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Application of Lingchen PLC in photovoltaic capping machines

2025-06-11

In the production of photovoltaic (PV) modules, the junction box capping process is a critical step to ensure product quality and reliability. Leveraging high-precision control and multi-protocol compatibility, LingChen PLC provides an efficient and stable motion control solution for PV junction box capping machines. This article explores the core value of this solution from the perspectives of product features, equipment composition, technical strengths, and control advantages.

 

  1. 1. Product Overview and Process Flow凌臣
  2. Core Function

After the junction box is attached to the PV panel, glue detection and capping ensure the protective integrity of the box.

 

  1. Production Process

Sorting → Scribing → Single Soldering → String Welding → Stacking → Visual Inspection → Lamination → Trimming → Final Appearance Check → Framing → Junction Box Attachment → Curing → Cleaning → Testing → Packaging

 

  1. 2. Equipment Composition and Working Principle凌臣2凌臣3
  2. Material Picking Module

Flexible Vibratory Feeder: Flips and positions the caps for precise pickup.

 

Junction Box Positioning Camera: Captures images to calculate pickup coordinates, which are sent to the PLC for precise cap retrieval.

 

  1. Glue Detection & Capping Robot Arm

Six-Axis Robot: Receives visual coordinates from three positioning cameras and is controlled by the PLC to perform glue detection and capping actions.

 

Post-Capping Inspection Camera: Inspects the capped junction boxes and feeds back results to downstream stations.

 

  1. Auxiliary Modules

Flow Channel Correction: Corrects alignment on both long and short edges to ensure precise PV panel positioning.

 

Mobile Module: Moves the inspection camera to conduct multi-station inspections.

 

  1. 3. Solution Highlights and Key Advantages凌臣4
  2. Communication Protocols and System Integration

Multi-Protocol Compatibility: Supports diverse protocols including PC vision (Modbus TCP/Server), vibratory feeder (Modbus TCP/Master), robot (EtherNet/IP Scanner), and servo control (EtherCAT).

 

Flexible Recipe Management: Enables quick adaptation to different PV panel and junction box models.

 

  1. Core Performance Benefits

Ultra-Short Synchronization Cycle: 1ms for 8 axes, 2ms for 16 axes, 4ms for 32 axes.

 

Integrated System Architecture: Combines HMI, motion controller, bus servo, and remote I/O modules.

 

Program Portability: Developed on the mature Codesys platform for easy migration and maintenance.

 

  1. Service and Ecosystem Support

On-Site Engineering Support: Full development assistance to help build an integrated “Industrial Control + Intelligent Drive” ecosystem.

 

The LingChen PLC solution significantly enhances the efficiency and consistency of PV junction box capping machines through high-precision visual positioning, multi-axis synchronized control, and flexible communication protocols. With a cycle time (CT) of 16 seconds per unit, positioning accuracy of 0.02 mm, and a comprehensive system architecture, the solution demonstrates clear technological leadership in the field of industrial automation. Looking forward, this solution will continue to empower the PV industry in its journey toward intelligent manufacturing and smart upgrades.