JP2013038293A - Terminal box for solar cell module, insertion inspection method of lead wire, insertion inspection device, and manufacturing system and method of solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a terminal box for a solar cell module including a terminal board having an insertion hole for a lead wire for connection with an electrode, and connecting the lead wire electrically while inserting the lead wire obliquely into the insertion hole, where the quality of insertion of the lead wire into the insertion hole can be determined reliably, and to provide an insertion inspection method of lead wire, an insertion inspection device, and a manufacturing system and a method of the solar cell module.SOLUTION: In a terminal box including a terminal board 20 having an insertion hole 14 into which a lead wire 126 led out from a solar cell module 116 is inserted, the terminal board 20 has an aperture 21 for observing the tip of the lead wire 126 inserted into the insertion hole 14.

Description

  The present invention relates to a terminal box for a solar cell module, a lead wire insertion inspection method, an insertion inspection device, a solar cell module manufacturing method, and a manufacturing system.

  A solar cell module is composed of a plurality of crystalline solar cells made of single crystal silicon / polycrystalline silicon attached on a glass substrate, and a thin film solar cell made of a thin film photoelectric conversion layer formed on a glass substrate. It is formed by sealing with a protective film or the like.

  In a general solar cell module, when taking out the generated electric power to the outside, the output lead wire connected to the solar cell is pulled out to the back side through a resin material or a protective film, and is electrically connected to a terminal box equipped with an output cable. Connected. The terminal box is fixed to the back surface of the solar cell module.

  As a conventional terminal box, there is one having an insertion hole through which a lead wire connected to an electrode in a solar cell module is inserted, and the lead wire is inserted into the insertion hole in an oblique direction and electrically connected to the terminal plate ( For example, Patent Document 1).

JP 2005-353734 A

  In such a terminal box for a conventional solar cell module, a method for reliably and simply determining whether or not the lead wire is inserted is proposed in a state where the lead wire is inserted through the insertion hole of the terminal plate. It wasn't.

  Therefore, the present invention includes a terminal plate that has an insertion hole through which a lead wire connected to an electrode is inserted, and that electrically connects the lead wire in a state where the lead wire is inserted obliquely into the insertion hole. Terminal box for a solar cell module that can reliably determine whether the lead wire is inserted into the insertion hole, a lead wire insertion inspection method, an insertion inspection device, and an insertion inspection method and insertion thereof. It aims at providing the manufacturing method and manufacturing system of a solar cell module containing an inspection apparatus.

  In order to solve the above problems, the present invention provides a terminal box for a solar cell module, a lead wire insertion inspection method, an insertion inspection device, a solar cell module manufacturing method, and a manufacturing system.

(1) Terminal box for solar cell module A terminal box having a terminal plate having an insertion hole for inserting a lead wire drawn from the solar cell module, wherein the terminal plate is inserted into the insertion hole. A terminal box for a solar cell module, characterized by having an observation opening for observing the tip of the lead wire.

(2) Lead wire insertion inspection method An insertion inspection method for performing an insertion inspection of the lead wire inserted into the insertion hole in the terminal box for a solar cell module according to the present invention, wherein the inspection is performed through the observation opening. A lead wire insertion inspection method, wherein when the lead wire can be confirmed, it is determined that the lead wire is normally inserted, and when the lead wire cannot be confirmed through the observation opening, it is determined that the insertion is poor.

(3) Lead wire insertion inspection device An insertion inspection for inspecting the position of the tip portion of the lead wire inserted through the insertion hole in the terminal box for the solar cell module according to the present invention in the observation opening. In the lead wire insertion inspection device to be performed, when the lead wire is inserted into the insertion hole, in the distal end portion of the lead wire inserted into the insertion hole in the observation opening of the terminal plate A recognition unit for recognizing a preset insertion position, and a case where the insertion position is located at a preset reference position of the observation opening as a result of recognizing the insertion position of the lead wire by the recognition unit A determination unit that determines that the insertion position is defective when the insertion position is not located at the reference position. Insertion inspection device.

(4) Manufacturing method of solar cell module A terminal plate having an insertion hole through which a lead wire drawn out from the solar cell module is inserted, and the terminal plate observes a tip portion of the lead wire inserted into the insertion hole. An installation step of installing in the solar cell module a terminal box having an observation opening for insertion, an insertion step of inserting the lead wire into the insertion hole of the terminal plate in the terminal box, and the observation A step of determining that the lead wire is normally inserted when the lead wire can be confirmed through the opening while determining that the lead wire is not inserted through the observation opening. A method for manufacturing a solar cell module.

(5) Solar cell module manufacturing system A terminal plate having an insertion hole through which a lead wire drawn out from the solar cell module is inserted, and the terminal plate observes a tip portion of the lead wire inserted into the insertion hole. An installation device for installing a terminal box having an observation opening for the solar cell module, an insertion device for inserting the lead wire into the insertion hole of the terminal plate in the terminal box, and the insertion hole An insertion inspection device that performs an insertion inspection for inspecting the position of the tip portion of the lead wire inserted through the observation opening, and the insertion inspection device has inserted the lead wire into the insertion hole. A recognition unit for recognizing a preset insertion position at the tip of the lead wire inserted through the insertion hole in the observation opening of the terminal board And, as a result of recognizing the insertion position of the lead wire in the recognition unit, it is determined that the insertion position is normal when the insertion position is located at a preset reference position of the observation opening, And a determination unit that determines that the insertion position is poor when the insertion position is not located at the reference position.

  According to the terminal box for a solar cell module according to the present invention, the operator can visually confirm the tip of the lead wire inserted through the insertion hole in the observation opening, or the insertion inspection. It can be recognized by the device and the insertion device. Thereby, it is possible to easily find a poor insertion of the lead wire into the insertion hole.

  Furthermore, according to the lead wire insertion inspection method, the insertion inspection device, and the solar cell module manufacturing method and manufacturing system according to the present invention, the degree (degree) of insertion of the lead wire into the insertion hole is normal or poorly inserted. It is possible to make sure that the operator confirms the above, or to make sure that the insertion inspection device and the insertion device recognize it.

  In the present invention, it is possible to exemplify a mode in which the observation opening is provided on an extension of the lead wire inserted into the insertion hole so as to be separated from the insertion hole. In this aspect, it is preferable that the reference position is a region between the upstream end and the downstream end in the insertion direction in which the lead wire of the observation opening is inserted into the insertion hole.

  In this specific matter, it is easy for an operator to confirm whether the degree (degree) of insertion of the lead wire into the insertion hole is normal or poorly inserted, or it is easy to recognize by the insertion inspection device and the insertion device. It becomes possible to do.

  In the present invention, it is possible to exemplify an aspect in which the observation opening is provided on an extension of the lead wire that communicates with the insertion hole and is inserted into the insertion hole. In this aspect, the reference position includes the first reference position set in advance from the upstream end in the insertion direction in which the lead wire of the observation opening is inserted into the insertion hole, and the upstream from the downstream end. It is preferable that the area is between the second reference position set in advance.

  In this specific matter, it is easy for an operator to visually confirm the position of the tip of the lead wire in the observation opening, or to be easily recognized by the insertion inspection device and the insertion device. You can do it.

  In this invention, the said terminal box can illustrate the aspect provided with the guide part which guide | induces the said lead wire penetrated by the said insertion hole to the said opening part for observation.

  In this specific matter, the leading end portion of the lead wire can be reliably guided toward the observation opening portion, and thereby the inspection accuracy of the insertion inspection can be improved.

  In the present invention, at least the distal end portion of the lead wire and at least the peripheral portion of the observation opening of the terminal plate may have physical properties (for example, light such as visible light and infrared light) at the distal end portion and the peripheral portion. An aspect in which optical characteristics such as reflectance and structural characteristics such as surface irregularities are different from each other, more specifically, at least the tip of the lead wire and at least the observation opening of the terminal plate Examples of the peripheral edge portion may be different in brightness or color tone from each other.

  With this specific matter, it is possible to easily distinguish the tip portion of the lead wire from the terminal plate.

  In the insertion inspection method according to the present invention, a reference position is set in advance between an upstream end and a downstream end in the insertion direction of the lead wire of the observation opening, and the lead wire is inserted into the insertion hole. When the leading end of the lead wire is located at the reference position when it is inserted, it is determined to be normal, and when the leading end is not located at the reference position, the insertion is poor. The mode which judges that can be illustrated.

  In this specific matter, whether or not the insertion is defective is reliably determined by setting the reference position between the upstream end and the downstream end in the insertion direction of the lead wire of the observation opening. It becomes possible to do.

  In the present invention, the insertion inspection device is characterized in that the physical properties (for example, the reflectance of light such as visible light and infrared light) at least the distal end portion of the lead wire and the peripheral portion of the observation opening of the terminal plate. Physical quantities corresponding to optical characteristics such as surface characteristics and structural characteristics such as surface irregularities) (for example, physical quantities such as contrast ratio and color tone obtained from reflected light from the tip and peripheral portions). A mode provided with a detection part can be illustrated.

  In this specific matter, the detection value detected by the detection unit is automatically different between the tip portion and the peripheral portion of the lead wire, so that the tip portion and the peripheral portion of the lead wire are automatically distinguished. It becomes possible to do.

  As described above, according to the terminal box for a solar cell module according to the present invention, the terminal plate has the observation opening at the tip of the lead wire inserted through the insertion hole. Thus, it is possible to easily find a poor insertion of the lead wire into the insertion hole.

  Furthermore, according to the lead wire insertion inspection method, the insertion inspection device, and the solar cell module manufacturing method and manufacturing system according to the present invention, the operator can determine whether the lead wire is inserted into the insertion hole normally or poorly. It is possible to confirm with certainty or to be surely recognized by the insertion inspection device and the insertion device.

It is a schematic sectional drawing which shows the terminal box part for solar cell modules which concerns on one Embodiment of this invention. It is the top view which looked at the terminal board part in the terminal box shown in FIG. 1 from the top. It is the perspective view which looked at the terminal board part in the terminal box shown in FIG. 1 from diagonally upward. It is a schematic side view which shows the manufacturing process of the manufacturing system which connects the lead wire in a solar cell module to the terminal board in a terminal box, and manufactures a solar cell module, Comprising: (a) is a terminal box on the back surface of a solar cell module main body. It is a figure which shows the state before inserting a lead wire in the insertion hole in a terminal board, and (b) is a figure which shows the state which has penetrated the lead wire in the insertion hole in a terminal board. (C) is a figure which shows the state which test | inspects the position in the opening part for observation of a terminal board with respect to the front-end | tip part of the lead wire penetrated by the penetration hole. It is a block diagram which shows roughly the control structure of the penetration inspection apparatus which concerns on this Embodiment. In the terminal box which concerns on this Embodiment, it is a schematic sectional drawing which shows the penetration state of the lead wire to the penetration hole of a terminal plate, Comprising: (a) shows the state by which the lead wire is normally penetrated by the penetration hole. (B) And (c) is a figure which shows each example of the poor insertion which generate | occur | produces when a lead wire is penetrated by the penetration hole. In the terminal box which concerns on this Embodiment, it is a schematic sectional drawing which shows the penetration state of the lead wire to the penetration hole of a terminal plate, Comprising: (a)-(e) is when a lead wire is penetrated by the penetration hole. It is a figure which shows each example of the poor penetration which generate | occur | produces. FIG. 3 is a schematic plan view showing an example in which an observation opening is provided on an extension of a lead wire that is inserted into the insertion hole at a distance from the insertion hole in the terminal board, and FIG. (B) is a schematic sectional view thereof. It is a schematic sectional drawing which shows an example in which the guide part is provided in the box case. It is a schematic plan view which shows an example which the opening part for observation communicates with the penetration hole in the terminal board, and is extended along the penetration direction. It is explanatory drawing of one structural example of the solar cell module in the middle of manufacture, Comprising: (a) is the disassembled perspective view, (b) is the perspective view. It is a disassembled perspective view which shows a solar cell module. FIG. 6 is a schematic cross-sectional view for explaining a problem that may occur when a lead wire is inserted into an insertion hole of a terminal plate in an example of a terminal box in which an observation opening is not provided in the terminal plate; ) Is a diagram showing a state in which the lead wire is normally inserted through the insertion hole, and (b) is a diagram showing an example of an insertion failure that occurs when the lead wire is inserted through the insertion hole. (C) is a figure which shows the other example of the penetration failure generate | occur | produced when a lead wire is penetrated by the penetration hole. It is a figure which shows an example which applied the terminal box which concerns on this Embodiment to the crystalline solar cell module, Comprising: (a) is the schematic sectional drawing, (b) is the exploded perspective view.

  Embodiments according to the present invention will be described below with reference to the drawings. The following embodiment is an example embodying the present invention, and does not limit the technical scope of the present invention.

[Description of solar cell module]
First, a configuration example of the solar cell module 116 to which the terminal box 1 according to an embodiment of the present invention is applied will be described with reference to FIGS. 11 and 12. In addition, in FIG.11 and FIG12 and each figure mentioned later, the same code | symbol is attached | subjected to the member of substantially the same structure.

  FIG. 11 is an explanatory diagram of a configuration example of the solar cell module 116 in the middle of manufacturing. FIG. 11A shows an exploded perspective view thereof, and FIG. 11B shows a perspective view thereof. FIG. 12 is an exploded perspective view showing the solar cell module 116.

  The solar cell module 116 is a thin film solar cell module, and includes a translucent insulating substrate 111, a pair of solar cells 115, 115, a pair of P-type electrode terminal portions 117, 117, and a pair of N-type electrodes. Terminal portions 118, 118, insulating film 119, a pair of positive electrode current collector portions 120, 120, a pair of negative electrode current collector portions 121, 121, a pair of positive electrode lead wires 122, 122, and a pair of negative electrode lead wires 123 , 123.

  A pair of solar cells 115, 115 are connected to each other by connecting one transparent electrode film (not shown) and the other back electrode film (not shown) to each other. The cells 115a,... Are connected in series.

The pair of solar cells 115, 115 are formed by laminating a transparent electrode film, a photoelectric conversion layer, and a back electrode film made of a transparent conductive film (not shown) on the translucent insulating substrate 111 in this order. Yes. Examples of the light-transmitting insulating substrate include heat-resistant resins such as glass and polyimide. Examples of the transparent electrode film include SnO ₂ , ZnO, ITO, and the like. A typical example of the photoelectric conversion layer is amorphous silicon.

  Specifically, the pair of solar cells 115, 115 is in the shape of an elongated strip, and has a length that extends over almost the entire width of the translucent insulating substrate 111.

  On one end portion of the transparent electrode film of one solar cell 115 in the solar cell module 116, a linear P-type electrode terminal portion 117 having substantially the same length as that of the one solar cell 115 is formed. On the other end portion of the back electrode film of the cell 115, a linear N-type electrode terminal portion 118 having substantially the same length as that of the one solar cell 115 is formed. Further, on one end portion of the transparent electrode film of the other solar battery cell 115 in the solar battery module 116, a linear P-type electrode terminal portion 117 having substantially the same length as that of the other solar battery cell 115 is formed. On the other end portion of the back electrode film of the solar battery cell 115, a linear N-type electrode terminal part 118 having the same length as that of the other solar battery cell 115 is formed.

  The pair of P-type electrode terminal portions 117 and 117 and the pair of N-type electrode terminal portions 118 and 118 serve as electrode extraction portions. By making the lengths the same as described above, the currents flowing in series in the individual cells 115a in the pair of solar cells 115, 115 are not concentrated locally, and the currents can be taken out uniformly. As a result, series resistance loss can be suppressed.

  And, the center part of one P-type electrode terminal part 117 and the center part of one N-type electrode terminal part 118 and the center part of the other P-type electrode terminal part 117, An insulating film 119 is laid on the solar cell module 116 so as to pass through the opening 119a and 119a between the other N-type electrode terminal portion 118 and the central portion. The insulating film 119 is laid so that the pair of positive lead wires 122 and 122 and the pair of negative lead wires 123 and 123 do not overlap the pair of P-type electrode terminal portions 117 and 117 and the pair of N-type electrode terminal portions 118 and 118. Has been. As the insulating film 119, a thermoplastic polymer film is preferable, and an insulating film made of EVA (ethylene vinyl acetate resin) is optimal.

  On the other hand, on the entire surface of the pair of P-type electrode terminal portions 117, 117, a pair of positive electrode current collector portions 120, 120 called bus bars made of copper foil having the same shape and size as the pair of P-type electrode terminal portions 117, 117 are provided. Are electrically and mechanically joined. Similarly, on the front surface of the pair of N-type electrode terminal portions 118, 118, a pair of negative electrode current collector portions 121, 121 having the same shape and the same size as the pair of N-type electrode terminal portions 118, 118 are electrically and Mechanically joined. As these joining means, soldering or conductive paste can be used.

  On the insulating film 119, a pair of positive electrode lead wires 122, 122 and a pair of negative electrode lead wires 123, 123 made of a flat cable are arranged in a parallel state with their distal ends shifted in the width direction.

  One end portions of the pair of positive electrode lead wires 122 and 122 are connected to the center positions of the pair of positive electrode current collector portions 120 and 120, respectively. Further, the other end portions of the pair of positive lead wires 122 and 122 are positioned at substantially the center of the main body of the solar cell module 116, and are bent up vertically with respect to the surface of the main body of the solar cell module 116. The output lead wires 126 and 126 are provided. Similarly, one end portions of the pair of negative electrode lead wires 123 and 123 are connected to the center position of the pair of negative electrode current collectors 121, respectively. The other ends of the negative pair of lead wires 123 and 123 are located at substantially the center of the main body of the solar cell module 116, and are bent up vertically with respect to the surface of the main body of the solar cell module 116. The output lead wires 126 and 126 are provided.

  The pair of positive electrode lead wires 122 and 122 and the pair of negative electrode lead wires 123 and 123 are made of the same material (that is, copper foil) as the positive electrode current collector 120 and the negative electrode current collector 121, and Soldering, spot welding, or the like can be used as a means for joining the electrical parts. The pair of positive electrode lead wires 122 and the pair of negative electrode lead wires 123 extend over the pair of solar cells 115 and 115, respectively, but an insulating film 119 is interposed between the pair of solar cells 115 and 115. Therefore, a short circuit with a pair of photovoltaic cells 115 and 115 can be effectively prevented. The width of the insulating film 119 is desirably sufficiently wider than the width of the pair of positive electrode lead wires 122 and 122 and the pair of negative electrode lead wires 123 and 123. The electric part 121 is arranged in the form of a single belt-like sheet.

  As shown in FIG. 12, a sealing insulating film 124 and a back film 125 as a back surface protection material for weather resistance and high insulation are laminated and sealed on the entire surface of the solar cell module 116 body having such a configuration. The At this time, a pair of positive lead wires 122, 122 and four through holes 124a, 124a, 124a, 124a and four through holes 125a, 125a, 125a, 125a provided in the sealing insulating film 124 and the back film 125 are provided. The output lead wires 126, 126, 126, 126 of the pair of negative electrode lead wires 123, 123 are respectively inserted.

  As the sealing insulating film 124, it is preferable to use a thermoplastic polymer film made of the same material as the insulating film 119, and among them, a film made of EVA (ethylene vinyl acetate resin) is optimal. As described above, the sealing insulating film 124 is made of a thermoplastic polymer film made of the same material as the insulating film 119, so that the molecular bond between the two can be effectively advanced at the time of thermal fusion at the time of laminate sealing. And integration after cooling can be performed completely. Thereby, the waterproof property of the solar cell module 116 can be improved.

  The back film 125 preferably has a three-layer structure of PET / Al / PET (PET: polyethylene terephthalate). The thickness of the insulating film 119 can be exemplified by about 100 μm, the thickness of the sealing insulating film 124 can be exemplified by about 600 μm, and the thickness of the back film 125 can be exemplified by about 100 μm.

  Thus, the output lead wires 126,..., 126 of the pair of positive electrode lead wires 122, 122 and the pair of negative electrode lead wires 123, 123 projecting upward from the through holes 125a,. The solar cell module 116 is produced by attaching and electrically connecting the terminal box 1 according to the embodiment of the present invention.

  Note that the electrode arrangement structure of the solar cell module 116 is merely an example, and is not limited to such an arrangement structure. For example, the arrangement positions of the pair of positive electrode lead wires 122 and 122 and the pair of negative electrode lead wires 123 and 123 may be closer to one end side than the center portion of the solar cell module 116 main body, There is no need to pull it out to the center.

[Description of terminal box]
FIG. 1 is a schematic cross-sectional view showing a terminal box 1 portion for a solar cell module 116 according to an embodiment of the present invention. FIG. 2 is a plan view of the terminal plates 20, 20, 20, 20 in the terminal box 1 shown in FIG. FIG. 3 is a perspective view of the terminal plates 20,..., 20 in the terminal box 1 shown in FIG.

  In the terminal box 1 according to the present embodiment, the output lead wires (hereinafter simply referred to as lead wires) 126,..., 126 drawn from the back surface of the solar cell module 116 through the back film 125 are the terminal plates 20, ..., 20 are electrically connected. The terminal box 1 includes a box case 11 placed and fixed on the back film 125 of the solar cell module 116 body, terminal plates 20,..., 20 formed on the box case 11, and an upper lid 15. .

  The box case 11 includes a case main body 12 placed and fixed on the back film 125 of the solar cell module 116 main body, and a terminal plate fixing portion for mounting and fixing the terminal plates 20,. 13. In the present embodiment, the case main body 12 has a box shape, and the terminal plate fixing portion 13 is formed in a rectangular parallelepiped shape. Reference numeral 17 in the figure denotes a bypass diode.

  Further, the terminal plates 20,..., 20 in the terminal box 1 are provided with insertion holes 14, 14, 14, 14 through which the lead wires 126,.

  The bottom plate 12a of the case body 12 is provided with an opening 12b (see FIG. 1) for receiving the lead wires 126,. The terminal plates 20,..., 20 lead the lead wires 126,..., 126 in the solar cell module 116 from the outside (upper side in FIG. 1) to the inner side (lower side in FIG. 1). Thus, it is configured to be electrically connected while being inserted in an oblique direction.

  Specifically, the lead wires 126,..., 126 pass through the openings 12b in the bottom plate 12a of the case body 12 and the base end portions 126a, 126a, 126a, 126a along the diagonally upper side of the terminal plates 20,. And the base end portions 126a, 126a, 126a, 126a are further bent obliquely downward on the side of the terminal plates 20,..., 20 and inserted into the insertion holes 14,. It has the front-end | tip part 126b, 126b, 126b, 126b (refer FIG. 1). In the present embodiment, the lead wires 126,..., 126 have base end portions as base end portions 126a, 126a, 126a, 126a, with the bending apex Q as a boundary, and the distal end sides have distal end portions 126b, 126b, 126b, 126b.

  In the present embodiment, in the terminal plates 20,... 20, the operator and / or the insertion of the leading end portions 126 b of the lead wires 126,. Observation openings 21, 21, 21, 21 for allowing the inspection apparatus 220 to observe are provided.

  By the way, in the structure of the terminal box in which the opening for observation is not provided in the terminal board, there are the following problems.

  FIG. 13 illustrates a problem that may occur when the lead wire A3 is inserted into the insertion hole A2 of the terminal plate A1 in an example of the terminal box A in which the terminal plate A1 is not provided with the observation opening. It is a schematic sectional drawing. FIG. 13A shows a state in which the lead wire A3 is normally inserted through the insertion hole A2, and FIG. 13B shows an insertion that occurs when the lead wire A3 is inserted through the insertion hole A2. An example of the defect is shown, and FIG. 13C shows another example of the insertion failure that occurs when the lead wire A3 is inserted through the insertion hole A2.

  The terminal box A is shown in FIG. 13 (a) in order to satisfactorily connect the lead wire A3 to the terminal plate A1 with the lead wire A3 inserted obliquely through the insertion hole A2 provided in the terminal plate A1. As described above, the edge A3b at the distal end A3a of the lead wire A3 inserted through the insertion hole A2 needs to be inserted obliquely from the insertion hole A2 to a position γ spaced from the back side (lower side) of the terminal board A1. . For example, as shown in FIG. 13B, the edge A3b at the tip A3a of the lead wire A3 is caught in the insertion hole A2, or as shown in FIG. 13C, the insertion hole of the tip A3a of the lead A3. If the insertion into A2 is shallow or the insertion is incomplete, an increase in electrical resistance or heat generation at the connection between lead A3 and terminal plate A1 due to poor connection between lead A3 and terminal plate A1. Or inconveniences such as incomplete soldering and insufficient connection strength.

  Similarly, the terminal box 1 shown in FIG. 1 has the terminal plates 20,..., 20 with the lead wires 126,..., 126 inserted obliquely through the insertion holes 14,. , 126 are inserted into the insertion holes 14,..., And the leading ends 126b,..., 126b of the lead wires 126. If the lead wire 126,..., 126 and the terminal plate 20,..., 20 are poorly connected unless they are inserted to the position γ separated from the back side (the lower side in FIG. 1), the lead wires 126,. There may be inconveniences such as an increase in electrical resistance or heat generation at the connecting portions of the plates 20, ..., 20 or incomplete soldering resulting in insufficient connection strength. For this reason, automatic insertion inspection is performed by visual inspection by a person or image recognition using an insertion inspection apparatus 220 described later. At this time, the lead wires 126,..., 126 are inserted into the insertion holes 14,. It may be difficult to determine poor insertion.

  In this respect, in the present embodiment, the terminal plates 20,..., 20 are provided with the observation openings 21, 21, 21, 21 so that the lead wires 126 inserted into the insertion holes 14,. , 126, the operator can visually confirm the insertion position at the distal end portions 126b,..., 126b at the observation openings 21,. it can. As a result, it is possible to easily find the poor insertion of the lead wires 126,..., 126 into the insertion holes 14,..., 14 and, as a result, the poor insertion can be reduced, and the lead wires 126,. It becomes possible to suppress poor connection with the terminal boards 20,.

  The terminal plates 20,..., 20 are provided with guide portions 130. The guide unit 130 will be described later.

  4 is a schematic side view showing a manufacturing process of a manufacturing system for manufacturing the solar cell module 116 by connecting the lead wires 126,..., 126 in the solar cell module 116 to the terminal plates 20,. is there. 4A shows a state in which the terminal box 1 is installed on the back surface of the main body of the solar cell module 116, and the lead wires 126,..., 126 are inserted into the insertion holes 14,. It shows the state before doing. FIG. 4B shows a state in which the lead wires 126,..., 126 are inserted through the insertion holes 14,. 4 (c) shows the observation openings 21 of the terminal plates 20,..., 20 with respect to the leading ends 126b,..., 126b of the lead wires 126,. ..., the state in which the position in 21 is inspected is shown. 4 and FIG. 6 and FIG. 7 to be described later, the bypass diode 17 and the like are not shown. Here, the lead wires 126,..., 126, the insertion holes 14,..., And the observation openings 21,..., 21 have four configurations, but may have two configurations or three configurations. There may be five or more of course. In addition, since these four configurations are all the same configuration, in FIG. 4 and FIGS. 6 to 9 described later, one of the four configurations is shown.

[Description of Manufacturing Method of Solar Cell Module]
The manufacturing system of the solar cell module 116 shown in FIG. 4 includes an installation process (A), an insertion process (B), an insertion inspection process (C), a soldering process (D), and a finishing process (E). Including manufacturing method.

  In the installation step (A), the terminal box 1 is installed on the back surface of the main body of the solar cell module 116 by the installation device 300 as shown in FIG. At this time, the lead wires 126,..., 126 in the solar cell module 116 are linearly formed along an oblique direction inclined toward the terminal plates 20,. As the installation apparatus 300, a conventionally known apparatus can be used. Therefore, detailed description of the installation apparatus 300 is omitted here. Moreover, it may replace with the installation apparatus 300 and an operator may install the terminal box 1 in the back surface of the solar cell module 116 main body.

  In the insertion step (B), as shown in FIG. 4B, the lead wires 126,..., 126 are bent toward the terminal plates 20,. , 14 are inserted through the leading ends 126b, ..., 126b of the lead wires 126, ..., 126. In this embodiment, the lead wires 126,..., 126 are inserted into the insertion holes 14,..., 14 through the lead holes 126,. A lead wire insertion device 200 (see FIG. 4A) is used. The insertion device 200 includes an insertion processing device (an example of an insertion device) 210 that inserts the lead wires 126,..., 126 into the insertion holes 14,. ing. The insertion processing device 210 is not limited to this, but a robot arm bends the lead wires 126,..., 126 to the terminal plates 20,..., 20 side and inserts them into the insertion holes 14,. The lead wires 126,..., 126 are bent by the tool toward the terminal plates 20,..., 20 and inserted into the insertion holes 14,. A conventionally known insert processing apparatus 210 can be used. Therefore, detailed description of the insertion processing device 210 is omitted here.

  In the insertion inspection step (C), the positions of the leading ends 126b, ..., 126b of the lead wires 126, ..., 126 inserted through the insertion holes 14, ..., 14 in the observation openings 21, ..., 21 are inspected. . Specifically, as shown in FIG. 4C, when the lead wires 126,..., 126 are inserted through the insertion holes 14,. , 126b is a preset insertion position α (see FIGS. 8A and 10 described later) is a reference position β set in advance of the observation openings 21,..., 21 (FIGS. 8A and 10 described later). If it is located at (see), it is determined to be normal. In this case, the process proceeds to the next soldering step (D). That is, the insertion inspection process (C) is performed before the soldering process (D). Before the soldering step (D), the lead wires 126,..., 126 and the terminal plates 20,..., 20 are free (movable) with each other. In the soldering step (D), the tips 126b, ..., 126b of the lead wires 126, ..., 126 are soldered at the contact portions with the insertion holes 14, ..., 14 of the terminal plates 20, ..., 20 ( Not shown). After performing the soldering, the state of soldering is confirmed using image recognition by an insertion inspection device 220 described later. Further, in the finishing step (E), a filler (not shown) is charged between the box case 11 and the terminal plates 20,..., 20 and filled, and then the upper lid 15 of the terminal box 1 (see FIG. 1). ).

  On the other hand, in the insertion inspection step (C), when the insertion position α is not located at the reference position β, it is determined that the insertion is defective. In this case, the leading ends 126b, ..., 126b of the lead wires 126, ..., 126 are reinserted into the insertion holes 14, ..., 14. When the leading ends 126b, ..., 126b of the lead wires 126, ..., 126b are reinserted into the insertion holes 14, ..., 14, the production line is stopped and the operator is informed that an insertion failure has occurred due to an alarm such as an alarm. . Then, the defective insertion product is automatically taken out from the production line and reinserted by the operator, or the operator reinserts it on the spot. When a defective insertion product is automatically removed from the production line, the production line can continue to operate as it is, and the lead wires 126,. can do.

  The insertion inspection in the insertion inspection step (C) may be a visual inspection by human eyes, but in this example, the insertion inspection device 220 is used.

  The insertion inspection device 220 is provided in the insertion device 200, and is a physical quantity corresponding to the physical properties of the surfaces of the leading ends 126b,..., 126b of the lead wires 126,. A detection unit 225 that detects (here, a difference in contrast ratio and color tone) and a control unit 222 (not shown in FIG. 4 and see FIG. 5 to be described later) that controls the entire insertion inspection apparatus 220 are provided. Here, the detection unit 225 includes an imaging unit 221 such as a camera that detects (specifically, captures) the front ends 126b,..., 126b and the surfaces of the terminal plates 20,. It is configured.

  The imaging unit 221 captures the positions of the leading ends 126b, ..., 126b of the lead wires 126, ..., 126 inserted through the insertion holes 14, ..., 14 in the terminal box 1 in the observation openings 21, ..., 21. It is supposed to be configured. Specifically, the imaging unit 221 is arranged at a position for photographing the inside of the observation openings 21,..., 21 so as to be vertically separated from the terminal plates 20,. It is installed.

  FIG. 5 is a block diagram schematically showing a control configuration of insertion inspection apparatus 220 according to the present embodiment.

  The control unit 222 includes a processing unit 222a such as a CPU and a storage unit 222b including a memory such as a ROM and a RAM. Specifically, in the insertion inspection device 220, the processing unit 222a of the control unit 222 controls various components by loading a control program stored in advance in the ROM of the storage unit 222b onto the RAM of the storage unit 222b and executing it. It is supposed to be.

  The control unit 222 is electrically connected to the imaging unit 221, and has a recognition unit 223 and a determination unit 224 that receives an image signal from the imaging unit 221.

  When the lead wires 126,..., 126 are inserted through the insertion holes 14,..., The recognition portions 223 are inserted into the insertion holes 14,. , 14 is inserted into the leading end portions 126b,..., 126b of the lead wires 126,..., 126 (see FIGS. 8A and 10 to be described later). The determination unit 224 recognizes the insertion position α of the lead wires 126,..., 126 by the recognition unit 223, and as a result, the insertion position α is a reference position β of the observation openings 21,. ) And (see FIG. 10), it is determined to be normal, while when the insertion position α is not located at the reference position β, it is determined that there is a poor insertion.

  Specifically, the control unit 222 performs image processing on the image signal from the imaging unit 221, so that the distal ends of the lead wires 126,..., 126 at the observation openings 21,. The insertion positions α at 126b,..., 126b are recognized. For such image processing, conventionally known image processing can be used, and description thereof is omitted here. In the present embodiment, the insertion inspection device 220 is provided in the insertion device 200, but may be an independent insertion inspection device.

  By the way, when the terminal openings 20,..., 20 are not provided with the observation openings 21,..., 21, even when the lead wires 126,. The insertion inspection may be recognized as normal by the image processing by the control unit 222 of the image signal from the imaging unit 221. However, according to the present embodiment, the terminal plates 20,..., 20 are provided with the observation openings 21,..., 21 so that the lead wires 126,. The lead wire 126 is normal when the position α is located at the reference position β in the observation openings 21,..., 21 and is poor when the insertion position α is not located at the reference position β. ,..., 126 are surely confirmed by the operator whether the degree (degree) of insertion into the insertion holes 14,..., 14 is normal or poorly inserted, or is reliably recognized by the insertion inspection device 220 in the insertion device 200. It is possible to make it.

  6 and 7 are schematic cross-sectional views showing a state in which the lead wires 126, ..., 126 are inserted into the insertion holes 14, ..., 14 of the terminal plates 20, ..., 20 in the terminal box 1 according to the present embodiment. is there. 6A shows a state in which the lead wires 126,..., 126 are normally inserted through the insertion holes 14,. 6 (b), FIG. 6 (c), and FIGS. 7 (a) to 7 (e) show the poor insertion that occurs when the lead wires 126,..., 126 are inserted through the insertion holes 14,. Each example is shown.

  As shown in FIG. 6A, in this embodiment, the lead wires 126,..., 126 are inserted obliquely into the insertion holes 14,. When the lead wires 126,..., 126 are connected to the terminal plates 20,..., 20 by the insertion inspection device 220 in the insertion device 200, the insertion holes 14 of the leading ends 126b,. ,..., 14 can be reliably inspected for normal insertion. On the other hand, as shown in FIG. 6B, the edges 126c, 126c, 126c, 126c at the leading ends 126b,..., 126b of the lead wires 126,. As shown in (c), when the insertion of the leading end portions 126b, ..., 126b of the lead wires 126, ..., 126 into the insertion holes 14, ..., 14 is shallow, the lead wires are inserted by the insertion inspection device 220 in the insertion device 200. 126,..., 126 can be reliably inspected that the leading end portions 126b,..., 126b are poorly inserted into the insertion holes 14,. As shown in FIG. 7A, the lead wires 126,..., 126 are floating with respect to the terminal plates 20,..., 20 or as shown in FIG. 126b is bent to the opposite side (upper side in FIG. 7) from the solar cell module 116 main body side and does not enter the insertion holes 14,..., 14 as shown in FIG. The leading ends 126b, ..., 126b of the lead wires 126, ..., 126 pass over the insertion holes 14, ..., 14 to block the observation openings 21, ..., 21 or as shown in Fig. 7 (d). In addition, the leading end portions 126b,..., 126b of the lead wires 126,..., 126 are bent toward the solar cell module 116 main body in front of the terminal plates 20, ..., 20, or as shown in FIG. Of the lead wires 126,. Even if the end portions 126b, ..., 126b warp before the terminal plates 20, ..., 20, the leading end portions 126b, ..., 126b of the lead wires 126, ..., 126 are inserted by the insertion inspection device 220 in the insertion device 200. It can be reliably inspected that the holes 14,.

  In the present embodiment, the observation openings 21,..., 21 are extended from the lead wires 126... 126 inserted into the insertion holes 14,. Is provided.

  FIG. 8 shows the lead wires 126 through which the observation openings 21,..., 21 are inserted into the insertion holes 14,. It is a figure which shows an example provided on extension of 126. FIG. 8A shows a schematic plan view thereof, and FIG. 8B shows a schematic sectional view thereof.

  As shown in FIG. 8, the reference position β is an insertion direction (in the direction of arrow X in the figure) in which the lead wires 126,..., 126 of the observation openings 21,. In the region between the upstream ends 21a, 21a, 21a, 21a and the downstream ends 21b, 21b, 21b, 21b. This makes it easy for the operator to check whether the degree (degree) of insertion of the lead wires 126,..., 126 into the insertion holes 14,. It is possible to make the insertion inspection device 220 easily recognize.

  Specifically, the insertion holes 14,..., 14 extend along a crossing direction (arrow Y direction in the drawing) that intersects the insertion direction X. Specifically, the insertion holes 14, ..., 14 have a rectangular shape. The length d1 in the longitudinal direction (cross direction Y) of the insertion holes 14,..., 14 is larger than the width (length in the cross direction Y) d2 of the lead wires 126. . The observation openings 21,..., 21 have a circular shape when viewed from a plane. The diameter φ of the observation openings 21,..., 21 is equal to the width d2 of the lead wires 126... 126, or a dimension set in advance from the width d2 from the viewpoint of facilitating recognition by the insertion inspection device 220. It is preferable that it is made only small. In this example, the diameter φ is slightly smaller than the width d2.

  In this embodiment, the insertion position α of the leading ends 126b,..., 126b of the lead wires 126,..., 126 is the position of the mark previously attached to the leading ends 126b,. However, here, the positions of the edges at the leading ends 126b, ..., 126b of the lead wires 126, ..., 126 (specifically, the edges 126c, ... in the insertion direction X of the leading ends 126b, ..., 126b). , 126c). By doing so, it is possible to save the trouble of previously marking the leading ends 126b,..., 126b of the lead wires 126,. In addition, the insertion inspection can be performed without marking the tip portions 126b,..., 126b of the lead wires 126,.

  For example, at least the peripheral portions of the observation openings 21,..., 21 of the terminal plates 20,..., And the at least tips 126 b,. Is a metal material such as aluminum), the brightness or color tone is almost the same. Then, at the recognition part 223 of the insertion inspection device 220, at least the peripheral portions of the observation openings 21,..., 21 of the terminal plates 20,..., And the lead wires 126,. In the overlapped part, it is difficult to distinguish the insertion position α from the reference position β.

  Therefore, from the viewpoint of making it easy to distinguish the tip portions 126b,..., 126b of the lead wires 126,. And the terminal plate 20,..., 20 are the physical properties (for example, optical properties such as the reflectance of light such as visible light and infrared light) and surface properties at the tip end portions 126b,. Structural characteristics such as uneven shape are different from each other. Specifically, the leading ends 126b,..., 126b of the lead wires 126,..., 126 and the terminal boards 20,.

  In the present embodiment, the leading ends 126b,..., 126b of the lead wires 126,..., 126 and the terminal plates 20,. The detection values of the detection unit 225 for detecting corresponding physical quantities (here, contrast ratio and color tone difference) have physical properties with different physical quantities. By doing so, it becomes possible to automatically distinguish the tip portions 126b,..., 126b of the lead wires 126,.

  As a mode in which the physical properties of the tip portions 126b,..., 126b and the terminal plates 20,... 20 are different from each other, the tip portions 126b,. , 20, and the terminal board 20 by adding predetermined processing even if the lightness, color tone, contrast, and the like are different from each other, and even if the apparent brightness, color tone, contrast, etc. are the same. .., 20 can be exemplified by different physical quantities such as contrast ratio and color tone. For example, when one of the tip portions 126b,..., 126b and the terminal plates 20,..., 20 has a higher reflectance of predetermined light having a peak in a specific wavelength region than the other, the detection unit 225 is connected to the imaging unit 221. , 126 b and the terminal plate 20,..., 20 are detected through the optical filter that transmits light in a specific wavelength region, and a physical quantity such as a contrast ratio is detected by the recognition unit 223. It may be configured to detect the difference, or one of the tip portions 126b,..., 126b and the terminal plates 20,..., 20 has a predetermined light (for example, infrared light) having a peak in a specific wavelength region than the other. , 126b and the terminal plates 20,..., 20 are irradiated with predetermined light (for example, infrared light), and the imaging unit 221 causes the distal end portion to be detected. 26b,..., 126b and the reflected light (for example, infrared light) reflected by the terminal plates 20,..., 20 may be detected, and the recognition unit 223 may detect a difference in physical quantity such as a contrast ratio. .

  Specifically, if the terminal plates 20,..., 20 are gold-based materials such as brass and the lead wires 126,..., 126 are silver-based materials such as aluminum, the terminal plates 20,. Since the lead wires 126,..., 126 have different color tones and are easy to distinguish, the recognition unit 223 can facilitate image recognition. Note that even if the terminal plates 20,..., And the lead wires 126,..., 126 are made of the same material, the surface of at least one (for example, the terminal plates 20,. By applying different material plating, the surface state can be made different (specifically, scattered light from the surface can be made different, so that the brightness or color tone can be made different, and the aforementioned materials are made different from each other. Similar to the configuration, the recognition unit 223 can facilitate image recognition.

  In the present embodiment, the terminal plates 20,..., 20 are guide portions 130 that guide the lead wires 126,..., 126 inserted through the insertion holes 14,. , 130, 130, 130 (see FIG. 8B).

  As described above, since the terminal plates 20,..., 20 are provided with the guide portions 130,..., 130, the leading ends 126b,. 21 can be surely guided, thereby improving the inspection accuracy of the insertion inspection by the insertion inspection device 220.

  Specifically, the guide portions 130,..., 130 are provided on the terminal plates 20,..., 20 and are for observation from the upstream ends 14a, 14a, 14a, 14a of the insertion holes 14,. .., 21 is inclined obliquely toward a direction vertically separated from the inside of the openings 21,..., 21 (below the observation openings 21,..., 21 in FIG. 8B). Specifically, the guide portions 130,..., 130 are formed integrally with the terminal plates 20,.

  Here, the guide portions 130,..., 130 are individually provided for each of the lead wires 126,..., 126, but are common to the lead wires 126,. A single unit formed integrally). Further, the guide portions 130,..., 130 may be provided in the box case 11.

  FIG. 9 is a schematic cross-sectional view showing an example in which the guide portions 130,... 130 are provided in the box case 11.

  As shown in FIG. 9, when the guide portions 130,..., 130 are provided in the box case 11 (specifically, the case body 12), the upstream end 14 a of the insertion holes 14,. ,..., 14a (downward in FIG. 9) from the observation openings 21,..., 21 to the direction perpendicular to the inside of the observation openings 21,. And may be inclined obliquely. Specifically, the guide portions 130,... 130 may be formed integrally with the case main body 12.

  By the way, in the present embodiment, the observation openings 21,..., 21 are separated from the insertion holes 14,. In this case, if the lead wires 126,..., 126 are not inserted through the insertion holes 14,..., 14 (that is, the leading end portions 126b of the lead wires 126,. 126b does not reach the observation openings 21,..., 21 (see FIG. 6C), the observation openings 21,..., 21 separated from the insertion holes 14,. 126,... 126b does not represent the shape, so how much lead wires 126,..., 126 are inserted, the leading ends 126b of the lead wires 126,. 126b, see insertion position α (see FIG. 8A). ) Do is hard to understand reaches the reference position β reference (FIG. 8 (a)).

  From this point of view, in the present embodiment, in the terminal plates 20,..., The observation openings 21,..., 21 are communicated with the insertion holes 14,. Is preferred.

  FIG. 10 is a schematic plan view showing an example in which the observation openings 21,..., 21 communicate with the insertion holes 14,. .

  In the terminal box 1 shown in FIG. 10, the observation openings 21,..., 21 communicate with the insertion holes 14,. The reference position β is set to a first reference position β1 set downstream from the upstream end 21a in the insertion direction X of the observation openings 21,..., 21 and a second set reference set upstream from the downstream end 21b. It can be a region between the position β2. This makes it easier for the operator to visually confirm the positions of the leading ends 126b, ..., 126b of the lead wires 126, ..., 126 in the observation openings 21, ..., 21, or The insertion inspection device 220 in the insertion device 200 can be easily recognized. Even if the lead wires 126,..., 126 are shallowly inserted into the insertion holes 14,..., 14 (see FIG. 6C), the observation openings 21,. The leading ends 126b,..., 126b of the lead wires 126,..., 126 can be easily shown in the figure 21, so that the lead wires 126,. , 126b at the leading end portions 126b,..., 126b (specifically, the positions of the edges 126c,..., 126c) reach the reference position β (specifically, between β1 and β2). It becomes possible. It should be noted that the first reference position β1 and the second reference position β2 of the terminal plates 20,.

  Specifically, in the terminal box 1 shown in FIG. 10, the insertion holes 14,..., 14 have a rectangular shape extending along the intersecting direction Y. The length d3 in the longitudinal direction (cross direction Y) of the insertion holes 14,..., 14 is larger than the width (length in the cross direction Y) d4 of the lead wires 126. . The observation openings 21,..., 21 have a rectangular shape extending along the insertion direction X. The width d5 of the observation openings 21,..., 21 is equal to the width d4 of the lead wires 126... 126, or a dimension set in advance from the width d4 from the viewpoint of making the insertion inspection device 220 easily recognize. It is preferable that it is made only small. In this example, the width d2 is about half of the width d4.

  Specifically, the observation openings 21,..., 21 extending along the insertion direction X and the insertion holes 14,..., 14 extending along the intersecting direction Y may have an L shape. However, the example shown in FIG. 10 has a T-shape. By doing so, the observation openings 21,..., 21 extending along the insertion direction X can be provided at the center of the insertion direction 14,. . Thereby, even if the lead wires 126,..., 126 are offset to one side in the cross direction Y with respect to the insertion holes 14,..., 14, the leading ends 126b,. .., 21 can be easily shown from the observation openings 21,..., 21 extending along the direction X, and the insertion positions α (specifically, the leading ends 126 b,..., 126 b of the lead wires 126,. The positions of the edges 126c,..., 126c) may be surely confirmed by the operator visually at the observation openings 21,..., 21 or may be reliably recognized by the insertion inspection device 220 and the insertion device 200. it can.

  In addition, although the terminal box 1 which concerns on this Embodiment was applied to the thin film solar cell module here, you may apply to a crystalline solar cell module.

  FIG. 14 is a diagram illustrating an example in which the terminal box 1 according to the present embodiment is applied to the crystalline solar cell module 30. FIG. 14A shows a schematic cross-sectional view thereof, and FIG. 14B shows an exploded perspective view thereof.

  A crystalline solar cell module 30 shown in FIG. 14 is formed of single crystal silicon or polycrystalline silicon on a transparent plate 31 made of a transparent material such as glass or plastic via a transparent adhesive layer 32 made of a resin material such as EVA. A plurality of solar cells 34,... Made of a semiconductor material such as silicon, amorphous, compound semiconductor, etc., and connected to each other by the wiring member 33 are stacked, and a resin such as EVA is provided on the back side of the solar cells 34,. A back film (back surface moisture-proof layer) 36 in which a metal layer such as aluminum is sandwiched between resin materials such as PET (polyethylene terephthalate) resin and PVF (polyvinyl fluoride) resin is laminated through an adhesive layer 35 made of the material. These laminates were bonded (thermocompression bonding) at a predetermined pressure (for example, 1 atm) and a predetermined temperature (for example, 100 ° C.). Than is.

  The crystal solar cell module 30 is provided with openings 37 and 38 in the adhesive layer 35 on the back side and the back film (back surface moisture-proof layer) 36, respectively, and the terminal box 1 is attached to the openings 37 and 38, The lead wire 126 connected to the wiring member 33 is taken out from the openings 37 and 38, and the lead wire 126 taken out from the openings 37 and 38 is connected to the terminal plate 20 in the terminal box 1 (FIG. 14A). And an external circuit (not shown) via an output cable 39 (see FIG. 14B).

DESCRIPTION OF SYMBOLS 1 Terminal box 11 Box case 12 Case main body 13 Terminal board fixing | fixed part 14 Insertion hole 14a Upstream side end 20 (through hole) Terminal board 21 Observation opening 21a Upstream side end 21b (Observation opening) Downstream end 116 of solar cell module 126 lead wire 126a base end portion 126b distal end portion 126c edge 130 guide portion 200 insertion device 210 insertion processing device (an example of an insertion device)
220 Insertion inspection device 221 Imaging unit 222 Control unit 223 Recognition unit 224 Determination unit 225 Detection unit 300 Installation device X Insertion direction Y Cross direction α Insertion position β Reference position β1 First reference position β2 Second reference position

In order to solve the above-described problems, the present invention provides a terminal box for a solar cell module, a lead wire insertion inspection method, an insertion inspection device, a solar cell module manufacturing method, and a manufacturing system according to the following first and second embodiments. I will provide a.

( 1-1 ) Terminal box for a solar cell module according to the first aspect A terminal box having a terminal plate having an insertion hole through which a lead wire drawn out from a solar cell module is inserted, wherein the terminal plate An observation opening for observing a distal end portion of the lead wire inserted through the hole, and the observation opening is formed on the extension of the insertion direction of the lead wire into the insertion hole. Is a terminal box for a solar cell module, wherein the terminal box is spaced apart .
(1-2) Terminal box for the solar cell module of the second aspect
A terminal box having a terminal plate having an insertion hole through which a lead wire drawn out from a solar cell module is inserted, wherein the terminal plate is for observing a distal end portion of the lead wire inserted through the insertion hole. An observation opening is provided, and the observation opening is provided in communication with the insertion hole on the extension of the insertion direction of the lead wire into the insertion hole, and intersects the insertion direction of the lead wire. A terminal box for a solar cell module, wherein a width of the observation opening in a direction is equal to or less than a width of the lead wire.

(2) Lead wire insertion inspection method An insertion inspection method for performing an insertion inspection of the lead wire inserted into the insertion hole in the terminal box for the solar cell module according to the first aspect or the second aspect of the present invention. When the lead wire can be confirmed through the observation opening, it is determined that the lead wire is normally inserted, and when the lead wire cannot be confirmed through the observation opening, it is determined that the insertion is poor. Lead wire insertion inspection method.

(3) Lead wire insertion inspection device In the observation opening of the tip of the lead wire inserted into the insertion hole in the terminal box for the solar cell module according to the first aspect or the second aspect of the present invention. A lead wire insertion inspection device that performs an insertion inspection to inspect the position of the lead wire when the lead wire is inserted through the insertion hole, and is inserted into the insertion hole in the observation opening of the terminal plate. As a result of recognizing the insertion position of the lead wire by the recognition unit, the insertion position is preset in the observation opening. A determination unit that determines that the insertion position is normal when the insertion position is not at the reference position, while determining that the insertion position is defective when the insertion position is not at the reference position. Lead wire insertion inspection device.

(4) Manufacturing method of solar cell module
An installation step of installing the terminal box for the solar cell module according to the first aspect or the second aspect of the present invention in the solar cell module, and insertion for inserting the lead wire into the insertion hole of the terminal plate in the terminal box. A step of determining that the lead wire is normally inserted when the lead wire can be confirmed through the observation opening, and a step of determining a poor insertion when the lead wire cannot be confirmed through the observation opening. The manufacturing method of the solar cell module characterized by including.

(5) Solar cell module manufacturing system
The installation apparatus which installs the terminal box for solar cell modules of the 1st aspect or the 2nd aspect which concerns on the said this invention in a solar cell module, The insertion which penetrates the said lead wire in the said insertion hole of the said terminal board in the said terminal box And an insertion inspection device that performs an insertion inspection for inspecting the position of the tip portion of the lead wire inserted through the insertion hole in the observation opening, and the insertion inspection device is provided in the insertion hole. A recognition unit for recognizing a preset insertion position at the distal end portion of the lead wire inserted through the insertion hole in the observation opening of the terminal plate when the lead wire is inserted; As a result of recognizing the insertion position of the lead wire, it is determined that the insertion position is normal when the insertion position is located at a preset reference position of the observation opening. , Manufacturing system of the solar cell module, characterized in that the insertion position is a a determination unit which is inserted through defect if not located in the reference position.

According to the terminal box for the solar cell module of the first aspect and the second aspect according to the present invention, the tip end portion of the lead wire inserted through the insertion hole is visually confirmed by an operator at the observation opening. Or, it can be recognized by the insertion inspection device and the insertion device. Thereby, it is possible to easily find a poor insertion of the lead wire into the insertion hole.
Moreover, in the terminal box for the solar cell module according to the first aspect, the observation opening is provided on the extension of the lead wire in the insertion direction so as to be separated from the insertion hole. It is possible to make it easier for an operator to check whether the degree (degree) of insertion of the lead wire into the insertion hole is normal or defective, or to make it easy to recognize by the insertion inspection device and the insertion device. It becomes.
In the terminal box for a solar cell module according to the second aspect, the observation opening is provided in communication with the insertion hole on an extension of the insertion direction of the lead wire, and the insertion of the lead wire The width of the observation opening in the direction intersecting the direction is equal to or smaller than the width of the lead wire, so that the operator can determine where the tip of the lead wire is in the observation opening. It can be easily confirmed by visual observation, or can be easily recognized by the insertion inspection device and the insertion device.

In the terminal box for the solar cell module according to the first aspect, the reference position is an upstream end and a downstream end in the insertion direction in which the lead wire of the observation opening is inserted into the insertion hole. It is preferable that it is set as the area | region between.

Further, in the terminal box for a solar cell module according to the second aspect, the reference position is preset in advance from the upstream end in the insertion direction in which the lead wire of the observation opening is inserted into the insertion hole. The first reference position is preferably a region between the downstream end and the preset second reference position on the upstream side.

One end portions of the pair of positive electrode lead wires 122 and 122 are connected to the center positions of the pair of positive electrode current collector portions 120 and 120, respectively. Further, the other end portions of the pair of positive lead wires 122 and 122 are positioned at substantially the center of the main body of the solar cell module 116, and are bent up vertically with respect to the surface of the main body of the solar cell module 116. The output lead wires 126 and 126 are provided. Similarly, one end portions of the pair of negative electrode lead wires 123 and 123 are connected to the center position of the pair of negative electrode current collectors 121, respectively. The other end of the negative electrode lead wire 123, 123 of a pair are located substantially at the center of the solar cell module 116 body, and is bent perpendicularly respective to the plane of the solar cell module 116 body Standing The output lead wires 126 and 126 are raised.

Through inspection in the insertion inspection step (C) may be by that visual inspection to the human eye, in this example, using an insertion inspection device 220.

Claims (11)

A terminal box comprising a terminal plate having an insertion hole for inserting a lead wire drawn from a solar cell module,
The terminal box for a solar cell module, wherein the terminal plate has an observation opening for observing a tip end portion of the lead wire inserted through the insertion hole. The terminal box according to claim 1,
The solar cell module terminal box, wherein the observation opening is provided on an extension of the lead wire inserted into the insertion hole so as to be separated from or communicated with the insertion hole. The terminal box according to claim 1 or 2,
A terminal box for a solar cell module, comprising a guide portion for guiding the lead wire inserted through the insertion hole toward the observation opening. The terminal box according to any one of claims 1 to 3,
A terminal for a solar cell module, wherein at least the tip portion of the lead wire and at least the peripheral portion of the terminal opening of the terminal plate have different physical properties at the tip portion and the peripheral portion. box. The terminal box according to claim 4,
A terminal box for a solar cell module, wherein at least the tip portion of the lead wire and at least the peripheral portion of the observation opening of the terminal plate have different brightness or color tone. An insertion inspection method for performing an insertion inspection of the lead wire inserted into the insertion hole in the terminal box for a solar cell module according to claim 1,
When the lead wire can be confirmed through the observation opening, it is determined that the lead wire is normally inserted,
A lead wire insertion inspection method, wherein when the lead wire cannot be confirmed through the observation opening, it is determined that the insertion is poor. The insertion inspection method according to claim 6,
A reference position is set in advance between the upstream end and the downstream end in the insertion direction of the lead wire of the observation opening,
When the lead wire is inserted through the insertion hole, the lead wire is determined to be normal when the tip portion is located at the reference position, while the tip portion is located at the reference position. A lead wire insertion inspection method, characterized in that it is determined that the insertion failure is not found. A lead wire insertion inspection device that performs an insertion inspection for inspecting a position of the tip portion of the lead wire inserted into the insertion hole in the terminal box for a solar cell module according to claim 1 in the observation opening. There,
A recognition unit for recognizing a preset insertion position at the tip of the lead wire inserted through the insertion hole in the observation opening of the terminal plate when the lead wire is inserted through the insertion hole; ,
As a result of recognizing the insertion position of the lead wire in the recognition unit, the insertion position is determined to be normal when the insertion position is located at a preset reference position of the observation opening, while the insertion position A lead wire insertion inspection apparatus, comprising: a determination unit that determines that the insertion is defective when the position is not at the reference position. The lead wire insertion inspection device according to claim 8,
A lead wire penetration inspection device comprising: a detection unit for detecting a physical quantity corresponding to a physical property in at least the distal end portion of the lead wire and at least a peripheral portion of the observation opening of the terminal plate. . A terminal plate having an insertion hole through which the lead wire drawn out from the solar cell module is inserted, and the terminal plate has an observation opening for observing a tip portion of the lead wire inserted through the insertion hole; An installation process for installing the terminal box on the solar cell module;
An insertion step of inserting the lead wire into the insertion hole of the terminal plate in the terminal box;
A step of determining that the lead wire is normally inserted when the lead wire can be confirmed through the observation opening, and determining that the lead wire cannot be confirmed through the observation opening. The manufacturing method of the solar cell module characterized by these. A terminal plate having an insertion hole through which the lead wire drawn out from the solar cell module is inserted, and the terminal plate has an observation opening for observing a tip portion of the lead wire inserted through the insertion hole; An installation device for installing the terminal box on the solar cell module;
An insertion device for inserting the lead wire into the insertion hole of the terminal plate in the terminal box;
An insertion inspection device that performs an insertion inspection for inspecting the position of the distal end portion of the lead wire inserted through the insertion hole in the observation opening, and
The insertion inspection device has a preset insertion position at the tip end portion of the lead wire inserted through the insertion hole in the observation opening of the terminal plate when the lead wire is inserted through the insertion hole. And when the insertion position is located at a preset reference position of the observation opening as a result of recognizing the insertion position of the lead wire by the recognition section. On the other hand, the solar cell module manufacturing system includes a determination unit that determines that the insertion position is defective when the insertion position is not located at the reference position.

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