CN115805397A - Photovoltaic module battery piece welding detecting system - Google Patents
Photovoltaic module battery piece welding detecting system Download PDFInfo
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- CN115805397A CN115805397A CN202310119777.9A CN202310119777A CN115805397A CN 115805397 A CN115805397 A CN 115805397A CN 202310119777 A CN202310119777 A CN 202310119777A CN 115805397 A CN115805397 A CN 115805397A
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- 238000003466 welding Methods 0.000 title claims abstract description 98
- 238000001514 detection method Methods 0.000 claims abstract description 120
- 229910000679 solder Inorganic materials 0.000 claims description 49
- 230000002950 deficient Effects 0.000 claims description 19
- 238000004458 analytical method Methods 0.000 claims description 12
- 238000012545 processing Methods 0.000 claims description 9
- 238000003062 neural network model Methods 0.000 claims description 8
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- 230000010365 information processing Effects 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 4
- 238000012544 monitoring process Methods 0.000 claims description 4
- 238000003860 storage Methods 0.000 claims description 3
- 230000005856 abnormality Effects 0.000 claims description 2
- 238000000034 method Methods 0.000 abstract description 8
- 230000000694 effects Effects 0.000 abstract description 2
- 238000010586 diagram Methods 0.000 description 8
- 238000005476 soldering Methods 0.000 description 8
- 238000012549 training Methods 0.000 description 7
- 238000007689 inspection Methods 0.000 description 5
- 238000013519 translation Methods 0.000 description 5
- 238000012360 testing method Methods 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 239000005038 ethylene vinyl acetate Substances 0.000 description 2
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 2
- 238000010248 power generation Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000003703 image analysis method Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000000741 silica gel Substances 0.000 description 1
- 229910002027 silica gel Inorganic materials 0.000 description 1
- 239000005341 toughened glass Substances 0.000 description 1
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
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Abstract
The application relates to a photovoltaic module cell welding detection system, which belongs to the technical field of photovoltaic module detection, and the method is characterized in that the photovoltaic module cell welding detection system comprises: the device comprises a collecting frame, a support, a line scanning camera and a line scanning light source, wherein the collecting frame is arranged at the downstream of an outlet of a confluence welding machine, a conveying belt is arranged on the collecting frame, a support is fixed above the outlet of the confluence welding machine, the support is provided with the line scanning camera and the line scanning light source, and the line scanning light source and a camera of the line scanning camera are downward; the support is also provided with a universal support, the universal support is provided with a code scanning gun, and a code label which can be scanned and identified by the code scanning gun is arranged on a product; the line scanning camera and the code scanning gun are connected with the detection device, and the detection device is used for receiving pixel lines sent by the line scanning camera to obtain image information and receiving product information sent by the code scanning gun. This application has the effect that improves detection efficiency.
Description
Technical Field
The application relates to the technical field of photovoltaic module detection, in particular to a photovoltaic module cell welding detection system.
Background
The photovoltaic module is the minimum effective power generation unit and mainly comprises a battery piece, interconnection bars, bus bars, toughened glass, EVA (ethylene vinyl acetate), a back plate, aluminum alloy, silica gel, a junction box and other core parts. The single photovoltaic cell has limited power generation amount and can be used as a power supply only by being connected in series and packaged into a component. During the preparation process, the welding strips are required to be welded on the side-by-side cell pieces, so that the cell pieces are connected in series, and the end parts of the plurality of welding strips are welded with the bus bars, so that a complete photovoltaic module is formed.
However, since there is an error between the position of the battery piece, the solder strip, or the bus bar and the predetermined position, there may be problems of continuous soldering, solder strip offset, solder strip-bus bar overlapping, or bus bar position offset after soldering, and therefore it is necessary to detect the soldering position after soldering is completed, and find out the defective product for repair. Most of the conventional methods are manual detection, and the detection efficiency is low.
Disclosure of Invention
In order to improve detection efficiency, the application provides a photovoltaic module battery piece welding detecting system.
The application provides a photovoltaic module battery piece welding detecting system adopts following technical scheme:
a photovoltaic module battery piece welding detection system comprises: the device comprises a collecting frame, a support, a line scanning camera and a line scanning light source, wherein the collecting frame is arranged at the downstream of an outlet of a confluence welding machine, a conveying belt is arranged on the collecting frame, a support is fixed above the outlet of the confluence welding machine, the support is provided with the line scanning camera and the line scanning light source, and the line scanning light source and a camera of the line scanning camera are downward;
the universal support is further arranged on the support, the code scanning gun is arranged on the universal support, and a coded label which can be scanned and identified by the code scanning gun is arranged on a product;
still include detection device, the camera is swept to the line with sweep a yard rifle all with detection device connects, detection device is used for receiving the pixel line that the camera was sent is swept to the line obtains image information, receives sweep the product information that a yard rifle sent.
Through adopting above-mentioned technical scheme, the product is conveyed on accepting the frame from the export of the welding machine that converges, the product sweeps light source and line from the line and sweeps camera below and pass through, the line is swept the light source and is shone the product surface, the line is swept the camera and is shot the light position, along with the removal of product, it obtains a plurality of pixel lines to shoot, a plurality of pixel lines can be handled through detection device and obtain image information, sweep the code label that the sign indicating number rifle scanned the product, obtain product information, detection device carries out the analysis according to image information and product information, carry out the automated inspection product, realize automated inspection.
Further, the detection device includes:
the acquisition module is used for acquiring image information of a product;
the dividing module is used for dividing the image information into a plurality of sub-image information, and each sub-image information corresponds to one area of a product;
the analysis module is used for analyzing the sub-image information and determining whether the area corresponding to each sub-image information is qualified or not;
the determining module is used for determining the detection result of the product according to the result of whether each region is qualified, and comprises any one of the following steps:
if the unqualified area exists, determining that the detection result of the product is a defective product;
and if the unqualified area does not exist, determining that the detection result of the product is a good product.
By adopting the technical scheme, the acquisition processing module detection device acquires the image information of the product and then divides the image information to obtain a plurality of sub-image information, the analysis module analyzes each sub-image information to determine whether the corresponding area is qualified, when the unqualified area exists in the product, the determination module determines that the corresponding product is a defective product, and when each area of the product is qualified, the determination module determines that the product is a good product, so that the product is automatically detected by an image analysis method, and the working efficiency is improved.
Further, the area failures include cold joint, solder strip to bus bar overlap, solder strip offset, and bus bar offset, the analysis module including:
the first comparison submodule is used for comparing the subimage information with image information with problems of cold joint and overlapping of a solder strip and a bus bar in big data in sequence, and when any one of the comparison is consistent, determining that the area corresponding to the subimage information is unqualified;
the first marking subimage generating submodule is used for inputting the subimage information into a trained neural network model, identifying a bus bar and/or a welding strip in the subimage information, and respectively marking the bus bar and the welding strip in the subimage information to generate first marking subimage information;
the second marked image information generation sub-module is used for splicing the first marked sub-image information according to the actual position of the corresponding area to generate second marked image information;
the second comparison sub-module is used for comparing the second marked image information with standard image information with a standard product and judging whether the area corresponding to each sub-image information has the problem of welding strip deviation and/or bus bar deviation; and if so, determining that the area corresponding to the sub-image information is unqualified.
By adopting the technical scheme, the first comparison sub-module detection device determines whether the area corresponding to the sub-image information has the problems of insufficient solder and overlapping of the solder strip and the bus bar through big data, so that automatic detection is realized, on the other hand, the first marked sub-image generation sub-module detection device identifies the bus bar and/or the welding rod in the sub-image information through a neural network model and marks the bus bar and/or the welding rod, the second marked image information generation sub-module splices the first sub-image information with the marks into second marked image information, so that the second comparison sub-module can compare the second marked image information with standard image information, and whether each area has the problem of solder strip offset and/or bus bar offset is determined.
Further, the second comparison sub-module includes:
the coordinate determination unit is used for establishing a coordinate system, coinciding one corner of a product in the second marked image information with an original point in the coordinate system, and coinciding two right-angle sides adjacent to one corner of the product with a horizontal coordinate and a vertical coordinate of the coordinate system respectively;
the standard image information processing unit is used for generating standard image information of a standard product in the coordinate system, enabling one corner of the standard product in the standard image information to coincide with an original point in the coordinate system, and enabling two right-angle sides adjacent to one corner of the standard product to coincide with a horizontal coordinate and a vertical coordinate of the coordinate system respectively;
the transparency setting unit is used for increasing the transparency of the standard image information to a preset transparency value;
the judging unit is used for judging whether the coincidence rate of each bus bar and the welding strip in the second mark image information and the standard image information reaches a preset value or not;
if so, determining that the area corresponding to each sub-image information is qualified;
if the coincidence rate of the current bus bar in the second marked image information and the bus bar at the corresponding position in the standard image information does not reach a preset value, determining that the current bus bar is deviated, and the area corresponding to the current sub-image information is unqualified;
if the coincidence rate of the current welding strip in the second marked image information and the welding strip at the corresponding position in the standard image information does not reach a preset value, determining that the current welding strip is deviated, and the area corresponding to the current subimage information is unqualified.
By adopting the technical scheme, the coordinate determination unit, the standard image information processing unit and the transparency setting unit detection device enable the second marked image information and products in the standard image information to be overlapped in the same coordinate system, the judgment unit judges the coincidence rate of the welding strip and the bus bar in the second marked image and the standard welding strip and the bus bar, if the coincidence rate reaches a preset value, the area corresponding to the subimage information is judged to be qualified, the positions of the welding strip and the bus bar can be determined to be basically correct, if the coincidence rate does not reach the preset value, the welding strip and the bus bar are probably caused by deviation, the area corresponding to the subimage is judged to be unqualified, and the area welding result can be quickly and accurately detected.
Further, the judging unit includes:
a first acquiring subunit, configured to acquire a plurality of first regions of bus bars and a plurality of second regions of solder strips in the standard image information;
a second acquiring subunit configured to acquire a plurality of third regions of the bus bar and a plurality of fourth regions of the solder ribbon in the second marker image information;
the first processing subunit is used for determining the overlapping area of the third area and the first area at the corresponding position, calculating a first ratio of the overlapping area to the total area of the first area, and determining whether the overlapping rate of the bus bars in the second mark image information and the standard image information reaches a preset value according to the first ratio;
a second processing subunit, configured to determine an overlapping area between the fourth area and the second area at the corresponding position, calculate a second ratio between the overlapping area and a total area of the second area, and determine, according to the second ratio, whether an overlapping rate of a solder strip in the second marker image information and the standard image information reaches a preset value
By adopting the technical scheme, the first acquiring subunit, the second acquiring subunit and the first processing subunit detecting device determine the overlapping area of the third area and the first area of the same bus bar, a first ratio is obtained by calculation according to the overlapping area and the total area of the first area, the first ratio is the overlapping rate, therefore, the overlapping rate can be compared with a preset value, whether the overlapping rate of the bus bar reaches the preset value is judged, and similarly, the second processing subunit detecting device can determine whether the overlapping rate of the welding strip reaches the preset value.
Further, the detection device further comprises:
the product information acquisition module is used for acquiring product information obtained by scanning a bar code corresponding to the product, and the product information comprises a product batch, a product number and a production date;
the identification image information generation module is used for identifying the reason that the corresponding area of each sub-image is unqualified in the image information to generate identification image information;
the storage module is used for storing the image information or the identification image information of the product and the detection result corresponding to the product information;
and the sending module is used for sending the product information of the defective products to the repair end.
By adopting the technical scheme, the product information acquisition module detection device stores the product information according to the bar code, and the identification image information generation module correspondingly stores the image information and the product information, so that the image information and the product information are conveniently filed and recorded, automatic filing is realized, and the detection convenience is improved.
Further, the detection device further comprises:
the repeated monitoring module is used for repeatedly acquiring image information of a product for multiple times, analyzing the image information and determining the detection result of the product to obtain multiple detection results of the product;
the repeated judging module is used for judging whether the plurality of detection results comprise the detection result of the defective product or not;
if yes, determining the possibility of each area being unqualified according to the ratio of the frequency of each area being determined to be unqualified to the total detection frequency;
otherwise, determining the detection result of the product as a good product.
By adopting the technical scheme, after the detection device detects the defective products, repeated monitoring is carried out for repeated detection for many times, and the repeated judgment module rechecks the detection results again according to the proportion of the defective products in the detection results, so that the misjudgment rate is reduced, and the detection accuracy is improved.
Further, the detection device further comprises:
the problem judgment module is used for judging whether the problem of welding strip deviation or bus bar deviation exists in the current area;
if so, generating error information, wherein the error information comprises the abnormality of the welding equipment corresponding to the current area;
if not, generating feedback information, wherein the feedback information comprises that the welding equipment corresponding to the current area is normal.
By adopting the technical scheme, when the problem of lap joint of the cold joint or the welding strip and the bus bar exists in the current area, the problem judgment module judges whether the problem of offset of the welding strip or the bus bar exists in the current area, if so, the possibility of abnormity of the welding equipment is higher, and therefore the condition of the welding equipment can be reversely deduced according to the detection result of the product.
In summary, the present application includes at least one of the following beneficial technical effects:
1. the product is conveyed to the bearing frame from an outlet of the confluence welding machine, the product passes through the lower part of the line scanning light source and the line scanning camera, the line scanning light source irradiates the surface of the product, the line scanning camera shoots the position of the light, a plurality of pixel lines are obtained by shooting along with the movement of the product, the plurality of pixel lines can be processed by the detection device to obtain image information, the code scanning gun scans the code label of the product to obtain product information, the detection device analyzes according to the image information and the code label to automatically detect the product, so that the automatic detection is realized, and the working efficiency is improved;
2. the detection device determines whether the areas corresponding to the subimage information have the problems of cold joint and overlapping of the solder strip and the bus bar through big data to realize automatic detection, and on the other hand, the detection device determines whether each area has the problems of solder strip offset and/or bus bar offset through a neural network model to pertinently judge the problems existing in each area.
Drawings
Fig. 1 is a schematic structural diagram of a welding detection system for photovoltaic module cells in an embodiment of the present application.
Fig. 2 is a block diagram of a detection device in the embodiment of the present application.
Fig. 3 is a schematic structural diagram of a product in an embodiment of the present application.
A in fig. 4 is a schematic diagram of sub-image information including the battery plate and the solder ribbon; b is a schematic diagram of sub-image information including the solder ribbon and the bus bar.
FIG. 5-1 is a schematic view of the weld being good; 5-2 is a schematic view of a cold joint; and 5-3 is a schematic diagram of the lap joint of the welding strip and the bus bar.
FIG. 6, 6-1, is a schematic view of the bus bar translation; 6-2 is a schematic view of the inclination of the bus bar.
Reference numerals: 1. a receiving frame; 2. a conveyor belt; 3. a confluence welding machine; 4. a support; 5. a camera mount; 6. a line scan camera; 7. a line scanning light source; 8. a gimbal; 9. a code scanning gun; 10. a battery piece; 11. welding a strip; 12. a bus bar; 200. a detection device; 201. an acquisition module; 202. a dividing module; 203. an analysis module, 204 and a determination module.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
In addition, the term "and/or" herein is only one kind of association relationship describing an associated object, and means that there may be three kinds of relationships, for example, a and/or B, which may mean: a exists alone, A and B exist simultaneously, and B exists alone. In addition, the character "/" herein generally indicates that the former and latter related objects are in an "or" relationship, unless otherwise specified.
The embodiment of the application discloses photovoltaic module battery piece welding detecting system, refer to fig. 1 and 2, photovoltaic module battery piece welding detecting system is provided with conveyer belt 2 including accepting frame 1 on accepting frame 1, accepts frame 1 and sets up in the export low reaches that converges welding machine 3, and after the product after the welding is accomplished is released from the export that converges welding machine 3, accepts frame 1 and accepts the product.
A support 4 is fixed above an outlet of the confluence welding machine 3, a camera fixing piece 5 is fixed on the support 4, a line scanning camera 6 and a line scanning light source 7 are installed on the camera fixing piece 5, and cameras of the line scanning light source 7 and the line scanning camera 6 are downward.
The line scanning light source 7 generates a light perpendicular to the moving direction of the product, the light illuminates the product, one end of the product starts to move from the lower side of the line scanning camera 6 until the other end leaves from the lower side of the line scanning camera 6, when the product passes in front of the line scanning camera 6, the line scanning camera 6 scans the position illuminated by the light, a new pixel line is acquired, and a plurality of continuous pixel lines are shot by the line scanning camera 6 along with the continuous movement of the product.
The support 4 is also provided with a universal support 8, and the universal support 8 is provided with a code scanning gun 9. The product is provided with a code, the position of the universal support 8 is adjusted, the code scanning gun 9 is enabled to be opposite to the position of the code, when the code moves to the position below the code scanning gun 9, the code scanning gun 9 scans the code, and the product information corresponding to the code and stored is obtained.
The photovoltaic module cell welding detection system further comprises a detection device 200, the line scanning camera 6 and the code scanning gun 9 are connected with the detection device 200, the detection device 200 receives pixel lines sent by the line scanning camera 6 and product information sent by the code scanning gun 9, an image acquisition card is connected to the detection device 200, the image acquisition card processes the pixel lines, and the lines are gathered to form a surface to obtain image information of a product.
The detection device 200 analyzes and detects the image information, and stores the detection result in correspondence with the product information.
Referring to fig. 2, the detection apparatus 200 includes:
the acquiring module 201 is configured to acquire image information of a product.
Specifically, the line scan camera can perform real-time transmission, so that the detection apparatus 200 automatically acquires image information of the product.
The dividing module 202 is configured to divide the image information into a plurality of sub-image information, where each sub-image information corresponds to an area of the product.
Specifically, referring to fig. 3, the product includes a plurality of rows of battery plates 10, and a plurality of solder strips 11 are welded to each row of battery plates 10, so that the battery plates 10 are connected in series, and both ends of each solder strip 11 are welded to a bus bar 12. Therefore, the number of welding points on the product is large and complicated, and the detection apparatus 200 divides the image information to quickly analyze the image information.
When the detection device 200 acquires the image information, the image information is automatically cut according to a preset cutting rule to obtain a plurality of sub-image information, wherein each sub-image corresponds to one area of the product. And each sub-image obtained by cutting according to a preset cutting rule is provided with at least one welding point.
For example, referring to fig. 3 and 4, the detection apparatus 200 may divide the sub-image regions a and B, where a is sub-image information of a region corresponding to each battery piece, a plurality of solder strips are soldered to the battery piece, B is sub-image information corresponding to the bus bars, and only one bus bar, one solder strip, and a solder joint between the bus bar and the solder strip are located in the sub-image information corresponding to each bus bar.
Further, the inspection apparatus 200 may be further subdivided, such as C, and each sub-image information includes a solder strip.
After the detection device 200 divides the area into a plurality of sub-image information, the sub-image information and the area of the product are stored in a one-to-one correspondence manner.
The analysis module 203 is configured to analyze the sub-image information and determine whether the area corresponding to each sub-image information is qualified.
Specifically, area failures include cold solder joint, solder strip to bus bar overlap, solder strip offset, and bus bar offset. Taking fig. 5 as an example, 5-1 is welding well, i.e. the welding spot completely covers two objects to be welded; 5-2, cold joint, incomplete welding of welding spots; 5-3, the welding strip is lapped with the bus bar, namely the welding strip is connected with the bus bar without welding spots; the welding strip deviation comprises two conditions of welding strip inclination and welding strip translation; bus bar deflection includes both bus bar tilting and bus bar translation.
An analysis module 203, comprising:
and the first comparison submodule is used for comparing the subimage information with image information with problems of cold joint, welding strip and bus bar lapping in the big data in sequence, and when any comparison is consistent, determining that the area corresponding to the subimage information is unqualified.
And the first marking subimage generation submodule is used for inputting subimage information into the trained neural network model, identifying the bus bar and/or the welding strip in the subimage information, marking the bus bar and the welding strip in the subimage information respectively, and generating first marking subimage information.
Specifically, when training a neural network model for identifying bus bars and/or solder strips, the detection device 200 respectively forms a training data set, a verification set and a test set by sample data with bus bars and/or solder strips, applies training data and trains the model, and adjusts parameters of the model in the training process so that the output of the model is as close as possible to the sample data in the training data set, and fits the data in the training data set as much as possible. And finally, verifying the resolution capability of the trained model by using a test data set, thereby training to obtain a neural network model, inputting subimage information, and automatically identifying bus bars and/or solder strips in the subimage information.
Further, the inspection apparatus 200 may mark the bus bar and the solder strip in the sub-image information with different colors, respectively.
And the second marked image information generation submodule is used for splicing the first marked sub-image information according to the actual position of the corresponding area to generate second marked image information.
Specifically, the inspection apparatus 200 reduces the area of the image for analysis by identifying the bus bars and the solder strips in the sub-image information, and reduces the time taken when the analysis is performed by the entire image information.
The second comparison sub-module is used for comparing the second marked image information with standard image information with a standard product and judging whether the area corresponding to each sub-image information has the problem of welding strip deviation and/or bus bar deviation; and if so, determining that the area corresponding to the sub-image information is unqualified.
The second comparison sub-module includes:
and the coordinate determining unit is used for establishing a coordinate system, coinciding one corner of the product in the second marked image information with an original point in the coordinate system, and coinciding two right-angle sides adjacent to one corner of the product with the abscissa and the ordinate of the coordinate system respectively.
Specifically, due to the imprecise positioning of the product entering the receiving rack, the four sides of the product in the second label image information may not be parallel to the four sides of the second label image information, respectively, and for further analysis, the detecting device 200 establishes a coordinate system and identifies a corner of the product.
The detecting apparatus 200 may use the mark at the edge of the second mark image information as a corner of the product. For example, the lower left corner in the second marker image is marked with a bus bar, and then a point at the leftmost end of the bus bar is determined as a corner of the product.
And then, one corner of the product determined in the second marked image information is coincided with the original point, and then the two right-angle sides are respectively coincided with the horizontal coordinate and the vertical coordinate.
And the standard image information processing unit is used for generating standard image information of a standard product in a coordinate system, enabling one corner of the standard product in the standard image information to coincide with an original point in the coordinate system, and enabling two right-angle sides adjacent to one corner of the standard product to coincide with the abscissa and the ordinate of the coordinate system respectively.
Specifically, the welding position of the welding strip, the bus bar and the battery plate in the standard product is standard, so the standard product can be used as a reference for comparison. Further, the detection apparatus 200 also places the standard picture information of the standard product in the coordinate system, and then the second marker image information and the standard image information are overlapped in the coordinate system.
And the transparency setting unit is used for adjusting the transparency of the standard image information to a preset transparency value.
Specifically, when the detection apparatus 200 increases the transparency of the standard image information to a preset transparency value, the standard image information reaches a semi-transparent state.
The judging unit is used for judging whether the coincidence rate of each bus bar and the welding strip in the second mark image information and the standard image information reaches a preset value; if so, determining that the area corresponding to each sub-image information is qualified;
otherwise, if the coincidence rate of the current bus bar in the second marked image information and the bus bar at the corresponding position in the standard image information does not reach a preset value, determining that the current bus bar is deviated, and the area corresponding to the current sub-image information is unqualified;
if the coincidence rate of the current welding strip in the second marked image information and the welding strip at the corresponding position in the standard image information does not reach a preset value, determining that the current welding strip is deviated, and the area corresponding to the current subimage information is unqualified.
The preset value is a value preset by the detection device 200, and is used for judging whether the bus bar or the welding strip deviates.
Further, the judging unit includes:
and the first acquisition subunit is used for acquiring a plurality of first areas of the bus bars and a plurality of second areas of the solder strips in the standard image information.
Specifically, the detection apparatus 200 inputs the standard image information into the trained neural network model, identifies the solder strip and the bus bar, and generates the identifier. Further, the detection device 200 determines the region for marking the bus bar as the first region and the region for marking the solder ribbon as the second region.
And a second acquiring subunit for acquiring a plurality of third areas of the bus bar and a plurality of fourth areas of the solder ribbon in the second marker image information.
Specifically, the detection device 200 determines the region identified as the bus bar as the third region and the fourth region identified as the solder ribbon in the second marker image information.
And the first processing subunit is used for determining the overlapping area of the third area and the first area at the corresponding position, calculating a first ratio of the overlapping area to the total area of the first area, and determining whether the overlapping rate of the bus bar in the second mark image information and the standard image information reaches a preset value according to the first ratio.
Specifically, the detection device 200 calculates a first ratio of the overlapping area to the area of the first region, determines the overlapping rate of the third region to the first region at the corresponding position, and when the overlapping rate reaches a preset value, a small translation or rotation occurs between the current bus bar and the preset position, and the deviation can be ignored; if the coincidence rate does not reach the preset value, the deviation is large, and the probability of producing insufficient soldering and missing soldering is high.
For example, fig. 6-1 in fig. 6 is a schematic diagram of the bus bar translating from the preset position, where a is the first region, b is the third region, a first ratio of the areas of the shaded portion and the first region a is the overlapping rate, and if the preset overlapping rate is 90% and the current overlapping rate is 92%, the overlapping rate is determined to reach the preset value.
Fig. 6-2 is a schematic diagram of the bus bar being inclined from the preset position, where a is a first region, b is a second region, and a first ratio of the areas of the shaded portion and the first region a is an overlap ratio, and if the preset overlap ratio is 90% and the current overlap ratio is 88%, it is determined that the overlap ratio does not reach the preset value.
And the second processing subunit is used for determining the overlapping area of the fourth area and the second area at the corresponding position, calculating a second ratio of the overlapping area to the total area of the second area, and determining whether the overlapping rate of the second mark image information and the solder strip in the standard image information reaches a preset value or not according to the second ratio.
Specifically, the detection device 200 calculates a second ratio of the overlapping area to the area of the second region, and determines the overlapping rate of the fourth region and the second region at the corresponding position, when the overlapping rate reaches a preset value, a small translation or rotation occurs between the current welding strip and the preset position, and the deviation is negligible, so that it can be determined that the second marked image information overlaps the current welding strip in the standard image information; and if the coincidence rate does not reach the preset value, the deviation is large, the probability of producing insufficient soldering and missing soldering is large, and it is determined that the second mark image information is not coincident with the current solder strip in the standard image information.
The determining module 204 is configured to determine a detection result of the product according to a result of whether each region is qualified, where the result includes any one of:
if the unqualified area exists, determining that the detection result of the product is a defective product;
and if the unqualified area does not exist, determining that the detection result of the product is good.
Specifically, in order to ensure the product quality, when unqualified areas exist in the product, the product needs to be repaired, so that the unqualified products can be accurately screened out.
In another possible implementation manner, the detection apparatus 200 further includes:
and the product information acquisition module is used for acquiring product information obtained by scanning the bar code corresponding to the product, and the product information comprises a product batch, a product number and a production date.
Specifically, after the product is produced, the detection device 200 encrypts the product batch, the product serial number and the production diary to generate a bar code, and attaches the bar code to a certain position of the product, so that the detection device 200 acquires the product information sent by the code scanning gun.
And the identification image information generation module is used for identifying the reason that the corresponding area of each sub-image is unqualified in the image information to generate identification image information.
Specifically, after the detection device 200 detects the product, the image information of the product is saved, and the corresponding position of the unqualified area is marked. The method for detecting the mark of the device 200 can adopt different colors to distinguish unqualified reasons, and can also mark characters on a corresponding area, so that the repair personnel can conveniently and quickly search and identify the characters.
In another possible implementation, the detection apparatus 200 may also identify qualified areas.
And the storage module is used for storing the image information or the identification image information of the product and the detection result corresponding to the product information.
Specifically, the detection device 200 stores the detection results in a one-to-one correspondence, which facilitates subsequent file-checking.
And the sending module is used for sending the product information of the defective products to the repair end.
Specifically, the detection results are automatically classified, and the product information of the defective products is stored in an independent folder and sent to the repair end.
In another possible implementation manner, in order to reduce the false detection rate, after the determining module 204 determines that the detection result of the product is a defective product, the detecting apparatus 200 further includes:
and the repeated monitoring module is used for repeatedly acquiring the image information of the product for multiple times, analyzing the image information and determining the detection result of the product to obtain multiple detection results of the product.
Specifically, when any product is determined to be a defective product, the detection apparatus 200 repeatedly detects the current product for a plurality of times to obtain a plurality of detection results, and analyzes whether the conclusion that the current product is determined to be a defective product is reliable or not according to the plurality of detection results.
The repeated judging module is used for judging whether the plurality of detection results comprise the detection result of the defective product or not;
if so, determining the probability of each area being unqualified according to the ratio of the number of times of each area being determined to be unqualified to the total number of times of detection;
specifically, if the number of times the current area fails is larger in the case of a plurality of tests, the probability of failure is larger. For example, the detection apparatus 200 repeatedly detects three times, wherein the number of times the area a is determined to be unqualified is two, and the probability of the area a being unqualified is 66.7%; if the number of times that the area B is determined to be defective is three times, the probability that the area B is defective is 100%.
Otherwise, determining the detection result of the product as a good product.
Specifically, when the test is repeated for multiple times, each area is not unqualified, and the first unqualified area may be misjudged, so that the detection result of the current product is determined to be a good product.
Further, the reason why the product is not qualified is related to the welding equipment, when the welding equipment is abnormal, the welding point may be incomplete, and in order to check whether the welding equipment has a problem, the detection device 200 further analyzes the detection result of the product.
In another possible implementation manner, if the cause of the failure in the current area includes a continuous welding or a welding strip overlapping the bus bar, the detecting device 200 further includes:
and the problem judgment module is used for judging whether the current area has the problem of welding strip deviation or bus bar deviation.
If yes, generating error information, wherein the error information comprises the welding equipment abnormity corresponding to the current area.
If not, generating feedback information, wherein the feedback information comprises that the welding equipment corresponding to the current area is normal.
Specifically, the solder strip or the bus bar is offset, which may cause the problem of cold joint or overlap of the solder strip and the bus bar in the partial area welding. On the contrary, if the problem of cold joint or overlapping of the solder strip and the bus bar exists in the current area, but the problem of solder strip deviation or bus bar deviation does not exist, the welding equipment is likely to be abnormal, so that error information is generated and the user is prompted.
The above embodiments are preferred embodiments of the present application, and the protection scope of the present application is not limited by the above embodiments, so: all equivalent changes made according to the structure, shape and principle of the present application shall be covered by the protection scope of the present application.
In addition, it is to be understood that relational terms such as first and second, and the like, are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Claims (8)
1. The photovoltaic module cell welding detection system is characterized by comprising a bearing frame (1) arranged at the downstream of an outlet of a confluence welding machine (3), wherein a conveying belt (2) is arranged on the bearing frame (1), a support (4) is fixed above the outlet of the confluence welding machine (3), a line scanning camera (6) and a line scanning light source (7) are installed on the support (4), and cameras of the line scanning light source (7) and the line scanning camera (6) are downward;
the support (4) is also provided with a universal support (8), the universal support (8) is provided with a code scanning gun (9), and a product is provided with a coded label which can be scanned and identified by the code scanning gun (9);
still include detection device (200), line sweep camera (6) with sweep yard rifle (9) and all with detection device (200) are connected, detection device (200) are used for receiving the pixel line that camera (6) sent is swept to the line obtains image information, receives sweep the product information that yard rifle (9) sent.
2. The system according to claim 1, characterized in that said detection means (200) comprise:
an acquisition module (201) for acquiring image information of a product;
a dividing module (202) for dividing the image information into a plurality of sub-image information, each of the sub-image information corresponding to an area of a product;
the analysis module (203) is used for analyzing the sub-image information and determining whether the area corresponding to each sub-image information is qualified;
a determining module (204) for determining the detection result of the product according to the result of whether each of the regions is qualified, wherein the determining module comprises any one of the following:
if the unqualified area exists, determining that the detection result of the product is a defective product;
and if the unqualified area does not exist, determining that the detection result of the product is a good product.
3. The system of claim 2, wherein the area failures include cold solder joint, solder ribbon overlap with bus bar, solder ribbon offset, and bus bar offset, the analysis module (203) comprising:
the first comparison submodule is used for comparing the subimage information with image information with problems of cold joint and overlapping of a solder strip and a bus bar in big data in sequence, and when any one of the comparison is consistent, determining that the area corresponding to the subimage information is unqualified;
the first marking subimage generating submodule is used for inputting the subimage information into a trained neural network model, identifying a bus bar and/or a welding strip in the subimage information, and respectively marking the bus bar and the welding strip in the subimage information to generate first marking subimage information;
the second marked image information generation sub-module is used for splicing the first marked sub-image information according to the actual position of the corresponding area to generate second marked image information;
the second comparison submodule is used for comparing the second marked image information with standard image information with a standard product and judging whether the area corresponding to each sub-image information has the problem of welding strip offset and/or bus bar offset; and if so, determining that the area corresponding to the sub-image information is unqualified.
4. The system of claim 3, wherein the second comparison sub-module comprises:
the coordinate determination unit is used for establishing a coordinate system, coinciding one corner of a product in the second marked image information with an original point in the coordinate system, and coinciding two right-angle sides adjacent to one corner of the product with a horizontal coordinate and a vertical coordinate of the coordinate system respectively;
the standard image information processing unit is used for generating standard image information of a standard product in the coordinate system, enabling one corner of the standard product in the standard image information to coincide with an original point in the coordinate system, and enabling two right-angle sides adjacent to one corner of the standard product to coincide with a horizontal coordinate and a vertical coordinate of the coordinate system respectively;
the transparency setting unit is used for increasing the transparency of the standard image information to a preset transparency value;
the judging unit is used for judging whether the coincidence rate of each bus bar and the welding strip in the second mark image information and the standard image information reaches a preset value or not;
if so, determining that the area corresponding to each sub-image information is qualified;
if the coincidence rate of the current bus bar in the second marked image information and the bus bar at the corresponding position in the standard image information does not reach a preset value, determining that the current bus bar is deviated, and the area corresponding to the current sub-image information is unqualified;
and if the coincidence rate of the current welding strip in the second marked image information and the welding strip at the corresponding position in the standard image information does not reach a preset value, determining that the current welding strip is deviated, and the area corresponding to the current subimage information is unqualified.
5. The system according to claim 4, wherein the judging unit includes:
a first acquiring subunit, configured to acquire a plurality of first areas of a bus bar and a plurality of second areas of a solder ribbon in the standard image information;
a second acquiring subunit configured to acquire a plurality of third regions of the bus bar and a plurality of fourth regions of the solder ribbon in the second marker image information;
the first processing subunit is used for determining the overlapping area of the third area and the first area at the corresponding position, calculating a first ratio of the overlapping area to the total area of the first area, and determining whether the overlapping rate of the bus bars in the second mark image information and the standard image information reaches a preset value according to the first ratio;
and the second processing subunit is used for determining the overlapping area of the fourth area and the second area at the corresponding position, calculating a second ratio of the overlapping area to the total area of the second area, and determining whether the overlapping rate of the second mark image information and the solder strip in the standard image information reaches a preset value according to the second ratio.
6. The system according to claim 2, wherein the detection device (200) further comprises:
the product information acquisition module is used for acquiring product information obtained by scanning a bar code corresponding to the product, and the product information comprises a product batch, a product number and a production date;
the identification image information generation module is used for identifying the reason that the corresponding area of each sub-image is unqualified in the image information to generate identification image information;
the storage module is used for storing the image information or the identification image information of the product and the detection result corresponding to the product information;
and the sending module is used for sending the product information of the defective products to the repair end.
7. The system according to claim 2, wherein the detection device (200) further comprises:
the repeated monitoring module is used for repeatedly acquiring image information of a product for multiple times, analyzing the image information and determining the detection result of the product to obtain multiple detection results of the product;
the repeated judging module is used for judging whether the plurality of detection results comprise detection results of defective products or not;
if so, determining the probability of each area being unqualified according to the ratio of the number of times of each area being determined to be unqualified to the total number of times of detection;
otherwise, determining the detection result of the product as a good product.
8. The system according to claim 4, wherein the detection device (200) further comprises:
the problem judging module is used for judging whether the problem of welding strip deviation or bus bar deviation exists in the current area;
if so, generating error information, wherein the error information comprises the abnormality of the welding equipment corresponding to the current area;
if not, generating feedback information, wherein the feedback information comprises that the welding equipment corresponding to the current area is normal.
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