Shulou(Shulou.com)11/24 Report--

Under the trend of "double carbon", the photovoltaic track is hot, and the competition in the photovoltaic glass industry is becoming increasingly fierce. According to statistics, there are 32 new ignition furnaces in 2022, and the production capacity of new ignition and resumption of production accounts for 46.85% of the total production capacity of the whole year. At the same time, the price of photovoltaic glass is approaching the cost, and the upgrading of quality and efficiency becomes very important. Under the tremendous pressure of improving quality and efficiency, the leading photovoltaic glass enterprise (hereinafter referred to as Company A) chose to cooperate with Ling Yunguang to build an intelligent factory, successfully upgrading production capacity and releasing 83% of the workload of visual inspection workers. At present, it has been in stable operation for more than one year, and there are no related quality complaints.

Every minute counts.

In the spacious factory building, the photovoltaic glass production line operates efficiently, and the quality inspector stands next to the assembly line, staring closely at the 4.2-meter-wide photovoltaic glass, trying to check bubbles, stones and other minor defects. Because of the high transmittance of photovoltaic glass, workers need to pay constant attention and adjust their perspective, like a quick glimpse of the scales on a swimming fish to tell the difference.

"these glass panels all look the same. I missed them inadvertently. I really can't see them." The factory quality inspector said.

This kind of testing is highly dependent on experience and concentration, workers monitor the whole process for a long time, easy to be affected by fatigue, misjudgment and omission.

With the continuous development of production technology, the speed of the production line has been greatly improved, the speed of the original production line has increased from 8 m / min to 17 m / min, while the deep processing production line has increased from 17 m / min to 50 m / min. The types of defects that need to be tested are also increasing, which brings great testing pressure to the workers.

In order to upgrade the production capacity as soon as possible, Company A decided to introduce an automatic photovoltaic glass detection system to achieve an intelligent and automated detection process. They have strictly tested and evaluated the automatic testing systems at home and abroad, requiring the system not only to have industry-leading technical capabilities to ensure excellent detection rates, but also to provide excellent technical services to respond quickly to the needs of operation and maintenance.

"Ling Yunguang has more than 20 years of experience in machine vision inspection, and according to the special requirements of Company A, we provide round-the-clock factory service to ensure that customer production is not affected. Once the photovoltaic glass production line is started, it has to operate 24 hours a day." The head of Ling Yunguang's research and development said.

The golden eye, intelligent classification

Compared with ordinary glass, photovoltaic glass should have the characteristics of high light transmittance, high temperature resistance, oxidation resistance and corrosion resistance. therefore, the manufacture of photovoltaic glass involves many key technical links, and the problems in each link may affect the product quality and the rate of good products.

Photovoltaic glass looks transparent, but it will form minor defects such as bubbles and stones on the surface (including the interior) in the forming process, which may cause glass or components to break, and there is a risk of bursting in the subsequent transportation and use.

In order to meet this challenge, Ling Yunguang created the photovoltaic glass original sheet detection and deep processing inspection solution, realized automatic defect detection and classification through real-time detection and data analysis of the quality management system, and formed quality big data at the same time, obtained the digital model of positive correlation between defect scale and burst probability, and minimized the operating cost of the enterprise on the premise of ensuring the rate of good products.

"in order to reduce misdetection and misdetection, we need to classify defects accurately. For example, open-mouth bubbles and closed-mouth bubbles may look similar in the image, but their positions are different. The closed bubbles are located inside the glass and affect the appearance of the glass, while the open bubbles are located on the surface of the glass and are at risk of bursting. At present, 16 lines have been installed at the customer site, and each production line can be reduced from 3 people / shift to 1 person / shift. Stable operation for more than 1 year, no related quality complaints occurred. " Ling Yunguang's R & D engineer added.

Surface defect detection of photovoltaic original film

Installation before cutting, including complete defect detection, classification (open bubbles, closed bubbles, stones, etc.) and defect data management system, after the completion of testing, defective products automatically fall off.

1. For defects of closed vesicles, open vesicles and stones, the missed detection rate is 0.05%.

2. The widest adaptable glass 4500mm

3. The fastest production line speed 800mm/s

Appearance inspection of photovoltaic deep-processed glass

Installed after toughening and cleaning, the surface and corners form a complete quality management system. After the inspection is completed, the defective products are automatically removed, and the good products are packaged and delivered directly.

1. Minimum defect 0.25mm ², close to the limit of the human eye

2. for the defects of closed vesicles, open vesicles and stones, the missed detection rate is 0.03%, and the detection rate is 25 times higher than that of manual work.

In the future, the photovoltaic glass industry will usher in a more prosperous development. Ling Yunguang will continue technological innovation, provide customers with reliable solutions, open up the whole photovoltaic glass production process, and establish a unified digital quality standard system. make the product quality controllable and manageable.

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