( 3 ) resting contact ( 2 ) in one of the photovoltaic module ( 3 ) protruding end position a pressing jaws ( 12 ) assigned. Apparatus according to claim 8, characterized in that the pressing jaws ( 12 ) has a profile by means of which by pressing the terminal ( 2 ) in its final position between bending jaws ( 5 ) and pressing jaws ( 12 ) a shape for stiffening the terminal ( 2 ) he follows. Device according to one of claims 8 or 9, characterized in that the pressing jaws ( 12 ) has a ramp, by means of which during the Aufbiegens the system of the terminal ( 2 ) at the Biegebacken ( 5 ) is supported.

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