光伏組件生產(chǎn)流程——串焊

串焊機(jī)是光伏組件生產(chǎn)過程中的核心設(shè)備，其主要作用是通過焊接手段，把單片電壓大約0.5V的太陽能電池片串聯(lián)起來，以達(dá)到使用所需的電壓，并形成穩(wěn)定的光伏組件。典型的太陽能板組件由60或者72片電池片組成，這些電池片需要每10或者12片通過串焊機(jī)進(jìn)行串聯(lián)焊接。

The string soldering machine is a core device in the production process of photovoltaic modules. Its main function is to connect solar cell pieces with a single voltage of about 0.5V in series through soldering to achieve the required voltage for use and form a stable photovoltaic module. A typical solar panel module consists of 60 or 72 cell pieces, which need to be connected in series by the string soldering machine every 10 or 12 pieces.

串焊用材：將電池片串聯(lián)起來，那肯定有一個用于連接兩電池片之間的導(dǎo)電介質(zhì)，這個就是光伏焊帶。

光伏焊帶是由基材和表面涂層構(gòu)成，一般是銅基鍍錫；銅材要求尺寸精確、導(dǎo)電性能好，具有一定的強(qiáng)度；表面涂層法、真空沉積法、噴涂法活熱浸法等特殊工藝，將錫合金等涂層材料按照一定的成分比例和厚度均勻地覆裹在銅基材表面。之所以要鍍錫，是因為銅的熔點(diǎn)較高，沒有良好的焊接性能，所以鍍一層錫，焊帶就能很好的焊在電池片表面的主柵上。

String Soldering Materials**: To connect the cell pieces in series, there must be a conductive medium between the two cell pieces, which is the photovoltaic soldering ribbon.

The photovoltaic soldering ribbon is composed of a base material and a surface coating, generally copperbased and tinplated; the copper material requires precise dimensions, good electrical conductivity, and certain strength; special processes such as surface coating, vacuum deposition, spraying, or hotdipping are used to evenly coat the surface of the copper base material with tin alloy and other coating materials at a certain component ratio and thickness. The reason for tin plating is that copper has a high melting point and does not have good soldering properties. Therefore, a layer of tin is plated so that the soldering ribbon can be well soldered to the main grid on the surface of the cell piece.

除開串頭和串尾的焊帶只有電池片長度多一點(diǎn)，中間的焊帶長度大概為2塊半片電池片長度，它從一片電池片的背面，連接到另一個電池片的正面，這樣兩片電池片便形成了串聯(lián)，重復(fù)這一步驟，便可以將多個電池片串聯(lián)起來。

Except for the soldering ribbons at the beginning and end of the string, which are only slightly longer than the length of the cell piece, the length of the middle soldering ribbon is about 2.5 times the length of a cell piece. It connects from the back of one cell piece to the front of another cell piece, thus forming a series connection between the two cell pieces. By repeating this step, multiple cell pieces can be connected in series.

了解完焊帶和電池片串，下面我簡單介紹一下串焊機(jī)串焊機(jī)：它是利用機(jī)械傳動裝置，將電池片串聯(lián)焊接在一起的機(jī)器。組成部分：放線軸：放置焊帶卷的地方，它會隨著機(jī)器的運(yùn)轉(zhuǎn)，不斷的選擇放出焊帶。（一般情況下，焊帶都是一卷一卷的）上料系統(tǒng)：吸盤會將電池片從料盒里面吸上來放置皮帶上，并傳輸至CCD檢測平臺上CCD系統(tǒng)：CCD系統(tǒng)可以對電池片進(jìn)行拍照并識別，主要是檢查電池片有沒有破損，或位置偏移等。

After understanding the soldering ribbon and cell string, I will briefly introduce the string soldering machine: It is a machine that uses a mechanical transmission device to connect cell pieces in series by soldering. Components: Pay-off reel: The place to put the soldering ribbon roll, it will continuously release the soldering ribbon as the machine operates. (Generally, the soldering ribbon is in rolls) Feeding system: The suction cup will pick up the cell piece from the material box and place it on the belt, and then transport it to the CCD inspection platform. CCD system: The CCD system can take pictures of the cell piece and identify it, mainly to check whether the cell piece is damaged or has position deviation.

焊帶拉伸系統(tǒng)：主要是完成焊帶的拉伸，切斷，放置到電池片上等動作。

機(jī)械臂系統(tǒng)：機(jī)械臂會抓取電池片放置在焊帶上，并同時抓取加熱工裝放置在前一電池片上。

焊接系統(tǒng)：串聯(lián)好的電池片會在傳送帶上經(jīng)過加熱燈箱，加熱燈箱會將熱量傳導(dǎo)到加熱工裝上，這樣焊帶便和電池片焊接在一起了。

分串系統(tǒng)：電池串連續(xù)焊接時，兩個電池串中間會預(yù)留好足夠長的焊帶，經(jīng)過分串處會被分開來，144半片版型一般是12個半片為一串。

EL檢測系統(tǒng)：檢測電池串有無缺陷的，如隱裂、虛焊、焊帶搭接等等。

Soldering ribbon stretching system: Mainly to complete the stretching, cutting, and placing of the soldering ribbon on the cell piece.

Mechanical arm system: The mechanical arm will pick up the cell piece and place it on the soldering ribbon, and at the same time pick up the heating fixture and place it on the previous cell piece.

Welding system: The cell pieces connected in series will pass through the heating lamp box on the conveyor belt, and the heat from the heating lamp box will be conducted to the heating fixture, so that the soldering ribbon is welded to the cell piece.

String separation system: When the cell strings are continuously welded, a sufficiently long soldering ribbon will be reserved between two cell strings, and they will be separated at the string separation position. For the 144 halfpiece version, generally 12 half-pieces are in one string.

EL inspection system: To detect defects in the cell string, such as microcracks, virtual soldering, soldering ribbon overlap, etc.

第一步，焊帶拉伸系統(tǒng)會拉伸出一根焊帶放置在傳輸皮帶上，然后機(jī)械臂會抓取一片電池片放置在焊帶頭上。

第二步，焊帶拉伸系統(tǒng)再次拉伸出一根焊帶放置到位,其中有一部分會搭在電池片上方，并預(yù)留下一電池片的位置

第三步，機(jī)械臂同時抓取電池片和加熱工裝，電池放置在焊帶預(yù)留的電池片位置上，加熱工裝放置在電池片上，會將焊帶與電池片緊緊壓在一起。

第四步焊帶拉伸系統(tǒng)再次拉伸焊帶放置到位，和焊帶一樣，搭在前一電池片上方，并預(yù)留下一電池片位置。

第五步，機(jī)械臂抓取電池片和工裝放置到位

串焊機(jī)就是不斷重復(fù)以上步驟，將電池片串聯(lián)焊接在一起的，如果設(shè)定電池串?dāng)?shù)量為12片電池片的話，在第12到13片電池片之間的間距會更長，焊帶也更長，到分串位置就會被切斷。

Step one, the soldering ribbon stretching system will stretch out a soldering ribbon and place it on the transmission belt, and then the mechanical arm will pick up a cell piece and place it on the head of the soldering ribbon.

Step two, the soldering ribbon stretching system will stretch out another soldering ribbon and place it in position, with a part of it overlapping on the cell piece and reserving the position for the next cell piece.

Step three, the mechanical arm will pick up the cell piece and the heating fixture at the same time, place the cell piece on the reserved position on the soldering ribbon, and place the heating fixture on the cell piece, which will tightly press the soldering ribbon and the cell piece together.

Step four, the soldering ribbon stretching system will stretch the soldering ribbon and place it in position again, overlapping on the previous cell piece and reserving the position for the next cell piece.

Step five, the mechanical arm will pick up the cell piece and the fixture and place them in position.

The string soldering machine continuously repeats the above steps to connect the cell pieces in series by soldering. If the number of cell pieces in the string is set to 12, the spacing between the 12th and 13th cell pieces will be longer, and the soldering ribbon will also be longer, which will be cut at the string separation position.

下面說一下串焊常見的問題；

虛焊：在EL成像上虛焊位置顯示為黑色，這會導(dǎo)致組件功率下降，甚至可能出現(xiàn)層壓時焊帶脫落搭到其他電池串上，引起組件內(nèi)部短路；一般是焊接溫度過低或焊接時間過短導(dǎo)致。

焊帶偏離主柵：焊帶焊接電池片主要是焊接在電池的主柵上，如果焊帶偏離主柵，容易造成虛焊、內(nèi)部組件電阻增大（主柵是收集和傳輸電流，焊帶偏移會讓內(nèi)部電子需要傳輸?shù)木嚯x增加）、遮擋電池片影響發(fā)電效率（柵線位置并不能發(fā)電，再加上焊帶偏移也會遮擋部分電池片面積，這樣電池片發(fā)電效率會下降）。

Let's talk about the common problems of string soldering;

Virtual soldering: In EL imaging, the virtual soldering position is displayed in black, which will lead to a decrease in the power of the component, and may even cause the soldering ribbon to fall off and overlap with other cell strings during lamination, causing a short circuit inside the component. It is generally caused by too low soldering temperature or too short soldering time.

Soldering ribbon deviating from the main grid: The soldering ribbon is mainly soldered to the main grid of the cell. If the soldering ribbon deviates from the main grid, it is easy to cause virtual soldering, increase the internal resistance of the component (the main grid collects and transmits current, and the deviation of the soldering ribbon will increase the distance that the internal electrons need to travel), and block the cell to affect the power generation efficiency (the grid line position cannot generate electricity, and the deviation of the soldering ribbon will also block part of the cell area, which will reduce the power generation efficiency of the cell).