Online Vision Measurement for Welding-quality Parameters of Solar Silicon Chips
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摘要: 针对硅电池片高速串焊系统，根据焊接质量参数在线检测的技术指标对视觉测量系统的核心部件进行了选型计算；对视觉测量系统的内部参数进行了标定，完成了畸变校正与像素当量计算；设计了焊后硅片视觉检测流程，研究了图像预处理、图像掩膜ROI提取、改进双阈值Otsu图像分割技术；建立了硅电池片焊带偏移参数测量模型，提出了一种硅电池片焊接质量参数在线视觉测量方法。最后将该在线视觉测量方法应用于某硅电池片高速串焊生产线，其综合检测率和单帧检测时间满足焊接质量在线检测的精度和实时性要求，为提高太阳能电池组件的焊接质量和生产效率打下了良好的技术基础。Abstract: A vision measurement system is firstly designed by selecting its key components and calculating their performance parameters for the online detection requirements of welding quality for a high-speed serial welding system of silicon chip. Secondly, the intrinsic parameters of the vision measurement system are calibrated, which is then used for distortion correction and pixel-equivalent calculation. Thirdly, the vision detection process is designed for the silicon chip after welding, in which the techniques of image preprocessing, image-masking ROI extraction and improved double-threshold Otsu image segmentation are investigated, and a measurement model for welding-strip offset parameter is established. On this basis, an online vision measurement approach is developed for the welding-equality parameters of solar silicon chips. Finally, the present measurement approach is applied to a high-speed serial welding system of silicon chip. The comprehensive detection rate and measurement time per frame meet the accuracy and real-time requirements in the process of online measurement for welding equality, which lays a good technical foundation for improving welding equality and production efficiency of solar battery modules.
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Key words:
- welding defect /
- online detection /
- vision measurement /
- defect recognition /
- image processing
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表 1 串焊检测系统在线视觉测量技术指标
检测对象 电池串(单晶/多晶8-12片/串) 检测范围 125 mm×125 mm、156 mm×156 mm、78 mm×156 mm 检测节拍 2 s 总误检率 小于0.2% 漏检率 小于0.2% 片间距 检测范围1~5 mm, 误差在0.1 mm以内 焊带偏移 长度小于30 mm允许3处, 检测
精度0.1mm, 偏移量自由设置起焊点 同一片多条主栅起焊点位置偏差
小于0.5 mm, 误差0.2mm以内
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表 2 CCD摄像机标定结果
名称 标定结果 内参数矩阵 
径向畸变 k1=0.0926, k2=-0.1754 标定误差 (kx, ky)=(3.36, 3.12)
(u0, v0)=(0.826, 0.715)
(k1, k2)=(0.003, 0.005)
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表 3 像素当量标定结果
编号 1 2 3 4 5 相邻圆心
距/pixel65.292 3 65.293 3 65.292 3 65.288 0 65.292 3 像素当
量/μm61.263 61.262 61.263 61.267 61.263
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表 4 串检综合检测率
序号 nf nt nk/ng me/mo η 1 9 406 855 831/24 9/0 98.92% 2 10 341 940 925/15 6/1 92.68% 3 9 109 828 815/13 0/8 99.02% 4 9 934 903 885/18 1/9 93.43% 5 10 088 917 901/16 0/5 99.45%
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