Junction Box Welding Machine KS-01C - Fully Automatic Solar Module Junction Box Soldering System
The Ooitech KS-01C Junction Box Welding Machine is an advanced fully automatic soldering system engineered for high-precision junction box welding on solar PV modules. Designed to meet the demands of modern solar panel manufacturing, this machine integrates automatic hot bar tin welding and high frequency welding technologies with intelligent CCD visual positioning to deliver outstanding soldering accuracy of ±0.1mm. The KS-01C is compatible with a wide range of module configurations including 5BB to 12BB full cell, half-cut modules, bifacial modules, single junction boxes, 3-separate junction boxes, and black module junction boxes with black busbars. With a rapid cycle time of 16 seconds or less and a welding quality yield rate of 99.6%, the KS-01C is the ideal solution for solar panel production lines ranging from 5MW to 1GW capacity.
The machine features a comprehensive suite of intelligent functions including AI-powered image inspection, automatic repair welding, pre-welding and post-welding detection, real-time welding temperature preservation, and full MES system interaction. Its robust mechanical design, advanced electrical control system, and user-friendly HMI interface make the KS-01C a reliable and efficient cornerstone for any solar module manufacturing facility.
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Technical Parameters
General Specifications
| Parameter | Specification |
|---|
| Model | KS-01C |
| Application | 5BB-12BB full cell, half-cut module, bifacial module, single junction box, 3-separate junction box, black module junction box (customizable) |
| Applicable Junction Box Specifications | Conventional, terminal triad, middle 3-separate junction box, black component junction box (extensible to custom specifications) |
| Module Size | Max: 2650mm x 1400mm; Min: 1644mm x 985mm; Frame thickness: 20-45mm |
| Maximum Module Weight | 40kg/PCS |
| Welding Method | Automatic hot bar tin welding / High frequency welding |
| Positioning Mode | CCD photo positioning, accuracy ±0.1mm |
| Cycle Time | ≤16s |
| Opening Probability | >99.0% |
| Welding Quality Yield | 99.6% |
| Welding Tension Qualified Rate | 100% |
| Noise | ≤65 dB |
| Equipment Lifetime | ≥10 years |
| Version Switching | Quick switching<10 min (initial switching <2 hours) |
Welding and Tinning Parameters
| Parameter | Specification |
|---|
| Welding Temperature | 180-500°C adjustable, temperature accuracy ±10°C |
| Automatic Tinning | Tin amount settable, accuracy ±0.1mm |
| Compatible Tin Weight | 1-3kg |
| Tin Wire Diameter | 0.5-2mm |
| Fast Refueling Time | <1 min |
| Pulling Force After Welding | ≥80N |
| Welding Scar Size | Effective welding area >80% |
| Welding Head Life | ≥35,000 times |
| Welding Head Cleaning | Automatic cleaning by time set + cycle cleaning (daily maintenance<5 min) |
| R Deviation Correction | ≤30° adjustable range |
Power and Utility Requirements
| Parameter | Specification |
|---|
| Power Supply | 380V / 50Hz / Three-phase five-wire |
| Power Rating | 60/20KW |
| Wire Diameter | 6mm |
| Air Supply Pressure | 6 kg |
| Air Flow | 400 L/min |
| Air Pipe Diameter | 10mm |
| Exhaust Air | Double port, 2m³/min, diameter 170mm |
| Cooling | Built-in chiller unit |
Detection and Inspection System
| Function | Description |
|---|
| Pre-welding Inspection | Lead wire pressing detection (100% accuracy), lead line deviation detection, junction box installation deviation detection with abnormal alarm |
| Post-welding Detection | Height measurement and visual inspection, automatic defective product identification and alarm, automatic repair welding |
| AI Imaging System | AI automatic learning function, overpass rate ≤0.5%, missing rate 0% |
| Tin Wire Detection | Detects tin wire presence and abnormality, automatic re-take when no tin wire detected |
| Real-time Temperature Preservation | Image-saved welding temperature stored as database file for high traceability |
Technical Advantages
Intelligent AI-Powered Visual Inspection
The KS-01C incorporates an advanced AI imaging system with automatic learning capability. The system achieves an overpass rate of 0.5% or less and a missing rate of absolute zero, ensuring every welding defect is detected. Real-time welding temperature images are saved as database files, providing full traceability for quality management.
Automatic Repair Welding Capability
When the post-welding inspection system identifies abnormal solder joints, the machine automatically initiates repair welding without operator intervention. This eliminates virtual welding, welding leakage, and other defects, maintaining the 99.6% quality yield rate throughout continuous production.
High-Precision CCD Positioning System
The CCD-based positioning system captures precise images of junction box locations with an accuracy of ±0.1mm. Combined with the R deviation correction function that handles junction box installation angle deviations of up to 30 degrees, the system ensures consistent welding quality regardless of minor placement variations.
Comprehensive Pre-welding and Post-welding Detection
Pre-welding detection achieves 100% accuracy on lead wire pressing inspection, lead line deviation, and junction box installation deviation. Post-welding detection includes height measurement and visual inspection with automatic defective product identification and alarm functionality.
Advanced Automatic Tinning System
The automatic tinning system provides precise tin amount control with ±0.1mm accuracy. Fast refueling takes less than 1 minute, and the system is compatible with tin wire diameters ranging from 0.5mm to 2mm with 1-3kg capacity. Intelligent alarms notify operators of material shortage or tin abnormalities.
Rapid Cycle Time and High Efficiency
With a cycle time of 16 seconds or less and an opening probability exceeding 99.0%, the KS-01C maximizes production throughput. Quick version switching in under 10 minutes enables flexible production scheduling across different module types and configurations.
Robust Mechanical and Electrical Design
The machine body utilizes European standard 40x80 aluminum or equivalent-strength welded steel frame construction for overall stability with zero vibration during operation. The welding head lifespan exceeds 35,000 cycles, and the overall equipment lifetime is rated at 10 years or more.
Full MES System Integration
The KS-01C supports comprehensive MES interaction with data collection capabilities including component information, equipment operation parameters (temperature, test pictures, welding time, barcode information), consumables replacement records, maintenance records, and maintenance reminders. Data and pictures are stored for over 1 month with automatic coverage functionality.
User-Friendly HMI and Multi-level Control
The human-machine interface supports formula-based mode switching with 50 formula storage capacity. The system includes 4 levels of user hierarchical permission control, fault state manual test with single step operation, simulation action capabilities, and automatic wire feeding speed calculation based on wire diameter, density, and tin amount parameters.
Complete Quality Assurance
The machine ensures no diode short circuit or other short circuits during welding. The welding head maintains clean contact without tin contamination that could cause hidden cracks. No soldering residue is left in the wiring box or on the backplane, and flat, even tin piles are achieved without missing gaps or suspension.
Product Applications
The Ooitech KS-01C Junction Box Welding Machine is designed for a broad range of solar panel manufacturing applications:
Solar Module Production Lines
Ideal for integration into complete solar panel production lines with capacities ranging from 5MW to 1GW. The machine supports all mainstream module formats including standard full-cell modules, half-cut cell modules, and bifacial modules for both PERC and TOPCon cell technologies.
Multi-Busbar (MBB) Production Lines
Fully compatible with 5BB to 12BB configurations, the KS-01C is perfectly suited for modern MBB solar panel production lines. It supports the latest cell technologies including M6, M10, and M12 wafer sizes.
Junction Box Type Compatibility
The machine accommodates conventional junction boxes, terminal triad configurations, middle 3-separate junction boxes, and specialized black component junction boxes with black busbars. Custom junction box specifications can be accommodated through equipment customization.
Diverse Module Formats
From standard rectangular modules up to 2650mm x 1400mm to compact modules as small as 1644mm x 985mm with frame thicknesses between 20-45mm, the KS-01C handles diverse module form factors with quick version switching capability.
Smart Factory Integration
With full MES system compatibility, real-time data collection, barcode information processing, and comprehensive data storage, the KS-01C integrates seamlessly into Industry 4.0 smart factory environments for solar panel manufacturing.
Contact Ooitech to Get Your Junction Box Welding Machine
Ooitech, founded in 2013, is a trusted provider of turnkey solar energy solutions with over 10 years of experience in the PV industry and industrial laser applications. Our equipment has been exported to Poland, Hungary, Korea, Mexico, Egypt, Algeria, India, Saudi Arabia, Syria, Kazakhstan, and many other countries worldwide.
Ooitech provides complete turnkey solutions including:
5MW to 1GW solar module production line supply
Traditional PV line upgrade to the latest MBB production line
Factory construction consultation and facility layout design
Raw material selection guidance
Production procedure assistance and solar power station installation support
For more information about the KS-01C Junction Box Welding Machine or our complete range of solar panel production line equipment, please contact us:
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