Automatic Triple Chamber Laminator

 Technical Agreement
For Three Chamber Laminator BSL2446STC

Technical Indicators
Laminating Size: 2400 mm ×4600mm(can be customized)
Overall Dimension: 26980mm×3280mm×2200mm（for reference only）
Heating Mode: Conduction oil heating
Compressed Air Pressure: 0.7～0.8MPa
Operation Vacuum: 100～40Pa
Evacuation Speed: ≥70L/S
Temperature Control Accuracy: ±1.5℃
Temperature Range: indoor temperature–175℃
Temperature Uniformity: ±1.5℃
Height of Vacuum Chamber: 30mm
Evacuation Time: Depending on the process, suggest: 5 ~ 8 min
Upper Cover moving range: 300mm

Laminator Structure
Major Structure: Loading + Heat laminating Section1+Heat laminating Section 2 + cooling section + Unloading. Three sets of vacuum pumps, two sets of heating stations, one chiller and one roots pump

-Loading Section
Apply PVC conveyor belt 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 adopts 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 silicone rubber sheet, maintenance and cleaning work.

– Cooling Section
Cooling the laminated modules
Circulating of cooling water be forced to circulate by chiller
Lower cooling plate adopts the structure of perforated steel plate.
Module cooling time, module temperature and cooling water temperature can be set by operator, usually at ≤5-10min.
Water temperature setting range: 15-50℃

-Unloading Section
The transmission adopts stainless steel rollers which are driven by gear motor. It is optional to set a cooling fan under 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.
Equipped with a forcing unloading push button, if the photoelectric sensor at the end is blinded, the products can be forced to be unloaded manually.

-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.
Air charging speed in upper chamber is adjustable.

-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 actualize 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
STC01-HB-type laminator has three heating chambers and two heating sections, each chamber has independent heating and vacuum system, suitable for mono/polycrystalline silicon and amorphous silicon module production. The cooling section can make modules being fast cooled down.
Strong compatibility for module: 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.
Increase annual capacity: STC01-HB -type laminator adopts two-section heat lamination with the work time be 40%-50% less than the original one so as to improve the production efficiency; the annual capacity reaches 1.8-1.9 times than the ordinary single-chamber laminator
Saving floor space: its greatest advantage is that the length of the loading/unloading tables is shortened to save equipment floor space. Especially for the laminators of longer heating plates or more working sections (such as heating + heating + cooling), it significantly reduces the total length of laminators to make whole structure be more compact.
The upper chamber of STC01-HB type is designed with circulating Teflon sheet (high temperature cloth) which can synchronously work with lower conveyor belt. It can be connected to automatic production line.
The stacker adopts three-bar structure, use three bars to bear the modules when being loaded in mode of two-two, and use two bars to bear the modules when being loaded in mode of one-one one which reaches high flexibility.
The lifting structure of the stacker adopts servomotor and synchronous belt structure to actualize quick, stable and accurate receiving and discharging.
Set up safety fences along the machine body to protect operator’s safe.

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.

Main Spare Parts