光伏串焊機焊接質量不佳是什么原因

光伏串焊機焊接質量不佳可能由材料因素、工藝參數(shù)設置不當、機械裝置故障或設計缺陷、操作與人為因素等多方面原因導致，以下是詳細分析：

Poor welding quality of photovoltaic string welders may be caused by various factors such as material factors, improper setting of process parameters, mechanical device failures or design defects, operation and human factors. The following is a detailed analysis:

材料因素

Material Factors

焊帶問題：

- 焊帶錫層厚度不均或過薄，會影響焊接質量，容易出現(xiàn)虛焊現(xiàn)象。

- 焊帶在生產(chǎn)、收卷、運輸過程中可能產(chǎn)生扭擰現(xiàn)象，導致焊頭下壓時無法克服其扭力而產(chǎn)生虛焊。

- 焊帶屈服強度過高或抗拉強度過低，也可能導致焊接過程中出現(xiàn)偏移、露白等問題。

Ribbon issues:

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Uneven or too thin tin layer on the ribbon will affect the welding quality and easily lead to cold solder joints.

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The ribbon may twist during production, winding, and transportation, causing the welding head to fail to overcome the torque when pressed down, resulting in cold solder joints.

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Excessively high yield strength or too low tensile strength of the ribbon may also cause problems such as offset and exposure during welding.

電池片問題：

- 電池片本身的質量問題，如銀漿不匹配、漿料在高溫下被氧化等，都可能導致焊接不良。

- 電池片在焊接或搬運過程中受外力造成隱裂，也會影響焊接質量。

Cell issues:

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Quality problems of the cells themselves, such as mismatched silver paste and oxidation of the paste at high temperatures, may lead to poor welding.

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Hidden cracks in the cells caused by external forces during welding or handling will also affect the welding quality.

助焊劑問題：

- 助焊劑濃度不夠或特性變化，會影響焊接過程中的可焊性，導致虛焊等問題。

- 助焊劑補充系統(tǒng)故障，如助焊劑被烤干、補充不及時等，也會影響焊接質量。

Flux issues:

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Insufficient flux concentration or changes in properties will affect the weldability during welding, leading to problems such as cold solder joints.

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Failures in the flux replenishment system, such as the flux being baked dry or not replenished in time, will also affect the welding quality.

工藝參數(shù)設置不當

Improper Setting of Process Parameters

焊接溫度：

- 焊接溫度過低，不能使錫層充分熔化，會產(chǎn)生虛焊。

- 焊接溫度過高，則可能造成過焊、電池片翹曲度大等問題。

Welding temperature:

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If the welding temperature is too low, the tin layer cannot be fully melted, resulting in cold solder joints.- Excessively high welding temperature may cause over

-welding and large warpage of the cells.

焊接時間：

- 焊接時間過短，涂錫層不能充分熔化，容易出現(xiàn)虛焊。

- 焊接時間過長，則可能造成過焊、電池片損壞等問題。

Welding time:

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If the welding time is too short, the tinned layer cannot be fully melted, which may easily lead to cold solder joints.- Excessively long welding time may cause over

-welding and damage to the cells.

加熱時間：加熱時間不夠，同樣會影響焊接質量。Heating time: Insufficient heating time will also affect the welding quality.

壓針與模組頂針：

- 壓針脫落或位置不合適，未能將焊帶壓實在柵線上，會導致虛焊。

- 模組頂針卡滯或未頂?shù)轿?，焊帶與電池片接觸不良，也會影響焊接質量。Pressure pins and module ejector pins:

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If the pressure pin falls off or is in an inappropriate position and fails to press the ribbon firmly on the grid line, it will lead to cold solder joints.

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Jamming of the module ejector pin or failure to reach the proper position, resulting in poor contact between the ribbon and the cell, will also affect the welding quality.

機械裝置故障或設計缺陷 Mechanical Device Failures or Design Defects

焊頭問題：

- 焊頭位置過高或水平度不夠，會影響焊接過程中的熱傳導效率，導致虛焊。

- 焊頭體溫偏低，如預熱次數(shù)不夠，也會影響焊接質量。

Welding head issues:

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A too high position or insufficient levelness of the welding head will affect the heat conduction efficiency during welding, leading to cold solder joints.

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A low temperature of the welding head, such as insufficient preheating times, will also affect the welding quality.

冷卻壓塊問題：

- 冷卻壓塊不水平，會導致焊帶一側虛焊，且這種虛焊更加隱蔽。

Cooling block issues:

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An unlevel cooling block will cause cold solder joints on one side of the ribbon, and such cold solder joints are more hidden.

各焊接單元同步性：

- 如果各焊接單元氣缸的下壓和提升動作不一致，將會導致電池片各柵線的焊接時間或冷卻時間不一致，從而出現(xiàn)虛焊。

Synchronization of each welding unit:

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If the pressing and lifting actions of the cylinders in each welding unit are inconsistent, it will lead to inconsistent welding or cooling times of each grid line of the cell, resulting in cold solder joints.

切刀裁切問題：

- 切刀的動刀與定刀之間需無間隙，否則裁切后的斷口會向下彎曲，導致焊帶頭部與電池片不能貼合，造成虛焊。

Cutting knife cutting issues:

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There should be no gap between the moving knife and the fixed knife of the cutting knife; otherwise, the cut after cutting will bend downward, causing the head of the ribbon to fail to fit the cell, resulting in cold solder joints.

操作與人為因素

Operation and Human Factors

操作手勢不當：

- 單串焊手勢過重，未按工藝要求操作，可能導致電池片損壞或焊接不良。

- 層壓人員蓋層壓布手勢不正確，也可能影響焊接質量。

Improper operation gestures:

- Excessive force in single string welding gestures and failure to operate according to process requirements may lead to cell damage or poor welding.

- Incorrect gestures of laminating personnel when covering the laminating cloth may also affect the welding quality.

培訓不足：

- 新員工對設備操作不熟悉，缺乏必要的培訓和指導，可能導致焊接質量不佳。

Insufficient training:

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New employees are not familiar with equipment operation and lack necessary training and guidance, which may lead to poor welding quality.

生產(chǎn)環(huán)境：

- 車間生產(chǎn)環(huán)境不佳，如存在異物、灰塵等，可能污染電池片或焊帶，影響焊接質量。

Production environment:

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A poor production environment in the workshop, such as the presence of foreign objects and dust, may contaminate the cells or ribbons, affecting the welding quality.