Laser Welding Technology Applied in Precision of Photovoltaic Junction Boxes

The core product of the photovoltaic industry is the “solar cell”. Relying on this product, the production line involves numerous welding demands that require visual positioning. The photovoltaic junction box is an accessory of the solar cell, and every solar panel must have the "junction box" welded onto it before leaving the factory.

Picture of Photovoltaic Junction Box

The photovoltaic junction box is an essential component in photovoltaic power generation systems, connecting solar panels, batteries, and loads. It typically consists of a plastic housing, connectors, cables, and electronic components. Its function is to transfer the electrical energy generated by solar panels to batteries for storage or directly to loads for use. Since photovoltaic junction boxes need to carry high voltage and current, their quality and reliability are critical to the safety and efficiency of the entire photovoltaic power generation system.

Laser welding technology can be applied to the welding of photovoltaic junction boxes. Due to its high energy density and precise positioning control capabilities, laser welding enables high-quality joints, thereby enhancing the reliability and efficiency of photovoltaic junction boxes. During the welding process, this technology allows accurate control over both the welding location and duration, ensuring consistent quality and reliability. Additionally, laser welding supports automated production, which boosts efficiency and reduces manufacturing costs. Compared to traditional welding methods, laser welding offers higher energy utilization and shorter processing times, significantly improving overall production efficiency.

Songsheng High-Power Coaxial Temperature Measurement Imaging Laser Welding Head

Songsheng Optoelectronics has launched a new generation constant-temperature welding system for photovoltaic junction boxes. This system consists of a high-power coaxial temperature measurement imaging laser welding head, a temperature feedback system, a CCD coaxial positioning system, and a 1000W semiconductor laser system. Equipped with temperature feedback and CCD coaxial positioning capabilities, the system effectively ensures constant-temperature welding of junction box solder joints and precise alignment of delicate components, thereby guaranteeing high production yield in mass manufacturing.

Advantages of the Photovoltaic Junction Box Constant-Temperature Welding System:

1. Non-contact laser welding eliminates mechanical stress damage and minimizes thermal impact, effectively avoiding issues such as obscured solder joints, large heat-affected zones damaging workpieces, and physical extrusion commonly encountered in traditional welding processes.

2. Instant heating with laser technology combined with a proprietary temperature feedback system enables real-time monitoring and closed-loop control of solder joint temperature. The system displays live welding temperature curves, ensuring high welding yield.

3. Fully coaxial integrated optical path seamlessly combines laser, CCD imaging, and temperature measurement beams into a single axis. This innovation solves the industry challenge of multi-optical path alignment and eliminates complex calibration.

4. High-precision coaxial CCD positioning and processing monitoring provides clear imaging of solder joints and enables real-time coordinate correction. The system automatically compensates for dimensional and positional deviations of micro-components, supporting high-volume precision welding production lines while reducing reliance on rising labor costs. The CCD system also allows real-time monitoring of the welding process.

5. User-friendly software offers intuitive operation and high safety, enabling rapid deployment on production lines.

6. Proven reliability backed by 20 years of R&D and application experience in semiconductor lasers and 10 years of expertise in automated precision welding.