串焊機(jī)：光伏組件制造的核心利器

在光伏組件的生產(chǎn)過程中，串焊機(jī)是實(shí)現(xiàn)電池片串聯(lián)的關(guān)鍵設(shè)備。它通過自動化焊接技術(shù)，將單個電池片精準(zhǔn)連接，形成電池串，進(jìn)而完成組件的電氣連接。今天，我們將深入解析高速串焊機(jī)的工作原理和機(jī)械構(gòu)造，帶您了解這一設(shè)備在光伏制造中的重要作用。

In the production process of photovoltaic modules, the stringing machine is a key device for the series connection of solar cells. It connects individual solar cells precisely through automated welding technology to form cell strings, thereby completing the electrical connection of the module. Today, we will delve into the working principle and mechanical structure of the high-speed stringing machine to help you understand the important role of this equipment in photovoltaic manufacturing.

一、串焊機(jī)的工作原理

（一）自動進(jìn)料

串焊機(jī)的自動化進(jìn)料系統(tǒng)是整個焊接流程的起點(diǎn)。焊帶通過專用的送帶機(jī)構(gòu)自動運(yùn)行至主機(jī)，同時，電池片通過自動進(jìn)料機(jī)構(gòu)被精準(zhǔn)送入焊接系統(tǒng)。這一過程實(shí)現(xiàn)了物料的自動化供應(yīng)，確保焊接過程的連續(xù)性和高效性。

1. Automatic Feeding

The automatic feeding system of the stringing machine is the starting point of the entire welding process. The solder ribbon is automatically conveyed to the main machine through a dedicated ribbon feeding mechanism, while the solar cells are precisely fed into the welding system through the automatic feeding mechanism. This process achieves the automated supply of materials, ensuring the continuity and efficiency of the welding process.

（二）焊帶處理

焊帶在進(jìn)入焊接環(huán)節(jié)之前，需要經(jīng)過處理。在處理機(jī)構(gòu)中，焊帶首先被涂抹助焊劑，助焊劑的作用是降低焊接界面的表面張力，提高焊接的潤濕性和可靠性。隨后，焊帶被自動切斷至合適的長度，以匹配電池片的尺寸，為后續(xù)的焊接做好準(zhǔn)備。

2. Ribbon Processing

Before entering the welding stage, the solder ribbon needs to be processed. In the processing mechanism, the ribbon is first coated with flux. The flux reduces the surface tension of the welding interface, improving the wetting and reliability of the welding. Subsequently, the ribbon is automatically cut to the appropriate length to match the size of the solar cells, preparing for the subsequent welding.

（三）電池片預(yù)熱

焊接前的預(yù)熱是提高焊接質(zhì)量和效率的關(guān)鍵步驟。電池片通過下部預(yù)熱單元進(jìn)行預(yù)熱，預(yù)熱單元通常采用加熱板或熱風(fēng)裝置，將電池片加熱至設(shè)定溫度。預(yù)熱可以減少焊接過程中的熱應(yīng)力，避免因溫差過大導(dǎo)致的電池片損壞，同時提高焊接效率。

3. Preheating of Solar Cells

Preheating before welding is a crucial step to improve welding quality and efficiency. The solar cells are preheated through a lower preheating unit, which usually uses a heating plate or a hot air device to heat the cells to a set temperature. Preheating reduces thermal stress during the welding process, prevents cell damage caused by excessive temperature differences, and increases welding efficiency.

（四）焊接

焊接是串焊機(jī)的核心環(huán)節(jié)。焊帶與電池片在加熱底板上通過熱風(fēng)管的高溫氣體或激光束的加熱作用進(jìn)行焊接。焊接過程中，壓板施加一定的壓力，使焊帶與電池片緊密接觸，形成牢固的焊接點(diǎn)。焊接溫度和壓力的精確控制是確保焊接質(zhì)量的關(guān)鍵因素。

4. Welding

Welding is the core process of the stringing machine. The solder ribbon and solar cells are welded together on the heated base plate through the heating action of high-temperature gas from the hot air pipe or a laser beam. During the welding process, a pressure plate applies a certain pressure to ensure close contact between the ribbon and the cells, forming a strong weld point. The precise control of welding temperature and pressure is the key to ensuring welding quality.

（五）質(zhì)量檢測與收集

焊接完成后，焊接質(zhì)量需要進(jìn)行嚴(yán)格檢測。串焊機(jī)配備CCD外觀檢測及定位系統(tǒng)，通過高分辨率攝像頭和圖像處理軟件，對焊接點(diǎn)的外觀、尺寸和位置進(jìn)行檢測。合格的電池串通過翻面收集機(jī)構(gòu)自動收集整理，進(jìn)入下一工序。

5. Quality Inspection and Collection

After welding is completed, the welding quality needs to be strictly inspected. The stringing machine is equipped with a CCD appearance inspection and positioning system, which uses high-resolution cameras and image processing software to inspect the appearance, size, and position of the weld points. Qualified cell strings are automatically collected and sorted by the flipping collection mechanism and then proceed to the next process.

二、串焊機(jī)的機(jī)械構(gòu)造

（一）CTM-60BC自動串焊機(jī)

以中步擎天串焊機(jī)CTM-60BC，是一款集成多種功能的高效設(shè)備。它集成了電池片抓取、輸送、定位、預(yù)熱、焊接和冷卻等功能，具備高精度的運(yùn)動控制系統(tǒng)和溫度控制系統(tǒng)，能夠?qū)崿F(xiàn)自動化、高效率的焊接生產(chǎn)。

1. CTM-60BC Automatic Stringing Machine

The CTM-60BC stringing machine from Chintiyan(zbqt) Energy is a highly efficient device that integrates multiple functions. It integrates functions such as solar cell picking, conveying, positioning, preheating, welding, and cooling, and is equipped with a high-precision motion control system and a temperature control system, enabling automated and highly efficient welding production.

（二）電池片上料系統(tǒng)

電池片上料系統(tǒng)包括料盒裝載臺和自動上料機(jī)構(gòu)。料盒裝載臺用于放置電池片料盒，自動上料機(jī)構(gòu)則負(fù)責(zé)將電池片有序、無損地送至焊接工位，確保物料供應(yīng)的穩(wěn)定性和可靠性。

2. Solar Cell Feeding System

The solar cell feeding system includes a cassette loading table and an automatic feeding mechanism. The cassette loading table is used to place the solar cell cassettes, while the automatic feeding mechanism is responsible for orderly and undamaged delivery of the cells to the welding station, ensuring the stability and reliability of material supply.

（三）視覺識別系統(tǒng)

視覺識別系統(tǒng)是串焊機(jī)的“眼睛”。高分辨率攝像頭配合圖像處理軟件，能夠?qū)崟r捕捉和分析電池片的位置、角度和邊緣等特征。通過精確的視覺定位，確保焊接過程的高精度和高質(zhì)量。

3. Vision Recognition System

The vision recognition system is the "eye" of the stringing machine. High-resolution cameras, in conjunction with image processing software, can capture and analyze the position, angle, and edges of the solar cells in real time. Through precise visual positioning, it ensures the high precision and high quality of the welding process.

（四）預(yù)熱裝置

預(yù)熱裝置是焊接前的重要環(huán)節(jié)。它通過加熱元件對電池片和焊帶進(jìn)行預(yù)熱，使焊接材料達(dá)到合適的溫度，減少焊接過程中的熱應(yīng)力，提高焊接質(zhì)量。

4. Preheating Device

The preheating device is an important part before welding. It preheats the solar cells and solder ribbon through heating elements, bringing the welding materials to a suitable temperature to reduce thermal stress during the welding process and improve welding quality.

（五）焊接單元

焊接單元是串焊機(jī)的核心部件，包括焊帶送進(jìn)系統(tǒng)和平移/壓緊機(jī)構(gòu)。焊帶送進(jìn)系統(tǒng)能夠精確控制焊帶的長度和送進(jìn)速度，確保焊接過程中焊帶的穩(wěn)定供應(yīng)。平移/壓緊機(jī)構(gòu)則在焊接過程中施加適當(dāng)?shù)膲毫?，保證焊帶與電池片的緊密接觸。

5. Welding Unit

The welding unit is the core component of the stringing machine, including the ribbon feeding system and the translation/pressure mechanism. The ribbon feeding system can precisely control the length and feeding speed of the ribbon, ensuring the stable supply of the ribbon during the welding process. The translation/pressure mechanism applies appropriate pressure during welding to ensure close contact between the ribbon and the solar cells.

（六）溫度控制系統(tǒng)

溫度控制系統(tǒng)是確保焊接質(zhì)量的關(guān)鍵。通過精確控制焊接區(qū)域的溫度，溫度控制系統(tǒng)能夠保證焊點(diǎn)的質(zhì)量符合工藝要求，同時避免電池片因過熱而受到損害。

6. Temperature Control System

The temperature control system is key to ensuring welding quality. By precisely controlling the temperature of the welding area, the temperature control system ensures that the quality of the weld points meets process requirements and prevents the solar cells from being damaged by excessive heat.

（七）冷卻系統(tǒng)

焊接完成后，冷卻系統(tǒng)迅速對電池片進(jìn)行冷卻。冷卻過程不僅能夠固化焊點(diǎn)，還能降低熱應(yīng)力，防止電池片因高溫而產(chǎn)生變形或損壞。

7. Cooling System

After welding is completed, the cooling system quickly cools the solar cells. The cooling process not only solidifies the weld points but also reduces thermal stress, preventing the cells from deforming or being damaged due to high temperatures.

（八）質(zhì)量檢測系統(tǒng)

質(zhì)量檢測系統(tǒng)通常采用AOI（自動光學(xué)檢測）設(shè)備。AOI設(shè)備能夠在線或離線檢測焊接質(zhì)量和電池片的完整性，及時發(fā)現(xiàn)焊接缺陷，確保產(chǎn)品的高質(zhì)量。

8. Quality Inspection System

The quality inspection system usually uses AOI (Automatic Optical Inspection) equipment. AOI equipment can detect welding quality and the integrity of solar cells online or offline, promptly identifying welding defects to ensure high product quality.

（九）自動化傳送系統(tǒng)自動化傳送系統(tǒng)負(fù)責(zé)將完成焊接的電池串轉(zhuǎn)移到下一工序，如層壓、裝框等。傳送系統(tǒng)的自動化設(shè)計提高了生產(chǎn)效率，減少了人工干預(yù)。

9. Automated Conveying SystemThe automated conveying system is responsible for transferring the welded cell strings to the next process, such as lamination and framing. The automated design of the conveying system improves production efficiency and reduces manual intervention.

（十）工藝監(jiān)控和數(shù)據(jù)分析系統(tǒng)工藝監(jiān)控和數(shù)據(jù)分析系統(tǒng)是串焊機(jī)的“大腦”。它能夠?qū)崟r收集和分析生產(chǎn)過程中的大量數(shù)據(jù)，幫助優(yōu)化工藝參數(shù)，提高串焊制程的穩(wěn)定性和效率。

10. Process Monitoring and Data Analysis SystemThe process monitoring and data analysis system is the "brain" of the stringing machine. It can collect and analyze a large amount of data in the production process in real time, helping to optimize process parameters and improve the stability and efficiency of the stringing process.

三、總結(jié)高速串焊機(jī)是光伏組件制造中不可或缺的設(shè)備。通過自動化進(jìn)料、焊帶處理、電池片預(yù)熱、焊接、質(zhì)量檢測等一系列高效、精準(zhǔn)的操作，串焊機(jī)實(shí)現(xiàn)了電池片的快速串聯(lián)，提高了生產(chǎn)效率，確保了焊接質(zhì)量。其復(fù)雜的機(jī)械構(gòu)造和先進(jìn)的控制系統(tǒng)，使其在光伏制造領(lǐng)域發(fā)揮著重要作用。隨著技術(shù)的不斷進(jìn)步，串焊機(jī)將繼續(xù)為光伏產(chǎn)業(yè)的高效發(fā)展提供有力支持。

III. ConclusionThe high-speed stringing machine is an indispensable device in photovoltaic module manufacturing. Through a series of efficient and precise operations such as automatic feeding, ribbon processing, preheating of solar cells, welding, and quality inspection, the stringing machine achieves the rapid series connection of solar cells, improves production efficiency, and ensures welding quality. Its complex mechanical structure and advanced control system play an important role in the photovoltaic manufacturing field. With continuous technological progress, the stringing machine will continue to provide strong support for the efficient development of the photovoltaic industry.