INPUT AREA+STAGE 1(LAMINATING AREA)+STAGE 2 (CURVING AREA)+OUTPUT AREA+
two pcs oil heating station + 1pcs 2X70 Vacuum pump+1 pcs ZJP600 vacuum pump combined with one 2X70 Vacuum pump.
1. INPUT AREA ( Feeding section ) (1) The horizontal transmission is an anti-deviation transmission belt, which is controlled simultaneously by frequency conversion system + photoelectric positioning system + encoder anti-jamming, and the transmission speed is continuously adjustable from 4 to 14 M/min.
(3)Feeding Section set transmission point button, can choose automatic or manual feeding mode and emergency handling.
(4) A photoelectric sensor is arranged at the end of the OUT PUT AREA ( discharging section ) for protecting and locating the component.
2. STAGE 1 ( LAMINATING AREA )
(1)STAGE 1 has one upper chamber and one lower chamber. The solar PV modules are vacuumized and heated ,finally laminated on the heating plate at this lower chamber.The heating plate is heated inside by the heat transfer oil from the oil heating station. Temperature rise speed:1.5ºC/min. Temperature deviation:±2ºC
(2)Heating plate is made of Q235 steel with thickness 65 mm,surface irregularity:≤200 μm/m².
(3)Temperature sensor: 5 pcs each plate. Timely display.
(4)Upper chamber is separated with the lower chamber by the sealing O ring and the silicon sheet.
(5)Upper chamber and lower chamber can be separately vacuumized, air charged according to the settings upon the different raw materials used on the solar PV module. Laminating process can be set as max 3 steps. Vacuum inside can be shown timely on the gauge and the touched LCD. One more PA vacuum meter is for checking the vacuum data with PA accuracy inside the lower chamber
(6)ZJP600 Combined with 2X70 Vacuum pump station is for the laminating area, vacuum pumping speed is not less than 630m³/h. Vacuum inside the lower chamber reaching 100Pa will need less than 90S, air charging speed can be re-adjusted at the range: 0-50L/S.
(7)Upper chamber lifting method:Pneumatic lifting.
(8)The solar PV modules are moved to the Laminating area (STAGE 1) then curving area (STAGE 2) by the Teflon sheet one frame by one frame. The frame is mounted on the chain driven by deceleration motor+variable frequency speed regulation+encoder control system for precise positioning, and the repeated positioning accuracy is within ±10mm.
(9)Two brush rollers are installed near the upper and lower conveyor belts to clean the waste EVA on the Teflon sheets.
3. Stage 2 (Curving area )
(1)Each stage has one upper chamber and one lower chamber. The laminated solar PV modules from STAGE 1 are vacuumized and heated ,finally laminated AGAIN on the heating plate at this lower chamber AS CURVING PROCESS.The heating plate is heated inside by the heat transfer oil from the oil heating station. Temperature rise speed:1.5ºC/min. Temperature deviation:±2ºC.
(2)Heating plate is made of Q235 steel with thickness 65 mm,surface irregularity:≤200 μm/m².
(3)Temperature sensor: 5 pcs each plate. Timely display.
(4)Upper chamber is separated with the lower chamber by the sealing O ring and the silicon sheet.
(5)Upper chamber and lower chamber can be separately vacuumized, air charged according to the settings upon the different raw materials used on the solar PV module. Laminating process can be set as max 3 steps. Vacuum inside can be shown timely on the gauge and the touched LCD. One more PA vacuum meter is for checking the vacuum data with PA accuracy inside the lower chamber
(6)One 2X70 Vacuum pump is for STAGE 2 (curving area), vacuum pumping speed is not less than 70L/S. Vacuum inside the lower chamber reaching 100Pa will need less than 90S, air charging speed can be re-adjusted at the range: 0-50L/S.
(7)Upper chamber lifting method:Pneumatic lifting.
(8)The laminated solar PV modules are moved from laminating area (STAGE 1) to the curving area (STAGE 2) by the Teflon sheet one frame by one frame. The frame is mounted on the chain driven by deceleration motor+variable frequency speed regulation+encoder control system for precise positioning, and the repeated positioning accuracy is within ±10mm.
4. OUTPUT AREA
(1)The laminated and curved solar PV modules are transferred to the OUTPUT AREA by the stainless steel rollers controlled by frequency conversion system, and the transmission speed can be adjusted by frequency conversion to ensure that it is consistent with the feeding and host speed.
(3)The front and rear ends of the OUTPUT AREA are provided with photoelectric sensors to detect the discharging in real time and prevent the solar PV module from falling.
(4)There are cooling fans under the rollers for cooling the solar PV module.
5 Transmission system
(1) STAGE 1 and STAGE 2 transmission adopts deceleration motor frequency control encoder control system, solar PV modules on the Teflon sheet are driven by the SAME chains, accurate positioning, repeated positioning accuracy within ±10mm.
(2)INPUT AREA and OUTPUT AREA adopts decelerating motor + variable frequency speed regulation control system to ensure that it matches the speed of the main engine.
(3)The Teflon sheet transmission system of the laminating host (laminating section curing section) adopts the way of connecting multiple Teflon sheet as a whole circular movement, and keeps opening in the whole transmission process. The connection interaction point of the upper and lower moving Teflon sheet shall not contact the upper surface of the solar PV module.
(4)The synchronous gear design is adopted to make the circulation system of the upper and lower Teflon sheet move synchronously all the time.
(5)Equipped with special chain tension design and anti-jump gear mechanism to reduce the chain loose caused by long-term use , to ensure smooth transmission.
6. Lifting system
(1)STAGE 1 (Laminating area) and STAGE 2 (Curving area) adopts pneumatic lifting system, controlled by three-position five-way solenoid valve. The key components (lifting solenoid valve, inflatable solenoid valve, etc.) are all SMC pneumatic components with more stable performance.
(2)Each cylinder inlet and outlet are equipped with exhaust throttle valve, which is used to adjust the speed of cylinder lifting to ensure the smooth and synchronous lifting of multiple cylinders.
(3)Equipped with independent air control safety system, can be in the case of power failure or tracheal burst to prevent accidents, resulting in the top box fall.
7. Heating system
(1) STAGE 1 (Laminating area) and STAGE 2 (Curving area) have separated heating systems. The heating plate is heated by the heat transfer oil circulating in the perforated plate and the oil heating station. The heating rate is less than 1.5 °C/min and the temperature deviation of the heating plate is less than ± 2 °C.
(2)Multi-point temperature control, temperature control accuracy ± 2 °C, the number of heating plate temperature measurement points are not less than 5.
(3)Heating Control using standard temperature module, Pid self-tuning technology, accurate control, to achieve good temperature uniformity, oil temperature control using dual protection, thermal oil does not exceed temperature, to ensure safe operation.
(4) Using the oil heating station produced by the qualified manufacturer, the temperature and pressure are real-time monitored, the over-temperature, over-pressure, over-flow and liquid level are real-time alarm, and automatic processing, to ensure the control accuracy and use safety.
8. VACUUM SYSTEM
(1) STAGE 1 (Laminating area) uses 2X-70( Rotary Vane )vacuum pump + ZJP600( roots )pump, and STAGE 2 ( Curing AREA ) uses 2X-70 Rotary Vane vacuum pump, which is controlled by High Vacuum Pneumatic Butterfly Valve to control the vacuum process in each chamber.
(2) The limit vacuum in the lower Chamber can reach below 40Pa under the condition of working temperature and no solar PV module inside. And it can reach less than 100Pa under the automatic operation mode.
(3) Each STAGE is equipped with two-way zero pressure differential pneumatic solenoid valve (Brand:SMC, Model:VXZ260KG) for air charging . The air charging speed is in the range of 0.70 l/s and can be adjusted arbitrarily to ensure the stability and reliability of the set vacuum pressure value.
(4)SMC Pressure Sensor is installed in each chamber to monitor chamber pressure in real time. A PA level vacuum gauge (Pilani) is installed in the lower chamber of STAGE 1, and a touch screen displays the real-time pressure.
(5) Each stage has one emergency cover open system to reduce the loss caused by failure operation.
9. CONTROL SYSTEM
(1)The total machine is controlled by PLC(SIEMENS BRAND)+TOUCHED LCD with program inside.
(2) Different process formula can be writen and saved and selected for different RAW MATERIALS from different suppliers or in different time, or for different requests from different customers.
(3)Parameter settings are saved automatically without lose.
(4)It has the statistic function of Lamination Times: It is convenient to check the times of work and the output of solar PV module, and it can be used as a reference for the maintenance and replacement of consumables .
(5)The equipment is equipped with a safety light curtain to prevent accidents during the process of opening or closing the cover.
(6) Online/Offline, Manual / AUTO work state can be selected according to different condition.
(7) All the parameter settings and real-time data can be displayed on the screen. Temperature history curve,alarm info and history info, working mode and process,etc can be shown on the screen.
(8) PLC reserved interface, can be connected with the production line, multi-point positioning control , to achieve unattended laminating process.
(9) Three Emergency stop buttons are installed at the INPUT AREA, OUTPUT AREA, CONTROL PANEL. |
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