Method and device for fully automatically selecting and packing photovoltaic modules

Abstract

The invention relates to a method and to a device for fully automatically selecting and packing photovoltaic solar modules ( 6 ) produced in mass production, having the following characteristics: a) a production line ( 1 ), b) a quality checking device ( 2 ) having devices for mechanical final testing and electrical final testing, c) an assembly device ( 3 ) for module carriers, d) a device for distributing and stacking ( 4, 15 ) the solar modules ( 6 ) in the horizontal and vertical direction according to particular selection criteria at acceptance locations corresponding to said selection criteria, e) devices for placing strips ( 19 ) as spacers between stacked modules, wherein different types of strips can be taken from a magazine, f) devices for collating packages of a plurality of solar modules ( 6 ) at each acceptance location, wherein said devices each comprise a film wrapper ( 7 ), a protective cap applicator ( 8 ), and a strapping device ( 9 ).

1 . A device for fully automatically selecting and packing photovoltaic solar modules which were produced in large batches, having the following features:
 (a) a production line,   (b) a quality testing device having devices for mechanical final tests and electrical final tests as well as a device for allocating a barcode, the mechanical final test comprising optical devices, vibration test devices and ultrasonic devices and the electrical final test comprising devices for the effects of cold at certain points and devices for measuring impedances,   (c) an assembly device for module carriers, different module carriers being able to be removed from a magazine,   (d) a device for distributing and stacking the solar modules in the horizontal and vertical directions according to particular selection criteria at removal stations corresponding to these selection criteria, the device for distributing and stacking the modules consisting of a lifting sucker mount and a running rail, the lifting sucker being able to move solar modules horizontally and vertically, the running rail being able to be lengthened as desired and the height of the running rail supports being able to be adjusted in a controlled manner,   (e) devices for laying strips as spacers between stacked modules, different types of strips being able to be removed from a magazine,   (f) devices for assembling packages from a plurality of solar modules at each removal station,   (g) a return line via angle conveyors for transporting solar modules onto the production line.   
     
     
         2 . A device for fully automatically selecting and packing photovoltaic solar modules which were produced in large batches, having the following features:
 (a) a production line,   (b) a quality testing device having devices for mechanical final tests and electrical final tests as well as a device for allocating a barcode, the mechanical final test comprising optical devices, vibration test devices and ultrasonic devices and the electrical final test comprising devices for the effects of cold at certain points and devices for measuring impedances,   (c) an assembly device for module carriers, different module carriers being able to be removed from a magazine,   (d) a device for storing and temporarily storing the solar modules ( 6 ) in the horizontal or vertical direction,   (e) devices for loading and unloading the store and for allocating to or stacking solar modules at particular removal stations,   (f) devices for laying strips as spacers between stacked modules ( 6 ), different types of strips being able to be removed from a magazine,   (g) devices for assembling packages from a plurality of solar modules at each removal station,   (h) a return line via angle conveyors for transporting solar modules onto the production line.   
     
     
         3 . The device as claimed in  claim 2 , wherein the module carriers comprise different materials and different fastening means are used when fastening the carrier to the module. 
     
     
         4 . The device as claimed in  claim 2 , wherein the magazine containing the strips which act as spacers contains not only strips of different thickness and length but also strips of different materials and degrees of hardness. 
     
     
         5 . The device as claimed in  claim 2 , wherein the devices for assembling packages each have a film winder, a protective cap applicator and a strapping device. 
     
     
         6 . A method for fully automatically selecting and packing photovoltaic solar modules which were produced in large batches, having the following features:
 a) solar modules of different quality are delivered on a production line from ongoing production,   (b) the delivered solar modules pass through a quality testing device having devices for mechanical final tests and electrical final tests as well as a device for allocating an electronic identifier according to the quality level determined, the solar modules being conveyed onward for packing only when the corresponding tests have been successfully passed and otherwise being conveyed to the stacking station for reject modules,   (c) the solar modules are assigned to corresponding customers according to the quality level determined and are provided with module carriers desired by the respective customer or else are left without a module carrier if desired,   (d) the solar modules which are thus finished are then picked up by a lifting sucker and are conveyed, via the running rails, to the corresponding removal stations according to their quality class or their customer and are stacked on top of one another in said stations,   (e) in the removal stations, strips are automatically laid, as spacers, onto each stored solar module until the desired delivery is complete,   (f) a complete delivery is wrapped by a film winder and is then provided with a protective cap on two sides or else on all four sides by a protective cap applicator and is finally combined with strip-like packaging material in the region of the protective caps under stress by a strapping device.   
     
     
         7 . A method for fully automatically selecting and packing photovoltaic solar modules which were produced in large batches, having the following features:
 (a) solar modules of different quality are delivered on a production line from ongoing production,   (b) the delivered solar modules pass through a quality testing device having devices for mechanical final tests and electrical final tests as well as a device for allocating an electronic identifier according to the quality level determined, said modules being conveyed onward for packing only when the corresponding tests have been successfully passed and otherwise being conveyed to the stacking station for reject modules,   (c) the solar modules are assigned to corresponding customers according to the quality level determined and are provided with module carriers desired by the respective customer or else are left without a module carrier if desired,   (d) the solar modules which are thus finished are then picked up by devices, are transported to a store and are subsequently conveyed to the corresponding removal stations according to their quality class or their customer and are stacked on top of one another in said stations,   (e) in the removal stations, strips are automatically laid, as spacers, onto each stored solar module until the desired delivery is complete,   (f) a complete delivery is wrapped by a film winder, is then provided with a protective cap on two sides or else on all four sides by a protective cap applicator and is finally combined with strip-like packaging material in the region of the protective caps under stress by a strapping device.   
     
     
         8 . The method as claimed in  claim 6 , wherein a return line via angle conveyors for transporting solar modules onto the production line is provided, this path being open to solar modules which have passed through the quality testing device with an entirely or partially negative result which warrants repair. 
     
     
         9 . The method as claimed in  claim 6 , wherein the mechanical final test comprises optical investigations, vibration tests and investigations with ultrasound and the electrical final test comprises the effects of cold at certain points and subsequent measurements of impedances. 
     
     
         10 . The method as claimed in  claim 6 , wherein the module carriers comprise different materials and different fastening methods are used when fastening said carrier to the module. 
     
     
         11 . The method as claimed in  claim 6 , wherein the modules are distributed and stacked using a lifting sucker mount on a running rail, the lifting sucker being able to move solar modules horizontally and vertically, the running rail being able to be lengthened as desired and the height of the running rail supports being able to be adjusted in a controlled manner. 
     
     
         12 . The method as claimed in  claim 6 , wherein the device for assembling packages wraps the stacked solar modules in film and welds them and/or provides the stacked solar modules with caps which are made of packaging material and can be plugged on, the package produced in this manner being connected to strip-like packaging material with a particular, adjustable tensile force in the strapping device. 
     
     
         13 . A computer program having a program code for carrying out the method steps as claimed in  claim 6  when the program is executed in a computer. 
     
     
         14 . A machine-readable carrier having the program code of a computer program for carrying out the method as claimed in  claim 6  when the program is executed in a computer.