WO2019171966A1 - 集光型太陽光発電モジュールの製造方法、及び搬送治具 - Google Patents
集光型太陽光発電モジュールの製造方法、及び搬送治具 Download PDFInfo
- Publication number
- WO2019171966A1 WO2019171966A1 PCT/JP2019/006479 JP2019006479W WO2019171966A1 WO 2019171966 A1 WO2019171966 A1 WO 2019171966A1 JP 2019006479 W JP2019006479 W JP 2019006479W WO 2019171966 A1 WO2019171966 A1 WO 2019171966A1
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- Prior art keywords
- bottom plate
- frame
- power generation
- housing
- jig
- Prior art date
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- 238000000034 method Methods 0.000 title claims abstract description 37
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 238000010248 power generation Methods 0.000 claims abstract description 66
- 239000011347 resin Substances 0.000 claims abstract description 20
- 229920005989 resin Polymers 0.000 claims abstract description 20
- 230000002093 peripheral effect Effects 0.000 claims abstract description 18
- 229910052751 metal Inorganic materials 0.000 claims abstract description 9
- 239000002184 metal Substances 0.000 claims abstract description 9
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- 238000010079 rubber tapping Methods 0.000 claims description 6
- 238000007789 sealing Methods 0.000 abstract 1
- 238000007689 inspection Methods 0.000 description 11
- 238000005452 bending Methods 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
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- 229910000838 Al alloy Inorganic materials 0.000 description 3
- 239000011521 glass Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- -1 Poly Butylene Terephthalate Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
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- 230000017525 heat dissipation Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/054—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
- H01L31/0543—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means comprising light concentrating means of the refractive type, e.g. lenses
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
- H01L31/1876—Particular processes or apparatus for batch treatment of the devices
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S20/00—Supporting structures for PV modules
- H02S20/30—Supporting structures being movable or adjustable, e.g. for angle adjustment
- H02S20/32—Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S30/00—Structural details of PV modules other than those related to light conversion
- H02S30/10—Frame structures
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
- Y02E10/52—PV systems with concentrators
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- the present invention relates to a method for manufacturing a concentrating solar power generation module and a conveying jig.
- This application claims priority based on Japanese Patent Application No. 2018-038644 filed on Mar. 5, 2018, and incorporates all the content described in the above Japanese application.
- a unit that forms a basic unit of an optical system includes, for example, a primary condensing lens that is a convex lens, a secondary condensing lens that is a spherical lens, and a power generation element.
- a primary condensing lens that is a convex lens
- a secondary condensing lens that is a spherical lens
- a power generation element a solar battery cell using a compound semiconductor element with high power generation efficiency is used. Sunlight is condensed by the primary condenser lens and incident on the secondary condenser lens, and is further condensed by the secondary condenser lens and reaches the power generation element.
- a large number of the concentrating solar power generation units are arranged in a matrix to form a concentrating solar power generation module, and a large number of the modules are arranged in a matrix to form a concentrating solar power generation panel.
- the concentrating solar power generation panel constitutes a concentrating solar power generation device together with a driving device for causing the panel to follow the sun.
- a large number of power generation elements are mounted on the surface of the bottom plate of the housing.
- a thin metal plate for example, aluminum or the like
- the frame which forms the outer frame of the housing supports the outer edge portion of the bottom plate.
- a resin material may be used for this frame in order to reduce manufacturing costs.
- a method for manufacturing a solar power generation module includes a plurality of power generation elements in which sunlight is collected by a plurality of condensing lenses, and a housing that houses the plurality of power generation elements.
- Manufacture of a concentrating solar power generation module including a resin frame and a metal bottom plate that closes the bottom opening of the frame and has the plurality of power generation elements disposed on the inner surface
- the second step includes the supporting portion and an outer side of the bottom plate. It said housing in a state where the peripheral edge is abutted is fixed to the transport jig.
- a transport jig is a transport jig for transporting a housing for a photovoltaic power generation module that houses a plurality of power generation elements in which sunlight is collected by a plurality of condenser lenses.
- the housing includes a resin frame, and a metal bottom plate that closes a bottom opening of the frame and has the plurality of power generating elements disposed on an inner surface thereof, and an inner surface of the bottom plate
- the bottom plate is fixed to the frame body in a state where the peripheral edge of the frame body is in contact with the bottom end surface of the frame body, is formed corresponding to the bottom end surface of the frame body, and is in contact with the peripheral edge of the outer surface of the bottom plate
- a support portion that supports the housing from below is provided in a state, and the housing is transported in a state in which the housing is laid horizontally.
- FIG. 1 is a perspective view showing an example of a concentrating solar power generation device.
- FIG. 2 is a perspective view showing an example of the configuration of the module.
- FIG. 3 is a diagram illustrating an assembly process of the photovoltaic power generation module.
- FIG. 4 is an exploded perspective view showing the frame, the bottom plate, and the conveying jig 35.
- FIG. 5 is a perspective view showing the conveying jig.
- FIG. 6 is a diagram illustrating a state in which the pad of the support portion and the bottom plate of the housing are in contact with each other.
- FIG. 7 is a partial cross-sectional view of the conveying jig to which the fixing member is fixed.
- FIG. 8 is an exploded perspective view showing the frame 30, the bottom plate 31, and the conveying jig 35, and shows the conveying jig 35 according to another embodiment.
- FIG. 9 is an enlarged perspective view of the clip 65.
- the frame constituting the casing of the concentrating solar power generation module is formed of a resin material
- the rigidity of the frame is relatively low because the frame is a resin material.
- the casing may be bent during conveyance between processes. Such bending that occurs in the housing during assembly work or transportation affects product errors and performance as a module, and is preferably suppressed as much as possible.
- the present disclosure has been made in view of such circumstances, and an object thereof is to provide a technique capable of suppressing the bending that occurs in the housing during assembly work or transportation.
- a method for manufacturing a photovoltaic power generation module includes a plurality of power generation elements in which sunlight is collected by a plurality of condensing lenses, and a housing that houses the plurality of power generation elements.
- the housing includes a resin frame and a metal bottom plate that closes the bottom opening of the frame and has the plurality of power generation elements disposed on the inner surface thereof.
- a method for manufacturing a module comprising: a first step of obtaining the casing by bringing a peripheral edge of an inner surface of the bottom plate into contact with a bottom end surface of the frame and fixing the bottom plate to the frame; and A second step of fixing the housing to a transport jig that transports the body in a horizontally laid state, wherein the transport jig is formed corresponding to a bottom end surface of the frame body.
- the second step includes the supporting portion and the bottom plate. It said housing being in contact with the peripheral side surface is fixed to the transfer jig.
- the housing is transported and cured in a state in which the support portion formed corresponding to the bottom end surface of the frame body and the peripheral edge of the outer surface of the bottom plate are in contact with each other. Since it fixes to a tool, a housing
- casing can be supported by a conveyance jig so that a resin-made frame may not bend. Therefore, by performing the subsequent work process on the housing fixed to the transport jig, it is possible to suppress the bending that occurs in the housing during the assembly work or during transport between processes.
- the first step includes bonding and fixing the bottom plate and the frame
- the second step includes the support between the bottom end surface of the frame and the support.
- the casing is fixed to the conveying jig by a fixing member that sandwiches the portion and the bottom plate.
- the bottom plate and the frame can be brought into close contact with each other by pressing the support portion toward the bottom plate while preventing the base plate and the frame from relatively moving by the fixing member. As a result, it is possible to appropriately bond the bottom plate and the frame body, and to proceed to the next work process while bonding the bottom plate and the frame body.
- the said fixing member is a tapping screw which penetrates the said support part and the said baseplate, and is screwed together in the hole provided in the bottom end surface of the said frame. It is preferable.
- the frame is made of resin, if a hole is provided in the frame, the fixing member can be screwed into the hole, and the housing can be easily fixed to the conveying jig. . Further, the fixing member can be screwed into the hole from the outside of the housing, and the housing can be easily fixed and removed from the transport jig. Furthermore, the conveying jig and the fixing member removed from the housing can be reused.
- an output cord connected to the plurality of power generation elements is provided on an outer surface of the bottom plate, and the second step includes the output cord. Even if the output cord is allowed to escape to the outside of the support part from a gap provided in the support part in order to escape to the outside of the support part, the housing is fixed to the transport jig. Good. In this case, output inspection as a photovoltaic power generation module can be performed in a state where the housing is fixed to the conveyance jig.
- a cord holding portion for holding the output cord is provided on the outer surface of the bottom plate corresponding to the gap portion
- the second step includes the step of In order to allow the output cord to escape to the outside of the support portion, the output cord is allowed to escape to the outside of the support portion from a gap provided in the support portion, and further, the output cord is moved outside the support portion by the cord holding portion. It may be held in a state where it is released and the casing is fixed to the transport jig. In this case, it is easy to fix the housing to the conveying jig in a state where the output cord is escaped to the outside of the support portion.
- the conveyance jig which is other embodiment is a conveyance jig for conveying the housing
- the housing includes a resin frame, and a metal bottom plate that closes a bottom opening of the frame and has the plurality of power generation elements disposed on an inner surface thereof, and the bottom plate The bottom plate is fixed to the frame with the peripheral edge of the inner surface being in contact with the bottom end surface of the frame, and is formed corresponding to the bottom end surface of the frame.
- a support portion that supports the housing from below is provided in contact with the housing, and the housing is transported in a state in which the housing is laid horizontally.
- the transport jig having the above-described configuration, it is possible to suppress bending that occurs in the housing during assembly work or during transport between processes by advancing to the subsequent work process while the housing is fixed to the transport jig. it can.
- the conveyance jig may further include a handle for handling the conveyance jig.
- the conveying jig can be moved without directly touching the bottom plate and the frame that are bonded to each other.
- the conveyance jig further includes a ball roller that contacts the floor surface on which the conveyance jig is placed and allows the conveyance jig to travel freely. In this case, it is easy to transport the housing fixed to the transport jig.
- the conveyance jig further includes a rectangular frame-shaped main body portion on which the support portion is provided, and a bottom plate holding portion that is provided across the frame of the main body portion and holds the bottom plate from below. Preferably it is.
- the bottom plate is held by the holding member so as not to bend downward while the casing is fixed to the transfer jig and transferred to each process. Thereby, workability
- FIG. 1 is a perspective view showing an example of a concentrating solar power generation device.
- the solar power generation device 100 includes an array (the entire solar power generation panel) 1 having a shape that is continuous on the upper side and divided into left and right on the lower side, and a support device 2.
- the array 1 is configured by aligning a plurality of modules 1M.
- the support device 2 includes a support column 21, a base 22, a biaxial drive unit 23, and a horizontal shaft 24 serving as a drive shaft.
- the column 21 has a lower end fixed to the foundation 22 and a biaxial drive unit 23 at the upper end.
- the support column 21 is parallel to the vertical direction
- the horizontal axis 24 is parallel to the horizontal direction.
- the biaxial drive unit 23 can rotate the horizontal axis 24 in two directions, that is, an azimuth angle (an angle with the column 21 as a central axis) and an elevation angle (an angle with the horizontal axis 24 as a central axis).
- FIG. 1 shows the support device 2 that supports the array 1 with one support column 21, the configuration of the support device 2 is not limited to this. In short, any support device that can support the array 1 so as to be movable in two axes (azimuth angle and elevation angle) may be used.
- FIG. 2 is a perspective view showing an example of the configuration of the module 1M.
- the module 1M includes, as an external physical form, for example, a metal-made rectangular flat-bottomed container-like housing 11 and a light collecting portion 12 attached thereon like a lid. ing.
- the condensing unit 12 is configured, for example, by attaching a resin condensing lens 12f to the back surface of one transparent glass plate 12a.
- each of the illustrated square (10 ⁇ 14) sections is a Fresnel lens as the condensing lens 12f, and can converge sunlight to a focal position.
- the housing 11 includes a resin frame 30 and a bottom plate 31 that closes the bottom opening 30a of the frame.
- the frame body 30 is formed in a rectangular cylinder shape using a resin material such as PBT (Poly Butylene Terephthalate) resin filled with glass fibers.
- the bottom plate 31 is a plate-like member formed of, for example, an aluminum alloy.
- a flexible printed wiring board 13 is disposed on the inner surface 31 a of the bottom plate 31.
- a cell package 14 that holds cells (power generation elements) is mounted at a predetermined position on the flexible printed wiring board 13.
- 2 is an enlarged view of the light receiving unit R.
- a secondary lens 15 is provided on the cell package 14, and a protective plate 16 is provided around the secondary lens.
- the secondary lens 15 is, for example, a ball lens.
- the protection plate 16 is, for example, an annular metal body, and a commercially available washer can be used.
- the protective plate 16 prevents the convergent light from thermally damaging the periphery of the cell when the convergent light of the sunlight is removed from the secondary lens 15. Further, even when the convergent light is entirely contained in the secondary lens 15, the protective plate 16 receives scattered light in the housing 11 and reflects it.
- the light receiving parts R are provided in the same number and at the same intervals corresponding to each of the condenser lenses 12f. Therefore, sunlight is condensed on each light receiving part R by the condenser lens 12f.
- a shielding plate 17 is provided between the light receiving unit R and the light collecting unit 12. In the shielding plate 17, openings 17a corresponding to one condenser lens 12f are formed at positions corresponding to the individual condenser lenses 12f. Sunlight converged by the condenser lens 12f passes through the opening 17a. When the incident direction of sunlight and the optical axis of the light receiving portion R are greatly deviated, the light to be condensed at the deviated position hits the shielding plate 17.
- FIG. 3 is a diagram illustrating an example of an assembly process of the above-described photovoltaic power generation module 1M.
- the flexible printed wiring board 13 is disposed on the inner side surface 31a of the bottom plate 31 (step S1).
- the casing 11 is assembled (step S2), and the obtained casing 11 is attached and fixed to the transport jig (step S3).
- FIG. 4 is an exploded perspective view showing the frame 30, the bottom plate 31, and the conveying jig 35.
- the bottom plate 31 is shown upside down so that the outer side surface 31 b of the frame body 30 faces upward in the drawing.
- the assembly of the housing 11 in step S ⁇ b> 2 is performed by bringing the peripheral edge of the inner surface 31 a of the bottom plate 31 into contact with the bottom end surface 30 b of the frame body 30 and fixing the bottom plate 31 to the frame body 30.
- a caulking agent as an adhesive to the peripheral edge of the inner side surface 31a and the bottom end surface 30b of the bottom plate 31, the peripheral edge of the inner side surface 31a of the bottom plate 31 and the bottom end surface 30b are brought into contact with each other.
- a caulking agent hardens
- a projection 30c is formed on the bottom end surface 30b of the frame 30, and a notch 31c is formed on the bottom plate 31 at a position corresponding to the projection 30c.
- the protrusion 30c and the notch 31c perform positioning between the frame 30 and the bottom plate 31.
- the protrusion 30c and the notch 31c are formed asymmetrically left and right, and can be combined only when the orientation of the frame 30 and the orientation of the bottom plate 31 are in a correct relationship. Accordingly, the protrusion 30c and the notch 31c guide the frame body 30 and the bottom plate 31 so that the directions are combined in a correct relationship.
- the protrusion 30c and the notch 31c are exemplarily shown at one place, but the protrusion 30c and the notch 31c are provided at a plurality of places.
- FIG. 5 is a perspective view showing the conveying jig 35.
- the transport jig 35 is a jig for transporting the housing 11 mounted on the upper side thereof with the housing 11 lying horizontally.
- the conveying jig 35 includes a rectangular frame 36 (main body portion), a support portion 37 provided on the upper surface 36 a of the frame 36, and a plurality of ball rollers 38 provided on the lower surface 36 b of the frame 36.
- the frame 36 is configured in a frame shape by assembling rods made of an aluminum alloy having a C-shaped cross section into a rectangular shape.
- the dimension on the short side of the frame 36 is slightly larger than the dimension on the short side of the frame 30, and the dimension on the long side of the frame 36 is slightly smaller than the dimension on the long side of the frame 30.
- the frame 36 is provided with a handle (handle) 35a for handling the conveying jig 35 to which the housing 11 is fixed.
- the support portion 37 is a member that is formed over substantially the entire circumference of the frame 36 and supports the housing 11 from below.
- the support portion 37 includes a bracket 40 fixed to the upper surface 36 a of the frame 36, and a pad 41 fixed to the upper surface of the bracket 40 and in contact with the bottom plate 31 of the housing 11.
- the bracket 40 is a plate-like member made of an aluminum alloy.
- a portion of the bracket 40 provided on the short side of the frame 36 extends along the short side and is provided so as to protrude outward from the outer surface of the frame 36.
- a portion of the bracket 40 provided on the long side of the frame 36 extends along the long side and is provided so as to protrude inward from the inner side surface of the frame 36.
- the pad 41 is a member made of resin, and is fixed to the upper surface of the end portion of the bracket 40. Therefore, the portion of the pad 41 provided on the short side of the frame 36 is disposed outside the outer surface of the frame 36. Further, the portion of the pad 41 provided on the long side of the frame 36 is disposed on the inner side of the inner side surface of the frame 36.
- the housing 11 is fixed to the transport jig 35 with the bottom plate 31 of the housing 11 in contact with the upper surface of the pad 41.
- the pad 41 is made of resin, it is possible to prevent the bottom plate 31 from being damaged when the pad 41 contacts the bottom plate 31.
- the plurality of ball rollers 38 are grounded to the floor surface and freely move the conveying jig 35. This facilitates the conveyance of the casing 11 fixed to the conveyance jig 35.
- step S3 first, the pad 41 of the support portion 37 and the bottom plate 31 of the housing 11 are brought into contact with each other.
- the pad 41 of the support portion 37 is formed corresponding to the bottom end surface 30 b of the frame body 30. That is, the pad 41 is provided along substantially the entire circumference of the bottom end surface 30 b of the frame body 30. For this reason, if the pad 41 of the support part 37 and the bottom plate 31 of the housing
- FIG. 6 is a diagram illustrating a state in which the pad 41 of the support portion 37 and the bottom plate 31 of the housing 11 are in contact with each other.
- a pair of junction boxes 45 and an output cable 46 extending from each of the pair of junction boxes 45 are provided on the outer surface 31 b of the bottom plate 31.
- the output cable 46 is a cable (output cord) for taking out the electric power output from the plurality of cells arranged on the inner surface 31a.
- a gap portion 47 for allowing the output cable 46 to escape to the outside of the support portion 37 is provided in a portion provided on the short side of the frame 36 in the support portion 37. Therefore, when the pad 41 of the support part 37 is brought into contact with the bottom plate 31 of the housing 11, the tip of the output cable 46 is allowed to escape from the gap part 47 to the outside. Thereby, in the state which fixed the housing
- the fixing member 50 is, for example, a tapping screw, and is attached to each portion of the support portion 37 provided on the short side of the frame 36.
- FIG. 7 is a partial cross-sectional view of the conveying jig 35 to which the fixing member 50 is fixed, and is a cross-sectional view of a portion to which the fixing member 50 is attached.
- a hole 30 d for screwing the fixing member 50 is provided on the bottom end surface 30 b of the frame 30.
- the fixing member 50 can be screwed if a hole having a diameter that allows the fixing member 50 to be screwed is formed.
- the support portion 37 and the bottom plate 31 are provided with a through hole 37 a and a through hole 31 d at positions corresponding to the hole portions 30 d of the frame body 30.
- the fixing member 50 is inserted into the through hole 37 a of the support portion 37 and the through hole 31 d of the bottom plate 31, and is screwed into and tightened into the hole portion 30 d provided on the bottom end surface 30 b of the frame body 30. By screwing the fixing member 50 into the hole 30d, the housing 11 and the transport jig 35 can be relatively positioned.
- the fixing member 50 is screwed into the hole 30d and tightened, so that the support portion 37 and the bottom plate 31 are sandwiched between the head 50a of the fixing member 50 and the bottom end surface 30b of the frame 30. To do. As a result, the fixing member 50 presses the pad 41 of the support portion 37 toward the periphery of the outer surface 31 b of the bottom plate 31. In this manner, the fixing member 50 sandwiches the support portion 37 and the bottom plate 31 between the bottom end surface 30 b of the frame body 30 and fixes the housing 11 to the transport jig 35.
- the fixing member 50 prevents the bottom plate 31 and the frame body 30 from moving relative to each other while pressing the pad 41 toward the periphery of the outer side surface 31 b of the bottom plate 31, so that the inner side surface 31 a of the bottom plate 31 is pressed.
- the periphery and the bottom end surface 30b of the frame 30 can be brought into close contact with each other.
- the bottom plate 31 and the frame body 30 can be appropriately bonded.
- the caulking agent that adheres between the bottom plate 31 and the frame body 30 is in a state before drying and in the bottom plate 31. Even when the adhesion between the frame body 30 and the frame 30 is not completely completed, the housing 11 can be transported and can be advanced to the next work process.
- the fixing member 50 is a tapping screw, and the frame 30 is made of resin. Therefore, if the hole 30d is provided in the frame 30, the fixing member 50 is screwed into the hole 30d.
- the casing 11 can be easily fixed to the conveying jig 35 without embedding a nut or the like in the frame 30 or forming a screw.
- the fixing member 50 can be screwed into the hole 30d from the outside of the housing 11, and the housing 11 can be easily fixed to and removed from the conveying jig 35. Furthermore, the conveyance jig 35 and the fixing member 50 removed from the housing 11 can be reused.
- the housing 11 fixed to the transport jig 35 in step S3 is transported to the next process.
- the housing 11 fixed to the conveying jig 35 is advanced to the next inspection process (step S4).
- the inspection process an insulation withstand voltage inspection of a plurality of cells and the like arranged on the inner side surface 31a, an airtight inspection between the bottom plate 31 and the frame body 30, and the like are performed (step S4).
- the housing 11 fixed to the conveying jig 35 is advanced to the attaching process of the light collecting unit 12 (FIG. 2).
- the light collecting unit 12 is attached to the housing 11 (step S5). Thereby, the photovoltaic power generation module 1M is obtained.
- the housing 11 fixed to the conveying jig 35 is advanced to the output inspection process (step S6), and the output inspection as the photovoltaic power generation module 1M is performed. Thereafter, the housing 11 fixed to the transport jig 35 is advanced to the transport jig removing step, and the housing 11 is removed from the transport jig 35 (step S7). Thereby, the photovoltaic power generation module 1M is completed.
- the support portion 37 formed corresponding to the bottom end surface 30b of the frame body 30, and the peripheral edge of the outer side surface 31b of the bottom plate 31. Since the housing 11 is fixed to the transport jig 35 in a state of being in contact with each other, the housing 11 can be supported (reinforced) by the transport jig 35 so that the resin frame 30 is not bent. it can. Therefore, by performing the subsequent work process on the housing 11 fixed to the transport jig 35, it is possible to suppress the bending that occurs in the housing 11 during assembly work or during transport between processes.
- the conveyance jig 35 of this embodiment is provided with a handle 35a for handling the conveyance jig 35, the conveyance jig 35 can be attached without directly touching the bottom plate 31 and the frame 30 to be bonded to each other. Can be moved.
- the transport jig 35 of the present embodiment includes the ball roller 38 that contacts the floor surface, the transport jig 35 can freely travel. Furthermore, by making it possible for the conveying jig 35 to travel by the ball roller 38, the frame 36 can be constituted by a plate material or the like instead of a bar, and the degree of freedom in designing the conveying jig 35 can be increased.
- FIG. 8 is an exploded perspective view showing the frame 30, the bottom plate 31, and the conveying jig 35, and shows the conveying jig 35 according to another embodiment.
- the conveyance jig 35 of the present embodiment is provided with a holding member 60 for holding the bottom plate 31 so as not to bend toward the conveyance jig 35.
- the holding member 60 includes a long plate-like holding plate 61 that crosses the inside of the rectangular frame-like frame 36 and connects the long sides of the frame 36, and a protective pad that is interposed between the holding plate 61 and the bottom plate 31. 62.
- the base plate 31 is held by the holding member 60 so as not to bend downward while the housing 11 is fixed to the transfer jig 35 and transferred to each process. Thereby, workability
- the bottom plate 31 is more reliably held between the column portion 30 e and the holding member 60. be able to.
- a clip 65 (a cord holding portion) for holding the output cable 46 on the outer side surface 31b is provided on the outer side surface 31b of the bottom plate 31 of the present embodiment.
- FIG. 9 is an enlarged perspective view of the clip 65.
- the clip 65 is provided at a position corresponding to the gap 47, and holds the output cable 46 so that the connector 46a provided at the tip of the output cable 46 is exposed to the outside. To do.
- the connector 46a can be positioned with respect to the baseplate 31 (housing
- the casing 11 can be fixed to the conveying jig 35 while being held in a state of being escaped to the outside.
- the case where a clip is used to hold the output cable 46 is illustrated.
- the output cable 46 is held such as a band fixed to the outer surface 31b and detachably holding the output cable 46. Configurations that can be used can be used.
- the case where a tapping screw is used as the fixing member 50 is exemplified, but the present invention is not limited to this.
- a general bolt can be used as the fixing member 50 by embedding a nut in the frame 30 or forming a screw.
- the case 11 can be easily fixed to the transport jig 35 when the tapping screw is used.
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Abstract
Description
本出願は、2018年3月5日出願の日本出願第2018-038644号に基づく優先権を主張し、前記日本出願に記載された全ての記載内容を援用するものである。
上記集光型太陽光発電モジュールの筐体を構成する枠体を樹脂材料によって形成した場合、枠体が樹脂材料であるために剛性が比較的低く、集光型太陽光発電モジュールの組み立て作業時や、工程間の搬送時において、筐体が撓んでしまうおそれがあった。
このような、組み立て作業時や搬送時において筐体に生じる撓みは、モジュールとしての製品誤差や、性能に影響を及ぼすため、できるだけ抑制することが好ましい。
本開示によれば、組み立て作業時や搬送時において筐体に生じる撓みを抑制することができる。
[実施形態の概要]
(1)一実施形態である太陽光発電モジュールの製造方法は、複数の集光レンズによって太陽光が集光される複数の発電素子と、前記複数の発電素子を収容する筐体と、を備え、前記筐体が、樹脂製の枠体と、前記枠体の底側開口を塞ぐともに内側面に前記複数の発電素子が配置された金属製の底板と、を備えた集光型太陽光発電モジュールの製造方法であって、前記底板の内側面の周縁を前記枠体の底端面に当接させ、前記底板を前記枠体に固定することで前記筐体を得る第1ステップと、前記筐体を水平に寝かせた状態で搬送する搬送治具に前記筐体を固定する第2ステップと、を含み、前記搬送治具は、前記枠体の底端面に対応して形成され前記筐体を下方から支持する支持部を備え、前記第2ステップは、前記支持部と、前記底板の外側面の周縁とを当接させた状態で前記筐体を前記搬送治具に固定する。
この場合、固定部材によって底板と枠体とが相対移動するのを防止しつつ、支持部を底板に向けて押圧させ、底板と枠体とを密着させることができる。この結果、底板と枠体とを適切に接着することができるとともに、底板と枠体とを接着させつつ次の作業工程へ進ませることができる。
この場合、枠体が樹脂製であることから、枠体に孔部を設ければ、固定部材を孔部に螺合させることができ、容易に筐体を搬送治具に固定することができる。
また、固定部材を筐体の外側から孔部に螺合させることができ、搬送治具に対する筐体の固定及び取り外しが容易となる。
さらに、筐体から取り外された搬送治具及び固定部材は再利用することができる。
この場合、筐体を搬送治具に固定した状態で、太陽光発電モジュールとしての出力検査を行うことができる。
この場合、出力コードを支持部の外側へ逃がした状態で、筐体を搬送治具に固定することが容易となる。
この場合、互いに接着される底板や枠体に直接触れることなく搬送治具を移動させることができる。
この場合、搬送治具に固定される筐体の搬送を容易にする。
この場合、筐体が搬送治具に固定され、各工程に搬送される間、底板は、保持部材によって下方向へ撓まないように保持される。これにより、各工程において底板に対する作業を行う際の作業性を向上させることができる。
以下、好ましい実施形態について図面を参照しつつ説明する。
なお、以下に記載する各実施形態の少なくとも一部を任意に組み合わせてもよい。
図1は、集光型の太陽光発電装置の一例を示す斜視図である。
図1において、この太陽光発電装置100は、上部側で連続し、下部側で左右に分かれた形状のアレイ(太陽光発電パネル全体)1と、その支持装置2とを備えている。アレイ1は、複数のモジュール1Mを整列させて構成されている。図1の例では、左右のウイングを構成する(96(=12×8)×2)個と、中央の渡り部分の8個との、合計200個のモジュール1Mの集合体として、アレイ1が構成されている。
図1において、支柱21は鉛直方向に平行であり、水平軸24は水平方向に平行である。2軸駆動部23は、水平軸24を、方位角(支柱21を中心軸とした角度)及び仰角(水平軸24を中心軸とした角度)の2方向に回動させることができる。
なお、図1では1本の支柱21でアレイ1を支える支持装置2を示したが、支持装置2の構成は、これに限られるものではない。要するに、アレイ1を、2軸(方位角、仰角)で可動なように支持できる支持装置であればよい。
枠体30は、例えば、ガラス繊維が充填されたPBT(Poly Butylene Terephtalate)樹脂等の樹脂材料を用いて矩形筒状に形成されている。
底板31は、例えば、アルミニウム合金により形成された板状の部材である。
図2中の、二点鎖線の「○」で囲んでいる部位は、受光部Rの拡大図である。受光部Rにおいて、セルパッケージ14上には2次レンズ15があり、二次レンズの周りには保護板16がある。2次レンズ15は例えばボールレンズである。保護板16は、例えば、円環状の金属体であり、市販のワッシャを用いることができる。保護板16は2次レンズ15から太陽光の収束光が外れた場合に、収束光がセル周辺に熱的なダメージを与えることを防止している。また、保護板16は、収束光が全て2次レンズ15に入っている場合であっても、筐体11内での散乱光を受けてこれを反射する。
受光部Rと集光部12との間には、遮蔽板17が設けられている。遮蔽板17には、個々の集光レンズ12fに対応した位置に、1つの集光レンズ12fに対応した開口17aが形成されている。集光レンズ12fによって収束される太陽光は、開口17aを通過する。太陽光の入射方向と受光部Rの光軸とが大きくずれた場合には、ずれた位置に集光しようとする光は遮蔽板17に当たるようになっている。
図3は、上述の太陽光発電モジュール1Mの組み立て工程の一例を示した図である。
まず、太陽光発電モジュール1Mを組み立てるには、まず、底板31の内側面31aにフレキシブルプリント配線板13を配置する(ステップS1)。
次いで、筐体11を組み立て(ステップS2)、さらに、得られた筐体11を搬送治具に取り付けて固定する(ステップS3)。
ステップS2における筐体11の組み立ては、底板31の内側面31aの周縁を枠体30の底端面30bに当接させ、底板31を枠体30に固定することで行われる。このとき、底板31の内側面31aの周縁、及び底端面30bに、接着剤としてのコーキング剤を塗布した後、底板31の内側面31aの周縁、及び底端面30bを当接させる。これにより、両者の周囲及び両者の間でコーキング剤が硬化し、両者を接着するコーキング剤層が形成される。このコーキング剤層によって、両者は接着固定される。
図5は、搬送治具35を示す斜視図である。図5及び図4を参照して、搬送治具35は、その上側に筐体11が水平に寝かせた状態で搭載され、筐体11を搬送するための治具である。
フレーム36は、例えば、断面C型のアルミニウム合金からなる棒材を矩形状に組み立てることで枠状に構成されている。フレーム36の短辺側の寸法は、枠体30の短辺側の寸法よりもやや大きく、フレーム36の長辺側の寸法は、枠体30の長辺側の寸法よりもやや小さい。
また、フレーム36には、筐体11が固定される搬送治具35をハンドリングするための把手(ハンドル)35aが設けられている。
ブラケット40はアルミニウム合金からなる板状の部材である。ブラケット40においてフレーム36の短辺に設けられた部分は、短辺に沿って延びているとともに、フレーム36の外側面よりも外側方向に突出して設けられている。また、ブラケット40においてフレーム36の長辺に設けられた部分は、長辺に沿って延びているとともに、フレーム36の内側面よりも内側方向に突出して設けられている。
筐体11は、このパッド41の上面に筐体11の底板31が当接した状態で搬送治具35に固定される。
ここで、パッド41は樹脂により形成されているので、パッド41が底板31に当接したときに当該底板31に傷を付けるのを防止することができる。
ここで、支持部37のパッド41は、枠体30の底端面30bに対応して形成されている。すなわち、パッド41は、枠体30の底端面30bのほぼ全周に沿って設けられている。
このため、支持部37のパッド41と、筐体11の底板31とを当接させると、パッド41は、底板31の外側面31bの周縁のほぼ全周に当接する。
底板31の外側面31bには、一対のジャンクションボックス45と、一対のジャンクションボックス45それぞれから延びる出力ケーブル46とが設けられている。出力ケーブル46は、内側面31aに配置された複数のセルが出力する電力を取り出すためのケーブル(出力コード)である。
よって、支持部37のパッド41と、筐体11の底板31とを当接させる際、出力ケーブル46の先端を隙間部47から外側へ逃がしておく。
これにより、筐体11を搬送治具35に固定した状態で、後の作業工程において太陽光発電モジュール1Mとしての出力検査を行うことができる。
固定部材50は、例えば、タッピングビスであり、支持部37においてフレーム36の短辺に設けられた部分に2箇所ずつ取り付けられる。
図7に示すように、枠体30の底端面30bには、固定部材50を螺合させるための孔部30dが設けられている。なお、本実施形態において枠体30は樹脂製であるため、固定部材50が螺合可能な直径の孔を形成すれば、固定部材50を螺合させることができる。
固定部材50は、支持部37の貫通孔37a及び底板31の貫通孔31dに挿通され、枠体30の底端面30bに設けられた孔部30dに螺合して締め付けられる。
この固定部材50を孔部30dに螺合することにより、筐体11と搬送治具35との相対的な位置決めを行うことができる。
これにより、固定部材50は、支持部37のパッド41を、底板31の外側面31bの周縁に向けて押圧させる。
このようにして、固定部材50は、枠体30の底端面30bとの間で、支持部37及び底板31を挟持し、筐体11を搬送治具35に固定する。
また、固定部材50によって、底板31と枠体30との間の相対移動が防止されるので、底板31と枠体30との間を接着するコーキング剤が乾燥する前の状態であって底板31と枠体30との接着が完全に終わっていない状態であっても、筐体11を搬送することができ、次の作業工程へ進ませることができる。
また、固定部材50を筐体11の外側から孔部30dに螺合させることができ、搬送治具35に対する筐体11の固定及び取り外しが容易となる。
さらに、筐体11から取り外された搬送治具35及び固定部材50は再利用することができる。
搬送治具35に固定された筐体11は、次工程である検査工程(ステップS4)に進められる。検査工程では、内側面31aに配置された複数のセル等の絶縁耐圧検査や、底板31と枠体30との気密検査等が行われる(ステップS4)。
その後、搬送治具35に固定された筐体11は、集光部12(図2)の取付工程に進められる。集光部12の取付工程では、筐体11に集光部12が取り付けられる(ステップS5)。これにより、太陽光発電モジュール1Mが得られる。
さらに、搬送治具35に固定された筐体11は、出力検査工程に進められ(ステップS6)、太陽光発電モジュール1Mとしての出力検査が行われる。
その後、搬送治具35に固定された筐体11は、搬送治具取り外し工程に進められ、筐体11が搬送治具35から取り外される(ステップS7)。
これにより、太陽光発電モジュール1Mが完成する。
図8は、枠体30と、底板31と、搬送治具35とを示した分解斜視図であり、他の実施形態に係る搬送治具35を示している。
本実施形態の搬送治具35は、底板31が搬送治具35側へ撓まないように保持するための保持部材60が設けられている。
保持部材60は、矩形枠状のフレーム36の枠内を横断しフレーム36の長辺同士を接続する長尺板状の保持板61と、保持板61と底板31との間に介在する保護パッド62とを備えている。
これにより、コネクタ46aを底板31(筐体11)に対して位置決めすることができる。
よって、支持部37のパッド41と、筐体11の底板31とを当接させる際、出力ケーブル46のコネクタ46aを隙間部47から外側へ逃がし、さらに、クリップ65によってコネクタ46aを隙間部47から外側へ逃がした状態で保持し、筐体11を搬送治具35に固定することができる。
さらに、筐体11を搬送治具35に固定した状態で行われる出力検査において、コネクタ46aが筐体11に対して位置決めされるので、出力検査のための検査装置に対する接続が容易となる。
なお、今回開示された実施の形態はすべての点で例示であって制限的なものではないと考えられるべきである。
上記実施形態では、底端面30bにおける枠体30の短辺部分に孔部30dを形成し、底端面30bの短辺部分を固定部材50によって搬送治具35に固定した場合を示したが、長辺部分に孔部30dを設け、底端面30bの長辺部分を固定部材50によって固定してもよい。
1M 太陽光発電モジュール
2 支持装置
11 筐体
12 集光部
12a ガラス板
12f 集光レンズ
13 フレキシブルプリント配線板
14 セルパッケージ
15 2次レンズ
16 保護板
17 遮蔽板
17a 開口
21 支柱
22 基礎
23 軸駆動部
24 水平軸
30 枠体
30a 底側開口
30b 底端面
30c 突起
30d 孔部
30e 柱部
31 底板
31a 内側面
31b 外側面
31c 切欠部
31d 貫通孔
35 搬送治具
35a 把手
36 フレーム
36a 上面
36b 下面
37 支持部
37a 貫通孔
38 ボールローラ
40 ブラケット
41 パッド
45 ジャンクションボックス
46 出力ケーブル
46a コネクタ
47 隙間部
50 固定部材
50a 頭部
60 保持部材
61 保持板
62 保護パッド
65 クリップ
100 太陽光発電装置
R 受光部
Claims (9)
- 複数の集光レンズによって太陽光が集光される複数の発電素子と、前記複数の発電素子を収容する筐体と、を備え、前記筐体が、樹脂製の枠体と、前記枠体の底側開口を塞ぐともに内側面に前記複数の発電素子が配置された金属製の底板と、を備えた集光型太陽光発電モジュールの製造方法であって、
前記底板の内側面の周縁を前記枠体の底端面に当接させ、前記底板を前記枠体に固定することで前記筐体を得る第1ステップと、
前記筐体を水平に寝かせた状態で搬送する搬送治具に前記筐体を固定する第2ステップと、
を含み、
前記搬送治具は、前記枠体の底端面に対応して形成され前記筐体を下方から支持する支持部を備え、
前記第2ステップは、前記支持部と、前記底板の外側面の周縁とを当接させた状態で前記筐体を前記搬送治具に固定する
集光型太陽光発電モジュールの製造方法。 - 前記第1ステップは、前記底板と前記枠体とを接着固定し、
前記第2ステップは、前記枠体の底端面との間で、前記支持部及び前記底板を挟持する固定部材によって前記筐体を前記搬送治具に固定する
請求項1に記載の太陽光発電モジュールの製造方法。 - 前記固定部材は、前記支持部及び前記底板を貫通し、前記枠体の底端面に設けられた孔部に螺合するタッピングビスである
請求項2に記載の太陽光発電モジュールの製造方法。 - 前記底板の外側面には、前記複数の発電素子に接続された出力コードが設けられており、
前記第2ステップは、前記出力コードを前記支持部の外側へ逃がすために当該支持部に設けられた隙間部から前記出力コードを前記支持部の外側へ逃がした上で、前記筐体を前記搬送治具に固定する
請求項1から請求項3のいずれか一項に記載の太陽光発電モジュールの製造方法。 - 前記底板の外側面には、前記出力コードを保持するコード保持部が前記隙間部に対応して設けられており、
前記第2ステップは、前記出力コードを前記支持部の外側へ逃がすために当該支持部に設けられた隙間部から前記出力コードを前記支持部の外側へ逃がし、さらに、前記コード保持部によって前記出力コードを前記支持部の外側へ逃がした状態で保持し、前記筐体を前記搬送治具に固定する
請求項4に記載の太陽光発電モジュールの製造方法。 - 複数の集光レンズによって太陽光が集光される複数の発電素子を収容する太陽光発電モジュール用の筐体を搬送するための搬送治具であって、
前記筐体は、樹脂製の枠体と、前記枠体の底側開口を塞ぐともに内側面に前記複数の発電素子が配置された金属製の底板と、を備えるとともに、前記底板の内側面の周縁を前記枠体の底端面に当接させた状態で前記底板が前記枠体に固定され、
前記枠体の底端面に対応して形成され、前記底板の外側面の周縁に当接した状態で前記筐体を下方から支持する支持部を備え、
前記筐体を水平に寝かせた状態で搬送する
搬送治具。 - 前記搬送治具をハンドリングするための把手をさらに備えている
請求項6に記載の搬送治具。 - 前記搬送治具が載置される床面に接地し当該搬送治具を自在に走行させるボールローラをさらに備えている
請求項6又は請求項7に記載の搬送治具。 - 前記支持部が設けられる矩形枠状の本体部と、
前記本体部の枠内を横断して設けられ、前記底板を下方から保持する底板保持部をさらに備えている
請求項6から請求項8のいずれか一項に記載の搬送治具。
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US16/976,928 US11742454B2 (en) | 2018-03-05 | 2019-02-21 | Method for manufacturing concentrator photovoltaic module, and transport jig |
JP2020504913A JPWO2019171966A1 (ja) | 2018-03-05 | 2019-02-21 | 集光型太陽光発電モジュールの製造方法、及び搬送治具 |
AU2019230301A AU2019230301A1 (en) | 2018-03-05 | 2019-02-21 | Method for Manufacturing Concentrator Photovoltaic Module, and Transport Jig |
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MA58647B1 (fr) | 2022-12-30 |
AU2019230301A1 (en) | 2020-09-24 |
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