TITLE: AUTOMATED INTERCONNECT (Tab) CUTTING DEVICE ADAPTABLE IN
THE MANUFACTURING PROCESS OF PHOTOVOLTAIC (PV) MODULES".
FIELD OF INVENTION
This invention relates to a new device for a Interconnect Cutting Machine
suitable for automatically cutting the thin and delicate interconnecting solder
coated copper strips (ribbon) form rolls or bobbins adaptable to manufacturing of
Photovoltaic (PV) modules.
BACKGROUND OF THE INVENTION
Solar cells are manufactured using 125-mm or 156-mm size mono/multi
crystalline silicon wafers. Typically, each 125-mm solar cell generates a power
output of 2.2 to 2.3 watts. 36-nos. of these cells are interconnected in series by
connecting and soldering two number of interconnecting strips between the cells
to get PV Modules of 75 to 85-watts power output (12-V application) and 72-nos.
of cells are interconnected in series to get PV Modules of 150 to 170-watts power
output (24-V application).
• The interconnecting thin strips are imported at high cost and are received
in bobbins or rolls. The interconnects have been cut to sort lengths as
required in the panel. This (interconnect) is required in large quantities to
meet the daily production requirements. Cutting was so far done after
unwinding the string like interconnects from the bobbin and measuring
with tapes or scale. Conventional scissors were used for cutting which
caused burr at cut edges.

The indigenously developed equipment incorporates PLC based electronic
controls, servomotor, HMI (Human Machine Interface), and pneumatics 10
unwind the interconnect from the bobbins, feed the required length into the
machine, cut the material without burr and collect neatly for easy neural. The
machine can be programmed using the touch screen HMI for the length, number
of pieces, speed of feeding and speed of cutting. Necessary interlocks have been
provided for ensuring safe operation of the equipment.
OBJECT OF THE INVENTION
It is therefore, an object of the present invention to propose a device for
automatically measuring and cutting the interconnects from bobbins without
distortion or burr.
Another object of the present invention is to propose a device for automatically
measuring and cutting the interconnects from bobbins which eliminates distortion
and edge bent during cutting.
A still another object of present invention is to propose a device for automatically
measuring and cutting the interconnects from bobbin which minimizes wastage
of the costly imported interconnect materials.
A further object of the present invention is to propose a device for automatically
measuring and cutting the interconnect from bobbin which increase productivity
by generating multi-cutting at a time.

A still further object of the present invention is to propose a device for
automatically measuring and cutting interconnect from bobbin which fields
consistent length with an accuracy of 0.5 mm. By incorporation of a servomotor
system.
An yet further object of the present invention is to propose a device for
automatically measuring and cutting interconnect from bobbins which allows tie
operator of the machine to do other job while the machine is functioning
programmable job.
SUMMARY OF THE INVENTION
A device for automatically measuring and cutting interconnect from bobbins in
the measuring process of Photo voltaic (PV) modules comprises a sequential
follow steps.
(a) 1st of all switching on the machine.
(b) Loading the bobbin with solder coated copper strips
(c) Set to manual mode in panel whereas setting length and quantity required
are furnished on the monitor of the computer, (e) inserting interconnects
using pressure switches cutting to trim using manual down image and (g)
set unto mode for touching start cycle.
(d) Collect material when tray is full Figure 11.

BRIEF DESCRIPTION OF THE ACCOMPANYING PHOTOS AND
DIAGRAMS:
Figure 1, shows the Line diagram of the full machine.
Figure 2, shows Photograph of Automatic tab cutting machine.
Figure 3, shows Photograph of Bobbin holding arrangement.
Figure 4, shows Line diagram of bobbin holder arrangement.
Figure 5, shows Photograph of Measuring, Pinch and Guide Rollers
Figure 6, shows Line diagram of Measuring, Pinch and Guide Rollers
Figure 7, shows Photograph showing Moving and stationary ram and cutting
blades
Figure 8, shows Line diagram of ram and blades
Figure 9, shows Photograph showing Touch sensitive operative panel
Figure 10, shows Photograph showing display on the screen
Figure 11, shows Flow diagram of the machine operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
According to this invention a new device has been provided to automatically
produce the cut interconnects from the 5 bobbins/rolls simultaneously by an
easy, user friendly and highly technical method.
Incorporating Servo system has taken care to produce the tables uniformly
within an accuracy of 0.5.mm.

Touch screen programming method eases the programming operation for tne
operator. The bobbin or rolls can be loaded by the operating personal without
difficulty.
Necessary sensing method has been provided to bypass the finished roll in the
counting process.
In the present invention, provision has been made to operate with five bobb ns
at a time. All the five tabs will be produced to the same length as the pressure
applied on each bobbin is maintained equal using pneumatic actuators.
Independent blades for cutting each tab at each bobbin have been provided for
easy maintenance of worn-out blades. These blades have been made from hard
material to give longer life.
KEY FEATURES OF THE MACHINE
The machine has been incorporated with the following key features.
• Spooling system with provision for mounting 5-spools simultaneously
• Programmability of the Length and Quantity of interconnects
• Tab length accuracy of +/-0.5 mm with respect to set length of the tabs
• Producing Flat and straight interconnects

Bobbin holding arrangement
Five numbers of bobbin holders (figure 3) have been incorporated to facilitate
loading five bobbins at a time for simultaneously cutting the interconnects from
all bobbins. At each cutting there will be five tabs at the out tray.
Bobbin spindles are provided with roller bearings for fnctionless rotation. The
interconnect is unwound and is made to have a free loop to avoid stress on the
ribbon which is needed to get straight interconnects. This is established by the
actuation of stepper motors connected to the bobbin spindles which gets the
feedback from the sensors mounted in each bobbin.
Measuring, Pinch and Guide Rollers
The interconnect from the bobbin is passed through the guide roller and then it
is positioned in between the measuring roller and the pinch roller (ref figure 5).
The measuring roller, which is connected to the servomotor by timing belt
rotates at each stroke to feed the interconnect exactly to the programmed
length.
The pinch roller has been designed to hold the interconnect over the measuring
roller with a constant pressure. This pressure is applied through the pneumatic
cylinders fitted to the rollers (figure 6).

The guide rollers supports and guide the interconnects so that the interconnects
pass through the measuring rollers in an aligned path without slipping from
measurement.
Both measuring and pinch rollers have been rubberized to feed the interconnect
without any slippage which is required for accurate measurement.
Moving and stationary ram and cutting blades (figure 6)
Five sets of cutting blades have been incorporated to cut the interconnects
without any burr. The top blades are mounted to the moving ram which is
connected to two numbers of pneumatic cylinders. The bottom blades are
mounted to the stationary ram.
Touch sensitive operator panel
The touch screen operator panel (figure 7) has been incorporated in the machine
to facilitate the operating personnel to program the machine initially. All
parameters like length to be cut, number of pieces to be processed and speed
can be set in the panel with ease.
For the comfort and easy visual reading, the display is presented in the panel in
multicolor. The sequence of settings is displaced in simple menu for absolutely
easy setting.

KEY FEATURES
Reference Character Figure
numerals
1 guide Roller 1,5
2 Bobbin 1,2,4
2A Loaded Bobbin 3,
3 Measuring Roller 1,6
4 ' Pinch Roller 1, 2, 5, 9, 6
5 pneumatic cylinder 1,8,6
6 operator Panel 1,2
7 moving RAM and blade 1,8,7
8 Bottom tool 1
9 Servomotor 1,9,6
10 Free Hanging interconnect 1,6
11 Feed Roller 2,5
12 Stepper motor 3,4

14 Empty Spindle 3
15 Feedback Sensors 3
16 Bearing loaded Spindle 4
17 Extending ARM 4
18 Belt Tinning 6
19 Top moving Blade 8

20 Fixed bottom blade 7,8
21 Cutting point 8
22 Interconnect in position before 8
23 Touch sensitive operator panel 9
24 Display Screen 10

WE CLAIM:
1. An Automated interconnect (Tab) cutting device adaptable in the manufacturing
process of photovoltaic (PV) modules comprises,
- a plurality of spooling system;
- a programmality means of the length and quantity of interconnects to obtain accurate size;
- incorporation of servo system to produce the tabs uniformly;
- a touch screen programming means eases the programming operation
for the operator;
- a sensing means has been provided to bypass the finished roll in the
counting process;
- a plurality of bobbins and bobbin holders;
- a plurality of stepper motor (12);
- a guide roller (1);
- a servomotor (9);
- a pinch roller (4), and
- a moving ram (7).
wherein the said device is capable of producing a multiple interconnects having
accurate size and quantity within accepted tolerances, flats and straight
interconnects.
2. The device as claimed in claim 1, wherein a plurality of bobbins holders (figure
3) have been provided to facilitate loading multiple bobbins (2) at a time for
simultaneously cutting interconnects from a bobbin (2).

3. The device as claimed in claim 2, wherein stepper motors (12) connected to the
bobbin spindles which gets feedback from sensors mounted in each bobbin tc
avoid stress on ribbon.
4 The device as claimed in claim 1, wherein the interconnect from the bobbin is
passed through the guide roller (1) and then it is positioned in between the
measuring roller (3) and the pinch roller (4).
5 The device as claimed in claim 4, wherein the measuring roller (3) which is
connected to the servomotor (9) by timing belt rotates at each stroke to feed the interconnects exactly to the programmed length
6. The device as claimed in claim 4, wherein the pinch roller (4) has been designed
to hold the interconnect over the measuring roller (3) with a constant pressure
(figure 5).
7. The device as claimed in claim 6, wherein the pressure is applied to measuring
roller (3) through the preamble cylinders fitted to the rollers
8 The device as claimed in claim 1, wherein the guide rollers (1) support and
guide the interconnects so that the interconnects pass through the measuring
rollers (3) in an aligned path without slipping from measurement
9 The device as claimed in claim 4, wherein both measuring and pinch rollers (4)
have been rubberized to feed the interconnect without any slippage which is
required for accurate measurement
10 The device as claimed in claim 1, wherein a plurality sets of cutting blade have
been incorporated to cut the interconnects without any burr.
11.The device as claimed in claim 10, wherein a top blades are mounted to the
moving ram (7) which is connected to two numbers of pneumatic cylinders and
the bottom blades are mounted to the stationary ram.

12.The device as claimed in claim 1, wherein touch screen operator panel (figure 7)
has been incorporated in the machine to facilitate the operating personnel to
program machine initially
13 The device as claimed in claim 12, wherein all parameter like length to be cut,
number of pieces to be process and speed can be set with panel with ease
14.The device as claimed in claim 12, wherein a visual display means is provided
in the panel in multicolor and the sequence of settings is displayed in simple
menu for absolutely easy settings.

ABSTRACT

TITLE: AUTOMATED INTERCONNECT (TAB) CUTTING DEVICE ADAPTABLE IN
THE MANUFACTURING PROCESS OF PHOTOVOLTAIC (PV) MODULES
An Automated interconnect (Tab) cutting device adaptable in the manufacturing
process of photovoltaic (PV) modules comprises, a plurality of spooling system; a
programmality means of the length and quantity of interconnects to obtain accurate
size; incorporation of servo system to produce the tabs uniformly; a touch screen
programming means eases the programming operation for the operator; a sensing
means has been provided to bypass the finished roll in the counting process; a
plurality of bobbins and bobbin holders; a plurality of stepper motor (12); a guide
roller (1); a servomotor (9); a pinch roller (4); and a moving ram (7) wherein the said
device is capable of producing a multiple interconnects having accurate size and
quantity within accepted tolerances, flats and straight interconnects.