使用吸盘上料铺设对碎片率影响的分析报告2013-11.doc

使用吸盘上料铺设对碎片率影响的分析报告一、数据统计11月1822日3#与6#铺设线使用吸盘上料（因气源压力不足，19日夜班与20白班未用吸盘），4#与5#铺设线手动上料，针对这一周EL检测仪检测出电池片隐裂的组件进行数据汇总并对比，3、4#线多晶250P60和5、6#线多晶290P72两个不同型号的组件，重点对发生隐裂的电池片在组件上的位置进行了统计。根据以下表格的数据，可以发现不管铺设上料使用吸盘与否，两种型号组件隐裂的电池片发生的位置主要集中在灰色区域，即每个串条两端的位置。详细数据如下表：250P60多晶156组件隐裂位置汇总（3#铺设线使用吸盘）1610103374541494531451214128130162323接线盒73222480223632213245381210141429 250P60组件不同位置隐裂数量占总隐裂数量的百分比（3#线使用吸盘）串列1234567891015.18%3.24%3.24%0.97%0.97%2.27%1.29%1.62%1.29%4.53%22.91%1.29%1.62%0.97%0.32%1.29%1.62%3.88%4.53%3.88%32.59%0.32%0.97%0.00%0.32%1.94%0.65%0.97%0.65%0.97%接线盒42.27%0.97%0.65%0.65%0.65%1.29%2.59%0.00%0.65%7.44%51.94%0.97%0.65%0.65%0.32%0.97%0.65%1.29%1.62%0.97%62.59%0.32%0.65%0.32%0.00%0.32%1.29%0.32%1.29%9.39%合计17.48%7.12%7.77%3.56%2.59%8.09%8.09%8.09%10.03%27.18%250P60多晶156组件隐裂位置汇总（4#铺设线未用吸盘）1553331200552320140486230121119接线盒24212020225522002110472110210121250P60组件不同位置隐裂数量占总隐裂数量的百分比（4#线使用吸盘）串列1234567891018.11%2.70%1.62%1.62%1.62%0.54%1.08%0.00%0.00%2.70%22.70%1.08%1.62%1.08%0.00%0.54%2.16%0.00%2.16%4.32%33.24%1.08%1.62%0.00%0.54%1.08%0.54%0.54%0.54%4.86%接线盒41.08%2.16%1.08%0.54%1.08%0.00%1.08%0.00%1.08%13.51%52.70%1.08%1.08%0.00%0.00%1.08%0.54%0.54%0.00%2.16%63.78%1.08%0.54%0.54%0.00%1.08%0.54%0.00%0.54%11.35%合计21.62%9.19%7.57%3.78%3.24%4.32%5.95%1.08%4.32%38.92%290P72多晶156组件隐裂分布汇总（6#铺设线使用吸盘）84711200206546432124034151434021531326接线盒4031233211267432242322344222210246322290P72组件不同位置隐裂数量占总隐裂数量的百分比（6#铺设线使用吸盘）串列12345678910111213.28%1.64%2.87%0.41%0.41%0.82%0.00%0.00%0.82%0.00%2.46%2.05%21.64%2.46%1.64%1.23%0.82%0.41%0.82%1.64%0.00%1.23%1.64%6.15%35.74%1.23%1.64%0.00%0.82%0.41%2.05%1.23%0.41%1.23%0.82%2.46%接线盒41.64%0.00%1.23%0.41%0.82%1.23%1.23%0.82%0.41%0.41%0.82%2.46%52.87%1.64%1.23%0.82%0.82%1.64%0.82%1.23%0.82%0.82%1.23%1.64%61.64%0.82%0.82%0.82%0.82%0.41%0.00%0.82%1.64%2.46%1.23%9.02%合计16.80%7.79%9.43%3.69%4.51%4.92%4.92%5.74%4.10%6.15%8.20%23.77% 290P72多晶156组件隐裂分布汇总（5#铺设线未用吸盘）102633330026577940021124131237122321527接线盒42302330003118130211225634112041236328串列12345678910111213.85%0.77%2.31%1.15%1.15%1.15%1.15%0.00%0.00%0.77%2.31%1.92%22.69%2.69%3.46%1.54%0.00%0.00%0.77%0.38%0.38%0.77%1.54%5.00%34.62%1.15%2.69%0.38%0.77%0.77%1.15%0.77%0.38%1.92%0.77%2.69%接线盒41.54%0.77%1.15%0.00%0.77%1.15%1.15%0.00%0.00%0.00%1.15%4.23%53.08%0.38%1.15%0.00%0.77%0.38%0.38%0.77%0.77%1.92%2.31%1.15%61.54%0.38%0.38%0.77%0.00%1.54%0.38%0.77%1.15%2.31%1.15%10.77%合计17.31%6.15%11.15%3.85%3.46%5.00%5.00%2.69%2.69%7.69%9.23%25.77%290P72组件不同位置隐裂数量占总隐裂数量的百分比（5#铺设线未用吸盘） 二、结论1、铺设使用吸盘摆串与手动摆串隐裂位置情况相似。2、组件两侧，即第1列与250P60组件第10列（290P72组件第12列）隐裂率明显高于其它列，而250P60第10列（250P72第12列）（靠近接线盒位置）最高，主要集中在铺设背板条、EVA条及边缘汇流带位置。原因分析见下。3、用吸盘摆串造成的隐裂或裂片数量低于手动摆串造成的，采用吸盘摆串能够减少铺设造成的碎片量。 三、存在问题及整改措施（一）吸盘操作1、由于有时气源压力不稳定，吸电池串时吸不稳，会造成机械性裂片。故此需要对真空泵和管道进行排查，并判定现阶段气源气压是否满足使用摆串吸盘。2、吸盘摆串人员由于操作手法不规范、不熟练，造成摆串速度慢，压碎裂片多。整改：采用以点带面方式进行逐步推进，在气源满足情况下逐步进行规范。（二）焊接1、陶瓷压针不灵活，导致焊带位置隐裂。焊接操作前，应重点检查、保养维护该部位；2、助焊剂喷涂不到位，导致虚焊。焊接操作前，应重点检查、保养维护该部位；（三）铺设操作1、铺设EVA条和背板条时，作业人员将汇流带翘起，导致应