Junction Box Installation System for Photovoltaic Modules

The Spi-Auto Boxer is a flexible, automated workstation that performs a variety of tasks needed to attach and seal a junction box to the back surface of a photovoltaic module.

Modules are transported on a powered roller conveyor and positioned with a two-axis edge aligner. A four-axis robot with a tool changer selects from several different end-effectors (tools) that can be customized to suit the box design and the installation process. Spire has designed end-effectors for the following tasks:

• Lift metal ribbon output leads and bend them to an upright position
• Clean the module surface with alcohol and a brush, dry the alcohol with filtered compressed air, and dispense sealant in a pattern that matches the junction box
• Pick up a junction box from a feeder, position it, and place it with controlled force on the sealant

A junction box feeder dispenses boxes from a stack to a nest for pick up by the robot. The box stack is located outside the safety guards that protect the operator from the robot, so the stacks can be refilled without interrupting machine operation.

Features & Benefits

• Quick-change tooling provides process flexibility
• Custom tooling designed for your box and process
• Interlocked enclosure protects operator from robot
• Clutch on robot protects arm from damage in collision
• Sensors alert operator to refill box stack when parts are low
• Boxes can be loaded during the box installation process for uninterrupted operation
• Upstream and downsteam handshakes provided for passing modules
• Touch screen monitor and keyboard user interface