WO2024103864A1 - 一种光伏铝合金框的成型工艺 - Google Patents

一种光伏铝合金框的成型工艺 Download PDF

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Publication number
WO2024103864A1
WO2024103864A1 PCT/CN2023/113113 CN2023113113W WO2024103864A1 WO 2024103864 A1 WO2024103864 A1 WO 2024103864A1 CN 2023113113 W CN2023113113 W CN 2023113113W WO 2024103864 A1 WO2024103864 A1 WO 2024103864A1
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WO
WIPO (PCT)
Prior art keywords
straightening
seat
aluminum
frame
aluminum alloy
Prior art date
Application number
PCT/CN2023/113113
Other languages
English (en)
French (fr)
Inventor
唐开健
李飞庆
王超
樊祥勇
Original Assignee
安徽鑫铂科技有限公司
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Filing date
Publication date
Application filed by 安徽鑫铂科技有限公司 filed Critical 安徽鑫铂科技有限公司
Publication of WO2024103864A1 publication Critical patent/WO2024103864A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D3/00—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts
    • B21D3/02—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts by rollers
    • B21D3/05—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts by rollers arranged on axes rectangular to the path of the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D3/00—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts
    • B21D3/16—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts of specific articles made from metal rods, tubes, or profiles, e.g. crankshafts, by specially adapted methods or means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/74—Making other particular articles frames for openings, e.g. for windows, doors, handbags
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • 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
    • 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

Definitions

  • the invention relates to the technical field of aluminum profile forming, and in particular to a forming process of a photovoltaic aluminum alloy frame.
  • Solar photovoltaic modules usually include solar cell modules and frames.
  • Solar cell modules are generally composed of tempered glass, EVA layer, solar cell sheets, EVA layer and back panel, which are combined into one by a laminating machine; and the frames are mostly made of aluminum alloy, and the aluminum frames are fixedly connected by several profiles.
  • a Chinese patent document with publication number CN105537868B proposes a method for preparing an aluminum frame for a photovoltaic module.
  • the performance of the photovoltaic aluminum alloy frame is improved by processes such as drilling and injecting glue holes.
  • the solar panels can be effectively prevented from being scratched, and the bonding performance between the solar panels and the aluminum frame can be improved.
  • the preparation method does not make improvements to the hot shear extrusion and tension straightening steps. In the hot shear extrusion stage, due to the bending of long aluminum rods, it is not only difficult to feed the material, but also leads to an increase in waste from hot shear extrusion and an increase in consumables.
  • the extruded aluminum profiles need to be manually sorted and straightened with an independent straightening machine.
  • the ends of the aluminum profiles will also be flattened to produce end waste.
  • the present invention provides a forming process for a photovoltaic aluminum alloy frame, which has the advantages of using a straightening machine to synchronously straighten the raw material aluminum rods and the formed aluminum alloy frame, thereby solving a series of problems such as low forming efficiency of the photovoltaic aluminum alloy frame.
  • a photovoltaic aluminum alloy frame forming process comprising the following steps:
  • step S2 homogenization quenching: the aluminum rod produced in step S1 is placed in a homogenization furnace to improve the surface quality and mechanical properties of the finished aluminum rod, and then the aluminum rod is extruded into a frame by hot shear extrusion, and then the frame is quenched in a quenching furnace;
  • tension straightening placing the aluminum alloy frame treated in step S2 on a tension straightening mechanism for stretching and straightening;
  • step S4 aging storage: After the aluminum alloy frame treated in step S3 is artificially aged to remove internal stress, it is stored in a centralized manner. Placed in the semi-finished product warehouse to complete the forming process of the photovoltaic aluminum alloy frame; the above-mentioned process of manufacturing the photovoltaic aluminum alloy frame also involves the straightening equipment of the photovoltaic aluminum alloy frame, including a rod straightening unit installed on the base for straightening the raw aluminum rod required for hot shear extrusion, and a frame straightening unit for straightening the aluminum alloy frame, the rod straightening unit includes a plurality of matching groups of upper straightening rollers and lower straightening rollers, and a straightening cavity with different inner diameters is formed by the straightening groove opened between the upper straightening roller and the lower straightening roller, and a long aluminum rod is sleeved on the straightening cavity.
  • the rod straightening unit includes a plurality of matching groups of upper straightening rollers and lower straighten
  • the base is also provided with a lifting assembly for adjusting the height of the upper straightening roller
  • the frame straightening unit includes a fixed seat fixedly installed at one end of the vertical plate, and a slide seat slidably installed at the other end of the vertical plate.
  • a synchronization assembly is also provided between the slide seat and the lower straightening roller, and the synchronization assembly is used to drive the slide seat to keep reciprocating when the lower straightening roller rotates, and the slide seat and the fixed seat are both equipped with a rubber seat and a cylinder that are compatible with the aluminum frame.
  • two corresponding vertical seats are installed on the top of the base, and multiple groups of upper straightening rollers and lower straightening rollers are rotatably installed between the two vertical seats, and one end of multiple lower straightening rollers is sleeved with a driving gear, and a reversing gear is provided between adjacent driving gears.
  • the reversing gear is rotatably installed on the vertical seat on the corresponding side, and a reduction motor is also installed on one side of the vertical seat, and the output end of the reduction motor is connected to a driving gear meshing with one of the driving gears through a coupling.
  • a plurality of lifting seats are slidingly provided on the vertical seat, and the two ends of the upper straightening roller are respectively sleeved on the corresponding lifting seats.
  • a plurality of threaded sleeves are also installed on the top of the vertical seat, and a synchronous shaft is sleeved on the inner thread of the threaded sleeve.
  • the bottom end of the synchronous shaft is rotatably connected to the corresponding lifting seat, and the top ends of the plurality of synchronous shafts are sleeved with synchronous gears.
  • a plurality of intermediate shafts are rotatably mounted on the top of the vertical seat, intermediate gears are sleeved on the intermediate shafts, the intermediate gears are located between two corresponding adjacent synchronous gears and mesh with the corresponding synchronous gears, and a hand wheel is also connected to the top of the synchronous shaft at the end.
  • a reciprocating gear is rotatably installed on one side of the vertical seat
  • the vertical plate is installed on one side of the vertical seat on the corresponding side
  • a horizontal slot is opened on the vertical plate
  • the slide seat is slidably mounted in the horizontal slot
  • one side of the reciprocating gear and one side of the slide seat are rotatably connected to the same driving connecting rod.
  • the rubber seat is installed on the inner wall of one side of the sliding seat and the fixed seat, and the distance between the bottom side of the rubber seat and the bottom inner wall of the sliding seat or the fixed seat is consistent with the thickness of the aluminum frame, and one end edge of the rubber seat is also chamfered, and a group of guide strips are connected to the bottom inner walls of the sliding seat and the fixed seat.
  • the cylinder is installed on the top of the sliding seat and the fixed seat, and the telescopic end of the cylinder penetrates into the interior of the sliding seat or the fixed seat and is fixedly connected with a lifting plate adapted to the position of the corresponding rubber seat.
  • the bottom of the lifting plate is connected with a rubber pad which fits the top of the aluminum frame.
  • the reduction motor is provided with a controller electrically connected thereto, and pressure sensors corresponding to the end positions of the aluminum frame are provided on the inner walls of one side of the slide seat and the fixed seat, and the pressure sensors are electrically connected to the controller.
  • the present invention provides a photovoltaic aluminum alloy frame forming process, which has the following beneficial effects:
  • the forming process structure of the photovoltaic aluminum alloy frame is as follows: by inserting one end of the generated long aluminum rod into the straightening cavity of the corresponding size, the reduction motor is controlled to operate, and the driving gear at the end is driven to rotate through the coupling and the driving gear, thereby driving multiple driving gears to rotate synchronously through multiple reversing gears, that is, controlling multiple lower straightening rollers to rotate synchronously, thereby cooperating with the upper straightening roller to extrude and push the long aluminum rod through multiple straightening cavities in sequence, thereby using the extrusion force to straighten the long aluminum rod, thereby ensuring that the long aluminum rod can smoothly enter the subsequent hot shear extruder, and at the same time, it can also reduce the output of waste at its end in the hot shear extruder.
  • the hand wheel can be turned accordingly according to the size of the long aluminum bar to be straightened, so that through the synchronous driving action of multiple synchronous gears and intermediate gears, multiple synchronous shafts can be raised and lowered synchronously, and multiple lifting seats can be controlled to drive the upper straightening roller to rise and fall, so as to change the size of the straightening cavity formed between the lower straightening roller, so as to achieve straightening of long aluminum bars of different specifications.
  • the straightening cavities at the same height are of different sizes, so that long aluminum bars of different specifications can be straightened synchronously, which improves practicality.
  • the forming process structure of the photovoltaic aluminum alloy frame indirectly drives the long aluminum rod to move and straighten it by controlling the operation of the reduction motor.
  • the active gear drives the reciprocating gear meshing with it to rotate, so that under the guidance of the horizontal slot, the slide seat is pushed to move horizontally in the positive direction through the driving connecting rod.
  • one end of the quenched aluminum frame is pushed into the fixed seat under the guidance of the guide bar and is sleeved on the rubber seat at the corresponding end until one end of the aluminum frame contacts the pressure sensor on that side.
  • the rubber seat on the slide seat is butt-sleeved on the other end of the aluminum frame until the other end of the aluminum frame contacts the pressure sensor on the corresponding side, and then the connection is
  • the trigger signal is sent to the controller by the pressure signal.
  • the controller controls the operation of the cylinder, so that the telescopic end moves downward and drives the corresponding rubber pad through the lifting plate to cooperate with the corresponding rubber seat to press the end of the aluminum frame, thereby accompanying the continuous rotation of the reciprocating gear, causing the slide seat to move in the opposite direction, thereby cooperating with the clamping action of the cylinder to stretch and straighten the aluminum frame.
  • the cylinder operates in the opposite direction to release the clamping action on the aluminum frame.
  • the straightened aluminum frame is removed.
  • it can not only use the aluminum bar straightening machine to synchronously straighten the initially formed aluminum frame, realizing "one machine for two uses", but also does not need to set up an independent aluminum alloy frame straightening machine, which reduces the production cost investment while improving the utilization rate of production space.
  • the forming process structure of the photovoltaic aluminum alloy frame can also fill the end of the aluminum frame through the cooperation with the rubber seat during the straightening process, avoiding flattening the end of the aluminum frame during the clamping, stretching and straightening process, thereby reducing the waste output during the straightening process of the aluminum frame, further reducing production costs and improving the economic benefits of the enterprise.
  • FIG1 is a schematic diagram of the three-dimensional structure of a straightening device for a photovoltaic aluminum alloy frame according to the present invention.
  • FIG2 is a schematic diagram of the front view structure of the photovoltaic aluminum alloy frame straightening device of the present invention.
  • FIG3 is a schematic side view of the structure of the photovoltaic aluminum alloy frame straightening device of the present invention.
  • FIG4 is a schematic diagram of a partially enlarged structure of FIG3 of the present invention.
  • FIG5 is a schematic diagram of a partial three-dimensional structure of a straightening device for a photovoltaic aluminum alloy frame of the present invention.
  • FIG6 is a schematic diagram of a partial three-dimensional structure of FIG5 of the present invention.
  • FIG7 is a schematic diagram of a three-dimensional structure of a partial frame straightening unit of the present invention.
  • FIG8 is a schematic diagram of the three-dimensional structure of another part of the frame straightening unit of the present invention.
  • FIG9 is a schematic diagram of the three-dimensional structure of the slide seat of the present invention.
  • FIG. 10 is a schematic diagram of the side structure of the aluminum frame of the present invention.
  • the present application proposes a forming process for a photovoltaic aluminum alloy frame.
  • a photovoltaic aluminum alloy frame forming process includes the following steps:
  • step S2 homogenization quenching: the aluminum rod produced in step S1 is placed in a homogenization furnace to improve the surface quality and mechanical properties of the finished aluminum rod, and then the aluminum rod is extruded into a frame by hot shear extrusion, and then the frame is quenched in a quenching furnace;
  • tension straightening placing the aluminum alloy frame treated in step S2 on a tension straightening mechanism for stretching and straightening;
  • step S4 aging storage: After the aluminum alloy frame treated in step S3 is artificially aged to remove internal stress, it is centrally stored in the semi-finished product warehouse, completing the forming process of the photovoltaic aluminum alloy frame;
  • the above-mentioned process of manufacturing the photovoltaic aluminum alloy frame also involves straightening equipment for the photovoltaic aluminum alloy frame, including a rod straightening unit installed on the base 1 for straightening the raw aluminum rods required for hot shear extrusion, and a frame straightening unit for straightening the aluminum alloy frame.
  • the rod straightening unit includes a plurality of matching sets of upper straightening rollers 3 and lower straightening rollers 4.
  • a straightening cavity 6 with different inner diameters is formed by a straightening groove 5 between the upper straightening rollers 3 and the lower straightening rollers 4.
  • a long aluminum rod 7 is sleeved on the straightening cavity 6.
  • the base 1 is also provided with a lifting component for adjusting the height of the upper straightening roller 3.
  • the frame straightening unit includes a fixed seat 23 fixedly installed at one end of the vertical plate 19, and a slide seat 21 slidably installed at the other end of the vertical plate 19.
  • a synchronization component is also provided between the slide seat 21 and the lower straightening roller 4. The synchronization component is used to drive the slide seat 21 to keep reciprocating when the lower straightening roller 4 rotates, and
  • the sliding seat 21 and the fixed seat 23 are both equipped with a rubber seat 24 and a cylinder 27 that are compatible with the aluminum frame 31.
  • the aluminum rod After the aluminum rod is homogenized in the homogenizing furnace, it can be ensured that the aluminum rod enters the hot shear extruder smoothly after being straightened by the rod straightening unit, and the waste output of the aluminum rod during hot shear extrusion is reduced.
  • the aluminum alloy frame extruded by the hot shear can be stretched and straightened by the running frame straightening unit, realizing "one machine for two uses" without the need to set up an independent straightening machine, reducing the production cost investment and the occupied production space.
  • the lifting component can optimize the lifting accuracy of multiple upper straightening rollers 3.
  • two vertical seats 2 corresponding to each other are installed on the top of the base 1, and multiple groups of upper straightening rollers 3 and lower straightening rollers 4 are rotatably installed between the two vertical seats 2, and one end of multiple lower straightening rollers 4 is sleeved with a driving gear 9, and a reversing gear 11 is provided between adjacent driving gears 9.
  • the reversing gear 11 is rotatably installed on the vertical seat 2 on the corresponding side, and a reduction motor 10 is also installed on one side of the vertical seat 2.
  • the output end of the reduction motor 10 is connected to a driving gear meshing with one of the driving gears 9 through a coupling, and the vertical seat 2 slides
  • the card is provided with a plurality of lifting seats 8, and the two ends of the upper straightening roller 3 are respectively sleeved on the corresponding lifting seats 8.
  • the top of the vertical seat 2 is also equipped with a plurality of threaded sleeves 12, and the threaded sleeve 12 is internally threaded with a synchronous shaft 13, and the bottom end of the synchronous shaft 13 is rotatably connected to the corresponding lifting seat 8, and the tops of the plurality of synchronous shafts 13 are sleeved with synchronous gears 14, and the top of the vertical seat 2 is also rotatably equipped with a plurality of intermediate shafts 15, and the intermediate shafts 15 are sleeved with intermediate gears 16, and the intermediate gears 16 are located between the corresponding two adjacent synchronous gears 14 and mesh with the corresponding synchronous gears 14, and the end of the synchronous shaft 13 is The top end is also connected to a hand wheel 17.
  • one end of the generated long aluminum rod 7 is inserted into a straightening cavity 6 of corresponding size, and then the reduction motor 10 is controlled to operate.
  • the driving gear 9 at the driving end is driven to rotate, thereby driving multiple driving gears 9 to rotate synchronously through multiple reversing gears 11, that is, controlling multiple lower straightening rollers 4 to rotate synchronously, thereby cooperating with the upper straightening roller 3 to extrude and push the long aluminum rod 7 through multiple straightening cavities 6 in sequence, thereby utilizing the extrusion force to straighten the long aluminum rod 7, thereby ensuring that the long aluminum rod 7 can smoothly enter the subsequent hot shear extruder, and at the same time can reduce the output of waste at its end in the hot shear extruder, thereby reducing Low production cost.
  • the hand wheel 17 can be turned accordingly according to the size of the long aluminum bar 7 to be straightened, so that through the synchronous driving action of multiple synchronous gears 14 and the intermediate gear 16, multiple synchronous shafts 13 can be raised and lowered synchronously, and multiple lifting seats 8 can be controlled to drive the upper straightening roller 3 to rise and fall, so as to change the size of the straightening cavity 6 formed between the lower straightening roller 4, so that long aluminum bars 7 of different specifications can be straightened.
  • the straightening cavities 6 at the same height are of different sizes, so that long aluminum bars 7 of different specifications can be straightened synchronously, which improves practicality.
  • a reciprocating gear 18 meshing with the driving gear is also rotatably mounted on one side of the vertical seat 2
  • a vertical plate 19 is mounted on one side of the vertical seat 2 on the corresponding side
  • a horizontal card slot 20 is opened on the vertical plate 19
  • a slide seat 21 is slidably mounted in the horizontal card slot 20
  • one side of the reciprocating gear 18 and one side of the slide seat 21 are both rotatably connected to the same driving connecting rod 22
  • a rubber seat 24 is mounted on the inner wall of one side of the slide seat 21 and the fixed seat 23
  • the bottom side of the rubber seat 24 is connected to the slide seat 21 or
  • the distance between the inner walls of the bottom side of the fixed seat 23 is consistent with the thickness of the aluminum frame 31.
  • a chamfer 25 is also provided on one end edge of the rubber seat 24.
  • a group of guide strips 26 are connected to the inner walls of the bottom sides of the slide seat 21 and the fixed seat 23.
  • the cylinder 27 is installed on the top of the slide seat 21 and the fixed seat 23, and the telescopic end of the cylinder 27 penetrates into the inside of the slide seat 21 or the fixed seat 23, and is fixedly connected with a lifting plate 28 that matches the position of the corresponding rubber seat 24.
  • the bottom of the lifting plate 28 is connected to a rubber pad 29 that fits the top of the aluminum frame 31.
  • the reduction motor 10 is provided with a controller electrically connected thereto, and a pressure sensor 30 corresponding to the end position of the aluminum frame 31 is provided on the inner wall of one side of the slide 21 and the fixed seat 23, and the pressure sensor 30 is electrically connected to the controller.
  • the active gear drives the reciprocating gear 18 meshing therewith to rotate, so that under the guidance of the horizontal slot 20, the slide 21 is pushed to move horizontally in the positive direction through the driving connecting rod 22, at this time, the aluminum frame 3 after quenching is 1, under the guidance of the guide bar 26, is pushed into the fixed seat 23 and sleeved on the rubber seat 24 at the corresponding end until one end of the aluminum frame 31 contacts the pressure sensor 30 on the side. At this time, the aluminum frame 31 remains horizontally placed.
  • the rubber seat 24 on the slide seat 21 is butt-sleeved on the other end of the aluminum frame 31 until the other end of the aluminum frame 31 contacts the pressure sensor 30 on the corresponding side, and then the contact signal is sent to the controller by the pressure signal.
  • the controller receives the pressure signal
  • the cylinder 27 is controlled to operate, so that its telescopic end moves downward and drives the corresponding rubber pad 29 through the lifting plate 28 to cooperate with the corresponding rubber seat 24 to press the end of the aluminum frame 31, so that with the continuous rotation of the reciprocating gear 18, the slide seat 21 moves in the opposite direction, thereby cooperating with the clamping effect of the cylinder 27 to stretch and straighten the aluminum frame 31.
  • the cylinder 27 operates in the opposite direction to release the clamping effect on the aluminum frame 31.
  • the straightened aluminum frame 31 is removed.
  • it can not only use the aluminum bar straightening machine to synchronously straighten
  • the aluminum frame 31 that is initially formed straight can achieve "one machine with two uses”. There is no need to set up an independent aluminum alloy frame straightening machine, which can reduce the production cost investment while improving the utilization rate of the production space.
  • the end of the aluminum frame 31 can also be filled to avoid flattening the end of the aluminum frame 31 during the clamping, stretching and straightening process, thereby reducing the waste output during the straightening process of the aluminum frame 31, further reducing production costs, and improving the economic benefits of the enterprise. It has a good market prospect in the industry.
  • the working principle of the present invention is as follows: after being homogenized in a homogenizing furnace, one end of the generated long aluminum bar 7 is inserted into a straightening cavity 6 of corresponding size, and then the reduction motor 10 is controlled to operate, and the driving gear 9 at the driving end is driven to rotate through the coupling and the driving gear, thereby driving multiple driving gears 9 to rotate synchronously through multiple reversing gears 11, that is, controlling multiple lower straightening rollers 4 to rotate synchronously, thereby cooperating with the upper straightening roller 3 to extrude and push the long aluminum bar 7 through multiple straightening cavities 6 in sequence, thereby utilizing the extrusion force to straighten the long aluminum bar 7, thereby ensuring that the long aluminum bar 7 can smoothly enter the subsequent hot shear extruder, and at the same time can also reduce the output of waste at its end in the hot shear extruder, reducing Production cost.
  • the hand wheel 17 can be turned accordingly according to the size of the long aluminum bar 7 to be straightened, so that through the synchronous driving action of multiple synchronous gears 14 and the intermediate gear 16, multiple synchronous shafts 13 can be raised and lowered synchronously, and multiple lifting seats 8 can be controlled to drive the upper straightening roller 3 to rise and fall, so as to change the size of the straightening cavity 6 formed between the lower straightening roller 4, so that long aluminum bars 7 of different specifications can be straightened.
  • the straightening cavities 6 at the same height are of different sizes, so that long aluminum bars 7 of different specifications can be straightened synchronously, which improves practicality.
  • the active gear drives the reciprocating gear 18 meshing with it to rotate, so that under the guidance of the horizontal slot 20, the slide 21 is pushed to move horizontally in the positive direction through the driving connecting rod 22.
  • one end of the quenched aluminum frame 31 is pushed into the fixed seat 23 under the guidance of the guide bar 26 and is sleeved on the rubber seat 24 at the corresponding end until one end of the aluminum frame 31 contacts the pressure sensor 30 on this side.
  • the aluminum frame 31 is kept horizontally placed, and with the continuous rotation of the reciprocating gear 18, the rubber seat 24 on the slide seat 21 is butt-sleeved on the other end of the aluminum frame 31 until the other end of the aluminum frame 31 contacts the pressure sensor 30 on the corresponding side, and then the contact signal is sent to the controller by the pressure signal.
  • the controller controls the cylinder 27 to operate, so that its telescopic end moves downward and drives the corresponding rubber pad 29 through the lifting plate 28 to cooperate with the corresponding rubber seat 24 to press the end of the aluminum frame 31, thereby with the continuous rotation of the reciprocating gear 18,
  • the slide 21 moves in the opposite direction, thereby cooperating with the clamping action of the cylinder 27 to stretch and straighten the aluminum frame 31.
  • the cylinder 27 operates in the opposite direction to release the clamping action on the aluminum frame 31.
  • the straightened aluminum frame 31 is removed.
  • the aluminum bar straightening machine be used to synchronously straighten the initially formed aluminum frame 31, thus realizing "one machine for two uses", but there is no need to set up an independent aluminum alloy frame straightening machine, thereby reducing the production cost investment and improving the utilization rate of the production space.
  • the end of the aluminum frame 31 can also be filled to avoid flattening the end of the aluminum frame 31 during the clamping, stretching and straightening process, thereby reducing the waste output during the straightening process of the aluminum frame 31, further reducing the production cost and improving the economic benefits of the enterprise.

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  • Mechanical Engineering (AREA)
  • Photovoltaic Devices (AREA)
  • Forging (AREA)

Abstract

本发明涉及铝型材成型技术领域，公开了一种光伏铝合金框的成型工艺，包括安装在底座上用于矫直热剪挤压所需原料铝棒的棒体矫直单元，及用于矫直铝合金框体的框体矫直单元，所述棒体矫直单元包括多组上矫直辊与下矫直辊，上矫直辊与下矫直辊之间设有矫直腔，矫直腔上套设有长棒铝材，底座上还设有用于调整上矫直辊高度的升降组件，框体矫直单元包括固定安装在垂直板一端的固定座，以及滑动安装在垂直板另一端的滑座，滑座与下矫直辊之间还设有同步组件，同步组件用于驱动滑座在下矫直辊转动时保持往复移动，且滑座与固定座上均安装有与铝型框适配的橡胶座与气缸相较于现有技术，解决了光伏铝合金框成型效率低等系列问题。

Description

一种光伏铝合金框的成型工艺 技术领域
本发明涉及铝型材成型技术领域，具体为一种光伏铝合金框的成型工艺。
背景技术
太阳能作为一种新兴能源之一，由于其无污染，成本低等特点，其应用已遍布全球，深受人们的青睐。而随着太阳能的广泛利用，太阳能光伏产业正在逐渐成为一种新兴的朝阳产业。太阳能光伏组件通常包括太阳能电池组件和边框，太阳能电池组件一般由钢化玻璃、EVA层、太阳能电池片、EVA层和背板组成，通过层压机组合为一体；而边框大多采用铝合金材质，铝质边框由若干根型材固定连接。
现有技术中，公开号为CN105537868B的中国专利文献中提出了一种光伏组件用铝边框的制备方法，通过钻注胶孔等工艺提高光伏铝合金框的性能，在组装过程中可有效避免电池板被划伤，并能提高电池板与铝边框之间粘合性能，但是该制备方法并未对热剪挤压以及张力矫直步骤作出改进，其中，在热剪挤压阶段，由于长棒铝材存在弯曲现象，不但难以进料还会导致热剪挤压的废料增多，耗材增加，另外，在张力矫直阶段，需要人工手动对挤压出的铝型材进行排序，配合独立的矫直机进行矫直，并且还会将铝型材的端部压扁，产生端部废料，众多弊端均会影响铝型材的成型效率，因此，本申请公开了一种光伏铝合金框的成型工艺来满足光伏铝合金框的生产需求。
发明内容
(一)解决的技术问题
针对现有技术的不足，本发明提供了一种光伏铝合金框的成型工艺，具备利用矫直机同步矫直原材料铝棒与成型铝合金框等优点，解决了光伏铝合金框成型效率低等系列问题。
(二)技术方案
为实现上述目的，本发明提供如下技术方案：一种光伏铝合金框的成型工艺，包括以下操作步骤：
S1、初步挤压：将粗铝棒加热后推送至挤压机中，挤出多根规格一致的铝棒；
S2、均质淬火：经S1步骤产出后的铝棒放置进均匀化炉内，改善铝棒成品的表面质量与力学性能后，通过热剪挤压方式将铝棒挤压成框体，随即将该框体经过淬火炉淬火；
S3、张力矫直：将经S2步骤处理后的铝合金框体放置在张力矫直机构上拉伸矫直；
S4、时效入库：经S3步骤处理后的铝合金框体经过人工时效去除内应力后，集中存 放于半成品库，完成光伏铝合金框的成型过程；上述制造光伏铝合金框的过程中还涉及到光伏铝合金框的矫直设备，包括安装在底座上用于矫直热剪挤压所需原料铝棒的棒体矫直单元，及用于矫直铝合金框体的框体矫直单元，所述棒体矫直单元包括相适配的多组上矫直辊与下矫直辊，所述上矫直辊与所述下矫直辊之间还设有通过开设的矫直槽而形成内径大小不一的矫直腔，所述矫直腔上套设有长棒铝材，所述底座上还设有用于调整所述上矫直辊高度的升降组件，所述框体矫直单元包括固定安装在垂直板一端的固定座，以及滑动安装在所述垂直板另一端的滑座，所述滑座与所述下矫直辊之间还设有同步组件，所述同步组件用于驱动所述滑座在所述下矫直辊转动时保持往复移动，且所述滑座与所述固定座上均安装有与铝型框适配的橡胶座与气缸。
优选地，所述底座的顶部安装有两个位置相对应的垂直座，多组所述上矫直辊与所述下矫直辊均转动安装在两个所述垂直座之间，且多个所述下矫直辊的一端均套接有驱动齿轮，相邻所述驱动齿轮之间均设有换向齿轮，所述换向齿轮转动安装在对应侧的所述垂直座上，所述垂直座的一侧还安装有减速电机，所述减速电机的输出端通过联轴器连接有与其中一个所述驱动齿轮相啮合的主动齿轮。
优选地，所述垂直座上滑动卡设有多个升降座，所述上矫直辊的两端分别套接在对应的所述升降座上，所述垂直座的顶端还安装有多个螺纹套筒，所述螺纹套筒内螺纹套接有同步轴，所述同步轴的底端转动连接在对应的所述升降座上，且多个所述同步轴的顶端均套接有同步齿轮。
优选地，所述垂直座的顶端还转动安装有多个中间轴，所述中间轴上套接有中间齿轮，所述中间齿轮位于对应相邻的两个所述同步齿轮之间并与对应的所述同步齿轮相啮合，且端部的所述同步轴的顶端还连接有手轮。
优选地，所述垂直座的一侧还转动安装有往复齿轮，所述垂直板安装在对应侧所述垂直座的一侧，且所述垂直板上开设有水平卡槽，所述滑座滑动卡设在所述水平卡槽内，所述往复齿轮的一侧与所述滑座的一侧均转动连接有同一个驱动连杆。
优选地，所述橡胶座安装在所述滑座与所述固定座的一侧内壁上，且所述橡胶座的底侧与所述滑座或所述固定座的底侧内壁之间的距离与所述铝型框的厚度一致，所述橡胶座的一端边缘还开设有倒角，所述滑座与所述固定座的底侧内壁上均连接有一组导向条。
优选地，所述气缸安装在所述滑座与所述固定座的顶部，且所述气缸的伸缩端贯穿至所述滑座或所述固定座的内部，并固定连接有与对应所述橡胶座位置相适配的升降板，所 述升降板的底部连接有与所述铝型框顶部相贴合的橡胶垫。
优选地，所述减速电机上设有与其电性连接的控制器，所述滑座与所述固定座的一侧内壁上均设有与所述铝型框端部位置相对应的压力传感器，所述压力传感器与所述控制器电性连接。
(三)有益效果
与现有技术相比，本发明提供了一种光伏铝合金框的成型工艺，具备以下有益效果：
1、该光伏铝合金框的成型工艺构，通过将生成的长棒铝材的一端插接在对应尺寸的矫直腔内，随即控制减速电机运转，通过联轴器与主动齿轮传动，驱动端部的驱动齿轮转动，从而通过多个换向齿轮，带动多个驱动齿轮同步转动，即控制多个下矫直辊同步转动，从而配合上矫直辊挤压推进长棒铝材依次贯穿多个矫直腔，从而利用挤压力矫直长棒铝材，进而确保长棒铝材能够顺利进入后续的热剪挤压机内，同时还能缩减其端部在热剪挤压机内的废料产出，减小生产成本，另外，实际操作时，还能根据待矫直长棒铝材的尺寸，对应转动手轮，从而通过多个同步齿轮与中间齿轮的同步驱动作用，使得多个同步轴同步升降，控制多个升降座带动上矫直辊升降，以改变与下矫直辊之间形成矫直腔的大小，实现对不同规格的长棒铝材均能矫直，相较于独立控制安装在每个同步轴上的多个手轮单独转动，提高了操作精度，此外，同一高度下的矫直腔尺寸不一，这样一来便能同步矫直不同规格的长棒铝材，提高了实用性。
2、该光伏铝合金框的成型工艺构，通过控制减速电机运转，间接驱动长棒铝材移动并对其矫直的过程中，主动齿轮带动与其啮合的往复齿轮转动，从而在水平卡槽的导向作用下，通过驱动连杆推动滑座水平正向移动，此时，将经过淬火后的铝型框的一端，在导向条的导向作用下，推送至固定座内并套设在对应端的橡胶座上，直至铝型框的一端与该侧的压力传感器相接触，此时的铝型框保持水平放置，伴随往复齿轮的持续转动，滑座上的橡胶座对接套设在铝型框的另一端上，直至铝型框的另一端与对应侧的压力传感器相接触，随即将该接触信号由压力信号发送至控制器，控制器接收到该压力信号后控制气缸运作，使其伸缩端下移并通过升降板带动对应的橡胶垫配合相应的橡胶座将铝型框的端部压紧，从而伴随往复齿轮的持续转动，使得滑座反向移动，从而配合气缸的夹持作用，对铝型框进行拉伸矫直，随后，气缸反向运作，解除对铝型框的夹持作用，在人工介入下，降矫直后的铝型框取下，相较于现有技术，不但能够利用铝棒矫直机同步矫直初步成型的铝型框，实现“一机两用”，无需设置独立的铝合金框矫直机，减小生产成本投入的同时，还能提高生产空间的利用率。
3、该光伏铝合金框的成型工艺构，在矫直过程中，通过与橡胶座的相互配合，还能对铝型框的端部进行填充，避免在夹持拉伸矫直过程中压扁铝型框的端部，从而减小铝型框矫直过程中的废料产出，进一步缩减生产成本，提高了企业的经济效益。
附图说明
图1为本发明光伏铝合金框的矫直设备立体结构示意图；
图2为本发明光伏铝合金框的矫直设备主视结构示意图；
图3为本发明光伏铝合金框的矫直设备侧视结构示意图；
图4为本发明图3中部分放大结构示意图；
图5为本发明光伏铝合金框的矫直设备部分立体结构示意图；
图6为本发明图5中部分立体结构示意图；
图7为本发明部分框体矫直单元立体结构示意图；
图8为本发明另一部分框体矫直单元立体结构示意图；
图9为本发明滑座立体结构示意图；
图10为本发明铝型框侧视结构示意图。
图中：1、底座；2、垂直座；3、上矫直辊；4、下矫直辊；5、矫直槽；6、矫直腔；7、长棒铝材；8、升降座；9、驱动齿轮；10、减速电机；11、换向齿轮；12、螺纹套筒；13、同步轴；14、同步齿轮；15、中间轴；16、中间齿轮；17、手轮；18、往复齿轮；19、垂直板；20、水平卡槽；21、滑座；22、驱动连杆；23、固定座；24、橡胶座；25、倒角；26、导向条；27、气缸；28、升降板；29、橡胶垫；30、压力传感器；31、铝型框。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
正如背景技术所介绍的，现有技术中存在的不足，为了解决如上的技术问题，本申请提出了一种光伏铝合金框的成型工艺。
本申请的一种典型的实施方式中，如图1-10所示，一种光伏铝合金框的成型工艺，包括以下操作步骤：
S1、初步挤压：将粗铝棒加热后推送至挤压机中，挤出多根规格一致的铝棒；
S2、均质淬火：经S1步骤产出后的铝棒放置进均匀化炉内，改善铝棒成品的表面质量与力学性能后，通过热剪挤压方式将铝棒挤压成框体，随即将该框体经过淬火炉淬火；
S3、张力矫直：将经S2步骤处理后的铝合金框体放置在张力矫直机构上拉伸矫直；
S4、时效入库：经S3步骤处理后的铝合金框体经过人工时效去除内应力后，集中存放于半成品库，完成光伏铝合金框的成型过程；
上述制造光伏铝合金框的过程中还涉及到光伏铝合金框的矫直设备，包括安装在底座1上用于矫直热剪挤压所需原料铝棒的棒体矫直单元，及用于矫直铝合金框体的框体矫直单元，棒体矫直单元包括相适配的多组上矫直辊3与下矫直辊4，上矫直辊3与下矫直辊4之间还设有通过开设的矫直槽5而形成内径大小不一的矫直腔6，矫直腔6上套设有长棒铝材7，底座1上还设有用于调整上矫直辊3高度的升降组件，框体矫直单元包括固定安装在垂直板19一端的固定座23，以及滑动安装在垂直板19另一端的滑座21，滑座21与下矫直辊4之间还设有同步组件，同步组件用于驱动滑座21在下矫直辊4转动时保持往复移动，且滑座21与固定座23上均安装有与铝型框31适配的橡胶座24与气缸27，经过均匀化炉均质后的铝棒，通过棒体矫直单元矫直处理后，能够确保铝棒顺利进入热剪挤压机内，并且减小铝棒在热剪挤压时的废料产出，另外，利用棒体矫直单元矫直铝棒的同时，还能通过运转的框体矫直单元对热剪挤压出的铝合金框体进行拉伸矫直，实现“一机两用”，无需设置独立的矫直机，减小生产成本投入的同时还能减小占用的生产空间，另外，通过设置的升降组件，还能带动多组上矫直辊3同步升降，以配合下矫直辊4适配不同尺寸的铝棒矫直使用，并且，该升降组件相较于传统的控制方式，能够优化控制多个上矫直辊3的升降精度。
作为本实施例中的一种优选实施方式，参考附图2-6，底座1的顶部安装有两个位置相对应的垂直座2，多组上矫直辊3与下矫直辊4均转动安装在两个垂直座2之间，且多个下矫直辊4的一端均套接有驱动齿轮9，相邻驱动齿轮9之间均设有换向齿轮11，换向齿轮11转动安装在对应侧的垂直座2上，垂直座2的一侧还安装有减速电机10，减速电机10的输出端通过联轴器连接有与其中一个驱动齿轮9相啮合的主动齿轮，垂直座2上滑动卡设有多个升降座8，上矫直辊3的两端分别套接在对应的升降座8上，垂直座2的顶端还安装有多个螺纹套筒12，螺纹套筒12内螺纹套接有同步轴13，同步轴13的底端转动连接在对应的升降座8上，且多个同步轴13的顶端均套接有同步齿轮14，垂直座2的顶端还转动安装有多个中间轴15，中间轴15上套接有中间齿轮16，中间齿轮16位于对应相邻的两个同步齿轮14之间并与对应的同步齿轮14相啮合，且端部的同步轴13的 顶端还连接有手轮17，经过均匀化炉均质处理后，将生成的长棒铝材7的一端插接在对应尺寸的矫直腔6内，随即控制减速电机10运转，通过联轴器与主动齿轮传动，驱动端部的驱动齿轮9转动，从而通过多个换向齿轮11，带动多个驱动齿轮9同步转动，即控制多个下矫直辊4同步转动，从而配合上矫直辊3挤压推进长棒铝材7依次贯穿多个矫直腔6，从而利用挤压力矫直长棒铝材7，进而确保长棒铝材7能够顺利进入后续的热剪挤压机内，同时还能缩减其端部在热剪挤压机内的废料产出，减小生产成本，另外，实际操作时，还能根据待矫直长棒铝材7的尺寸，对应转动手轮17，从而通过多个同步齿轮14与中间齿轮16的同步驱动作用，使得多个同步轴13同步升降，控制多个升降座8带动上矫直辊3升降，以改变与下矫直辊4之间形成矫直腔6的大小，实现对不同规格的长棒铝材7均能矫直，相较于独立控制安装在每个同步轴13上的多个手轮17单独转动，提高了操作精度，此外，同一高度下的矫直腔6尺寸不一，这样一来便能同步矫直不同规格的长棒铝材7，提高了实用性。
作为本实施例中的一种优选实施方式，参考附图3-9，垂直座2的一侧还转动安装有与主动齿轮相啮合的往复齿轮18，垂直板19安装在对应侧垂直座2的一侧，且垂直板19上开设有水平卡槽20，滑座21滑动卡设在水平卡槽20内，往复齿轮18的一侧与滑座21的一侧均转动连接有同一个驱动连杆22，橡胶座24安装在滑座21与固定座23的一侧内壁上，且橡胶座24的底侧与滑座21或固定座23的底侧内壁之间的距离与铝型框31的厚度一致，橡胶座24的一端边缘还开设有倒角25，滑座21与固定座23的底侧内壁上均连接有一组导向条26，气缸27安装在滑座21与固定座23的顶部，且气缸27的伸缩端贯穿至滑座21或固定座23的内部，并固定连接有与对应橡胶座24位置相适配的升降板28，升降板28的底部连接有与铝型框31顶部相贴合的橡胶垫29，减速电机10上设有与其电性连接的控制器，滑座21与固定座23的一侧内壁上均设有与铝型框31端部位置相对应的压力传感器30，压力传感器30与控制器电性连接，上述通过控制减速电机10运转，间接驱动长棒铝材7移动并对其矫直的过程中，主动齿轮带动与其啮合的往复齿轮18转动，从而在水平卡槽20的导向作用下，通过驱动连杆22推动滑座21水平正向移动，此时，将经过淬火后的铝型框31的一端，在导向条26的导向作用下，推送至固定座23内并套设在对应端的橡胶座24上，直至铝型框31的一端与该侧的压力传感器30相接触，此时的铝型框31保持水平放置，伴随往复齿轮18的持续转动，滑座21上的橡胶座24对接套设在铝型框31的另一端上，直至铝型框31的另一端与对应侧的压力传感器30相接触，随即将该接触信号由压力信号发送至控制器，控制器接收到该压力信号 后控制气缸27运作，使其伸缩端下移并通过升降板28带动对应的橡胶垫29配合相应的橡胶座24将铝型框31的端部压紧，从而伴随往复齿轮18的持续转动，使得滑座21反向移动，从而配合气缸27的夹持作用，对铝型框31进行拉伸矫直，随后，气缸27反向运作，解除对铝型框31的夹持作用，在人工介入下，降矫直后的铝型框31取下，相较于现有技术，不但能够利用铝棒矫直机同步矫直初步成型的铝型框31，实现“一机两用”，无需设置独立的铝合金框矫直机，减小生产成本投入的同时，还能提高生产空间的利用率，此外，在矫直过程中，通过与橡胶座24的相互配合，还能对铝型框31的端部进行填充，避免在夹持拉伸矫直过程中压扁铝型框31的端部，从而减小铝型框31矫直过程中的废料产出，进一步缩减生产成本，提高了企业的经济效益，在行业中具有良好的市场前景。
本发明工作原理：经过均匀化炉均质处理后，将生成的长棒铝材7的一端插接在对应尺寸的矫直腔6内，随即控制减速电机10运转，通过联轴器与主动齿轮传动，驱动端部的驱动齿轮9转动，从而通过多个换向齿轮11，带动多个驱动齿轮9同步转动，即控制多个下矫直辊4同步转动，从而配合上矫直辊3挤压推进长棒铝材7依次贯穿多个矫直腔6，从而利用挤压力矫直长棒铝材7，进而确保长棒铝材7能够顺利进入后续的热剪挤压机内，同时还能缩减其端部在热剪挤压机内的废料产出，减小生产成本，另外，实际操作时，还能根据待矫直长棒铝材7的尺寸，对应转动手轮17，从而通过多个同步齿轮14与中间齿轮16的同步驱动作用，使得多个同步轴13同步升降，控制多个升降座8带动上矫直辊3升降，以改变与下矫直辊4之间形成矫直腔6的大小，实现对不同规格的长棒铝材7均能矫直，相较于独立控制安装在每个同步轴13上的多个手轮17单独转动，提高了操作精度，此外，同一高度下的矫直腔6尺寸不一，这样一来便能同步矫直不同规格的长棒铝材7，提高了实用性。
以上通过控制减速电机10运转，间接驱动长棒铝材7移动并对其矫直的过程中，主动齿轮带动与其啮合的往复齿轮18转动，从而在水平卡槽20的导向作用下，通过驱动连杆22推动滑座21水平正向移动，此时，将经过淬火后的铝型框31的一端，在导向条26的导向作用下，推送至固定座23内并套设在对应端的橡胶座24上，直至铝型框31的一端与该侧的压力传感器30相接触，此时的铝型框31保持水平放置，伴随往复齿轮18的持续转动，滑座21上的橡胶座24对接套设在铝型框31的另一端上，直至铝型框31的另一端与对应侧的压力传感器30相接触，随即将该接触信号由压力信号发送至控制器，控制器接收到该压力信号后控制气缸27运作，使其伸缩端下移并通过升降板28带动对应的橡胶垫29配合相应的橡胶座24将铝型框31的端部压紧，从而伴随往复齿轮18的持续转动， 使得滑座21反向移动，从而配合气缸27的夹持作用，对铝型框31进行拉伸矫直，随后，气缸27反向运作，解除对铝型框31的夹持作用，在人工介入下，降矫直后的铝型框31取下，相较于现有技术，不但能够利用铝棒矫直机同步矫直初步成型的铝型框31，实现“一机两用”，无需设置独立的铝合金框矫直机，减小生产成本投入的同时，还能提高生产空间的利用率，此外，在矫直过程中，通过与橡胶座24的相互配合，还能对铝型框31的端部进行填充，避免在夹持拉伸矫直过程中压扁铝型框31的端部，从而减小铝型框31矫直过程中的废料产出，进一步缩减生产成本，提高了企业的经济效益。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。。

Claims (8)

  1. 一种光伏铝合金框的成型工艺，其特征在于：包括以下操作步骤：
    S1、初步挤压：将粗铝棒加热后推送至挤压机中，挤出多根规格一致的铝棒；
    S2、均质淬火：经S1步骤产出后的铝棒放置进均匀化炉内，改善铝棒成品的表面质量与力学性能后，通过热剪挤压方式将铝棒挤压成框体，随即将该框体经过淬火炉淬火；
    S3、张力矫直：将经S2步骤处理后的铝合金框体放置在张力矫直机构上拉伸矫直；
    S4、时效入库：经S3步骤处理后的铝合金框体经过人工时效去除内应力后，集中存放于半成品库，完成光伏铝合金框的成型过程；
    上述制造光伏铝合金框的过程中还涉及到光伏铝合金框的矫直设备，包括安装在底座(1)上用于矫直热剪挤压所需原料铝棒的棒体矫直单元，及用于矫直铝合金框体的框体矫直单元，所述棒体矫直单元包括相适配的多组上矫直辊(3)与下矫直辊(4)，所述上矫直辊(3)与所述下矫直辊(4)之间还设有通过开设的矫直槽(5)而形成内径大小不一的矫直腔(6)，所述矫直腔(6)上套设有长棒铝材(7)，所述底座(1)上还设有用于调整所述上矫直辊(3)高度的升降组件，所述框体矫直单元包括固定安装在垂直板(19)一端的固定座(23)，以及滑动安装在所述垂直板(19)另一端的滑座(21)，所述滑座(21)与所述下矫直辊(4)之间还设有同步组件，所述同步组件用于驱动所述滑座(21)在所述下矫直辊(4)转动时保持往复移动，且所述滑座(21)与所述固定座(23)上均安装有与铝型框(31)适配的橡胶座(24)与气缸(27)。
  2. 根据权利要求1所述的一种光伏铝合金框的成型工艺，其特征在于：所述底座(1)的顶部安装有两个位置相对应的垂直座(2)，多组所述上矫直辊(3)与所述下矫直辊(4)均转动安装在两个所述垂直座(2)之间，且多个所述下矫直辊(4)的一端均套接有驱动齿轮(9)，相邻所述驱动齿轮(9)之间均设有换向齿轮(11)，所述换向齿轮(11)转动安装在对应侧的所述垂直座(2)上，所述垂直座(2)的一侧还安装有减速电机(10)，所述减速电机(10)的输出端通过联轴器连接有与其中一个所述驱动齿轮(9)相啮合的主动齿轮。
  3. 根据权利要求2所述的一种光伏铝合金框的成型工艺，其特征在于：所述垂直座(2)上滑动卡设有多个升降座(8)，所述上矫直辊(3)的两端分别套接在对应的所述升降座(8)上，所述垂直座(2)的顶端还安装有多个螺纹套筒(12)，所述螺纹套筒(12)内螺纹套接有同步轴(13)，所述同步轴(13)的底端转动连接在对应的所述升降座(8)上，且多个所述同步轴(13)的顶端均套接有同步齿轮(14)。
  4. 根据权利要求3所述的一种光伏铝合金框的成型工艺，其特征在于：所述垂直座(2) 的顶端还转动安装有多个中间轴(15)，所述中间轴(15)上套接有中间齿轮(16)，所述中间齿轮(16)位于对应相邻的两个所述同步齿轮(14)之间并与对应的所述同步齿轮(14)相啮合，且端部的所述同步轴(13)的顶端还连接有手轮(17)。
  5. 根据权利要求2所述的一种光伏铝合金框的成型工艺，其特征在于：所述垂直座(2)的一侧还转动安装有往复齿轮(18)，所述垂直板(19)安装在对应侧所述垂直座(2)的一侧，且所述垂直板(19)上开设有水平卡槽(20)，所述滑座(21)滑动卡设在所述水平卡槽(20)内，所述往复齿轮(18)的一侧与所述滑座(21)的一侧均转动连接有同一个驱动连杆(22)。
  6. 根据权利要求5所述的一种光伏铝合金框的成型工艺，其特征在于：所述橡胶座(24)安装在所述滑座(21)与所述固定座(23)的一侧内壁上，且所述橡胶座(24)的底侧与所述滑座(21)或所述固定座(23)的底侧内壁之间的距离与所述铝型框(31)的厚度一致，所述橡胶座(24)的一端边缘还开设有倒角(25)，所述滑座(21)与所述固定座(23)的底侧内壁上均连接有一组导向条(26)。
  7. 根据权利要求6所述的一种光伏铝合金框的成型工艺，其特征在于：所述气缸(27)安装在所述滑座(21)与所述固定座(23)的顶部，且所述气缸(27)的伸缩端贯穿至所述滑座(21)或所述固定座(23)的内部，并固定连接有与对应所述橡胶座(24)位置相适配的升降板(28)，所述升降板(28)的底部连接有与所述铝型框(31)顶部相贴合的橡胶垫(29)。
  8. 根据权利要求7所述的一种光伏铝合金框的成型工艺，其特征在于：所述减速电机(10)上设有与其电性连接的控制器，所述滑座(21)与所述固定座(23)的一侧内壁上均设有与所述铝型框(31)端部位置相对应的压力传感器(30)，所述压力传感器(30)与所述控制器电性连接。
PCT/CN2023/113113 2022-11-16 2023-08-15 一种光伏铝合金框的成型工艺 WO2024103864A1 (zh)

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