In the context of solar cell assembly, an appropriate welding method compatible with a flexible assembly system is selected. Based on the movement characteristics of the grab robot and the welding manipulator, individual motion path schemes are designed for each. By simplifying the motion models in a rational way, detailed analysis and calculation of the motion paths are conducted separately for both robots, aiming to optimize their trajectories, thereby improving product quality and production efficiency.
Solar cells are devices that convert sunlight into electricity. Large solar panels formed by welding and assembling multiple solar cells can significantly increase the total amount of solar energy collected, thus enhancing the overall utilization of solar energy. The solar cell flexible assembly system consists of a grasping robot and a welding robot, enabling automatic assembly of solar cells according to their size parameters and physical characteristics.
1. **Welding Robot Welding Scheme**
As illustrated in Figure 1, during the welding process of solar cells, two adjacent electrodes must be overlapped—connecting the positive electrode of one cell to the negative electrode of another. The welded joint is embedded between two battery blocks. Due to the difficulty in heating the target welding area, fusion welding is not suitable. Pressure welding may cause deformation of the solar cell electrode under high temperature and pressure, which negatively affects the performance of the solar cell.
Therefore, brazing is employed as the preferred welding method for solar cells.
2. **Research on the Motion Path of the Grabbing Robot**
The grabbing robot is responsible for picking up and arranging solar cells according to pre-defined design requirements. It typically picks up 12 solar cells and arranges them in a 4-row by 3-column configuration.
Based on the global coordinate system, the initial position of the solar cell is set as the origin. When the solar cell is a regular object, its projection on the xoy plane is a rectangle. Each solar cell can be simplified as a mass point at its geometric center in the xoy plane. This allows the motion path of the grabbing robot to be modeled accordingly, as shown in the figure.
When the velocities along the x-axis (vx) and y-axis (vy) are different, the time required for movement in each direction varies. If vx is much greater than vy, the robot needs to move in the y-direction after completing the x-direction movement. Conversely, if vy is much greater than vx, the opposite applies.
According to the principle of the shortest line between two points, the ideal motion path of the grabbing robot in the xoy plane is linear. This ensures that both axes reach the endpoint simultaneously, minimizing both time and distance, resulting in the optimal motion path between two fixed points. The process of grabbing 12 batteries evolves into a series of linear movements from the origin to 12 different endpoints, as shown in Figure 3.
Considering that adjacent solar cells are stacked and overlapped, they cannot be placed randomly. A specific sorting order is necessary to meet the arrangement requirements. For example, if the first captured cell is placed at position 1, the second can be placed at 2 or 5. However, placing the first cell at position 2 may complicate the placement of the first cell, while placing it at positions 3 or 4 could lead to difficulties in handling adjacent cells. Similar issues arise in the second and third columns.
Based on this analysis, the grabbing robot preferentially moves along the positive x or y axis. If it moves along the x-axis, the optimal placement order is 1, 5, 9, 2, 6, 10, 3, 7, 11, 4, 8, 12. If it moves along the y-axis, the order is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12. Thus, the robot has multiple motion paths, all optimized along the x or y axis.
Figure 4 shows a sequential grabbing and arrangement path along the positive y-axis. Station 01 is the initial position, and station 02 is the battery position. The A1 process involves moving from station 01 to 02, preparing for the arrangement. The robot then grabs and places each solar cell one by one, returning to station 02 for the next cell.
After completing the row, the second and third rows are automatically arranged with a gap between them. Once the task is done, the robot returns along the C1 path. If more work is needed, it goes back to station 02; otherwise, it resets to station 01 for the next operation.
3. **Research on the Motion Path of the Welding Manipulator**
The welding manipulator is responsible for joining two adjacent solar cells. With the cells arranged in a 4x3 grid, there are 9 welding points. These are simplified into 9 mass points, connected in sequence to form the welding robot’s path, as shown in Figure 5.
Following the "S" shaped path, the total distance S1 for 9 welds is calculated as:
$$
S1 = 6m + 2n
$$
Given the solar cell dimensions (length $a$, width $b$, and gap $\delta$), where $a > b$, we have:
$$
m = b + \delta,\quad n = a
$$
Thus, the total distance becomes:
$$
S1 = 2a + 6b + 6\delta
$$
Once the motion paths for both the grabbing robot and welding manipulator are planned, the PLC system coordinates their operations, achieving the flexible assembly of solar cells.
4. **Conclusion**
The solar cell flexible assembly system features a simple structure, precise motion control, and high responsiveness. Research on the motion paths of the system's manipulators helps improve the quality and efficiency of solar cell assembly. The optimal motion path is along the positive x or y axis, and the "S-type" path is designed for the welding manipulator, meeting its operational requirements.
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