技术领域Technical Field
本发明申请涉及激光焊接技术领域，尤其是涉及一种接线盒的激光焊接装置及其激光焊接方法。The present invention relates to the technical field of laser welding, and in particular to a laser welding device and a laser welding method for a junction box.
背景技术Background Art
光伏太阳能组件技术是指可直接将太阳的光能转换为电能的技术，应用广泛，并且在节能减排方面的发展，成为新能源的发展的重要组成产品。太阳能光伏组件通常包括：正面玻璃，上下EVA/POE胶膜，电池串，汇流条，背板，接线盒（例如接线盒），边框等封装组成，接线盒与汇流条的引出线（即汇流条折弯部分）焊接质量的好坏直接影响了是太阳能光伏组件产品质量。Photovoltaic solar module technology refers to the technology that can directly convert the sun's light energy into electrical energy. It is widely used and has become an important component of the development of new energy in terms of energy conservation and emission reduction. Solar photovoltaic modules usually include: front glass, upper and lower EVA/POE films, battery strings, bus bars, back panels, junction boxes (such as junction boxes), frames and other packaging components. The quality of the welding between the junction box and the lead wire of the bus bar (i.e. the bent part of the bus bar) directly affects the quality of the solar photovoltaic module product.
现有接线盒（接线盒）与汇流条的引出线的焊接技术中，通常焊接方式包括：（1）烙铁热压焊接；（2）电阻热压焊接；（3）电磁焊接（涡流）。其中，烙铁热压焊接，它通过加热丝（通常是电热丝）产生热量，在通电的情况下，加热丝被加热，从而将热量传递给烙铁头，使其温度上升进行焊接。电阻热压焊接：是指利用电流通过焊件及接触处产生的电阻热作为热源将焊件局部加热，同时加压进行焊。电磁焊接（涡流）：电磁焊接原理是利用电流在金属导体中产生热效应，将两个或多个金属工件通过电磁力迫使接触面，紧密结合的一种焊接方法。In the existing welding technology of the lead wires of the junction box (junction box) and the busbar, the common welding methods include: (1) soldering iron hot pressure welding; (2) resistance hot pressure welding; (3) electromagnetic welding (eddy current). Among them, soldering iron hot pressure welding generates heat through a heating wire (usually an electric heating wire). When the power is turned on, the heating wire is heated, thereby transferring the heat to the soldering iron tip, causing its temperature to rise for welding. Resistance hot pressure welding: refers to using the resistance heat generated by the current passing through the weldment and the contact point as a heat source to locally heat the weldment, and at the same time pressurize it for welding. Electromagnetic welding (eddy current): The principle of electromagnetic welding is to use the current to generate a thermal effect in the metal conductor, and force two or more metal workpieces to contact the surface through electromagnetic force, and a welding method that is tightly combined.
烙铁热压焊接和电阻热压焊接都是需要采用热传导接触方式进行焊接，其中热传导部件在焊接加热冷却的过程中很容易产生氧化，焊接表面脏污等问题，引起焊接导热系数的失效，导致接线盒和引出线焊接虚焊脱焊，漏焊的现象发生；电磁焊接（涡流）焊接方式，采用的是电磁线圈加热，线圈在通断电的情况下容易产生元器件的老化，导致热效应的失效，产生接线盒和引出线焊接不良。Both soldering iron hot pressing welding and resistance hot pressing welding require heat conduction contact for welding. The heat conduction components are prone to oxidation during the welding heating and cooling process, and the welding surface is dirty, causing the failure of the welding thermal conductivity, resulting in cold soldering and desoldering of the junction box and lead wires, and leakage. The electromagnetic welding (eddy current) welding method uses electromagnetic coil heating. The coil is prone to aging of components when the power is on and off, resulting in failure of thermal effects and poor welding of the junction box and lead wires.
焊接前，通常会对汇流条引出线的位置进行检测，通常采用视觉检测技术，然而现有的视觉的焊接检测方式往往采用焊接引导定位和焊后检测，而焊接引导定位方式没有一个精准的定位，现有的定位方式是按照接线盒外形的模型去定位引导的，但是汇流条的引出线宽度要比接线盒穿孔位间距小，就存在了一个向上，或者向下的一个偏移，导致热源的焊头无法正常通过视觉检测引导焊接到汇流条的引出线与接线盒内部的焊盘之间，导致接线盒和引出线焊接失效。而且，实际过程中，影响焊接稳定性通常包括多个因素，例如：焊接前汇流条的外面，长度，宽度，形态，汇流条角度，表面有无脏污，焊接前的视觉检测不全面，都有引发接线盒和引出线焊接不良的发生。Before welding, the position of the busbar lead wire is usually inspected, usually using visual inspection technology. However, the existing visual welding inspection method often uses welding guidance positioning and post-weld inspection, and the welding guidance positioning method does not have an accurate positioning. The existing positioning method is to guide the positioning according to the model of the junction box shape, but the width of the busbar lead wire is smaller than the spacing of the junction box perforation position, so there is an upward or downward offset, which causes the welding head of the heat source to be unable to be guided by visual inspection to weld between the busbar lead wire and the pad inside the junction box, resulting in failure of the junction box and lead wire welding. Moreover, in the actual process, the factors that affect welding stability usually include multiple factors, such as: the appearance, length, width, shape, angle of the busbar before welding, whether the surface is dirty, and incomplete visual inspection before welding, which can cause poor welding of the junction box and the lead wire.
焊接后，通常需要对接线盒和引出线焊接质量检测，但是现有焊接后检测技术，只能通过如下方式进行：After welding, it is usually necessary to inspect the welding quality of the junction box and lead wires. However, the existing post-welding inspection technology can only be performed in the following ways:
（1）焊接结束后通过人工肉眼去检查，以及使用人工手动借用螺丝刀等工具去检查，对于这两种情况人工检测每个人判定基准手法都存在一定的差异，以及长时间，或者疲劳度都会存在漏检的风险，并且后者还可能会对线盒的本体造成外观及性能上面的损伤及影响，影响太阳能光伏组件产品的品质；(1) After welding, it is inspected by naked eyes or manually using tools such as screwdrivers. For both cases, there are certain differences in the judgment methods of each person, and there is a risk of missed inspections due to long time or fatigue. The latter may also cause damage and impact on the appearance and performance of the main body of the junction box, affecting the quality of solar photovoltaic module products;
（2）AOI视觉焊接后检测，通过检测某个焊点时，按照一个完好的焊点建立起标准数字化图像，与实测图像进行比较，检测结果是通过还是不通过，取决于标准图像、分辨力和所用检测程序。需要大量的不良数据收集进行匹配，焊接不良问题点有很多种，例如表面锡熔化，汇流条与底板之间未焊接产生的虚焊也无法实现内部的检测，根本上难以很好提高太阳能光伏组件产品的良率和生产效率。(2) AOI visual post-welding inspection: when inspecting a certain solder joint, a standard digital image is established according to a good solder joint and compared with the measured image. Whether the inspection result is passed or not depends on the standard image, resolution and the inspection procedure used. A large amount of bad data collection is required for matching. There are many types of bad welding problems, such as surface tin melting, and the cold solder joints caused by the lack of welding between the busbar and the base plate. It is also impossible to achieve internal inspection, which fundamentally makes it difficult to improve the yield and production efficiency of solar photovoltaic module products.
发明内容Summary of the invention
本发明申请的目的在于克服现有技术中存在的缺陷，提供一种接线盒的激光焊接装置及其激光焊接方法，以部分或全部解决现有接线盒与汇流条的引出线的焊接存在焊接不良，焊接失效，焊接后无法对焊接质量进行内部检测，影响太阳能光伏组件产品的品质、良率和生产效率的技术问题。为了实现上述目的，本发明申请提供如下的技术方案：The purpose of the present invention is to overcome the defects in the prior art and provide a laser welding device and a laser welding method for a junction box, so as to partially or completely solve the technical problems that the welding between the existing junction box and the lead wire of the bus bar is poor, welding failure, and the welding quality cannot be internally inspected after welding, which affects the quality, yield and production efficiency of solar photovoltaic module products. In order to achieve the above purpose, the present invention provides the following technical solutions:
第一方面，本发明申请提供一种接线盒的激光焊接装置，包括：激光单元、视觉检测单元、压合单元、图像射线检测单元，所述视觉检测单元连接所述压合单元；所述压合单元，对汇流条的引线和接线盒的焊盘进行贴合；所述视觉检测单元，对汇流条的引线和接线盒的焊盘贴合状态进行检测；所述激光单元，对贴合良好的汇流条的引线和接线盒的焊盘进行激光焊接；所述图像射线检测单元，对汇流条的引线和接线盒的焊盘焊接质量进行检测；所述图像射线检测单元包括图像检测部、射线检测部，所述图像检测部对焊接外观质量进行检测以获得焊接外观质量图像检测结果，所述射线检测部对焊接内外部质量进行检测以获得焊接内外部质量射线检测结果，所述图像射线检测单元对比及综合所述焊接外观质量图像检测结果和所述焊接内外部质量射线检测结果，输出汇流条的引线和接线盒的焊盘焊接质量结果。In a first aspect, the present invention provides a laser welding device for a junction box, comprising: a laser unit, a visual inspection unit, a pressing unit, and an image ray inspection unit, wherein the visual inspection unit is connected to the pressing unit; the pressing unit is used to bond the lead of a bus bar to the pad of a junction box; the visual inspection unit is used to detect the bonding state of the lead of the bus bar and the pad of the junction box; the laser unit is used to laser weld the lead of the bus bar and the pad of the junction box that are well bonded; the image ray inspection unit is used to detect the welding quality of the lead of the bus bar and the pad of the junction box; the image ray inspection unit comprises an image detection unit and a ray inspection unit, wherein the image detection unit is used to detect the welding appearance quality to obtain an image detection result of the welding appearance quality, the ray inspection unit is used to detect the internal and external quality of the welding to obtain a ray inspection result of the internal and external quality of the welding, and the image ray inspection unit compares and integrates the image detection result of the welding appearance quality and the ray inspection result of the internal and external quality of the welding, and outputs the welding quality result of the lead of the bus bar and the pad of the junction box.
可选地，所述焊接外观质量图像检测结果包括：在焊接外观图像中，两个引线上总焊缝条数为n，获取第1条焊缝，第2条焊缝，...,第n-1条焊缝和第n条焊缝的闭合轮廓，计算第1条焊缝的长度L11、宽度W11和面积S11，第2条焊缝的长度L12、宽度W12和面积S12，...,第n条焊缝的长度L1n、宽度W1n和面积S1n，第1条焊缝和第2条焊缝的间距D11，第2条焊缝和第3条焊缝的间距D12，...,第n-1条焊缝和第n条焊缝的间距D1n-1；所述焊接内外部质量射线检测结果包括：在焊接射线图像中，总焊缝条数为m，获取焊缝1，焊缝2，...,焊缝m-1和焊缝m的闭合轮廓，计算焊缝1的长度L21、宽度W21和面积S21，焊缝2的长度L22、宽度W22和面积S22，...,焊缝m的长度L2m、宽度W2m和面积S2m，焊缝1和焊缝2的间距D21，焊缝2和焊缝3的间距D22，...,焊缝m-1和焊缝m的间距D2m-1，焊接内部缺陷类型包括：未焊透、气孔、杂渣、无至少一种。Optionally, the welding appearance quality image detection result includes: in the welding appearance image, the total number of welds on the two leads is n, the closed contours of the first weld, the second weld, ..., the n-1th weld and the nth weld are obtained, and the length L11, width W11 and area S11 of the first weld, the length L12, width W12 and area S12 of the second weld, ..., the length L1n, width W1n and area S1n of the nth weld, the spacing D11 between the first weld and the second weld, the spacing D12 between the second weld and the third weld, ..., the spacing D1 between the n-1th weld and the nth weld are calculated. n-1; the welding internal and external quality radiographic detection results include: in the welding radiographic image, the total number of welds is m, the closed contours of weld 1, weld 2, ..., weld m-1 and weld m are obtained, the length L21, width W21 and area S21 of weld 1, the length L22, width W22 and area S22 of weld 2, ..., the length L2m, width W2m and area S2m of weld m, the spacing D21 between weld 1 and weld 2, the spacing D22 between weld 2 and weld 3, ..., the spacing D2m-1 between weld m-1 and weld m, and the types of internal welding defects include: incomplete penetration, pores, slag, and at least one of none.
可选地，所述图像射线检测单元包括第一匹配检测部、第二匹配检测部；所述第一匹配检测部，计算所述图像检测结果中焊缝条数与对应地所述射线检测结果中焊缝条数的比值以获得第一匹配系数P1，所述第一匹配系数P1用于评估图像检测结果中焊缝条数和对应地射线检测结果中的焊缝条数是否相等；所述第二匹配检测部，计算所述图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地所述射线检测结果中每条焊缝的长度、宽度、焊缝面积的比值，并建立焊缝序号-多个比值的散点分布图，统计位于预设区域内的落入散点总数t，计算所述落入散点总数t与总散点个数的比值以获得第二匹配系数P2，所述第二匹配系数P2用于评估所述图像检测结果中每条焊缝和对应地所述射线检测结果中每条焊缝的细节近似度。Optionally, the image radiation detection unit includes a first matching detection unit and a second matching detection unit; the first matching detection unit calculates the ratio of the number of welds in the image detection result to the corresponding number of welds in the radiation detection result to obtain a first matching coefficient P1, and the first matching coefficient P1 is used to evaluate whether the number of welds in the image detection result and the corresponding number of welds in the radiation detection result are equal; the second matching detection unit calculates the ratio of the length, width, and weld area of each weld in the image detection result to the length, width, and weld area of each weld in the radiation detection result, and establishes a scatter point distribution diagram of weld sequence number-multiple ratios, counts the total number of scatter points t falling within a preset area, and calculates the ratio of the total number of scatter points t to the total number of scatter points to obtain a second matching coefficient P2, and the second matching coefficient P2 is used to evaluate the detail similarity of each weld in the image detection result and the corresponding each weld in the radiation detection result.
可选地，所述汇流条的引线包括第一引线和第二引线，所述图像射线检测单元还包括第三匹配检测部；所述第三匹配检测部，计算所述图像检测结果中相邻两条焊缝的间距和对应地所述射线检测结果中相邻两条焊缝的间距比值以获得对比间距系数Q1；计算所述图像检测结果和对应地所述射线检测结果中所述第一引线上相邻两条焊缝的间距比值集Q11、Q12，所述第二引线上相邻两条焊缝的间距比值集Q21、Q22，利用间距比值集Q11、Q12、Q21、Q22获得相邻间距系数Q2，利用所述对比间距系数Q1与所述相邻间距系数Q2以获得第三匹配系数P3，所述第三匹配系数P3用于评估所述图像检测结果中多条焊缝和对应地所述射线检测结果中多条焊缝的排布一致度。Optionally, the leads of the busbar include a first lead and a second lead, and the image ray detection unit also includes a third matching detection unit; the third matching detection unit calculates the spacing between two adjacent welds in the image detection result and the spacing ratio of the two adjacent welds in the corresponding ray detection result to obtain a comparison spacing coefficient Q1; calculates the image detection result and the corresponding spacing ratio set Q11, Q12 of the two adjacent welds on the first lead in the ray detection result, and the spacing ratio set Q21, Q22 of the two adjacent welds on the second lead, uses the spacing ratio set Q11, Q12, Q21, Q22 to obtain the adjacent spacing coefficient Q2, uses the comparison spacing coefficient Q1 and the adjacent spacing coefficient Q2 to obtain a third matching coefficient P3, and the third matching coefficient P3 is used to evaluate the arrangement consistency of multiple welds in the image detection result and the corresponding multiple welds in the ray detection result.
可选地，所述第一匹配系数P1、所述第二匹配系数P2、所述第三匹配系数P3的计算公式分别为：n=m，P1=n/m，P2=t/3n，P3=Q1+Q2-1。Optionally, calculation formulas of the first matching coefficient P1, the second matching coefficient P2, and the third matching coefficient P3 are respectively: n=m, P1=n/m, P2=t/3n, P3=Q1+Q2-1.
可选地，所述压合单元包括连接板，与连接板连接的安装座，与安装座连接的安装板，设置在安装板侧面的传感器，与安装板连接的背板，设置在安装板上的气缸，与气缸连接的连接块，连接块连接滑块，连接在背板上的滑块导轨，滑块在滑块导轨上移动，与连接块固定连接的压合件，连接块连接感应件，感应件与传感器进行配合进行感应限位；和/或，所述图像检测部包括摄像机、X方向移动模块，X方向移动模块连接摄像机，X方向移动模块驱动摄像机沿X方向移动；所述射线检测部包括射线发生器、X方向移动模块一、Z方向移动模块一、射线接收器、X方向移动模块二、Z方向移动模块二、防护部，X方向移动模块一、Z方向移动模块一连接射线发生器、防护部，X方向移动模块二、Z方向移动模块二连接射线接收器，X方向移动模块一驱动射线发生器沿X方向移动,Z方向移动模块一驱动射线发生器沿Z方向移动，X方向移动模块二驱动射线接收器沿X方向移动,Z方向移动模块二驱动射线接收器沿Z方向移动。Optionally, the pressing unit includes a connecting plate, a mounting seat connected to the connecting plate, a mounting plate connected to the mounting seat, a sensor arranged on a side of the mounting plate, a back plate connected to the mounting plate, a cylinder arranged on the mounting plate, a connecting block connected to the cylinder, the connecting block connected to a slider, a slider guide rail connected to the back plate, the slider moves on the slider guide rail, a pressing piece fixedly connected to the connecting block, the connecting block connected to a sensing piece, the sensing piece cooperates with the sensor to sense limit; and/or, the image detection unit includes a camera and an X-direction moving module, the X-direction moving module is connected to the camera, and the X-direction moving module drives the camera to move along the X-direction The ray detection unit includes a ray generator, an X-direction moving module 1, a Z-direction moving module 1, a ray receiver, an X-direction moving module 2, a Z-direction moving module 2, and a protection unit. The X-direction moving module 1 and the Z-direction moving module 1 are connected to the ray generator and the protection unit. The X-direction moving module 2 and the Z-direction moving module 2 are connected to the ray receiver. The X-direction moving module 1 drives the ray generator to move in the X direction, the Z-direction moving module 1 drives the ray generator to move in the Z direction, the X-direction moving module 2 drives the ray receiver to move in the X direction, and the Z-direction moving module 2 drives the ray receiver to move in the Z direction.
第二方面，本发明申请提供一种接线盒的激光焊接装置的方法，采用上述第一方面任一所述的接线盒的激光焊接装置，包括如下步骤；In a second aspect, the present invention provides a method for a laser welding device for a junction box, using the laser welding device for a junction box described in any one of the first aspects above, comprising the following steps:
S100：将汇流条的引线和接线盒的焊盘进行接触贴合；S100: contact and bond the lead of the busbar to the pad of the junction box;
S200：对汇流条的引线和接线盒的焊盘贴合状态进行检测；S200: Detect the bonding status of the busbar lead and the pad of the junction box;
S300：当检测到汇流条的引线和接线盒贴合状态良好，进行步骤S300；当检测到汇流条的引线和接线盒贴合状态不良好，停机或回到步骤S100；S300: When it is detected that the lead wire of the busbar and the junction box are well fitted, proceed to step S300; when it is detected that the lead wire of the busbar and the junction box are not well fitted, stop the machine or return to step S100;
S400：对汇流条的引线和接线盒的焊盘进行激光焊接；S400: Laser welding of busbar leads and junction box pads;
S500：焊接完成后，对汇流条的引线和接线盒的焊盘焊接质量进行检测。S500: After welding is completed, the welding quality of the busbar leads and the pads of the junction box is inspected.
可选地，所述步骤500包括以下步骤：Optionally, step 500 includes the following steps:
步骤S501：检测焊接外观质量，获得所述焊接外观质量图像检测结果；Step S501: Detecting welding appearance quality and obtaining welding appearance quality image detection results;
步骤S502：检测焊接内外部质量，获得所述焊接内外部质量射线检测结果；Step S502: Detect the internal and external quality of welding and obtain the radiographic detection result of the internal and external quality of welding;
步骤S503：对比以及综合所述焊接外观质量图像检测结果和所述焊接内外部质量射线检测结果，输出汇流条的引线和接线盒的焊盘焊接质量结果。Step S503: Compare and integrate the welding appearance quality image detection result and the welding internal and external quality X-ray detection result, and output the welding quality result of the busbar lead and the junction box pad.
可选地，所述步骤S503包括：Optionally, the step S503 includes:
步骤S5031：计算所述图像检测结果中焊缝条数与对应地所述射线检测结果中焊缝条数的比值以获得所述第一匹配系数P1，并且判断焊接内部缺陷类型；Step S5031: Calculate the ratio of the number of welds in the image detection result to the number of welds in the corresponding X-ray detection result to obtain the first matching coefficient P1, and determine the type of internal welding defects;
步骤S5032：当所述第一匹配系数P1等于1，并且焊接内部缺陷类型均为无时，进入步骤S5033；当所述第一匹配系数P1不等于1或者判断焊接内部缺陷类型中至少有一个不是无时，输出汇流条的引线和接线盒的焊盘焊接质量结果：不合格；Step S5032: when the first matching coefficient P1 is equal to 1, and the welding internal defect types are all non-existent, proceed to step S5033; when the first matching coefficient P1 is not equal to 1 or it is determined that at least one of the welding internal defect types is not non-existent, output the welding quality result of the lead of the bus bar and the pad of the junction box: unqualified;
步骤S5033：计算所述图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地所述射线检测结果中每条焊缝的长度、宽度、焊缝面积的比值，并建立焊缝序号-多个比值的散点分布图，统计位于预设区域内的落入散点个数，计算所述落入散点个数与总散点个数的比值以获得所述第二匹配系数P2；Step S5033: Calculate the ratio of the length, width, and weld area of each weld in the image detection result to the length, width, and weld area of each weld in the corresponding radiographic detection result, and establish a scatter point distribution diagram of weld sequence number-multiple ratios, count the number of scatter points falling into the preset area, and calculate the ratio of the number of scatter points falling into the total number of scatter points to obtain the second matching coefficient P2;
步骤S5034：当所述第二匹配系数P2等于1时，进入步骤S5035；当所述第二匹配系数P2不等于1时，输出汇流条的引线和接线盒的焊盘焊接质量结果：不合格；Step S5034: when the second matching coefficient P2 is equal to 1, proceed to step S5035; when the second matching coefficient P2 is not equal to 1, output the welding quality result of the lead of the bus bar and the pad of the junction box: unqualified;
步骤S5035：计算所述图像检测结果中相邻两条焊缝的间距和对应地所述射线检测结果中相邻两条焊缝的间距比值以获得对比间距系数Q1；计算所述图像检测结果和对应地射线检测结果中第一引线上相邻两条焊缝的间距比值集Q11、Q12，第二引线上相邻两条焊缝的间距比值集Q21、Q22，利用间距比值集获得Q11、Q12、Q21、Q22获得相邻间距系数Q2，利用所述对比间距系数Q1与所述相邻间距系数Q2获得所述第三匹配系数P3；Step S5035: Calculate the spacing ratio between two adjacent welds in the image detection result and the spacing ratio between two adjacent welds in the corresponding radiographic detection result to obtain a comparison spacing coefficient Q1; calculate the spacing ratio set Q11, Q12 between two adjacent welds on the first lead in the image detection result and the corresponding radiographic detection result, and the spacing ratio set Q21, Q22 between two adjacent welds on the second lead, use the spacing ratio set to obtain Q11, Q12, Q21, Q22 to obtain an adjacent spacing coefficient Q2, and use the comparison spacing coefficient Q1 and the adjacent spacing coefficient Q2 to obtain the third matching coefficient P3;
步骤S5036：当P3<A时，所述图像检测结果中每条焊缝和对应地所述射线检测结果中多条焊缝的排布一致，输出汇流条的引线和接线盒的焊盘焊接质量结果：合格；当P3≥A时，所述图像检测结果中每条焊缝和对应地所述射线检测结果中多条焊缝的排布不一致，输出汇流条的引线和接线盒的焊盘焊接质量结果：不合格，其中，0.2≦A≦0.4。Step S5036: When P3<A, the arrangement of each weld in the image detection result and the corresponding multiple welds in the X-ray detection result are consistent, and the welding quality result of the bus bar lead and the pad of the junction box is output: qualified; when P3≥A, the arrangement of each weld in the image detection result and the corresponding multiple welds in the X-ray detection result are inconsistent, and the welding quality result of the bus bar lead and the pad of the junction box is output: unqualified, where 0.2≦A≦0.4.
可选地，步骤S100之前还包括步骤SF：所述视觉检测单元对汇流条的引线和接线盒的焊盘贴合准备情况进行检测，以确定汇流条的引线和接线盒的焊盘具备贴合情况。Optionally, before step S100, step SF is also included: the visual inspection unit inspects the preparation of the busbar leads and the pads of the junction box to determine whether the busbar leads and the pads of the junction box are ready for bonding.
综上所述，本发明申请具有以下有益技术效果：In summary, the present invention has the following beneficial technical effects:
（1）本发明申请的视觉检测单元能够检测汇流条的引线和接线盒的焊盘贴合准备情况，贴合准备情况检测内容至少包括：接线盒是否歪斜，引线是否偏移，接线盒是否±5°偏差，引线是否过长或是否过短或是否缺失，是否有接线盒，接线盒是否装反，接线盒是否用错。这样，可以使得接线盒、引出线的贴合准备良好，提前避免后续汇流条的引线和接线盒的焊盘贴合失败风险。(1) The visual inspection unit of the present invention can detect the preparation for the bonding of the busbar lead and the pad of the junction box. The bonding preparation inspection content at least includes: whether the junction box is skewed, whether the lead is offset, whether the junction box has a ±5° deviation, whether the lead is too long or too short or missing, whether there is a junction box, whether the junction box is installed upside down, and whether the junction box is used incorrectly. In this way, the junction box and the lead wire can be well prepared for bonding, avoiding the risk of subsequent failure of bonding the busbar lead and the pad of the junction box in advance.
（2）本发明申请通过第一匹配检测部的第一匹配系数P1、第二匹配检测部第一匹配系数P2、第三匹配检测部第三匹配系数P3的设置，避免依靠单一的图像检测结果或单一的射线检测结果作为汇流条的引线和接线盒的焊盘焊接质量的检测结果，而是从局部上评估图像检测结果中每条焊缝和对应地射线检测结果中每条焊缝的细节近似度，同时还从整体上评估图像检测结果中每条焊缝和对应地射线检测结果中多条焊缝的排布一致度，并还同时结合焊接内部质量检测的结果，从而提高焊接质量检测结果判断评估的准确度和可靠性，从根本上能够防止汇流条的引线和接线盒的焊盘焊接失效（例如虚焊）的问题产生，理论上来说焊接检查可靠性可以达到98%以上的检出率。(2) The present invention avoids relying on a single image detection result or a single X-ray detection result as the detection result of the welding quality of the busbar lead and the pad of the junction box by setting the first matching coefficient P1 of the first matching detection unit, the first matching coefficient P2 of the second matching detection unit, and the third matching coefficient P3 of the third matching detection unit. Instead, the present invention locally evaluates the detail similarity of each weld in the image detection result and each weld in the corresponding X-ray detection result. At the same time, the arrangement consistency of each weld in the image detection result and multiple welds in the corresponding X-ray detection result is evaluated as a whole. In addition, the results of the internal welding quality inspection are combined at the same time, so as to improve the accuracy and reliability of the welding quality inspection result judgment and evaluation. It can fundamentally prevent the problem of welding failure (such as cold solder joint) of the busbar lead and the pad of the junction box. Theoretically, the reliability of welding inspection can achieve a detection rate of more than 98%.
（3）焊接外观质量图像检测结果包括：焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距等，焊接内外部质量射线检测结果：焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距等、焊接内部缺陷类型等，相应可综合对比图像检测结果和射线检测检测结果的焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距等焊接质量参数进行检测，并结合焊接内部缺陷类型结果，即射线成像检测可以检测到隐藏在汇流条引线表面下焊缝的缺陷或问题，而图像检测可以捕捉焊缝外观的细节，二者比对配合，能够实现对汇流条的引线和接线盒的焊盘的焊接质量进行全面检测，包括内部质量和外观质量的问题，能够快速地对采集到的图像进行处理和分析，实现对光伏组件接线盒的安装质量的快速检测和评估，保证了光伏组件的质量。(3) The image detection results of welding appearance quality include: the number of welds, weld length, weld width, weld area, spacing between adjacent welds, etc. The X-ray detection results of welding internal and external quality include: the number of welds, weld length, weld width, weld area, spacing between adjacent welds, etc., and the types of internal defects in welding. Accordingly, the image detection results and X-ray detection results can be comprehensively compared to detect welding quality parameters such as the number of welds, weld length, weld width, weld area, spacing between adjacent welds, etc., and combined with the results of internal defects in welding, that is, X-ray imaging detection can detect defects or problems of welds hidden under the surface of busbar leads, while image detection can capture the details of weld appearance. The comparison and coordination of the two can realize comprehensive detection of the welding quality of busbar leads and junction box pads, including internal quality and appearance quality problems. The collected images can be quickly processed and analyzed to realize rapid detection and evaluation of the installation quality of the junction box of photovoltaic modules, thereby ensuring the quality of photovoltaic modules.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1是本发明申请的接线盒的激光焊接装置的部分简化结构示意图FIG. 1 is a partially simplified schematic diagram of the laser welding device for the junction box of the present invention.
图2是本发明申请的图像射线检测单元的部分简化结构示意图；FIG2 is a partially simplified schematic diagram of the structure of the image ray detection unit of the present invention;
图3是本发明申请焊接压合单元的结构示意图；FIG3 is a schematic structural diagram of a welding and pressing unit according to the present invention;
图4是本发明申请接线盒的激光焊接装置的部分结构示意图一；FIG4 is a partial structural schematic diagram of a laser welding device for a junction box according to the present invention;
图5是本发明申请接线盒的激光焊接装置的部分结构示意图二；FIG5 is a second schematic diagram of a partial structure of a laser welding device for a junction box according to the present invention;
图6是本发明申请的图像射线检测单元的部分结构示意图；FIG6 is a schematic diagram of a partial structure of an image ray detection unit of the present invention;
图7是本发明申请的焊缝外观图像中焊缝的部分示意图；FIG7 is a partial schematic diagram of a weld in a weld appearance image of the present invention;
图8是本发明申请的焊缝射线图像中焊缝的部分示意图；FIG8 is a partial schematic diagram of a weld in a weld radiographic image of the present invention;
图9是本发明申请的落入散点总数和预设区域的部分示意图一；FIG9 is a partial schematic diagram of the total number of scattered points and the preset area in the present invention;
图10中（a）是本发明申请的焊接内部缺陷类型为未融合的部分示意图；FIG. 10 (a) is a partial schematic diagram of a welding internal defect type of unfused welding according to the present invention;
图10中（b）是本发明申请的焊接内部缺陷类型为气泡的部分示意图；FIG. 10 ( b ) is a partial schematic diagram of a welding internal defect type of bubble in the present invention;
图10中（c）是本发明申请的焊接内部缺陷类型为杂渣的部分示意图；FIG. 10 (c) is a partial schematic diagram of the welding internal defect type of the present invention being slag;
图11是本发明申请的落入散点总数和预设区域的部分示意图二；FIG11 is a second partial schematic diagram of the total number of scattered points and the preset area in the present invention;
附图标记：Reference numerals:
100-激光单元；101-第一X方向移动模块；102-第一Z方向移动模块；103激光器；200-视觉检测单元；201-第二X方向移动模块；202-第二Z方向移动模块；203-相机；204-防护罩；300-压合单元；3001-连接板；3002-安装座；3003-气缸；3004-安装板；3005-传感器；3006-连接块；3007-定位板；3008-压合件；3009-背板；3010-滑块导轨；3011-感应件；400-光伏组件；401-接线盒；500-图像射线检测单元；501-防护部；502-摄像机；503-X方向移动模块；50T-射线发生器；504-X方向移动模块一；505-Z方向移动模块一；50R-射线接收器；506X-方向移动模块二；507-Z方向移动模块二。100-laser unit; 101-first X-direction moving module; 102-first Z-direction moving module; 103 laser; 200-visual detection unit; 201-second X-direction moving module; 202-second Z-direction moving module; 203-camera; 204-protective cover; 300-pressing unit; 3001-connecting plate; 3002-mounting seat; 3003-cylinder; 3004-mounting plate; 3005-sensor; 3006-connecting block; 3007-positioning Plate; 3008-pressing part; 3009-back plate; 3010-slider guide; 3011-sensing part; 400-photovoltaic module; 401-junction box; 500-image ray detection unit; 501-protection part; 502-camera; 503-X-direction moving module; 50T-ray generator; 504-X-direction moving module one; 505-Z-direction moving module one; 50R-ray receiver; 506X-direction moving module two; 507-Z-direction moving module two.
具体实施方式DETAILED DESCRIPTION
在下文的描述中，给出了大量具体的细节以便提供对本发明申请更为彻底的理解。然而，对于本领域技术人员而言显而易见的是，本发明申请可以无需一个或多个这些细节而得以实施。在其他的例子中，为了避免与本发明申请发生混淆，对于本领域公知的一些技术特征未进行描述。In the following description, a large number of specific details are provided to provide a more thorough understanding of the present invention. However, it is obvious to those skilled in the art that the present invention can be implemented without one or more of these details. In other examples, in order to avoid confusion with the present invention, some technical features well known in the art are not described.
参照图1-图8所示，第一方面，本发明申请提供一种接线盒的激光焊接装置，包括：激光单元100、视觉检测单元200、压合单元300、图像射线检测单元500，视觉检测单元200连接压合单元300；压合单元300，对汇流条的引线和接线盒401的焊盘进行贴合；视觉检测单元200，对汇流条的引线和接线盒401的焊盘贴合状态进行检测；激光单元100，对贴合良好的汇流条的引线和接线盒401的焊盘进行激光焊接；图像射线检测单元500，对汇流条的引线和接线盒的焊盘焊接质量进行检测。1 to 8 , in a first aspect, the present invention provides a laser welding device for a junction box, comprising: a laser unit 100, a visual inspection unit 200, a pressing unit 300, and an image ray inspection unit 500, wherein the visual inspection unit 200 is connected to the pressing unit 300; the pressing unit 300 is used to bond the leads of the bus bar to the pads of the junction box 401; the visual inspection unit 200 is used to detect the bonding state of the leads of the bus bar and the pads of the junction box 401; the laser unit 100 is used to laser weld the leads of the bus bar and the pads of the junction box 401 that are well bonded; and the image ray inspection unit 500 is used to detect the welding quality of the leads of the bus bar and the pads of the junction box.
在本发明申请中，首先，压合单元300对汇流条的引线和光伏组件400的接线盒的焊盘进行贴合；视觉检测单元200，对汇流条的引线和接线盒的焊盘贴合状态进行检测，当汇流条的引线和接线盒贴合状态良好，即汇流条的引线和接线盒的焊盘压紧，激光单元100可以对贴合良好的汇流条的引线和接线盒的焊盘进行激光焊接，当汇流条的引线和接线盒贴合状态不良好，即汇流条的引线和接线盒的焊盘未完全压紧，汇流条的引线和接线盒的焊盘将存在间隙，那么后续激光单元100对汇流条的引线和接线盒的焊盘进行激光焊接后会存在虚焊的问题，进而导致汇流条的引线和接线盒的焊盘焊接失效，视觉检测单元200的检测能够提前解决后续虚焊的问题；当汇流条的引线和接线盒的焊盘进行激光焊接完成后，图像射线检测单元500，对汇流条的引线和接线盒401的焊盘焊接质量进行检测，图像射线检测单元500可以对上述焊接完成后的焊接外观质量和焊接内外部质量进行检测，例如焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距、焊接内部缺陷类型等情况，进而图像射线检测单元500可以对汇流条的引线和接线盒的焊盘焊接前状态、焊接质量进行检测，进而从根本上能够防止汇流条的引线和接线盒的焊盘焊接失效（例如虚焊）的问题产生。In the present application, first, the pressing unit 300 fits the lead of the bus bar and the pad of the junction box of the photovoltaic module 400; the visual inspection unit 200 detects the fitting state of the lead of the bus bar and the pad of the junction box. When the lead of the bus bar and the junction box are in good fitting state, that is, the lead of the bus bar and the pad of the junction box are pressed tightly, the laser unit 100 can laser weld the lead of the bus bar and the pad of the junction box that are well fitted. When the lead of the bus bar and the junction box are not in good fitting state, that is, the lead of the bus bar and the pad of the junction box are not completely pressed tightly, there will be a gap between the lead of the bus bar and the pad of the junction box. Then, after the laser unit 100 performs laser welding on the lead of the bus bar and the pad of the junction box, there will be a problem of cold welding, which will lead to the lead of the bus bar and the junction box. If the pad welding fails, the inspection of the visual inspection unit 200 can solve the subsequent problem of cold welding in advance; when the laser welding of the busbar lead and the pad of the junction box is completed, the image ray inspection unit 500 inspects the welding quality of the busbar lead and the pad of the junction box 401. The image ray inspection unit 500 can inspect the welding appearance quality and the internal and external quality of the welding after the above welding is completed, such as the number of welds, weld length, weld width, weld area, adjacent weld spacing, welding internal defect type, etc., and then the image ray inspection unit 500 can inspect the pre-welding state and welding quality of the busbar lead and the pad of the junction box, thereby fundamentally preventing the problem of welding failure (such as cold welding) of the busbar lead and the pad of the junction box.
可选地，所述压合单元300包括连接板3001，与连接板3001连接的安装座3002，与安装座3002连接的安装板3004，设置在安装板3004侧面的传感器3005，与安装板3004连接的背板3009，设置在安装板3004上的气缸3003，与气缸3003连接的连接块3006，连接块3006连接滑块，连接在背板3009上的滑块导轨3010，滑块在滑块导轨3010上移动，与连接块3006固定连接的压合件3008，安装在连接块3006上的定位板3007，连接块3006连接感应件3011，感应件3011与传感器3005进行配合进行感应限位。Optionally, the pressing unit 300 includes a connecting plate 3001, a mounting base 3002 connected to the connecting plate 3001, a mounting plate 3004 connected to the mounting base 3002, a sensor 3005 arranged on the side of the mounting plate 3004, a back plate 3009 connected to the mounting plate 3004, a cylinder 3003 arranged on the mounting plate 3004, a connecting block 3006 connected to the cylinder 3003, the connecting block 3006 is connected to a slider, a slider guide rail 3010 connected to the back plate 3009, the slider moves on the slider guide rail 3010, a pressing piece 3008 fixedly connected to the connecting block 3006, a positioning plate 3007 installed on the connecting block 3006, the connecting block 3006 is connected to a sensing piece 3011, and the sensing piece 3011 cooperates with the sensor 3005 to perform sensing limit.
具体地，连接板3001连接的安装座3002，与安装座3002连接的安装板3004，设置在安装板3004侧面的传感器3005，与安装板3004连接的背板3009，设置在安装板3004上的气缸3003，与缸3003连接的连接块3006，连接块3006连接滑块，连接在背板3009上的滑块导轨3010。这样，因滑块可以配合滑块导轨3010上下移动，相应气缸3003可以带动连接块3006和压合件3008上下移动，进而驱动压合件3008压弯汇流条的引线以使得汇流条的引线与接线盒的焊盘接触贴合，同时连接块3006也会带动感应件3011，所述感应件3011与传感器3005进行配合进行感应限位。示例性，压合件3008有两个，汇流条的引线包括两个，即第一引线4021和第二引线4022，接线盒包括两个焊盘，即第一焊盘4011和第二焊盘4012，每个压合件3008将对应压合汇流条的引线和接线盒的焊盘以使得汇流条的第一引线4021和接线盒401的第一焊盘4011进行贴合，汇流条的第二引线4022和接线盒401的第二焊盘4012进行贴合。Specifically, the mounting seat 3002 connected to the connecting plate 3001, the mounting plate 3004 connected to the mounting seat 3002, the sensor 3005 arranged on the side of the mounting plate 3004, the back plate 3009 connected to the mounting plate 3004, the cylinder 3003 arranged on the mounting plate 3004, the connecting block 3006 connected to the cylinder 3003, the connecting block 3006 connected to the slider, and the slider guide rail 3010 connected to the back plate 3009. In this way, since the slider can move up and down in coordination with the slider guide rail 3010, the corresponding cylinder 3003 can drive the connecting block 3006 and the pressing piece 3008 to move up and down, and then drive the pressing piece 3008 to press and bend the lead of the busbar so that the lead of the busbar contacts and fits with the pad of the junction box, and at the same time, the connecting block 3006 will also drive the induction piece 3011, and the induction piece 3011 cooperates with the sensor 3005 to perform induction limit. Exemplarily, there are two pressing pieces 3008, the busbar includes two leads, namely a first lead 4021 and a second lead 4022, and the junction box includes two pads, namely a first pad 4011 and a second pad 4012, and each pressing piece 3008 will press the busbar leads and the pads of the junction box correspondingly so that the first lead 4021 of the busbar and the first pad 4011 of the junction box 401 are bonded, and the second lead 4022 of the busbar and the second pad 4012 of the junction box 401 are bonded.
可选地，激光单元100包括激光器103、第一X方向移动模块101、第一Z方向移动模块102，第一X方向移动模块101、第一Z方向移动模块102均连接激光器103，第一X方向移动模块101驱动激光器沿X方向移动,第一Z方向移动模块102驱动激光器沿Z方向移动。Optionally, the laser unit 100 includes a laser 103, a first X-direction moving module 101, and a first Z-direction moving module 102. The first X-direction moving module 101 and the first Z-direction moving module 102 are both connected to the laser 103. The first X-direction moving module 101 drives the laser to move along the X direction, and the first Z-direction moving module 102 drives the laser to move along the Z direction.
具体地，第一X方向移动模块101、第一Z方向移动模块102均连接激光器103，第一X方向移动模块101驱动激光器沿X方向移动,第一Z方向移动模块102驱动激光器沿Z方向移动，Y方向为光伏组件传送进入的方向，也即接线盒输送的方向，X方向、Y方向、Z方向两两垂直。这样焊接时，激光器可以运动至接线盒位置的上方，并对激光器的Z方向的位置进行调节，进而调节焊接位置或焊接能量，从而完成汇流条的引线和接线盒的焊盘的激光焊接。Specifically, the first X-direction moving module 101 and the first Z-direction moving module 102 are both connected to the laser 103. The first X-direction moving module 101 drives the laser to move in the X direction, and the first Z-direction moving module 102 drives the laser to move in the Z direction. The Y direction is the direction in which the photovoltaic components are transmitted, that is, the direction in which the junction box is transported. The X direction, the Y direction, and the Z direction are perpendicular to each other. In this way, during welding, the laser can move to the top of the junction box position, and the Z-direction position of the laser can be adjusted, thereby adjusting the welding position or welding energy, thereby completing the laser welding of the busbar lead and the pad of the junction box.
在一些实施中，激光焊接方式是利用高能量密度的激光束作为热源的一种高效精密焊接方法，焊接过程属热传导型，即激光辐射加热工件表面，表面热量通过热传导向内部扩散，通过控制激光脉冲方式、能量、速度等参数，使汇流条与底板进行熔化，形成特定的熔池接合起来，本发明申请实施例中激光脉冲方式为正弦，焊接能量为40%-80%，速度为80—140mm/S。本发明申请中激光至少垂直入射于已经处于贴合状态的接线盒的焊盘与折弯后汇流条的引线之间，进而将接线盒的焊盘与折弯后汇流条的引线进行焊接进而形成焊缝，焊缝的数量可以是多条，例如2条，3条，4条，5条，6条等。In some implementations, laser welding is an efficient and precise welding method that uses a high-energy-density laser beam as a heat source. The welding process is a heat conduction type, that is, the laser radiation heats the surface of the workpiece, and the surface heat diffuses to the inside through heat conduction. By controlling the laser pulse mode, energy, speed and other parameters, the busbar and the base plate are melted to form a specific molten pool to join them. In the embodiment of the present invention, the laser pulse mode is sinusoidal, the welding energy is 40%-80%, and the speed is 80-140mm/S. In the present invention, the laser is at least vertically incident between the pad of the junction box that is already in the bonding state and the lead of the bent busbar, and then the pad of the junction box and the lead of the bent busbar are welded to form a weld. The number of welds can be multiple, such as 2, 3, 4, 5, 6, etc.
可选地，视觉检测单元200包括第二X方向移动模块201、第二Z方向移动模块202、相机203、防护罩204，防护罩204连接相机203，第二X方向移动模块201驱动相机203沿X方向移动,第一Z方向移动模块202驱动相机203沿Z方向移动。Optionally, the visual inspection unit 200 includes a second X-direction moving module 201, a second Z-direction moving module 202, a camera 203, and a protective cover 204, wherein the protective cover 204 is connected to the camera 203, the second X-direction moving module 201 drives the camera 203 to move along the X direction, and the first Z-direction moving module 202 drives the camera 203 to move along the Z direction.
具体地，防护罩204连接相机203，防护罩204用于保护相机203，第二X方向移动模块201、第二Z方向移动模块202均连接相机203、防护罩204，第二X方向移动模块201驱动相机203、压合单元300沿X方向移动,第二Z方向移动模块202驱动相机203、压合单元300沿Z方向移动。Specifically, the protective cover 204 is connected to the camera 203, and the protective cover 204 is used to protect the camera 203. The second X-direction moving module 201 and the second Z-direction moving module 202 are both connected to the camera 203 and the protective cover 204. The second X-direction moving module 201 drives the camera 203 and the pressing unit 300 to move along the X direction, and the second Z-direction moving module 202 drives the camera 203 and the pressing unit 300 to move along the Z direction.
可选地，图像射线检测单元500包括图像检测部、射线检测部，图像检测部对焊接外观质量进行检测以获得焊接外观质量图像检测结果，射线检测部对焊接内外部质量进行检测以获得焊接内外部质量射线检测结果，图像射线检测单元500对比及综合所述焊接外观质量图像检测结果和所述焊接内外部质量射线检测结果，输出汇流条的引线和接线盒的焊盘焊接质量结果。Optionally, the image radiation detection unit 500 includes an image detection unit and a radiation detection unit. The image detection unit detects the welding appearance quality to obtain a welding appearance quality image detection result, and the radiation detection unit detects the internal and external quality of the welding to obtain a welding internal and external quality radiation detection result. The image radiation detection unit 500 compares and integrates the welding appearance quality image detection result and the welding internal and external quality radiation detection result, and outputs the welding quality result of the bus bar lead and the pad of the junction box.
具体地，图像射线检测单元500包括图像检测部、射线检测部，图像检测部对焊接外观质量进行检测以获得焊接外观质量图像检测结果，射线检测部对焊接内外部质量进行检测以获得焊接内外部质量射线检测结果，对比及综合焊接外观质量图像检测结果和焊接内外部质量射线检测结果，输出汇流条的引线和接线盒的焊盘焊接质量结果，示例性地，可以分别对比图像检测结果和射线检测检测结果的焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距等焊接质量参数进行检测，并结合焊接内部缺陷类型结果，进而可以综合得到并输出上述汇流条的引线和接线盒的焊盘焊接质量结果，以从根本上能够防止汇流条的引线和接线盒的焊盘焊接失效（例如虚焊）的问题产生。Specifically, the image radiation detection unit 500 includes an image detection unit and a radiation detection unit. The image detection unit detects the welding appearance quality to obtain a welding appearance quality image detection result. The radiation detection unit detects the internal and external quality of welding to obtain a welding internal and external quality radiation detection result. The welding appearance quality image detection result and the welding internal and external quality radiation detection result are compared and integrated, and the welding quality result of the bus bar lead and the pad of the junction box is output. By way of example, the welding quality parameters such as the number of welds, weld length, weld width, weld area, and adjacent weld spacing of the image detection result and the radiation detection result can be compared and inspected respectively, and combined with the welding internal defect type result, the above-mentioned bus bar lead and the pad of the junction box welding quality result can be comprehensively obtained and output, so as to fundamentally prevent the problem of welding failure (such as cold solder joint) of the bus bar lead and the pad of the junction box from occurring.
可选地，图像检测部包括摄像机502、X方向移动模块503，X方向移动模块503连接摄像机502，X方向移动模块503驱动摄像机502沿X方向移动；射线检测部包括射线发生器50T、X方向移动模块一504、Z方向移动模块一505、射线接收器50R、X方向移动模块二506、Z方向移动模块二507、防护部501，X方向移动模块一504、Z方向移动模块一505连接射线发生器50T、防护部501，X方向移动模块二506、Z方向移动模块二507连接射线接收器50R，X方向移动模块一504驱动射线发生器50R沿X方向移动,Z方向移动模块一505驱动射线发生器50R沿Z方向移动，X方向移动模块二506驱动射线接收器50R沿X方向移动,Z方向移动模块二507驱动射线接收器50R沿Z方向移动，防护部501用于隔绝射线发生器50R发射的X射线，减小X射线外溢对操作人员的伤害。Optionally, the image detection unit includes a camera 502 and an X-direction moving module 503, wherein the X-direction moving module 503 is connected to the camera 502 and drives the camera 502 to move along the X-direction; the ray detection unit includes a ray generator 50T, an X-direction moving module 1 504, a Z-direction moving module 1 505, a ray receiver 50R, an X-direction moving module 2 506, a Z-direction moving module 2 507, and a protection unit 501, wherein the X-direction moving module 1 504 and the Z-direction moving module 1 505 are connected to the ray generator 50T and the protection unit 501, X-direction moving module 2 506 and Z-direction moving module 2 507 are connected to the ray receiver 50R, X-direction moving module 1 504 drives the ray generator 50R to move along the X-direction, Z-direction moving module 1 505 drives the ray generator 50R to move along the Z-direction, X-direction moving module 2 506 drives the ray receiver 50R to move along the X-direction, and Z-direction moving module 2 507 drives the ray receiver 50R to move along the Z-direction. The protective part 501 is used to isolate the X-rays emitted by the ray generator 50R to reduce the damage of X-ray overflow to the operator.
在一些实施例中，图像检测部可以采用常见的AOI检测，X方向移动模块503驱动摄像机502沿X方向移动，摄像机502对焊接外观质量进行拍照获取焊接外观图像，并对焊接外观图像进行处理，从而可以获得焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距等，从而完成焊接外观质量检测，获得焊接外观质量图像检测结果。In some embodiments, the image detection unit can adopt common AOI detection, the X-direction moving module 503 drives the camera 502 to move along the X-direction, the camera 502 takes a picture of the welding appearance quality to obtain the welding appearance image, and processes the welding appearance image, so as to obtain the number of welds, weld length, weld width, weld area, adjacent weld spacing, etc., thereby completing the welding appearance quality detection and obtaining the welding appearance quality image detection result.
在一些实施例中，X方向移动模块一504驱动射线发生器50T沿X方向移动,Z方向移动模块一505驱动射线发生器50R沿Z方向移动，X方向移动模块二506驱动射线接收器50R沿X方向移动,Z方向移动模块二507驱动射线接收器50R沿Z方向移动，以使得射线发生器50T、射线接收器50R位置、高度向对应，进而可以进行汇流条的引线和接线盒的焊盘焊接完成后焊接内外部的射线成像。射线发生器50T可以X-ray（即X射线）发射器，X-ray发射器系统是通过X射线的穿透性，X射线成像原理基于X射线与物质的相互作用，当X射线通过物体时，它会与组织中的不同物质发生相互作用包括吸收、散射和透射，这种相互作用导致X射线在物体内部的强度分布发生变化，从而形成影像。基于上述X射线成像原理，射线发生器50T将X射线按照与Z方向呈10-25度的角度进行方向性的发生，优选地与Z方向呈角度为15度，进而在射线发生器50T与射线接收器50R之间的汇流条和接线盒穿透，并且一部分吸收一部分投射到射线接收器50R上形成焊接射线图像，射线接收器50R可以是平板检测器，进而通过X-ray的无损检测也可以检测到焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距等焊接外部质量结果，还可以检测到焊接内部缺陷类型等焊接内部质量结果或焊接状态结果，焊接内部缺陷类型可以包括：未焊透、气孔、杂渣、无等至少一种，示例性，例如引线和焊盘之间未焊透、引线和焊盘之间存在杂渣、引线和焊盘之间焊接后存在气泡等焊接缺陷类型，从而完成焊接内外部质量检测，获得焊接内外部质量射线检测结果。In some embodiments, the X-direction moving module 1 504 drives the ray generator 50T to move along the X-direction, the Z-direction moving module 1 505 drives the ray generator 50R to move along the Z-direction, the X-direction moving module 2 506 drives the ray receiver 50R to move along the X-direction, and the Z-direction moving module 2 507 drives the ray receiver 50R to move along the Z-direction, so that the positions and heights of the ray generator 50T and the ray receiver 50R correspond to each other, and then the ray imaging of the inside and outside of the welding after the busbar lead and the pad of the junction box are completed can be performed. The ray generator 50T can be an X-ray (i.e., X-ray) transmitter. The X-ray transmitter system is based on the penetration of X-rays. The principle of X-ray imaging is based on the interaction between X-rays and matter. When X-rays pass through an object, they interact with different substances in the tissue, including absorption, scattering and transmission. This interaction causes the intensity distribution of X-rays inside the object to change, thereby forming an image. Based on the above-mentioned X-ray imaging principle, the ray generator 50T generates X-rays directionally at an angle of 10-25 degrees to the Z direction, preferably at an angle of 15 degrees to the Z direction, and then penetrates the bus bar and junction box between the ray generator 50T and the ray receiver 50R, and absorbs part of the X-rays and projects part of the X-rays onto the ray receiver 50R to form a welding ray image. The ray receiver 50R can be a flat-panel detector, and then the number of welds, weld length, weld width, weld area, adjacent weld spacing and other welding external quality results can also be detected through X-ray non-destructive testing. Welding internal quality results or welding status results such as welding internal defect types can also be detected. The welding internal defect types can include at least one of: incomplete penetration, pores, slag, and none. For example, welding defect types such as incomplete penetration between the lead and the pad, slag between the lead and the pad, and bubbles between the lead and the pad after welding, thereby completing the internal and external quality inspection of welding and obtaining the internal and external quality ray inspection results of welding.
尽管，在实际过程中，图像检测部对焊接外观质量进行检测，获得焊接外观质量图像检测结果，射线检测部对焊接内外部质量进行检测，获得焊接内外部质量射线检测结果，可以充分利用图像检测结果和射线检测检测结果的各自优势，理论上也可以知晓，可以综合图像检测结果和射线检测结果，进而来确定汇流条的引线和接线盒的焊盘焊接质量。然而，具体如何利用图像检测结果和射线检测结果，判断评估汇流条的引线和接线盒的焊盘焊接质量的仍然是接线盒焊接行业内的重要技术难题，本发明申请发现并提出了上述技术问题，并对此进行了具体的技术研究。Although, in the actual process, the image detection unit detects the appearance quality of welding and obtains the image detection results of the appearance quality of welding, and the X-ray detection unit detects the internal and external quality of welding and obtains the X-ray detection results of the internal and external quality of welding, the respective advantages of the image detection results and the X-ray detection results can be fully utilized. In theory, it can also be known that the image detection results and the X-ray detection results can be combined to determine the welding quality of the busbar lead and the pad of the junction box. However, how to use the image detection results and the X-ray detection results to judge and evaluate the welding quality of the busbar lead and the pad of the junction box is still an important technical problem in the junction box welding industry. The present invention application discovered and proposed the above technical problems and conducted specific technical research on this.
可选地，焊接外观质量图像检测结果包括：在焊接外观图像中（如图7所示），两个引线上总焊缝条数为n，获取第1条焊缝，第2条焊缝，...,第n-1条焊缝和第n条焊缝的闭合轮廓，计算第1条焊缝的长度L11、宽度W11和面积S11，第2条焊缝的长度L12、宽度W12和面积S12，...,第n条焊缝的长度L1n、宽度W1n和面积S1n，第1条焊缝和第2条焊缝的间距D11，第2条焊缝和第3条焊缝的间距D12，...,第n-1条焊缝和第n条焊缝的间距D1n-1；焊接内外部质量射线检测结果包括：在焊接射线图像中（如图8所示），总焊缝条数为m，获取焊缝1，焊缝2，...,焊缝m-1和焊缝m的闭合轮廓，计算焊缝1的长度L21、宽度W21和面积S21，焊缝2的长度L22、宽度W22和面积S22，...,焊缝m的长度L2m、宽度W2m和面积S2m，焊缝1和焊缝2的间距D21，焊缝2和焊缝3的间距D22，...,焊缝m-1和焊缝m的间距D2m-1，也包括焊接内部缺陷类型，焊接内部缺陷类型包括：未焊透、气孔、杂渣、无等至少一种。Optionally, the welding appearance quality image detection result includes: in the welding appearance image (as shown in FIG. 7 ), the total number of welds on the two leads is n, the closed contours of the first weld, the second weld, ..., the n-1th weld and the nth weld are obtained, and the length L11, width W11 and area S11 of the first weld, the length L12, width W12 and area S12 of the second weld, ..., the length L1n, width W1n and area S1n of the nth weld, the spacing D11 between the first weld and the second weld, the spacing D12 between the second weld and the third weld, ..., the spacing D1n-1 between the n-1th weld and the nth weld are calculated; the internal welding The external quality radiographic inspection results include: in the welding radiographic image (as shown in FIG8 ), the total number of welds is m, the closed contours of weld 1, weld 2, ..., weld m-1 and weld m are obtained, and the length L21, width W21 and area S21 of weld 1, the length L22, width W22 and area S22 of weld 2, ..., the length L2m, width W2m and area S2m of weld m, the spacing D21 between weld 1 and weld 2, the spacing D22 between weld 2 and weld 3, ..., the spacing D2m-1 between weld m-1 and weld m are calculated. It also includes the types of internal welding defects, which include at least one of incomplete penetration, pores, slag, and none.
具体地，m的数值可以为1、2、3、4、5、6、7、8、9、10、12，n的数值可以为1、2、3、4、5、6、7、8、9、10、12，既要保证焊接的牢固性，又要保证激光焊接的工艺效率，一般来说，焊缝条数不会太多，m、n一般为2到12条。Specifically, the value of m can be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, and the value of n can be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12. It is necessary to ensure both the firmness of the welding and the process efficiency of the laser welding. Generally speaking, the number of welds will not be too many, and m and n are generally 2 to 12.
可选地，图像射线检测单元500包括第一匹配检测部、第二匹配检测部、第三匹配检测部；第一匹配检测部，计算图像检测结果中焊缝条数与对应地射线检测结果中焊缝条数的比值以获得第一匹配系数P1，第一匹配系数P1用于评估图像检测结果中焊缝条数和对应地射线检测结果中的焊缝条数是否相等；第二匹配检测部，计算图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地射线检测结果中每条焊缝的长度、宽度、焊缝面积的比值，并建立焊缝序号-多个比值的散点分布图，统计位于预设区域内的落入散点总数，计算落入散点总数与总散点个数的比值以获得第二匹配系数P2，第二匹配系数P2用于评估图像检测结果中每条焊缝和对应地射线检测结果中每条焊缝的细节近似度；第三匹配检测部，计算图像检测结果中相邻两条焊缝的间距和对应地射线检测结果中相邻两条焊缝的间距比值以获得对比间距系数Q1；计算图像检测结果和对应地射线检测结果中第一引线上相邻两条焊缝的间距比值集Q11、Q12，第二引线上相邻两条焊缝的间距比值集Q21、Q22，利用间距比值集Q11、Q12、Q21、Q22获得相邻间距系数Q2，利用对比间距系数Q1与相邻间距系数Q2以获得第三匹配系数P3，第三匹配系数P3用于评估图像检测结果中多条焊缝和对应地射线检测结果中多条焊缝的排布一致度。Optionally, the image radiation detection unit 500 includes a first matching detection unit, a second matching detection unit, and a third matching detection unit; the first matching detection unit calculates the ratio of the number of welds in the image detection result to the number of welds in the corresponding radiation detection result to obtain a first matching coefficient P1, and the first matching coefficient P1 is used to evaluate whether the number of welds in the image detection result and the number of welds in the corresponding radiation detection result are equal; the second matching detection unit calculates the ratio of the length, width, and weld area of each weld in the image detection result to the length, width, and weld area of each weld in the corresponding radiation detection result, and establishes a scatter distribution diagram of the weld number-multiple ratios, counts the total number of scatter points falling within the preset area, and calculates the ratio of the total number of scatter points falling to the total number of scatter points to obtain a second matching coefficient P2, and the second matching coefficient P2 is used Evaluate the detail similarity of each weld in the image detection result and the corresponding detail similarity of each weld in the radiographic detection result; a third matching detection unit calculates the spacing between two adjacent welds in the image detection result and the spacing ratio between two adjacent welds in the corresponding radiographic detection result to obtain a comparison spacing coefficient Q1; calculate the spacing ratio set Q11, Q12 of two adjacent welds on the first lead in the image detection result and the corresponding radiographic detection result, and the spacing ratio set Q21, Q22 of two adjacent welds on the second lead, use the spacing ratio set Q11, Q12, Q21, Q22 to obtain the adjacent spacing coefficient Q2, and use the comparison spacing coefficient Q1 and the adjacent spacing coefficient Q2 to obtain a third matching coefficient P3, the third matching coefficient P3 is used to evaluate the arrangement consistency of multiple welds in the image detection result and the corresponding radiographic detection result.
在第一匹配检测部中，第一匹配系数P1的计算公式为：P1=n/m。In the first matching detection unit, the calculation formula of the first matching coefficient P1 is: P1=n/m.
显然，当P1等于1,即m等于n时，即焊接外观图像中两个引线上总焊缝条数和焊接射线图像中总焊缝条数相等，相应可以初步确定汇流条的引线和接线盒的焊盘焊接质量初步合格；当P11不等于1，即m不等于n时，即焊接外观图像中两个引线上总焊缝条数和焊接射线图像中总焊缝条数不相等，明显表明两种检测结果的焊缝条数不一致，汇流条的引线和接线盒的焊盘焊接质量初步不合格。Obviously, when P1 is equal to 1, that is, m is equal to n, that is, the total number of welds on the two leads in the welding appearance image and the total number of welds in the welding radiographic image are equal, and accordingly, it can be preliminarily determined that the welding quality of the busbar leads and the pads of the junction box is preliminarily qualified; when P11 is not equal to 1, that is, m is not equal to n, that is, the total number of welds on the two leads in the welding appearance image and the total number of welds in the welding radiographic image are not equal, which obviously shows that the number of welds of the two test results is inconsistent, and the welding quality of the busbar leads and the pads of the junction box is preliminarily unqualified.
显然，焊缝条数只是初步的判断，其并不能完全表明汇流条的引线和接线盒的焊盘焊接质量是完全可靠的。因此，在第一匹配检测部的基础上，图像射线检测单元500还包括第二匹配检测部，以进一步提高判断评估汇流条的引线和接线盒的焊盘焊接质量结果的可靠性。在第二匹配检测部中，当P1等于1，即m等于n后（下面可以以n为例），可以利用第二匹配检测部评估图像检测结果中每条焊缝和对应地射线检测结果中每条焊缝的细节近似度，具体包括：Obviously, the number of welds is only a preliminary judgment, which cannot fully indicate that the welding quality of the busbar lead and the pad of the junction box is completely reliable. Therefore, on the basis of the first matching detection unit, the image ray detection unit 500 also includes a second matching detection unit to further improve the reliability of the judgment and evaluation of the welding quality results of the busbar lead and the pad of the junction box. In the second matching detection unit, when P1 is equal to 1, that is, m is equal to n (n can be taken as an example below), the second matching detection unit can be used to evaluate the detail similarity of each weld in the image detection result and each weld in the corresponding ray detection result, specifically including:
计算图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地射线检测结果中每条焊缝的长度、宽度、焊缝面积的比值，具体包括：计算第1条焊缝的长度L11、宽度W11和面积S11，第2条焊缝的长度L12、宽度W12和面积S12，...,第n条焊缝的长度L1n、宽度W1n和面积S1n与焊缝1的长度L21、宽度W21和面积S21，焊缝2的长度L22、宽度W22和面积S22，...,焊缝m的长度L2m、宽度W2m和面积S2m的比值，对应可以获得每条焊缝的长度比值、宽度比值、面积比值，即第1条焊缝的长度比值LC1、宽度比值WC1和面积比值SC1,第2条焊缝的长度比值LC2、宽度比值WC2和面积比值SC2,...,第n条焊缝的长度比值LCn、宽度比值WCn和面积比值SCn，即：Calculate the ratio of the length, width, and area of each weld in the image detection result to the length, width, and area of each weld in the corresponding radiographic detection result, specifically including: calculating the length L11, width W11, and area S11 of the first weld, the length L12, width W12, and area S12 of the second weld, ..., the length L1n, width W1n, and area S1n of the nth weld and the length L21, width W21, and area S21 of weld 1, the length L1n, width W1n, and area S1n of weld 2 22, width W22 and area S22, ..., the ratio of the length L2m, width W2m and area S2m of weld m, corresponding to the length ratio, width ratio and area ratio of each weld, that is, the length ratio LC1, width ratio WC1 and area ratio SC1 of the first weld, the length ratio LC2, width ratio WC2 and area ratio SC2 of the second weld, ..., the length ratio LCn, width ratio WCn and area ratio SCn of the nth weld, that is:
LC1=L11/L21,LC2=L12/L22,...,LCn=L1n/L2mLC1=L11/L21,LC2=L12/L22,...,LCn=L1n/L2m
WC1=W11/W21,WC2=W12/W22,...,WCn=W1n/W2mWC1=W11/W21,WC2=W12/W22,...,WCn=W1n/W2m
SC1=S11/S21,SC2=S12/S22,...,SCn=S1n/S2mSC1=S11/S21,SC2=S12/S22,...,SCn=S1n/S2m
建立焊缝序号-多个比值的散点分布图，统计位于预设区域内的落入散点总数，计算落入散点总数与总散点个数的比值以获得第二匹配系数P2，具体包括：以焊缝序号作为x轴的数值，以对应每条焊缝的长度比值、宽度比值、面积比值作为y轴的数值，进而可以建立焊缝序号-多个比值的散点分布图，参见图9所示；然而（n/2，1）为中心，以半长边的长度n/2+0.5，半宽边的宽度0.5建立堆成的长方形预设区域（同样参见图7所示），统计位于预设区域内的落入散点总数t，计算落入散点总数t与总散点个数3n的比值以获得第二匹配系数P2，P2的计算过公式为：P2=t/3n。A scatter point distribution diagram of weld number-multiple ratios is established, the total number of scatter points falling into the preset area is counted, and the ratio of the total number of scatter points falling into the preset area is calculated to obtain a second matching coefficient P2, specifically including: taking the weld number as the value of the x-axis, and taking the length ratio, width ratio, and area ratio corresponding to each weld as the value of the y-axis, and then a scatter point distribution diagram of weld number-multiple ratios can be established, as shown in FIG9; however, with (n/2, 1) as the center, a stacked rectangular preset area is established with the length of the semi-long side n/2+0.5 and the width of the semi-wide side 0.5 (also see FIG7), the total number of scatter points t falling into the preset area is counted, and the ratio of the total number of scatter points t falling into the preset area is calculated to obtain a second matching coefficient P2, and the calculation formula of P2 is: P2=t/3n.
显然，当P2=1,即t等于3n时，即图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地射线检测结果中每条焊缝的长度、宽度、焊缝面积基本相似，即图像检测结果中每条焊缝和对应地射线检测结果中每条焊缝的细节近似度呈现基本相近，相应可以二次确定汇流条的引线和接线盒的焊盘焊接质量良好；当P2不等于1，即t不等于3n时，即图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地射线检测结果中每条焊缝的长度、宽度、焊缝面积至少有一条不存在相似，即图像检测结果中每条焊缝和对应地射线检测结果中每条焊缝的细节近似度至少有一条存在不相近，相应可以确定汇流条的引线和接线盒的焊盘焊接非良好。Obviously, when P2=1, that is, t is equal to 3n, that is, the length, width, weld area of each weld in the image detection results and the length, width, weld area of each weld in the corresponding radiographic detection results are basically similar, that is, the detail approximation of each weld in the image detection results and the corresponding radiographic detection results are basically similar, and accordingly, it can be secondary determined that the welding quality of the busbar lead and the pad of the junction box is good; when P2 is not equal to 1, that is, t is not equal to 3n, that is, at least one of the length, width, weld area of each weld in the image detection results and the length, width, weld area of each weld in the corresponding radiographic detection results is not similar, that is, at least one of the detail approximation of each weld in the image detection results and the corresponding radiographic detection results is not similar, and accordingly, it can be determined that the welding of the busbar lead and the pad of the junction box is not good.
显然，焊缝条数、焊缝细节近似度只是两次的判断，因预设区域的范围可能过大导致会存在汇流条的引线和接线盒的焊盘焊接质量判断评估结果存在部分偏差的风险或发生，相应仍需要进一步其能够提高判断评估汇流条的引线和接线盒的焊盘焊接质量结果的可靠性。由此，在第一匹配检测部、第二检测部的基础上，图像射线检测单元500还包括第三匹配检测部，以更进一步提高判断评估汇流条的引线和接线盒的焊盘焊接质量结果的可靠性。Obviously, the number of welds and the similarity of weld details are only judged twice. Because the range of the preset area may be too large, there is a risk or occurrence of partial deviation in the judgment and evaluation results of the welding quality of the busbar lead and the pad of the junction box. Accordingly, it is still necessary to further improve the reliability of the judgment and evaluation of the welding quality of the busbar lead and the pad of the junction box. Therefore, on the basis of the first matching detection unit and the second detection unit, the image ray detection unit 500 also includes a third matching detection unit to further improve the reliability of the judgment and evaluation of the welding quality of the busbar lead and the pad of the junction box.
在第三匹配检测部中，当P1等于1，即m等于n后，可以利用第三匹配检测部评估图像检测结果中每条焊缝和对应地射线检测结果中多条焊缝的各自或整体的排布一致度，具体包括：In the third matching detection unit, when P1 is equal to 1, that is, m is equal to n, the third matching detection unit can be used to evaluate the arrangement consistency of each weld in the image detection result and the corresponding multiple welds in the radiographic detection result, respectively or as a whole, specifically including:
计算图像检测结果中相邻两条焊缝的间距和对应地射线检测结果中相邻两条焊缝的间距比值以获得对比间距系数Q1，即：计算第1条焊缝和第2条焊缝的间距D11，第2条焊缝和第3条焊缝的间距D12，...,第n-1条焊缝和第n条焊缝的间距D1n-1与焊缝1和焊缝2的间距D21，焊缝2和焊缝3的间距D22，...,焊缝m-1和焊缝m的间距D2m-1比值，对应可以获得间距比值DC1，DC2，...,DCn-1。Calculate the ratio of the spacing between two adjacent welds in the image detection results and the spacing between two adjacent welds in the corresponding radiographic detection results to obtain the contrast spacing coefficient Q1, that is, calculate the spacing D11 between the 1st weld and the 2nd weld, D12 between the 2nd weld and the 3rd weld, ..., the spacing D1n-1 between the n-1th weld and the nth weld and the spacing D21 between weld 1 and weld 2, the spacing D22 between weld 2 and weld 3, ..., the spacing D2m-1 between weld m-1 and weld m, and the corresponding spacing ratios DC1, DC2, ..., DCn-1 can be obtained.
DC1=D11/D21,DC2=D12/D22,...,DCn=D1n/D2mDC1=D11/D21,DC2=D12/D22,...,DCn=D1n/D2m
相应地，对比间距系数Q1为：Q1=1/n（DC1+DC2+,...,+DCn）Accordingly, the contrast spacing coefficient Q1 is: Q1=1/n(DC1+DC2+,...,+DCn)
计算图像检测结果中第一引线4021上的邻两条焊缝的间距比值，第二引线4022上相邻两条焊缝的间距比值，具体包括：第一引线4021上形成有h条焊缝，第二引线4022上形成有k条焊缝，h+k=n=m（下面可以以n为例），相应地图像检测结果中第一引线4021上相邻两条焊缝的间距比值为：The ratio of the spacing between two adjacent welds on the first lead 4021 and the ratio of the spacing between two adjacent welds on the second lead 4022 in the image detection result are calculated, specifically including: there are h welds formed on the first lead 4021, and k welds formed on the second lead 4022, h+k=n=m (n may be taken as an example below), and accordingly, the ratio of the spacing between two adjacent welds on the first lead 4021 in the image detection result is:
DH11=D11/D12,DH12=D12/D13,...,DH1h-1=D1h-1/D11DH11=D11/D12,DH12=D12/D13,...,DH1h-1=D1h-1/D11
例如，当h=3时，DH11=D11/D12，DH12=D12/D11；当h=4时，DH11=D11/D12，DH12=D12/D13，DH13=D13/D11，相应地，比值集Q11为：For example, when h=3, DH11=D11/D12, DH12=D12/D11; when h=4, DH11=D11/D12, DH12=D12/D13, DH13=D13/D11. Correspondingly, the ratio set Q11 is:
Q11=[DH11,DH12,...,DH1h-1]Q11=[DH11,DH12,...,DH1h-1]
图像检测结果中第二引线4022上相邻两条焊缝的间距比值为：The ratio of the spacing between two adjacent welds on the second lead 4022 in the image detection result is:
DK11=(D1h+1/D1h+2),DK12=(D1h+2/D1h+3),...DK1k-1=(D1n-1/D1h+1)DK11=(D1h+1/D1h+2),DK12=(D1h+2/D1h+3),...DK1k-1=(D1n-1/D1h+1)
例如，当h=3,k=3时，DK11=D14/D15，DK12=D15/D14；当h=3,k=4时，DK11=D14/D15，DK12=D15/D16，DH13=D16/D14，相应地，比值集Q21为For example, when h=3, k=3, DK11=D14/D15, DK12=D15/D14; when h=3, k=4, DK11=D14/D15, DK12=D15/D16, DH13=D16/D14. Correspondingly, the ratio set Q21 is
Q21=[DK11,DK12,...,DK1k-1]Q21=[DK11,DK12,...,DK1k-1]
同时，计算射线检测结果中第一引线4021上相邻两条焊缝的间距比值，第二引线4022上相邻两条焊缝的间距比值，以获得相邻间距系数Q2，具体包括：第一引线4021上形成有h条焊缝，第二引线4022上形成有k条焊缝，相应地射线检测结果中第一引线4021上相邻两条焊缝的间距比值为：At the same time, the spacing ratio of two adjacent welds on the first lead 4021 and the spacing ratio of two adjacent welds on the second lead 4022 in the radiographic detection results are calculated to obtain the adjacent spacing coefficient Q2, which specifically includes: there are h welds formed on the first lead 4021, and k welds formed on the second lead 4022. Accordingly, the spacing ratio of two adjacent welds on the first lead 4021 in the radiographic detection results is:
DH21=D21/D22,DH12=D22/D23,...,DH2h-1=D2h-1/D21DH21=D21/D22,DH12=D22/D23,...,DH2h-1=D2h-1/D21
例如，当h=3时，DH21=D21/D22，DH12=D22/D21；当h=4时，DH21=D21/D22，DH22=D22/D23，DH23=D23/D21，相应地，比值集Q21为：For example, when h=3, DH21=D21/D22, DH12=D22/D21; when h=4, DH21=D21/D22, DH22=D22/D23, DH23=D23/D21. Accordingly, the ratio set Q21 is:
Q12=[DH21,DH22,...,DH2h-1]Q12=[DH21,DH22,...,DH2h-1]
射线检测结果中第二引线4022上相邻两条焊缝的间距比值为The ratio of the spacing between two adjacent welds on the second lead 4022 in the X-ray detection result is
DK21=(D2h+1/D2h+2),DK22=(D2h+2/D2h+3),...DK2k-1=(D2n-1/D2h+1)DK21=(D2h+1/D2h+2),DK22=(D2h+2/D2h+3),...DK2k-1=(D2n-1/D2h+1)
例如，当h=3,k=3时，DK21=D24/D25，DK22=D25/D24；当h=3,k=4时，DK21=D24/D25，DK22=D25/D26，DH23=D26/D24，当h=3,k=5时，DK21=D24/D25，DK22=D25/D26，DH23=D26/D27，DH24=D27/D24，相应地，比值集Q22为For example, when h=3, k=3, DK21=D24/D25, DK22=D25/D24; when h=3, k=4, DK21=D24/D25, DK22=D25/D26, DH23=D26/D24; when h=3, k=5, DK21=D24/D25, DK22=D25/D26, DH23=D26/D27, DH24=D27/D24. Correspondingly, the ratio set Q22 is
Q22=[DK21,DK22,...,DK2k-1]Q22=[DK21,DK22,...,DK2k-1]
利用间距比值集Q11、Q12、Q21、Q22获得相邻间距系数，对应的相邻间距系数Q2为：The adjacent spacing coefficient is obtained by using the spacing ratio set Q11, Q12, Q21, Q22, and the corresponding adjacent spacing coefficient Q2 is:
当h=k时，Q2=（DH11+DH12+,...,+DH1h-1）/（DH21+DH22+,...,+DH2h-1）-（DK11+DK12+,...,+DK1k-1）/（DK21+DK22+,...,+DK2k-1）+（DH11+DH12+,...,+DH1h-1）/（DK11+DK12+,...,+DK1k-1）-（DH21+DH22+,...,+DH2h-1）/（DK21+DK22+,...,+DK2k-1）When h=k, Q2=(DH11+DH12+,...,+DH1h-1)/(DH21+DH22+,...,+DH2h-1)-(DK11+DK12+,...,+DK1k- 1)/(DK21+DK22+,...,+DK2k-1)+(DH11+DH12+,...,+DH1h-1)/(DK11+DK12+,...,+DK1k-1)-(DH21 +DH22+,...,+DH2h-1)/(DK21+DK22+,...,+DK2k-1)
当h≠k时，Q2=（DH11+DH12+,...,+DH1h-1）/（DH21+DH22+,...,+DH2h-1）-（DK11+DK12+,...,+DK1k-1）/（DK21+DK22+,...,+DK2k-1）When h≠k, Q2=(DH11+DH12+,...,+DH1h-1)/(DH21+DH22+,...,+DH2h-1)-(DK11+DK12+,...,+DK1k- 1)/(DK21+DK22+,...,+DK2k-1)
示例性地，h的数值可以为1、2、3、4、5、6，k的数值可以为1、2、3、4、5、6，同样既要保证焊接的牢固性，又要保证激光焊接的工艺效率，焊缝条数不会太多,一般来说，3≦h≦6,3≦k≦6。在上述对比间距系数Q1和相邻间距系数Q2的基础上，利用对比间距系数Q1和相邻间距系数Q2以获得第三匹配系数P3，第三匹配系数P3计算过公式是：P3=Q1+Q2-1。For example, the value of h can be 1, 2, 3, 4, 5, 6, and the value of k can be 1, 2, 3, 4, 5, 6. Similarly, the firmness of welding and the process efficiency of laser welding must be guaranteed, and the number of welds will not be too many. Generally speaking, 3≦h≦6, 3≦k≦6. On the basis of the above-mentioned comparison of spacing coefficient Q1 and adjacent spacing coefficient Q2, the comparison of spacing coefficient Q1 and adjacent spacing coefficient Q2 is used to obtain the third matching coefficient P3. The third matching coefficient P3 is calculated by the formula: P3=Q1+Q2-1.
第三匹配系数P3用于评估图像检测结果中多条焊缝和对应地射线检测结果中多条焊缝的排布一致度，具体包括：当P3<A时，图像检测结果中多条焊缝和对应地射线检测结果中多条焊缝的排布一致；当P3≥A时，图像检测结果中多条焊缝和对应地射线检测结果中多条焊缝的排布不一致，其中，0.2≦A≦0.4。The third matching coefficient P3 is used to evaluate the consistency of the arrangement of multiple welds in the image detection results and the corresponding multiple welds in the X-ray detection results, specifically including: when P3<A, the arrangement of the multiple welds in the image detection results and the corresponding multiple welds in the X-ray detection results are consistent; when P3≥A, the arrangement of the multiple welds in the image detection results and the corresponding multiple welds in the X-ray detection results are inconsistent, where 0.2≦A≦0.4.
在另一些实施例中，可以设置预设条数，预设条数的数值包括h/2、h+k/2,可以h/2作为x轴的数值，以对应间距比值集Q11、Q21作为y轴的数值，同时以h+k/2作为x轴的数值，以对应间距比值集Q12、Q22作为y轴的数值，进而，可以建立预设条数-多个间距比值的散点分布图，同样以（n/2，1）为中心，以半长边的长度n/2+0.5，半宽边的宽度0.5建立堆成的长方形预设区域（同样参见图11所示，其以h=3,k=3为例），统计位于预设区域内的落入散点总数r，计算落入散点总数r与总散点个数2n-4的比值以获得第三匹配系数P3，P3的计算过公式为：P3=r/（2n-4)。同样，第三匹配系数P3用于评估图像检测结果中多条焊缝和对应地射线检测结果中多条焊缝的排布一致度，具体包括：当P3=1时，图像检测结果中多条焊缝和对应地射线检测结果中多条焊缝的排布一致；当P3≠1时，图像检测结果中多条焊缝和对应地射线检测结果中多条焊缝的排布不一致。进而，可以同时使用第二匹配系数P2和第三匹配系数P3通过预设区域共同判断，可以提高图像射线检测单元的检测速度和效率。In other embodiments, a preset number of bars can be set, and the values of the preset number of bars include h/2 and h+k/2. h/2 can be used as the value of the x-axis, and the corresponding spacing ratio sets Q11 and Q21 can be used as the values of the y-axis. At the same time, h+k/2 can be used as the value of the x-axis, and the corresponding spacing ratio sets Q12 and Q22 can be used as the values of the y-axis. Then, a scatter distribution diagram of the preset number of bars and multiple spacing ratios can be established. Similarly, with (n/2, 1) as the center, a stacked rectangular preset area is established with the length of the semi-long side n/2+0.5 and the width of the semi-wide side 0.5 (also see Figure 11, which takes h=3, k=3 as an example), and the total number of scatter points r falling into the preset area is counted, and the ratio of the total number of scatter points r to the total number of scatter points 2n-4 is calculated to obtain the third matching coefficient P3. The calculation formula of P3 is: P3=r/(2n-4). Similarly, the third matching coefficient P3 is used to evaluate the consistency of the arrangement of multiple welds in the image detection result and the corresponding multiple welds in the radiographic detection result, specifically including: when P3=1, the arrangement of multiple welds in the image detection result and the corresponding multiple welds in the radiographic detection result is consistent; when P3≠1, the arrangement of multiple welds in the image detection result and the corresponding multiple welds in the radiographic detection result is inconsistent. Furthermore, the second matching coefficient P2 and the third matching coefficient P3 can be used simultaneously to jointly judge through the preset area, which can improve the detection speed and efficiency of the image radiographic detection unit.
因此，本发明申请中的图像射线检测单元，首先可以确定判断确定焊接外观图像中两个引线上总焊缝条数和焊接射线图像中总焊缝条数相等，可以初步确定汇流条的引线和接线盒的焊盘焊接是否初步合格；然后，可以确定判断图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地射线检测结果中每条焊缝的长度、宽度、焊缝面积是否基本相似，即图像检测结果中每条焊缝和对应地射线检测结果中每条焊缝的细节近似度是否呈现基本相近，相应可以第二次确定汇流条的引线和接线盒的焊盘焊接是否良好；最后，可以确定判断图像检测结果中多条焊缝排布和对应地射线检测结果中多条焊缝排布是否基本一致，相应可以第三次确定汇流条的引线和接线盒的焊盘焊接质量是否可靠。Therefore, the image radiation detection unit in the application of the present invention can first determine whether the total number of welds on the two leads in the welding appearance image is equal to the total number of welds in the welding radiation image, and can preliminarily determine whether the welding of the busbar lead and the pad of the junction box is preliminarily qualified; then, it can determine whether the length, width, and weld area of each weld in the image detection result and the length, width, and weld area of each weld in the corresponding radiation detection result are basically similar, that is, whether the detail similarity of each weld in the image detection result and the detail similarity of each weld in the corresponding radiation detection result are basically similar, and accordingly, it can be determined for the second time whether the welding of the busbar lead and the pad of the junction box is good; finally, it can be determined whether the arrangement of multiple welds in the image detection result and the arrangement of multiple welds in the corresponding radiation detection result are basically consistent, and accordingly, it can be determined for the third time whether the welding quality of the busbar lead and the pad of the junction box is reliable.
由此，本发明申请中通过第一匹配检测部的第一匹配系数P1、第二匹配检测部第一匹配系数P2、第三匹配检测部第三匹配系数P3的设置，避免依靠单一的图像检测结果或单一的射线检测结果作为汇流条的引线和接线盒的焊盘焊接质量的检测结果，而是从局部上评估图像检测结果中每条焊缝和对应地射线检测结果中每条焊缝的细节近似度，同时还从整体上评估图像检测结果中每条焊缝和对应地射线检测结果中多条焊缝的排布一致度，并结合焊接内部缺陷类型结果，进而可以综合得到并输出上述汇流条的引线和接线盒的焊盘焊接质量结果，从而提高焊接质量检测结果判断评估的准确度和可靠性，从根本上能够防止汇流条的引线和接线盒的焊盘焊接失效（例如虚焊）的问题产生，理论上来说，焊接检查可靠性可以达到98%以上的检出率。Therefore, in the present application, by setting the first matching coefficient P1 of the first matching detection unit, the first matching coefficient P2 of the second matching detection unit, and the third matching coefficient P3 of the third matching detection unit, it is avoided to rely on a single image detection result or a single radiation detection result as the detection result of the welding quality of the busbar lead and the pad of the junction box. Instead, the detail similarity of each weld in the image detection result and each weld in the corresponding radiation detection result is locally evaluated. At the same time, the arrangement consistency of each weld in the image detection result and multiple welds in the corresponding radiation detection result is evaluated as a whole, and combined with the welding internal defect type result, the welding quality result of the busbar lead and the pad of the junction box can be comprehensively obtained and output, thereby improving the accuracy and reliability of the judgment and evaluation of the welding quality detection result, and fundamentally preventing the problem of welding failure (such as cold solder joint) of the busbar lead and the pad of the junction box. Theoretically, the reliability of welding inspection can reach a detection rate of more than 98%.
在一些实施例中，为了驱动单元的可靠性和稳定性，第一X方向移动模块101、第一Z方向移动模块102、第二X方向移动模块201、第二Z方向移动模块202、X方向移动模块503、X方向移动模块一504、Z方向移动模块一505、X方向移动模块二506、Z方向移动模块二507均可以采用常见的移动模组，例如高精度移动模组，常见的移动模组包括电机、减速器（也可以没有）、滑块、两侧导轨、限位传感器等，这样可以降低第一X方向移动模块101、第一Z方向移动模块102、第二X方向移动模块201、第二Z方向移动模块202、X方向移动模块503、X方向移动模块一504、Z方向移动模块一505、X方向移动模块二506、Z方向移动模块二507移动的晃动和不稳定性，两侧导轨的设计可以分担移动模组的重量，使得整个移动模组能够承受更大的载荷，不易产生变形或损坏，而且每侧两组滑轨的设置可以使移动模组在移动时保持更好的平衡，避免因为侧向力或不均匀负载导致的倾斜或歪斜。In some embodiments, for the reliability and stability of the driving unit, the first X-direction moving module 101, the first Z-direction moving module 102, the second X-direction moving module 201, the second Z-direction moving module 202, the X-direction moving module 503, the X-direction moving module 1 504, the Z-direction moving module 1 505, the X-direction moving module 2 506, and the Z-direction moving module 2 507 can all adopt common moving modules, such as high-precision moving modules. Common moving modules include motors, reducers (which may not be present), sliders, guide rails on both sides, limit sensors, etc., which can reduce the first X-direction moving module 1 01, the first Z-direction moving module 102, the second X-direction moving module 201, the second Z-direction moving module 202, the X-direction moving module 503, the X-direction moving module one 504, the Z-direction moving module one 505, the X-direction moving module two 506, and the Z-direction moving module two 507 can avoid the shaking and instability of movement. The design of the guide rails on both sides can share the weight of the moving module, so that the entire moving module can withstand a larger load and is not prone to deformation or damage. In addition, the setting of two sets of slide rails on each side can enable the moving module to maintain a better balance during movement, avoiding tilting or skewing due to lateral force or uneven load.
在一些实施例中，本发明申请的接线盒的激光焊接装置还包括控制单元，控制单元控制激光单元100、视觉检测单元200、压合单元300、图像射线检测单元500，具体控制激光单元100、视觉检测单元200、压合单元300、图像射线检测单元500整体和各个部件的动作、功能，以完成接线盒的激光焊接前检测和焊接后焊接质量检测，具体的控制方式，技术人员可以根据实际情况设置，本发明申请在此不再赘述。在一些实施例中，视觉检测单元200、压合单元300、接线盒可以有多个，例如视觉检测单元200、压合单元300、接线盒均为三个。In some embodiments, the laser welding device of the junction box of the present invention also includes a control unit, which controls the laser unit 100, the visual inspection unit 200, the pressing unit 300, and the image ray detection unit 500, and specifically controls the actions and functions of the laser unit 100, the visual inspection unit 200, the pressing unit 300, and the image ray detection unit 500 as a whole and each component to complete the laser welding pre-detection and welding quality inspection of the junction box after welding. The specific control method can be set by the technician according to the actual situation, and the present invention application will not be repeated here. In some embodiments, there can be multiple visual inspection units 200, pressing units 300, and junction boxes, for example, there are three visual inspection units 200, pressing units 300, and junction boxes.
第二方面，本发明申请提供一种接线盒的激光焊接的方法，其采用或不采用上述任一项所述的接线盒的激光焊接装置，包括如下步骤：In a second aspect, the present invention provides a method for laser welding of a junction box, which may or may not use any of the above-mentioned laser welding devices for a junction box, comprising the following steps:
S100：将汇流条的引线和接线盒的焊盘进行接触贴合；S100: contact and bond the lead of the busbar to the pad of the junction box;
具体地，步骤S100包括：Specifically, step S100 includes:
步骤S101：当输送单元将光伏组件移动到激光焊接装置下方时，视觉检测单元200获取接线盒、汇流条的引线的位置；Step S101: When the conveying unit moves the photovoltaic module to below the laser welding device, the visual inspection unit 200 obtains the positions of the leads of the junction box and the busbar;
步骤S102：第二X方向移动模块201根据接线盒、汇流条的引线的位置驱动视觉检测单元200、压合单元300沿X方向移动以使得压合单元300与汇流条的引线位置对应；Step S102: the second X-direction moving module 201 drives the visual inspection unit 200 and the pressing unit 300 to move along the X-direction according to the positions of the leads of the junction box and the busbar so that the pressing unit 300 corresponds to the position of the leads of the busbar;
步骤S103：当压合单元300与汇流条的引线位置对应时，第二Z方向移动模块202可以或者不可以驱动相机203、压合单元300沿Z方向移动，气缸3003驱动压合件3008压弯汇流条的引线以使得汇流条的引线与接线盒的焊盘接触贴合，进而完成汇流条的引线和接线盒的焊盘接触贴合，此时感应件3011与传感器3005进行配合进行感应限位，控制单元接受到感应限位信号后，气缸3003停止移动压合件3008，进而防止压合件3008压坏接线盒401。Step S103: When the pressing unit 300 corresponds to the lead position of the bus bar, the second Z-direction moving module 202 may or may not drive the camera 203 and the pressing unit 300 to move along the Z direction, and the cylinder 3003 drives the pressing part 3008 to bend the lead of the bus bar so that the lead of the bus bar contacts and fits with the pad of the junction box, thereby completing the contact and fitting of the lead of the bus bar and the pad of the junction box. At this time, the sensing part 3011 cooperates with the sensor 3005 to perform sensing limit. After the control unit receives the sensing limit signal, the cylinder 3003 stops moving the pressing part 3008, thereby preventing the pressing part 3008 from damaging the junction box 401.
需要说明的是，当视觉检测单元200、压合单元300、接线盒有多个时，每个视觉检测单元200、压合单元300都可以进行上述步骤S100的步骤内容，本发明申请对此不再赘述。It should be noted that when there are multiple visual inspection units 200, pressing units 300, and junction boxes, each visual inspection unit 200 and pressing unit 300 can perform the above-mentioned step S100, and the present application will not elaborate on this.
S200：对汇流条的引线和接线盒的焊盘贴合状态进行检测；S200: Detect the bonding status of the busbar lead and the pad of the junction box;
具体地，步骤S200包括：Specifically, step S200 includes:
汇流条的引线和接线盒的焊盘接触贴合后，视觉检测单元200可以再次对汇流条的引线和接线盒的焊盘的贴合状态进行检测，示例性地，视觉检测单元200的相机203可以是二维相机，也可以是三维点云相机，进而可以检测汇流条的引线和接线盒贴合的角度、方向是否正确，进而判断汇流条的引线和接线盒的焊盘贴合状态是否良好，从而便于后续进行汇流条的引线和接线盒的焊盘进行激光焊接。After the leads of the busbar and the pads of the junction box are in contact and fit together, the visual inspection unit 200 can again inspect the fitting status of the leads of the busbar and the pads of the junction box. Exemplarily, the camera 203 of the visual inspection unit 200 can be a two-dimensional camera or a three-dimensional point cloud camera, so as to detect whether the angle and direction of the fitting between the leads of the busbar and the junction box are correct, and then determine whether the fitting status of the leads of the busbar and the pads of the junction box is good, thereby facilitating the subsequent laser welding of the leads of the busbar and the pads of the junction box.
S300：当检测到汇流条的引线和接线盒贴合状态良好，进行步骤S300；当检测到汇流条的引线和接线盒贴合状态不良好，停机或回到步骤S100；S300: When it is detected that the lead wire of the busbar and the junction box are well fitted, proceed to step S300; when it is detected that the lead wire of the busbar and the junction box are not well fitted, stop the machine or return to step S100;
具体地，步骤S300包括：Specifically, step S300 includes:
步骤S301：当检测到汇流条的引线和接线盒贴合状态良好，进行步骤S300；Step S301: When it is detected that the lead wire of the busbar and the junction box are in good contact, proceed to step S300;
步骤S302：当检测到汇流条的引线和接线盒贴合状态不良好，例如贴合方向、贴合角度错位,即汇流条的引线和接线盒并贴合歪斜、贴合位置错误，通常需要停机，或者人工操作修正错误的贴合位置后，重新回到步骤S100汇流条的引线和接线盒的焊盘进行接触贴合。Step S302: When it is detected that the lead of the busbar and the junction box are not well fitted, for example, the fitting direction and fitting angle are misaligned, that is, the lead of the busbar and the junction box are crookedly fitted or the fitting position is wrong, it is usually necessary to stop the machine, or manually correct the wrong fitting position, and then return to step S100 to contact and fit the lead of the busbar and the pad of the junction box.
S400：对汇流条的引线和接线盒的焊盘进行激光焊接；S400: Laser welding of busbar leads and junction box pads;
具体地，步骤S400包括：Specifically, step S400 includes:
S401：根据视觉检测单元200对汇流条的引线和接线盒的焊盘的贴合状态信息，第一X方向移动模块101驱动激光器沿X方向移动，以使得激光器位于接线盒焊盘和汇流条引线的上方，S401: Based on the bonding status information of the busbar lead and the pad of the junction box by the visual inspection unit 200, the first X-direction moving module 101 drives the laser to move along the X-direction so that the laser is located above the pad of the junction box and the busbar lead.
S402：第一Z方向移动模块102驱动激光器沿Z方向移动至合适位置，激光器发射出激光以对汇流条的引线和接线盒的焊盘进行激光焊接；S402: The first Z-direction moving module 102 drives the laser to move to a suitable position along the Z-direction, and the laser emits laser light to perform laser welding on the lead of the bus bar and the pad of the junction box;
S403：第一X方向移动模块101驱动激光器沿X方向移动，激光器远离接线盒焊盘和汇流条引线。S403: The first X-direction moving module 101 drives the laser to move along the X-direction, and the laser is away from the junction box pad and the bus bar lead.
S500：焊接完成后，对汇流条的引线和接线盒401的焊盘焊接质量进行检测。S500: After welding is completed, the welding quality of the lead wires of the busbar and the welding pads of the junction box 401 is inspected.
具体地，步骤S500包括：Specifically, step S500 includes:
步骤S501：检测焊接外观质量，获得焊接外观质量图像检测结果；Step S501: Detect the welding appearance quality and obtain the welding appearance quality image detection result;
具体地，步骤S501包括：Specifically, step S501 includes:
步骤S5011：X方向移动模块503驱动摄像机502沿X方向移动，摄像机502进行拍照以获取焊接外观图像；Step S5011: the X-direction moving module 503 drives the camera 502 to move along the X-direction, and the camera 502 takes pictures to obtain welding appearance images;
步骤S5012：对焊接外观图像进行处理，从而获得焊接外观质量图像检测结果，焊接外观质量图像检测结果包括：焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距；Step S5012: Process the welding appearance image to obtain a welding appearance quality image detection result, where the welding appearance quality image detection result includes: the number of welds, the length of the weld, the width of the weld, the area of the weld, and the spacing between adjacent welds;
步骤S502：检测焊接内外部质量，获得焊接内外部质量射线检测结果；Step S502: Detect the internal and external quality of welding and obtain the radiographic detection result of the internal and external quality of welding;
具体地，步骤S502包括：Specifically, step S502 includes:
步骤S5021：根据视觉检测单元200检测到的汇流条的引线和接线盒的焊盘激光焊接位置信息或者根据摄像机502检测到的汇流条的引线和接线盒的焊盘激光焊接位置信息，X方向移动模块一504驱动射线发生器50R沿X方向移动,Z方向移动模块一505驱动射线发生器50R沿Z方向移动，X方向移动模块二506驱动射线接收器50R沿X方向移动,Z方向移动模块二507驱动射线接收器50R沿Z方向移动，以使得射线发生器50R、汇流条的引线和接线盒的焊盘激光焊接位置、射线接收器50R对应；Step S5021: according to the laser welding position information of the busbar lead and the pad of the junction box detected by the visual inspection unit 200 or according to the laser welding position information of the busbar lead and the pad of the junction box detected by the camera 502, the X-direction moving module 1 504 drives the ray generator 50R to move along the X direction, the Z-direction moving module 1 505 drives the ray generator 50R to move along the Z direction, the X-direction moving module 2 506 drives the ray receiver 50R to move along the X direction, and the Z-direction moving module 2 507 drives the ray receiver 50R to move along the Z direction, so that the ray generator 50R, the busbar lead and the pad of the junction box laser welding position, and the ray receiver 50R correspond to each other;
步骤S5023：射线发生器50T产生X射线，X射线穿透汇流条的引线和接线盒的焊盘激光焊接位置，并被射线接收器50R接收，进而获得汇流条的引线和接线盒的焊盘激光焊接的X射线图像；Step S5023: the ray generator 50T generates X-rays, which penetrate the laser welding position of the busbar lead and the pad of the junction box and are received by the ray receiver 50R, thereby obtaining an X-ray image of the laser welding of the busbar lead and the pad of the junction box;
步骤S5022：对X射线图像进行处理，从而可以获得焊接内外部质量射线检测结果，焊接内外部质量射线检测结果包括：焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距、焊接内部缺陷类型等。Step S5022: Process the X-ray image to obtain the internal and external quality X-ray detection results of the welding, which include: the number of welds, weld length, weld width, weld area, spacing between adjacent welds, and types of internal defects in welding.
步骤S503：对比以及综合焊接外观质量图像检测结果和焊接内外部质量射线检测结果，输出汇流条的引线和接线盒的焊盘焊接质量结果。Step S503: Compare and integrate the welding appearance quality image detection results and the welding internal and external quality X-ray detection results, and output the welding quality results of the busbar lead and the junction box pad.
具体地，步骤S503包括：Specifically, step S503 includes:
步骤S5031：计算图像检测结果中焊缝条数与对应地射线检测结果中焊缝条数的比值以获得第一匹配系数P1，并且判断焊接内部缺陷类型，其和上述第一方面中第一匹配系数P1的计算方式相同。Step S5031: Calculate the ratio of the number of welds in the image detection result to the number of welds in the corresponding X-ray detection result to obtain the first matching coefficient P1, and determine the type of internal welding defects, which is the same as the calculation method of the first matching coefficient P1 in the first aspect mentioned above.
步骤S5032：当第一匹配系数P1等于1，并且焊接内部缺陷类型均为无时，进入步骤S5033；当第一匹配系数P1不等于1或者判断焊接内部缺陷类型中至少有一个不是无时，输出汇流条的引线和接线盒的焊盘焊接质量结果：不合格。Step S5032: When the first matching coefficient P1 is equal to 1 and all welding internal defect types are non-existent, proceed to step S5033; when the first matching coefficient P1 is not equal to 1 or at least one of the welding internal defect types is not non-existent, output the welding quality result of the busbar lead and the junction box pad: unqualified.
显然，第一匹配系数为P1=n/m。显然，当P1等于1,即m等于n，并且焊接内部缺陷类型均为无时，即焊接外观图像中两个引线上总焊缝条数和焊接射线图像中总焊缝条数相等，相应可以初步确定汇流条的引线和接线盒的焊盘焊接初步合格；当P11不等于1，即m不等于n时，判断焊接内部缺陷类型中至少有一个不是无时，即焊接外观图像中两个引线上总焊缝条数和焊接射线图像中总焊缝条数不相等，明显表明两种检测结果的焊缝条数不一致，或者，判断焊接内部缺陷类型中至少存在一个缺陷，相应的汇流条的引线和接线盒的焊盘焊接质量明显为不合格。Obviously, the first matching coefficient is P1=n/m. Obviously, when P1 is equal to 1, that is, m is equal to n, and the welding internal defect types are all zero, that is, the total number of welds on the two leads in the welding appearance image and the total number of welds in the welding ray image are equal, it can be preliminarily determined that the busbar lead and the pad welding of the junction box are initially qualified; when P11 is not equal to 1, that is, m is not equal to n, it is judged that at least one of the welding internal defect types is not zero, that is, the total number of welds on the two leads in the welding appearance image and the total number of welds in the welding ray image are not equal, which obviously indicates that the number of welds of the two test results is inconsistent, or it is judged that there is at least one defect in the welding internal defect type, and the corresponding busbar lead and the pad welding quality of the junction box are obviously unqualified.
步骤S5033：计算图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地射线检测结果中每条焊缝的长度、宽度、焊缝面积的比值，并建立焊缝序号-多个比值的散点分布图，统计位于预设区域内的落入散点个数，计算落入散点个数与总散点个数的比值以获得第二匹配系数P2，其可以和上述第一方面中第二匹配系数P2的计算方式相同。Step S5033: Calculate the ratio of the length, width, and weld area of each weld in the image detection results to the length, width, and weld area of each weld in the corresponding X-ray detection results, and establish a scatter distribution diagram of the weld number-multiple ratios, count the number of scatter points falling within the preset area, and calculate the ratio of the number of scatter points falling into the preset area to obtain a second matching coefficient P2, which can be calculated in the same way as the second matching coefficient P2 in the first aspect mentioned above.
具体地，步骤S5033包括：Specifically, step S5033 includes:
步骤S50331：计算图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地射线检测结果中每条焊缝的长度、宽度、焊缝面积的比值。具体包括：计算第1条焊缝的长度L11、宽度W11和面积S11，第2条焊缝的长度L12、宽度W12和面积S12，...,第n条焊缝的长度L1n、宽度W1n和面积S1n与焊缝1的长度L21、宽度W21和面积S21，焊缝2的长度L22、宽度W22和面积S22，...,焊缝m的长度L2m、宽度W2m和面积S2m的比值，对应可以获得每条焊缝的长度比值、宽度比值、面积比值，即第1条焊缝的长度比值LC1、宽度比值WC1和面积比值SC1,第2条焊缝的长度比值LC2、宽度比值WC2和面积比值SC2,...,第n条焊缝的长度比值LCn、宽度比值WCn和面积比值SCn，即：Step S50331: Calculate the ratio of the length, width, and weld area of each weld in the image detection result to the length, width, and weld area of each weld in the corresponding X-ray detection result. Specifically, it includes: calculating the length L11, width W11 and area S11 of the first weld, the length L12, width W12 and area S12 of the second weld, ..., the length L1n, width W1n and area S1n of the nth weld and the length L21, width W21 and area S21 of weld 1, the length L22, width W22 and area S22 of weld 2, ..., the length L2m, width W2m and area S2m of weld m. Correspondingly, the length ratio, width ratio and area ratio of each weld can be obtained, that is, the length ratio LC1, width ratio WC1 and area ratio SC1 of the first weld, the length ratio LC2, width ratio WC2 and area ratio SC2 of the second weld, ..., the length ratio LCn, width ratio WCn and area ratio SCn of the nth weld, that is:
LC1=L11/L21,LC2=L12/L22,...,LCn=L1n/L2mLC1=L11/L21,LC2=L12/L22,...,LCn=L1n/L2m
WC1=W11/W21,WC2=W12/W22,...,WCn=W1n/W2mWC1=W11/W21,WC2=W12/W22,...,WCn=W1n/W2m
SC1=S11/S21,SC2=S12/S22,...,SCn=S1n/S2mSC1=S11/S21,SC2=S12/S22,...,SCn=S1n/S2m
步骤S50332：建立焊缝序号-多个比值的散点分布图，统计位于预设区域内的落入散点总数。具体包括：以焊缝序号作为x轴的数值，以对应每条焊缝的长度比值、宽度比值、面积比值作为y轴的数值，进而可以建立焊缝序号-多个比值的散点分布图，参见图9所示；然而（n/2，1）为中心，以半长边的长度n/2+0.5，半宽边的宽度0.5建立堆成的长方形预设区域（同样参见图7所示），统计位于预设区域内的落入散点总数t，步骤S50333：计算落入散点总数与总散点个数的比值以获得第二匹配系数P2。具体包括：Step S50332: Establish a scatter distribution diagram of weld number-multiple ratios, and count the total number of scattered points falling within the preset area. Specifically, it includes: using the weld number as the value of the x-axis, and the length ratio, width ratio, and area ratio of each weld as the value of the y-axis, and then establishing a scatter distribution diagram of weld number-multiple ratios, as shown in Figure 9; however, (n/2, 1) is used as the center, and a rectangular preset area is established with the length of the half-long side n/2+0.5 and the width of the half-wide side 0.5 (also see Figure 7), and the total number of scattered points t falling within the preset area is counted, and step S50333: Calculate the ratio of the total number of scattered points to the total number of scattered points to obtain the second matching coefficient P2. Specifically, it includes:
步骤S50333：计算落入散点总数t与总散点个数3n的比值以获得第二匹配系数P2，P2的计算过公式为：P2=t/3n。Step S50333: Calculate the ratio of the total number of scattered points t to the total number of scattered points 3n to obtain a second matching coefficient P2. The calculation formula of P2 is: P2=t/3n.
步骤S5034：当第二匹配系数P2等于1时，进入步骤S5035；当第二匹配系数P2不等于1时，输出汇流条的引线和接线盒的焊盘焊接质量结果：不合格；Step S5034: when the second matching coefficient P2 is equal to 1, proceed to step S5035; when the second matching coefficient P2 is not equal to 1, output the welding quality result of the lead wire of the bus bar and the pad of the junction box: unqualified;
显然，当P2=1,即t等于3n时，即图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地射线检测结果中每条焊缝的长度、宽度、焊缝面积基本相似，即图像检测结果中每条焊缝和对应地射线检测结果中每条焊缝的细节近似度呈现基本相近，相应可以二次确定汇流条的引线和接线盒的焊盘焊接质量良好；当P2不等于1，即t不等于3n时，即图像检测结果中每条焊缝的长度、宽度、焊缝面积和对应地射线检测结果中每条焊缝的长度、宽度、焊缝面积至少有一条不存在相似，即图像检测结果中每条焊缝和对应地射线检测结果中每条焊缝的细节近似度至少有一条存在不相近，相应可以确定汇流条的引线和接线盒的焊盘焊接质量非良好，即不合格。Obviously, when P2=1, that is, t is equal to 3n, that is, the length, width, weld area of each weld in the image detection results and the length, width, weld area of each weld in the corresponding radiographic detection results are basically similar, that is, the detail approximation of each weld in the image detection results and the corresponding radiographic detection results are basically similar, and accordingly, it can be secondary determined that the welding quality of the busbar lead and the pad of the junction box is good; when P2 is not equal to 1, that is, t is not equal to 3n, that is, at least one of the length, width, weld area of each weld in the image detection results and the length, width, weld area of each weld in the corresponding radiographic detection results is not similar, that is, at least one of the detail approximation of each weld in the image detection results and the corresponding radiographic detection results is not similar, and accordingly, it can be determined that the welding quality of the busbar lead and the pad of the junction box is not good, that is, unqualified.
步骤S5035：计算图像检测结果中相邻两条焊缝的间距和对应地射线检测结果中相邻两条焊缝的间距比值以获得对比间距系数Q1；计算图像检测结果和对应地射线检测结果中第一引线上相邻两条焊缝的间距比值集Q11、Q12，第二引线上相邻两条焊缝的间距比值集Q21、Q22，利用间距比值集Q11、Q12、Q21、Q22获得相邻间距系数Q2；利用对比间距系数Q1与相邻间距系数Q2获得第三匹配系数P3，其和上述第一方面中第三匹配系数P3的计算方式相同。Step S5035: Calculate the spacing ratio between two adjacent welds in the image detection results and the corresponding spacing ratio between two adjacent welds in the X-ray detection results to obtain a comparison spacing coefficient Q1; calculate the spacing ratio set Q11, Q12 of two adjacent welds on the first lead in the image detection results and the corresponding X-ray detection results, and the spacing ratio set Q21, Q22 of two adjacent welds on the second lead, and use the spacing ratio set Q11, Q12, Q21, Q22 to obtain the adjacent spacing coefficient Q2; use the comparison spacing coefficient Q1 and the adjacent spacing coefficient Q2 to obtain the third matching coefficient P3, which is calculated in the same way as the third matching coefficient P3 in the first aspect mentioned above.
具体地，步骤S5035包括：Specifically, step S5035 includes:
步骤S50351：计算图像检测结果中相邻两条焊缝的间距和对应地射线检测结果中相邻两条焊缝的间距比值以获得对比间距系数Q1。具体包括：Step S50351: Calculate the ratio of the distance between two adjacent welds in the image detection result and the distance between two adjacent welds in the corresponding radiographic detection result to obtain a comparison distance coefficient Q1. Specifically including:
计算图像检测结果中相邻两条焊缝的间距和对应地射线检测结果中相邻两条焊缝的间距比值以获得对比间距系数Q1，即：计算第1条焊缝和第2条焊缝的间距D11，第2条焊缝和第3条焊缝的间距D12，...,第n-1条焊缝和第n条焊缝的间距D1n-1与焊缝1和焊缝2的间距D21，焊缝2和焊缝3的间距D22，...,焊缝m-1和焊缝m的间距D2m-1比值，对应可以获得间距比值DC1，DC2，...,DCn-1，即：Calculate the spacing ratio between two adjacent welds in the image detection results and the spacing ratio between two adjacent welds in the corresponding radiographic detection results to obtain the contrast spacing coefficient Q1, that is, calculate the spacing D11 between the 1st weld and the 2nd weld, D12 between the 2nd weld and the 3rd weld, ..., the spacing D1n-1 between the n-1th weld and the nth weld and the spacing D21 between weld 1 and weld 2, the spacing D22 between weld 2 and weld 3, ..., the spacing D2m-1 between weld m-1 and weld m, and the corresponding spacing ratios DC1, DC2, ..., DCn-1 can be obtained, that is:
DC1=D11/D21,DC2=D12/D22,...,DCn=D1n/D2mDC1=D11/D21,DC2=D12/D22,...,DCn=D1n/D2m
相应地，对比间距系数Q1为：Accordingly, the contrast spacing factor Q1 is:
Q1=1/n（DC1+DC2+,...,+DCn）Q1=1/n（DC1+DC2+,...,+DCn）
步骤S50352：计算图像检测结果和对应地射线检测结果中第一引线上相邻两条焊缝的间距比值集Q11、Q12，第二引线上相邻两条焊缝的间距比值集Q21、Q22。具体包括：Step S50352: Calculate the spacing ratio set Q11, Q12 of two adjacent welds on the first lead and the spacing ratio set Q21, Q22 of two adjacent welds on the second lead in the image detection results and the corresponding X-ray detection results. Specifically including:
步骤S503521：计算图像检测结果中第一引线上相邻两条焊缝的间距比值集Q11，第二引线上相邻两条焊缝的间距比值集Q21。Step S503521: Calculate the spacing ratio set Q11 of two adjacent welds on the first lead and the spacing ratio set Q21 of two adjacent welds on the second lead in the image detection results.
计算图像检测结果中第一引线4021上的邻两条焊缝的间距比值，第二引线4022上相邻两条焊缝的间距比值，具体包括：第一引线4021上形成有h条焊缝，第二引线4022上形成有k条焊缝，3≦h≦6,3≦k≦6，h+k=n=m，相应地图像检测结果中第一引线4021上相邻两条焊缝的间距比值为：Calculating the spacing ratio of two adjacent welds on the first lead 4021 and the spacing ratio of two adjacent welds on the second lead 4022 in the image detection result, specifically includes: there are h welds formed on the first lead 4021, k welds formed on the second lead 4022, 3≦h≦6, 3≦k≦6, h+k=n=m, and accordingly, the spacing ratio of two adjacent welds on the first lead 4021 in the image detection result is:
DH11=D11/D12,DH12=D12/D13,...,DH1h-1=D1h-1/D11DH11=D11/D12,DH12=D12/D13,...,DH1h-1=D1h-1/D11
相应地，比值集Q11为：Correspondingly, the ratio set Q11 is:
Q11=[DH11,DH12,...,DH1h-1]Q11=[DH11,DH12,...,DH1h-1]
图像检测结果中第二引线4022上相邻两条焊缝的间距比值为：The ratio of the spacing between two adjacent welds on the second lead 4022 in the image detection result is:
DK11=(D1h+1/D1h+2),DK12=(D1h+2/D1h+3),...DK1k-1=(D1n-1/D1h+1)DK11=(D1h+1/D1h+2),DK12=(D1h+2/D1h+3),...DK1k-1=(D1n-1/D1h+1)
相应地，比值集Q21为：Correspondingly, the ratio set Q21 is:
Q21=[DK11,DK12,...,DK1k-1]Q21=[DK11,DK12,...,DK1k-1]
步骤S503522：计算射线检测结果中第一引线上相邻两条焊缝的间距比值集Q12，第二引线上相邻两条焊缝的间距比值集Q22。Step S503522: Calculate the spacing ratio set Q12 of two adjacent welds on the first lead and the spacing ratio set Q22 of two adjacent welds on the second lead in the X-ray detection results.
计算射线检测结果中第一引线4021上相邻两条焊缝的间距比值，第二引线4022上相邻两条焊缝的间距比值，以获得相邻间距系数Q2，具体包括：第一引线4021上形成有h条焊缝，第二引线4022上形成有k条焊缝，相应地射线检测结果中第一引线4021上相邻两条焊缝的间距比值为：The spacing ratio of two adjacent welds on the first lead 4021 and the spacing ratio of two adjacent welds on the second lead 4022 in the radiographic detection result are calculated to obtain the adjacent spacing coefficient Q2, specifically including: there are h welds formed on the first lead 4021, and k welds formed on the second lead 4022, and accordingly, the spacing ratio of two adjacent welds on the first lead 4021 in the radiographic detection result is:
DH21=D21/D22,DH12=D22/D23,...,DH2h-1=D2h-1/D21DH21=D21/D22,DH12=D22/D23,...,DH2h-1=D2h-1/D21
相应地，比值集Q21为：Correspondingly, the ratio set Q21 is:
Q12=[DH21,DH22,...,DH2h-1]Q12=[DH21,DH22,...,DH2h-1]
射线检测结果中第二引线4022上相邻两条焊缝的间距比值为The ratio of the spacing between two adjacent welds on the second lead 4022 in the X-ray detection result is
DK21=(D2h+1/D2h+2),DK22=(D2h+2/D2h+3),...DK2k-1=(D2n-1/D2h+1)DK21=(D2h+1/D2h+2),DK22=(D2h+2/D2h+3),...DK2k-1=(D2n-1/D2h+1)
相应地，比值集Q22为：Correspondingly, the ratio set Q22 is:
Q22=[DK21,DK22,...,DK2k-1]Q22=[DK21,DK22,...,DK2k-1]
步骤S50353：利用间距比值集Q11、Q12、Q21、Q22获得相邻间距系数Q2，对应的相邻间距系数Q2为：Step S50353: Obtain the adjacent spacing coefficient Q2 using the spacing ratio set Q11, Q12, Q21, Q22. The corresponding adjacent spacing coefficient Q2 is:
当h=k时，Q2=（DH11+DH12+,...,+DH1h-1）/（DH21+DH22+,...,+DH2h-1）-（DK11+DK12+,...,+DK1k-1）/（DK21+DK22+,...,+DK2k-1）+（DH11+DH12+,...,+DH1h-1）/（DK11+DK12+,...,+DK1k-1）-（DH21+DH22+,...,+DH2h-1）/（DK21+DK22+,...,+DK2k-1）When h=k, Q2=(DH11+DH12+,...,+DH1h-1)/(DH21+DH22+,...,+DH2h-1)-(DK11+DK12+,...,+DK1k- 1)/(DK21+DK22+,...,+DK2k-1)+(DH11+DH12+,...,+DH1h-1)/(DK11+DK12+,...,+DK1k-1)-(DH21 +DH22+,...,+DH2h-1)/(DK21+DK22+,...,+DK2k-1)
当h≠k时，Q2=（DH11+DH12+,...,+DH1h-1）/（DH21+DH22+,...,+DH2h-1）-（DK11+DK12+,...,+DK1k-1）/（DK21+DK22+,...,+DK2k-1）When h≠k, Q2=(DH11+DH12+,...,+DH1h-1)/(DH21+DH22+,...,+DH2h-1)-(DK11+DK12+,...,+DK1k- 1)/(DK21+DK22+,...,+DK2k-1)
步骤S50354：利用对比间距系数Q1与相邻间距系数Q2获得第三匹配系数P3，第三匹配系数P3计算公式是：P3=Q1+Q2-1。Step S50354: Obtain a third matching coefficient P3 by comparing the spacing coefficient Q1 with the adjacent spacing coefficient Q2. The calculation formula of the third matching coefficient P3 is: P3=Q1+Q2-1.
步骤S5036：当P3<A时，图像检测结果中每条焊缝和对应地射线检测结果中多条焊缝的排布一致，输出汇流条的引线和接线盒的焊盘焊接质量结果：合格；当P3≥A时，图像检测结果中每条焊缝和对应地射线检测结果中多条焊缝的排布不一致，输出汇流条的引线和接线盒的焊盘焊接质量结果：不合格，其中，0.2≦A≦0.4。Step S5036: When P3<A, the arrangement of each weld in the image detection result and the corresponding multiple welds in the X-ray detection result are consistent, and the welding quality result of the bus bar lead and the pad of the junction box is output: qualified; when P3≥A, the arrangement of each weld in the image detection result and the corresponding multiple welds in the X-ray detection result are inconsistent, and the welding quality result of the bus bar lead and the pad of the junction box is output: unqualified, where 0.2≦A≦0.4.
如图10所示，焊接内部缺陷类型可以包括：图10中（a）的未焊透、图10中（b）的气泡、图10中（c）的杂渣、无（即无缺陷类型）中至少一种，图10中（a）、（b）、（c）示例出了汇流条的引线和接线盒的焊盘焊接质量检测结果为不合格的类型。需要说明的是，步骤S501、步骤S502可以同时进行或先后进行。As shown in FIG10 , the internal welding defect types may include at least one of the following: incomplete penetration in FIG10 (a), bubbles in FIG10 (b), slag in FIG10 (c), and none (i.e., no defect type). FIG10 (a), (b), and (c) illustrate the types of unqualified welding quality test results of the busbar lead and the junction box pad. It should be noted that step S501 and step S502 may be performed simultaneously or successively.
步骤S100之前还包括步骤SF：视觉检测单元200对汇流条的引线和接线盒的焊盘贴合准备情况进行检测，以确定汇流条的引线和接线盒的焊盘具备贴合情况。具体地，步骤SF包括：视觉检测单元200检测汇流条的引线和接线盒的焊盘贴合准备情况，贴合准备情况检测内容至少包括：接线盒是否歪斜，引线是否偏移，接线盒是否±5°偏差，引线是否过长或是否过短或是否缺失，是否有接线盒，接线盒是否装反，接线盒是否用错。这样，可以使得接线盒、引出线的贴合准备良好，能够提前避免后续汇流条的引线和接线盒的焊盘贴合失败概率。Before step S100, step SF is also included: the visual inspection unit 200 detects the preparation for the fitting of the busbar lead and the pad of the junction box to determine whether the busbar lead and the pad of the junction box are in a fitted state. Specifically, step SF includes: the visual inspection unit 200 detects the preparation for the fitting of the busbar lead and the pad of the junction box, and the fitting preparation detection content at least includes: whether the junction box is skewed, whether the lead is offset, whether the junction box has a ±5° deviation, whether the lead is too long or too short or missing, whether there is a junction box, whether the junction box is installed upside down, and whether the junction box is used incorrectly. In this way, the junction box and the lead-out wires can be well prepared for fitting, and the probability of subsequent failure of fitting the busbar lead and the pad of the junction box can be avoided in advance.
由此，在本发明申请公开的第一方面和第二方面技术内容的基础上，首先，压合单元300对汇流条的引线和接线盒的焊盘进行贴合；视觉检测单元200，对汇流条的引线和接线盒的焊盘贴合状态进行检测，当汇流条的引线和接线盒贴合状态良好，即汇流条的引线和接线盒的焊盘压紧，激光单元100可以对贴合良好的汇流条的引线和接线盒的焊盘进行激光焊接，当汇流条的引线和接线盒贴合状态不良好，即汇流条的引线和接线盒的焊盘未完全压紧，汇流条的引线和接线盒的焊盘将存在间隙，那么后续激光单元100对汇流条的引线和接线盒的焊盘进行激光焊接后会存在虚焊的问题，进而导致汇流条的引线和接线盒的焊盘焊接失效，视觉检测单元200的检测能够提前解决后续虚焊的问题；Therefore, on the basis of the technical contents of the first and second aspects disclosed in the present application, first, the pressing unit 300 fits the lead of the busbar and the pad of the junction box; the visual inspection unit 200 detects the fitting state of the lead of the busbar and the pad of the junction box. When the lead of the busbar and the junction box are well fitted, that is, the lead of the busbar and the pad of the junction box are pressed tightly, the laser unit 100 can laser weld the lead of the busbar and the pad of the junction box that are well fitted. When the lead of the busbar and the junction box are not well fitted, that is, the lead of the busbar and the pad of the junction box are not completely pressed tightly, there will be a gap between the lead of the busbar and the pad of the junction box. Then, after the laser unit 100 performs laser welding on the lead of the busbar and the pad of the junction box, there will be a problem of cold welding, which will lead to failure of welding of the lead of the busbar and the pad of the junction box. The inspection of the visual inspection unit 200 can solve the problem of subsequent cold welding in advance.
同时，当汇流条的引线和接线盒的焊盘进行激光焊接完成后，图像射线检测单元500，对汇流条的引线和接线盒401的焊盘焊接质量进行检测，对比焊接外观质量图像检测结果和焊接内外部质量射线检测结果，输出汇流条的引线和接线盒的焊盘焊接质量结果，示例性地，可以分别对比图像检测结果和射线检测检测结果的焊缝条数、焊缝长度、焊缝宽度、焊缝面积、相邻焊缝间距等焊接质量参数进行检测，并结合焊接内部缺陷类型结果，进而视觉检测单元200和图像射线检测单元500可以配合对汇流条的引线和接线盒的焊盘前、焊接质量进行检测，进而从根本上能够防止汇流条的引线和接线盒的焊盘焊接失效（例如虚焊）的问题产生。At the same time, after the laser welding of the busbar lead and the pad of the junction box is completed, the image radiation detection unit 500 detects the welding quality of the busbar lead and the pad of the junction box 401, compares the welding appearance quality image detection result and the welding internal and external quality radiation detection result, and outputs the welding quality result of the busbar lead and the pad of the junction box. By way of example, the welding quality parameters such as the number of welds, weld length, weld width, weld area, and adjacent weld spacing of the image detection result and radiation detection result can be compared and detected respectively, and combined with the welding internal defect type result, the visual inspection unit 200 and the image radiation detection unit 500 can cooperate to detect the pre-welding and welding quality of the busbar lead and the pad of the junction box, thereby fundamentally preventing the problem of welding failure (such as cold solder joint) of the busbar lead and the pad of the junction box.
如上所述，尽管参照特定的优选实施例已经表示和表述了本发明申请，但其不得解释为对本发明申请自身的限制。在不脱离所附权利要求定义的本发明申请的精神和范围前提下，可对其在形式上和细节上做出各种变化。As mentioned above, although the present invention has been shown and described with reference to specific preferred embodiments, it should not be interpreted as limiting the present invention itself. Various changes can be made to it in form and detail without departing from the spirit and scope of the present invention defined in the appended claims.
| Application Number | Priority Date | Filing Date | Title |
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| CN202410915665.9ACN118455744B (en) | 2024-07-09 | 2024-07-09 | Laser welding device and laser welding method for junction box |
| Application Number | Priority Date | Filing Date | Title |
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| CN202410915665.9ACN118455744B (en) | 2024-07-09 | 2024-07-09 | Laser welding device and laser welding method for junction box |
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| CN118455744Atrue CN118455744A (en) | 2024-08-09 |
| CN118455744B CN118455744B (en) | 2024-11-01 |
| Application Number | Title | Priority Date | Filing Date |
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| CN202410915665.9AActiveCN118455744B (en) | 2024-07-09 | 2024-07-09 | Laser welding device and laser welding method for junction box |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20100133247A1 (en)* | 2008-11-21 | 2010-06-03 | Jyoti Mazumder | Monitoring of a welding process |
| DE102015016513A1 (en)* | 2015-12-18 | 2017-06-22 | Audi Ag | Online process monitoring and online process control in the method for positive or cohesive bonding of at least two components by a joining method by means of a Radiometrievorrichtung |
| CN110530877A (en)* | 2019-09-16 | 2019-12-03 | 西安中科光电精密工程有限公司 | A kind of welding shape quality inspection robot and its detection method |
| CN115692546A (en)* | 2022-10-13 | 2023-02-03 | 浙江晶科能源有限公司 | Photovoltaic module manufacturing process, manufacturing device and photovoltaic module |
| CN116352267A (en)* | 2023-04-11 | 2023-06-30 | 苏州智慧谷激光智能装备有限公司 | Junction box welding detection method |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20100133247A1 (en)* | 2008-11-21 | 2010-06-03 | Jyoti Mazumder | Monitoring of a welding process |
| DE102015016513A1 (en)* | 2015-12-18 | 2017-06-22 | Audi Ag | Online process monitoring and online process control in the method for positive or cohesive bonding of at least two components by a joining method by means of a Radiometrievorrichtung |
| CN110530877A (en)* | 2019-09-16 | 2019-12-03 | 西安中科光电精密工程有限公司 | A kind of welding shape quality inspection robot and its detection method |
| CN115692546A (en)* | 2022-10-13 | 2023-02-03 | 浙江晶科能源有限公司 | Photovoltaic module manufacturing process, manufacturing device and photovoltaic module |
| CN116352267A (en)* | 2023-04-11 | 2023-06-30 | 苏州智慧谷激光智能装备有限公司 | Junction box welding detection method |
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| CN118455744B (en) | 2024-11-01 |
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