太陽能電池片激光劃片機(jī)不同大小片劃片問題解決方案

2000型劃片機(jī)系列，是針對目前光伏市場所使用的主流硅材料太陽能電池的劃片加工所開發(fā)的一款機(jī)型。相較于傳統(tǒng)的手動劃片機(jī)，2000型自動劃片機(jī)擁有自動上下料、自動裂片等多項(xiàng)新功能。該機(jī)型劃片速度快，結(jié)構(gòu)緊湊性價比高，很好的滿足了中小型新能源企業(yè)的生產(chǎn)需求。

The 2000 series of solar cell laser scribing machines is designed for the scribing process of mainstream silicon-based solar cells in the photovoltaic market. Compared with traditional manual scribing machines, the 2000 series automatic scribing machine features multiple new functions such as automatic loading and unloading, and automatic cell breaking. This model is characterized by its fast scribing speed, compact structure, and high cost-effectiveness, meeting the production needs of small and medium-sized new energy enterprises well.

經(jīng)過多次的迭代升級，2000型自動劃片機(jī)已經(jīng)是一款穩(wěn)定且高效的機(jī)型。但在日常使用過程中，操作員的不規(guī)范使用可能會導(dǎo)致設(shè)備的穩(wěn)定性降低影響產(chǎn)品質(zhì)量。這里以自動裂片機(jī)為例收集了一些生產(chǎn)中的常見問題，為大家提供一些解決辦法。

After multiple iterations and upgrades, the 2000 series automatic scribing machine has become a stable and efficient model. However, improper use by operators in daily operations may reduce the stability of the equipment and affect product quality. Here, we have collected some common issues in production using the automatic cell breaking machine and provide some solutions.

一、大小片

1. 電池片自身誤差：

由于2000型劃片機(jī)采用的機(jī)械定位方式，這就導(dǎo)致客戶生產(chǎn)過程中可能出現(xiàn)的不同批次的電池片本身存在的尺寸誤差，影響最后產(chǎn)品的一致性。如果在生產(chǎn)中出現(xiàn)更換電池片導(dǎo)致的大小片問題時，可以通過軟件修改劃片程序的原點(diǎn)位置來調(diào)整劃片大小。

I. Size inconsistency of solar cells

1. Inherent size errors of solar cells:

The 2000 series scribing machine uses a mechanical positioning method, which can lead to size variations in solar cells from different batches during production. This affects the consistency of the final product. If size inconsistency occurs due to a change in solar cells during production, the size of the scribed cells can be adjusted by modifying the origin position of the scribing program in the software.

2. 電池片沒有靠邊導(dǎo)致無法定位：

實(shí)際生產(chǎn)過程中有多種因素會影響到劃片機(jī)的自動定位，最終結(jié)果就是出現(xiàn)大小片。在一些客戶的現(xiàn)場生產(chǎn)中，會有多臺設(shè)備共用一條供氣管道的情況，平時生產(chǎn)中可能也沒有發(fā)現(xiàn)問題，一旦出現(xiàn)多臺設(shè)備的多個氣動組件一起動作時就可能造成氣壓的瞬間降低。這種情況下取片過程中電池片就可能與吸盤發(fā)生相對運(yùn)動，導(dǎo)致吸盤到位電池片卻無法接觸定位檔條定位失敗。如果確實(shí)不能改善供氣條件時，可以將整機(jī)調(diào)壓閥調(diào)整到一個相對穩(wěn)定同時盡可能高的高位。同時調(diào)整吸盤的氣流量，保證吸附電池片產(chǎn)生的負(fù)壓能夠正常觸發(fā)壓力開關(guān)即可。

2. Solar cells not positioned properly:

In actual production, various factors can affect the automatic positioning of the scribing machine, resulting in size inconsistency. In some production sites, multiple machines share a single air supply line. While this may not cause issues during normal operation, simultaneous actions of multiple pneumatic components in different machines can lead to a sudden drop in air pressure. During the process of picking up the solar cells, this can cause relative movement between the solar cells and the suction cup, leading to positioning failure as the solar cells cannot contact the positioning stopper. If it is not possible to improve the air supply conditions, the machine's pressure regulator can be adjusted to a relatively stable and as high a position as possible. At the same time, the air flow of the suction cup should be adjusted to ensure that the negative pressure generated by the suction cup can normally trigger the pressure switch.

二、電池片劃完以后掰不開

1. 劃片臺平面度達(dá)不到要求：

生產(chǎn)運(yùn)輸過程中的震動和撞擊都有可能會導(dǎo)致劃片臺的平面度發(fā)生變化，臺面不平就會導(dǎo)致激光掃過的切割線深度不均勻或者深度不夠。如果是在劃片臺受到?jīng)_擊后其它參數(shù)不變的情況下劃不開電池片，則可以判定是劃片臺的平面度出了問題。平面度變化后，我們需要利用百分表矯正劃片臺的平面度，保證激光軸與劃片臺上表面各個點(diǎn)位的相對高度保持一致，誤差需在0.04mm以內(nèi)。

II. Solar cells cannot be separated after scribing

1. Insufficient planarity of the scribing table:

Vibrations and impacts during production and transportation can change the planarity of the scribing table. An uneven table surface can lead to uneven or insufficient depth of the laser cut lines. If the solar cells cannot be separated after scribing and the other parameters remain unchanged after the scribing table has been impacted, it can be concluded that the planarity of the scribing table is the issue. After the planarity has changed, we need to use a dial gauge to correct the planarity of the scribing table, ensuring that the relative height between the laser axis and each point on the surface of the scribing table is consistent, with an error tolerance of less than 0.04mm.

2. 激光聚焦點(diǎn)不在劃片臺上表面：

激光焦點(diǎn)位置丟失，只需要調(diào)整聚焦鏡與臺面的距離，重新將焦點(diǎn)控制在電池片的上表面即可。首先我們需要將激光的輸出功率調(diào)低到5%~10%,將聚焦鏡移動至劃片臺正上方放上電池片后打開激光。松開聚焦鏡上方的鎖定環(huán)，順時針轉(zhuǎn)動聚焦鏡，觀察激光光斑由亮轉(zhuǎn)暗，光斑消失后停止。此時記下聚焦鏡編號標(biāo)簽所指向的方位，然后逆時針轉(zhuǎn)動聚焦鏡，光斑出現(xiàn)后繼續(xù)轉(zhuǎn)動直至光斑再次消失記下此時標(biāo)簽紙方位。記下兩個極限位置時標(biāo)簽紙所處的方位以后，再將聚焦鏡轉(zhuǎn)回到兩個位置的中間位置即可。

2. The laser focus is not on the surface of the scribing table:

If the laser focus is lost, simply adjust the distance between the focusing lens and the table surface to reposition the focus on the upper surface of the solar cell. First, reduce the laser output power to 5%–10%, move the focusing lens directly above the scribing table, place the solar cell, and then turn on the laser. Loosen the locking ring above the focusing lens, and turn the focusing lens clockwise. Observe the laser spot becoming darker and then disappearing. Stop when the spot disappears. Note the direction indicated by the focusing lens label at this point. Then, turn the focusing lens counterclockwise. When the spot reappears, continue turning until it disappears again and note the direction of the label. After noting the directions at the two extreme positions, turn the focusing lens back to the midpoint between these two positions.

三、裂片時崩角

1. 劃片時預(yù)留給加減速的區(qū)間不夠：

劃片時由于各個軸需要從零開始加速，加減速過程直接劃片就會因?yàn)樗俣茸兓瘜?dǎo)致劃片深度不一致從而產(chǎn)生崩角。建議繪制劃片軌跡時，軌跡兩端超出電池片15~20mm。

III. Chipping during cell breaking

1. Insufficient allowance for acceleration and deceleration during scribing:

During scribing, each axis needs to accelerate from zero. If scribing occurs directly during the acceleration and deceleration process, the varying speed can lead to inconsistent scribing depth, resulting in chipping. It is recommended that when drawing the scribing trajectory, the ends of the trajectory should extend 15–20mm beyond the solar cell.

2. 電池片放置位置偏移導(dǎo)致無法吸附：

我們首先需要取出兩個上料盒觀察料盒擋邊位置是否一致，兩個料盒擋邊位置不一致會導(dǎo)致輪換料盒時兩次上料位置變化。兩個上料盒調(diào)整一致后再重新調(diào)整左右劃片臺整料位，保證整料完成后電池片能夠覆蓋劃片臺的邊緣吸附孔即可。

2. Solar cells not being adsorbed due to placement offset:

First, we need to take out the two loading boxes and check if the positions of the box edges are consistent. Inconsistent edge positions of the two boxes can cause changes in the loading positions when switching between boxes. After adjusting the two loading boxes to be consistent, readjust the material positions on the left and right scribing tables to ensure that the solar cells cover the edge suction holes of the scribing table after material alignment.