Automatic Laminator With Buffer On Loader & Unloader

 Technical Agreement For Double-Chamber Solar Module Laminator With Buffer

Technical Indicators
Model: BSL2455OAC-HB
Effective Laminating Area: 2400 mm × 5500mm (can be customized)
Overall Dimension: 18440mm (L)x3630mm(W)x2200mm(H)
Heating Mode: Oil conductive heating
Compressed Air Pressure: 0.7～0.9MPa
Operation Vacuum Degree: 100-40Pa
Evacuation Speed: 100L/S
Precision of Temperature Control: ±1.5℃
Operating Temperature Range: Room Temperature–180℃
Temperature Uniformity: Effective Laminating Area≤±2℃
Height of Laminating Chamber: 30mm
Evacuation Time: Depending on the process, suggest: 5 ~ 8 min
Upper Cover Moving Range: 300mm

Laminator Structure
Main Structures: Loading + Heat Laminating Section 1 + Heat Laminating Section 2 + Unloading. Two sets of Vacuum Pumps, one set of roots pump,two sets of Heating Stations.

– Loading Section
Apply roller to transmit, Gear motor drive, encoder positioning, stable transmission and accurate positioning.
Step distance can be set, and transmission speed frequency is adjustable.

– Heat Laminating Section (2 Sections)
The heating plate adopts the machined and perforated plate, the flatness of plate surface precedes ± 250um/㎡. The heating medium applies heat conductive oil which is heating fast, in other words, it reaches to 150℃≤110min under normal atmospheric temperature of 20 ℃.
The silicon rubber sheet is designed to be crease-resist to extend service life; it is fixed by fast clamps and tensioned by draw bar to save replacing time.
The conveying mechanism adopts chain and sprocket drive, gear motor drive, inverter and encoder control and photoelectric switch positioning. The adherent EVA and PVB on main conveyor belt to be cleaned up by roller brush.
Side protection mesh doors of machine body adopt air-spring design, which is easy to open for replacing silicon rubber sheet, maintenance and cleaning work.

-Unloading Section
The transmission adopts stainless steel roller. It is optional to set a cooling fan in flank of the rollers, and set a photoelectric-sensor positioning device at the end of unloading section to prevent from dropping.
Apply frequency converter for speed control, photoelectric sensor for positioning; it runs stable, reliable and positioning accurate.

-Vacuum System
Major parts of vacuum system are imported components, type of valve is pneumatic butterfly valve; ultimate vacuum of the equipment can reach to 30Pa. Vacuum chamber can rapidly reach to the limit of 120Pa at the atmospheric condition within 120 seconds.
Pirani vacuum gauge and digital display vacuum gauge test the vacuum.

-Control System
Integrated with three control modes of fully-automatic, semi-automatic and manually. It can be actualized fully-automatic loading, laminating and unloading as well as manually loading, laminating and unloading.
It is integrated with vacuum technology, pneumatic transmission technology, PID self-tuning technology, programmable control and relay control technology to actualize the complicated processes of laminating and solidifying for mono crystalline silicon and polycrystalline silicon solar-cell modules.
It has the recording function of characteristic curve for system important parameters (upper & lower vacuum degree, plate surface temperature) providing functions of sectional compression and optional compression speed.
Conveying system adopts chain and sprocket transmission structure which can realize continuous loading and unloading.
SIEMENS PCU can realize communication with computers meeting the requirement of modern industrial automation control.
Set up independent control buttons on the loading and unloading tables to be convenient for setting control mode of sectional moving. You may set a certain step-forward distance according to actual requirement, i.e. push the button once, the loading table automatically moves forward a certain distance to make the loading convenient.
The operation board adopts high-quality touch screen of which with friendly interface, high sensitivity, convenient operation, easy to learn. The major operating processes will be acousto-optic indicated in real time during the operation. Process parameters are easy to set, various process parameters to be displayed in same window which is convenient for monitoring. You can save various process recipes for productive option.
With automatic memory, process parameters will not be lost if it is reset or restarted; it will automatically record main operating steps, provide data of module-quality analysis. The system has the statistical function for laminating times which is convenient to check the work shifts and module output and also can be as a reference for equipment repairing, maintenance and replacement rate cycle of consumable parts.

Performance Feature
The HB-type laminator is designed as double-chamber structure with two heat-laminating sections, each section has independent heating and vacuum system which is adaptable to continuous production for mono crystalline, polycrystalline and amorphous silicon cells.

– Strong compatibility for modules

-Add one heat-laminating section to the original laminator, to separately control the temperature, vacuum and pressure of two sections, especially suitable to laminate double-glass and PVB modules.

– High rate of finished modules
The HB-type laminator makes the heating, evacuation and pressurization of the original single chamber as the first heat-laminating stage to execute the process of evacuation and heating, while the second laminating section to execute module laminating. The second section needs lower vacuum so as to increase the rate of finished modules.

-Prolong service life of consumable parts
Double-section heat-laminating structure, the working time of each section is reduced to 40%-50% compared with the original one, so that the service life of silica gel plates and strips is greatly prolonged.

-Increase annual production capacity
The HB-type laminator adopts two-section heat lamination to improve the production efficiency; the annual capacity reaches 1.8-1.9 times than the ordinary single-chamber laminator.

-Less floor space
Relative to two sets of traditional three-section equipment, HB-type laminator cuts down one pair of loading and unloading tables so as to save floor space.
The upper chamber of HB-type is designed with circulating Teflon sheet structure, synchronizing with lower conveyor belt, and may realize linking with the automatic assembly line.

Safety Measures
If the operator appears in the safety light-curtain protection area during the upper cover going downward, the cover will stop immediately to protect the operator’s safe. It is equipped with mechanical limit for limiting position of upper cover so as to provide mechanical protection for the operator getting into under the upper-cover area.
If an accident occurs, the general power supply of the laminator will be cut off, and the upper cover will be held in its previous position.
Equipped with a manually air-charging device, when power off, the operator can manually charge air into upper & lower vacuum chambers of laminator. It is also equipped with an emergency cover-open device to manually open laminator’s upper cover when suddenly power off.
Emergency buttons are set in several places, the operator can push the button immediately in case of emergency to actualize emergency shutdown.
Heating system is equipped with over-temperature protection, when the temperature exceeds the defining range, the heating will be forced to disconnect and then goes to be alarm shut down.
The heat conductive oil circulating system is equipped with low oil level detection and alarm shut down device to prevent the system from danger due to oil lack.
Vacuum Alarm System: When the laminator cannot satisfy the requirement within vacuum time, the system will trigger alarm.
If modules on the loading table are laid out of the defined range at front end, the system will trigger alarm and stop loading; the unloading table is equipped with end protection switch to prevent modules from dropping.
Tricolor alarm lamp will accurately provide equipment running state, to enable the operator getting accurate alarm information in time.
Unloading protection for unloading table: Modules will automatically stop at the limiting position.
Alarm nodes: over current, overvoltage, air source, vacuum, oil level, temperature etc can actualize visual and sound alarm.

Configuration of Main Spare Parts