A method of inline assembly and integral mounting of a photovoltaic array

Abstract

The application discloses a kind of photovoltaic array's assembly line type assembly and integral installation method, based on mobile work platform or tool type work platform, raw material processing section is arranged in the layout of the feeding end of work platform, array installation section is arranged away from the side of feeding end, and it is arranged as assembly section between the two;In photovoltaic array assembly assembly line, assembly personnel completes assembly work successively in the mode of assembly line beside rotatable array transfer frame;In array installation section, installation personnel places photovoltaic array semi-finished product in rotatable array transfer frame on the translation rod used for array installation, and sends photovoltaic array semi-finished product into predetermined installation position by translation rod, completes the installation of entire photovoltaic array.The application provides a kind of photovoltaic array's assembly line type assembly and integral installation method, because the assembly of photovoltaic array semi-finished product is completed in installation site, the assembled array semi-finished product does not need to be transported, so that factory assembly becomes feasible.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of photovoltaic array installation. More particularly, the present application relates to a method of assembly line installation of photovoltaic arrays. BACKGROUND

[0002] In the construction process of large centralized photovoltaic power station field, the main work content includes piling, erecting installation support on the top of pile, installing purlin on the installation support, connecting photovoltaic modules through purlin and other structural members such as tie bar to form photovoltaic array, and then collecting the current generated by photovoltaic modules through power collection line. The most labor-intensive link is the installation of purlin, module and wiring. The method commonly used at present is still pure manual work. Workers stand on the scaffold, first install the installation support on the pile head, then place the purlin on the installation support and complete the lengthening and adjustment of the purlin, then place and adjust and fasten the structural materials such as modules, tie bars and other structural materials on the purlin one by one, and finally complete grounding and wiring.

[0003] The problems of this traditional manual work method are firstly that the labor intensity of workers is large, and all equipment and materials are manually transferred to the installation operation height by multiple people; secondly, the working conditions are poor, and workers are in a working state like "standing on the scaffold and lifting up their heads to complete the snatch" for a long time, which is not only extremely tiring but also very unsafe, and inevitably leads to low efficiency.

[0004] Another main reason for low installation efficiency is that the photovoltaic array is installed on the pile foundation, and the positioning error of the pile foundation is usually about 50 mm (the specification requires not more than 50 mm), while the allowable error of the installation hole on the purlin for module installation is only 2.5 mm in the east-west direction and 0.5 mm in the north-south direction. It is necessary to adjust the position of the support inclined beam (6) relative to the pile foundation and the position of the support inclined beam (6) relative to the purlin during the installation of the support on the pile top and the installation of the purlin, so that the positioning error of the installed purlin meets the requirements of module installation. This adjustment process requires workers to have corresponding knowledge and experience accumulation. However, due to the rapid development of the photovoltaic industry, the human market cannot provide enough skilled workers, and most workers entering the industry are transferred from other trades in the construction industry and do not have the corresponding knowledge and experience of photovoltaic installation, so the overall efficiency is low. Usually, the installation of 5 2*26 arrays by a 6-member skilled worker installation team working 8 hours a day is the efficiency limit, and a 2-member skilled worker and 4-member novice worker installation team working 8 hours a day usually cannot complete the installation of 3 2*26 arrays.

[0005] The installation method designed by the inventor and has been patented (Patent No. 202310917066.6) shows that the method indeed improves the working conditions of workers, liberates the operating workers from the working state of "standing on the scaffold and lifting the head to complete the snatch", at the same time, the workers complete the connection between the assembly and the purlin on the pre-assembly rack with positioning partition, thereby eliminating the factors affecting the installation efficiency caused by the positioning error of the purlin, thereby effectively improving the work efficiency. With the cooperation of a car hoist, 2 skilled workers and 4 general workers can complete the installation of 8 2*26 arrays per day for 8 hours. However, the scene adaptability of this method is poor. First of all, most large photovoltaic base projects in China are built in "sand, gobi, and barren" areas, and such areas are mostly subject to frequent strong winds, which greatly limits hoisting operations. Secondly, it cannot adapt to the needs of recent offshore, beach, and large water surface photovoltaic field project construction.

[0006] The patent (Patent No. 202410775372.5) "Photovoltaic array semi-finished product assembly method" applied by Shanghai Bojiao Robot Co., Ltd. adopts factory-like flow operation to complete the assembly of photovoltaic array semi-finished products. The use of mechanical hands to replace manual placement of photovoltaic components and other materials, and the use of assembly lines to complete the transfer of materials and semi-finished products can effectively reduce the labor in the material handling stage and improve labor productivity. However, in the key assembly stage, the method still adopts the traditional method of workers standing below the photovoltaic components on the assembly line to complete the connection and locking of the components and purlins. This requires operating workers to be in a head-up operating state for a long time, which is prone to fatigue and will inevitably lead to low overall efficiency. On the other hand, a common photovoltaic power station site is composed of several square arrays, each square array is composed of several rows of parallel photovoltaic arrays, and the spacing between the parallel arrays is usually no more than 14 meters. A 13-meter-long material transport vehicle is difficult to turn around in the installation site, and the photovoltaic array semi-finished product is a large piece with a length of more than 30 meters and a width of more than 2.3 meters. Transporting such a large piece from the semi-finished product production workshop to the installation site to complete the installation of the semi-finished product will inevitably lead to high installation costs, so the application of this method has very high limitations.

[0007] In view of the above background, the problems we need to solve are:

[0008] 1. How to realize the assembly of array semi-finished products in the installation site with high efficiency;

[0009] 2. How to safely and efficiently install the photovoltaic array semi-finished product as a whole on the pile top support on site. SUMMARY

[0010] An object of the present application is to solve at least the above problems and / or deficiencies, and to provide at least the advantages to be described later.

[0011] In order to achieve the objects and other advantages of the present application, a method for pipeline assembly and integral installation of photovoltaic array is provided, a mobile work platform is built based on a tractor or a tool-type work platform is built on a pile, a photovoltaic array assembly pipeline and an array installation section are arranged, and the assembly and installation of the photovoltaic array are completed on the work platform.

[0012] The tool-type work platform can be dragged along the layout direction of the fixed pile.

[0013] The feeding end of the work platform is arranged as a raw material processing section, the side away from the feeding end is arranged as an array installation section, and the photovoltaic array assembly pipeline is arranged between the raw material processing section and the array installation section.

[0014] In the raw material processing section, the distribution, transfer, positioning, and purlin extension of the materials required for the assembly of the photovoltaic array are completed.

[0015] In the photovoltaic array assembly pipeline, the photovoltaic modules are pushed into the reversible array transfer frame one by one by the automatic pushing device cooperating with the automatic reversing step feeder, and the assembly personnel complete the assembly work in sequence beside the reversible array transfer frame in a pipeline operation mode.

[0016] In the array installation section, the installation personnel place the photovoltaic array semi-finished product in the reversible array transfer frame on the translation rod for array installation, so as to send the photovoltaic array semi-finished product to the predetermined installation position through the translation rod, thereby completing the installation of the entire photovoltaic array.

[0017] Preferably, the raw material processing section is provided with an automatic pushing device, a purlin extension, and a conveying line, and when the tool-type work platform is applied to land high piles and projects on mudflats and water surfaces, the raw material processing section is further provided with photovoltaic module automatic lifting equipment cooperating with the automatic pushing device, and when the work platform is mobile, the front end of the automatic pushing device is fed by manual operation or by setting an automatic reversing step feeder.

[0018] The photovoltaic array assembly pipeline forms an assembly production line through the reversible array transfer frame cooperating with the purlin conveying line and the automatic pushing device, so as to push the photovoltaic modules into the reversible array transfer frame one by one through the automatic pushing device, complete the connection and fastening work of the purlin and the photovoltaic module, the DC cable wiring work, the grounding wire installation work, and the tie rod installation work, so as to obtain the photovoltaic array semi-finished product.

[0019] Preferably, the reversible array transfer frame can be vertically arranged or horizontally arranged.

[0020] The automatic reversing step feeder reverses horizontally by 180 degrees in situ, and the step pushing mode is that the photovoltaic module stack is pushed to the predetermined pushing station one by one under the constraint of the clamping type conveying belt in the device at a set frequency, and the feeding operation is completed.

[0021] When the reversible array conveying frame is vertically arranged, the automatic reversing step feeder reverses vertically by 180 degrees in situ, and the step pushing mode is that the photovoltaic module stack is pushed to the predetermined pushing station one by one under the constraint of the clamping type conveying belt in the device at a set frequency, and the feeding operation is completed.

[0022] Preferably, a guide pulley for pulling the photovoltaic array semi-finished product in the reversible array conveying frame and laying down the photovoltaic array semi-finished product is arranged at the top end of the reversible array conveying frame and the corresponding position of the translation rod; the upper and lower ends of the reversible array conveying frame are respectively provided with a guide rail group for the photovoltaic array to run therein, and the side edge of the guide rail group towards the purlin side is arranged to be a movable or rotating movable edge, so as to realize the switching of the constraint state of the photovoltaic array in the guide rail by adjusting the state of the movable edge.

[0023] Preferably, the guide rail group can be arranged on both sides of the reversible array conveying frame, so as to complete the installation of two adjacent photovoltaic arrays by using one reversible array conveying frame.

[0024] Preferably, a winch and a winding drum matched with each other are arranged in the lower base of the reversible array conveying frame, the steel wire rope on the winding drum is wound around the guide pulley on the upper part of the reversible array conveying frame, and then the hook is connected with the array semi-finished product, so that the assembled photovoltaic array semi-finished product in the array conveying frame is pulled down on the translation rod by a plurality of steel wire ropes.

[0025] Preferably, the photovoltaic array semi-finished product assembled in the assembly section is moved from the assembly position to the pile top installation position by the translation rod.

[0026] Preferably, the number of the translation rods is consistent with the number of the supports on the top of the pile foundation.

[0027] The translation rod can be a multi-section hydraulic telescopic type or a traction type.

[0028] Preferably, the traction type is selected when the translation rod needs to be turned over in place, and the traction type translation rod comprises a straight rod, a traction rope, a trolley moving linearly on the straight rod by the traction of the traction rope, and a position limiter.

[0029] After the array semi-finished product is pulled down on the trolley, the trolley carries the photovoltaic array semi-finished product to the set position on the straight rod and stops by controlling the traction of the steel wire rope by the winch.

[0030] Preferably, after the installation of two adjacent photovoltaic arrays is completed simultaneously in the array installation section, the work platform moves once;

[0031] Among them, the south array adopts the method of flipping the semi-finished photovoltaic array around the hinge support to complete the installation of the photovoltaic array;

[0032] The north array uses the translation rod direct positioning method to complete the installation of the semi-finished photovoltaic array.

[0033] Preferably, the working mode of the method of flipping the translation rod around the hinge support includes:

[0034] NS1. Adjust the position of the flip array conveyor frame on the platform and install the hinge support and translation rod in conjunction with the translation rod at the position of the array near the pile head on the south side of the platform;

[0035] NS2, the first train on the south side, has been assembled in the assembly section;

[0036] NS3. Connect the wire rope hook to the semi-finished array in the conveyor rack, place the first south row on the trolley of the translation rod, start the winch to carry the trolley to the set position at the front end of the translation rod, release the trolley's restraint on the PV array on the translation rod, let the PV array fall onto the translation rod and temporarily fasten it, then retract the trolley;

[0037] NS4, repeat NS3 to complete the assembly of the second column on the south side and transport it into place;

[0038] NS5. After connecting the wire rope hook to the base of the translation rod, release the connection between the base of the translation rod and the platform. Under the action of gravity and the traction of the wire rope, the translation rod and the array on it rotate the entire south-facing array to the designed inclination angle;

[0039] NS6. Install the bracket on the south pile head, tighten the connecting bolts between the purlins and purlin supports, complete the south array installation, and retract the wire rope hook on the translation rod;

[0040] NS7. Remove the south translation rod and hinge support.

[0041] Preferably, the working mode of the translation rod direct placement method includes:

[0042] BS1. Adjust the position of the reversible array conveyor frame on the platform, install the translation rod, and complete the assembly of the first column on the north side;

[0043] BS2. Connect the hook on the wire rope to the first column on the north side, place the first column on the horizontal rod trolley, and retract the wire rope;

[0044] BS3. Connect the hook on the wire rope to the trolley on the translation rod, start the winch and move the first column on the north side to the set position at the front end of the translation rod;

[0045] BS4, install purlin bracket on the support of pile head, lower the translation rod, lay the first column on the north on the support inclined beam and connect and fasten with the purlin bracket, and then remove the translation rod;

[0046] BS5, after the second column on the north is assembled, connect the steel wire rope hook with the photovoltaic array semi-finished product in the conveying frame, start the hoist to put the array semi-finished product on the support of pile head, complete the connection and fastening of the purlin, the purlin bracket and the support, and after the other array parts such as the reinforcing bar are supplemented, the whole array installation on the north is completed.

[0047] The present application at least includes the following beneficial effects: first, because the assembly of the photovoltaic array semi-finished product is completed on the installation site, the assembled array semi-finished product does not need to be transported, so that the factory assembly becomes feasible. Second, the assembly of the photovoltaic array semi-finished product is completed by using the pipeline type working mode on the working platform, so that the assembly work of the photovoltaic array semi-finished product is standardized and orderly, the assembly quality and the overall efficiency are improved, the workers are changed from the working state of "standing on the scaffold and lifting the head" to the state of "screwing beside the pipeline", and the working conditions of the workers are completely changed. Third, because the corresponding mechanical equipment is used in the main process, the labor intensity of the workers is greatly reduced. Finally, because the assembly work is carried out in the conveying frame, the installation error does not need to be considered and adjusted during the assembly process, so that the assembly work becomes simple and repetitive labor, and the requirements for the related experience and knowledge of the workers are reduced.

[0048] Other advantages, objects and features of the present application will be partly embodied in the following description, and partly understood by those skilled in the art through research and practice of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0049] Figure 1 For the process plane schematic diagram of the embodiment of the present application, the south and north two arrays of the beach project share one platform;

[0050] Figure 2 For the process longitudinal section schematic diagram of the embodiment of the present application, the south and north two arrays of the beach project share one platform

[0051] Figure 3 For the schematic diagram of the step NS1 of the installation of the array on the south of the embodiment of the present application;

[0052] Figure 4 For the schematic diagram of the step NS2 of the installation of the array on the south of the embodiment of the present application;

[0053] Figure 5 For one of the schematic diagrams of the step NS3 of the installation of the array on the south of the embodiment of the present application;

[0054] Figure 6 Another schematic diagram of the installation step NS3 of the south array of the beach project in the embodiment of the present application is shown in FIG. 6;

[0055] Figure 7 Another schematic diagram of the installation step NS3 of the south array of the beach project in the embodiment of the present application is shown in FIG. 6;

[0056] Figure 8 Another schematic diagram of the installation step NS3 of the south array of the beach project in the embodiment of the present application is shown in FIG. 6;

[0057] Figure 9 A schematic diagram of the installation step NS5 of the south array of the beach project in the embodiment of the present application is shown in FIG. 8;

[0058] Figure 10 A schematic diagram of the installation step NS6 of the south array of the beach project in the embodiment of the present application is shown in FIG. 9;

[0059] Figure 11 A schematic diagram of the installation step NS7 of the south array of the beach project in the embodiment of the present application is shown in FIG. 10;

[0060] Figure 12 A schematic diagram of the installation step BS1 of the north array of the beach project in the embodiment of the present application is shown in FIG. 11;

[0061] Figure 13 A schematic diagram of the installation step BS2 of the north array of the beach project in the embodiment of the present application is shown in FIG. 12;

[0062] Figure 14 A schematic diagram of the installation step BS3 of the north array of the beach project in the embodiment of the present application is shown in FIG. 13;

[0063] Figure 15 A schematic diagram of the installation step BS4 of the north array of the beach project in the embodiment of the present application is shown in FIG. 14;

[0064] Figure 16 A schematic diagram of the installation step BS5 of the north array of the beach project in the embodiment of the present application is shown in FIG. 15;

[0065] Figure 17 A schematic diagram of the installation step BS6 of the north array of the beach project in the embodiment of the present application is shown in FIG. 16;

[0066] Figure 18 A schematic diagram of the installation step NS7 of the north array of the beach project in the embodiment of the present application is shown in FIG. 17;

[0067] Figure 19 A schematic diagram of the process plane of the mobile work platform carried by the vehicle in the embodiment of the present application is shown in FIG. 18;

[0068] Figure 20 A schematic diagram of the longitudinal section of the mobile work platform carried by the vehicle in the embodiment of the present application is shown in FIG. 19;

[0069] Figure 21 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S1;

[0070] Figure 22 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S2;

[0071] Figure 23 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S3;

[0072] Figure 24 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S4;

[0073] Figure 25 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S5;

[0074] Figure 26 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S6;

[0075] Figure 27 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S7;

[0076] Figure 28 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S8;

[0077] Figure 29 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S9;

[0078] Figure 30 For the embodiment of the present application, the installation method of assembling array semi-finished product directly on the translation rod, the installation schematic diagram of S10;

[0079] Figure 31 For the embodiment of the present application, the schematic diagram of the cross section of the mobile operation platform on the vehicle;

[0080] Figure 32 For the embodiment of the present application, the translation rod assembly drawing with a traction trolley;

[0081] Figure 33 For Figure 32 The enlarged schematic diagram of A part in the middle;

[0082] Figure 34 for Figure 32 Enlarged schematic diagram of part B in the middle. DETAILED DESCRIPTION

[0083] The present invention will be described in further detail below in conjunction with the accompanying drawings so that those skilled in the art can implement the invention with reference to the description.

[0084] The present invention provides a method for assembling a photovoltaic array in an assembly line and installing the entire array. The method mainly utilizes a mobile work platform or a tool-type work platform with a compact factory assembly line as a photovoltaic array assembly and work platform (when used in scenes such as mudflats, water surfaces, and high piles on land, the platform can be a draggable tool-type work platform set up on the pile body; when used in land projects such as "sand, spear, and wasteland", the platform can be a vehicle-mounted mobile work platform). Taking mudflat projects as an example, the following can be done: Figures 1-2 As shown, the construction is directly carried out on the engineering pile (4), and the photovoltaic array is assembled and installed by factory-style flow operation on the platform. It includes: the raw material processing section of the photovoltaic array; the photovoltaic array assembly line and the installation section; in the raw material processing section of the photovoltaic array, the main tasks are to complete the distribution and transportation of the required materials, the lengthening of the purlins (2), etc.; in the photovoltaic array assembly line, the automatic pushing equipment cooperates with the component automatic reversing feeding equipment to push the photovoltaic components (1) one by one into the array reversible array conveyor rack, and the assemblers complete the assembly tasks such as fastening the purlins (2) and the photovoltaic components (1), DC wiring, and grounding connection next to the array reversible array conveyor rack; in the array installation section, the installers flip the photovoltaic array semi-finished products in the reversible array conveyor rack and place them on the translation rod, and the array semi-finished products on the translation rod are dragged (or pushed) to the designed installation position to complete the installation of the entire photovoltaic array.

[0085] At the feed end of the mobile work platform, a raw material processing section is set up above and below the platform. The various materials such as photovoltaic components (1), cables, purlins (2) required for the installation of the photovoltaic array are pre-processed in this section (such as unpacking and unbundling, inspection, transfer and distribution of bracket materials, combined joints of purlins (2), flipping and turning of photovoltaic component boxes, and recycling of packaging materials) before entering the photovoltaic array assembly line assembly and installation section. In the photovoltaic array assembly line and installation section, the main tasks are to complete the connection and fastening of purlins (2) and components, DC cable wiring, grounding wire installation, and tie rod installation, thereby forming a photovoltaic array semi-finished product. The photovoltaic array semi-finished product is then translated to the designed pile top support by the translation rod (15) and the installation workers manually complete the connection and fastening. In actual operation, the support inclined beam (6) and the photovoltaic array semi-finished product can also be assembled on the translation rod first and then installed as a whole on the pile head, such as when using the hinge support flip-in-place method in which the array and the translation rod are matched.

[0086] For specific engineering projects, the assembly method or the installation method of the present application can also be used separately. For example, in land project construction, the installation method of the present application can be used separately to translate and drag the pre-assembled array semi-finished product as a whole to the support for installation. In project construction with good transportation conditions, the assembly method of the present application can be used separately to assemble the photovoltaic array semi-finished product in the workshop, and then the semi-finished product is transported to the installation site for installation by using the installation method of the present application.

[0087] As shown in Figures 1-2 , in the raw material processing section, a purlin lengthening and conveying line (13) is provided, and the conveying line, together with the reversible array conveying frame and the automatic pushing device, constitutes an assembly production line. The photovoltaic module (1) is pushed into the reversible array conveying frame one by one by the automatic pushing device to be connected and fastened with the purlin (2). The assembly workers stand beside the production line to complete the connection and fastening between the purlin (2) and the module and other assembly work. The purlin lengthening and conveying line can be a simple support non-powered roller line, the roller surface height is consistent with the height and plane position of the purlin (2) in the reversible array conveying frame (14). The purlin (2) is assembled with the purlin joint piece and lengthened at this station. The lengthened purlin (2) enters the reversible array conveying frame (14) together with the array semi-finished product assembled at the front end.

[0088] As shown in Figures 1-2 , when applied to land high-pile and beach projects using high-pile tool-type mobile platforms, the photovoltaic module automatic lifting device (11) is used for feeding in the material processing section to lift the photovoltaic module (1) from the lower part of the platform to the assembly station. The photovoltaic module automatic lifting device (11) can be linked with the automatic pushing device (12) to start the automatic pushing device (12) when the photovoltaic module (1) is lifted to a set height to push the photovoltaic module (1) into the reversible array conveying frame (14). The photovoltaic module automatic lifting device (11) can be a simple lifting machine. The main raw materials such as the photovoltaic module (1) of the assembled array are lifted to the work platform by the lifting and conveying device from the pile bottom (ground or water surface). The lifting machine can be linked with the automatic pushing device (12) to start the automatic pushing device (12) when the photovoltaic module (1) is lifted to a set height to push the photovoltaic module (1) into the reversible array conveying frame (14). When used to lift support materials, reinforcing bars, cables and other materials, the lifting machine stops and discharges when it is lifted to a set parking position. The photovoltaic module automatic lifting device (11) can be telescopic to adjust its length according to the change of tidal water level.

[0089] Further, an automatic pushing device (12) is arranged on the upper part of the raw material processing section platform. When the mobile operation platform is used for land vehicle, the pushing device acts according to the set frequency and the automatic reversing step feeder (17) acts at the same frequency; when it is used for land high-pile and beach and water surface projects, it can be linked with the automatic lifting device (11) of the photovoltaic module.

[0090] As shown in Figure 19 , when the raw material processing section is arranged on the mobile operation platform, the front end of the automatic pushing device can be manually placed or an automatic reversing step feeder (17) can be arranged to supply the material. The device acts at the same frequency as the automatic pushing device (12), and after the previous photovoltaic module (1) enters the reversible array transfer frame (14), the module in the automatic reversing step feeder (17) is sent into the working position between the automatic pushing device (12) and the reversible array transfer frame (14) under the action of the clamping transmission belt. When the positive and negative poles of the module need to be switched in the array according to the design requirements of the string connection, the reversing motor of the module automatic reversing feeder can be started to realize the module reversing. Specifically, the reversing mode of the automatic reversing step feeder (17) is to rotate 180 degrees vertically in place, and the step pushing mode is to push the photovoltaic module (1) one by one to the pushing working position at a set frequency under the constraint of the clamping type conveyor belt in the device.

[0091] In another possible application scenario, as shown in Figure 19 , when the array reversible array transfer frame is arranged horizontally, the reversing mode of the automatic reversing step feeder (17) is to rotate 180 degrees horizontally in place, and at this time the step feeding mode is to lift the photovoltaic module (1) one by one to the height of the module pushing device at a set frequency.

[0092] As shown in Figure 20 , on the upper part of the raw material processing section platform, a photovoltaic module element box turnover mechanism (18) is also arranged (the photovoltaic module element box turnover mechanism is mainly used for mobile operation platform and is optional). The unopened photovoltaic module raw material box (3) is pushed into the automatic reversing step feeder (17) after being turned over vertically by the device.

[0093] As shown in Figure 2 , Figure 20 , a reversible array transfer frame (14) is arranged in the assembly section. The reversible array transfer frame can be vertically arranged or horizontally arranged. When it is vertically arranged, the upper and lower ends of the reversible array transfer frame are provided with groove-shaped guide rail groups for the photovoltaic array to run in, and the photovoltaic module array is transferred in the groove-shaped guide rail groups.

[0094] The same side of the groove-shaped guide rail group (towards the purlin (2) side) is a movable or rotatable movable side, through the control of the movable side, the photovoltaic array in the guide rail can be constrained or released on the side (i.e. by moving the side to release the constraint of the array semi-finished product in the guide rail, so that the array semi-finished product can be separated from the reversible array conveying frame (14)).

[0095] At the same time, the lower roller of the lower end groove-shaped guide rail is rotatable, when the array semi-finished product is turned to separate from the reversible array conveying frame (14), the lower roller follows the array to rotate, that is, the lower end groove-shaped guide rail can rotate 90 degrees out of the axial plane, when the photovoltaic array in the turning guide rail is turned, the whole lower end groove-shaped guide rail can be turned accordingly with the photovoltaic array.

[0096] In addition, the groove-shaped guide rail group can be arranged on one side of the reversible array conveying frame, or on both sides of the reversible array conveying frame at the same time, and the installation of photovoltaic arrays on both sides is completed by using one reversible array conveying frame.

[0097] A winding drum driven by a winch is arranged in the lower base of the reversible array conveying frame (14), a plurality of guide pulleys (25) cooperating with the steel wire rope are arranged on the upper part of the reversible array conveying frame (14) (corresponding to the height of the upper purlin (2) of the photovoltaic array in the reversible array conveying frame). Figure 34 When it is needed to turn the photovoltaic array in the reversible array conveying frame to the translation rod out of the plane of the reversible array conveying frame, the steel wire rope connected to the winding drum and passing through the guide pulley provides traction for the turning of the photovoltaic array. That is, when the steel wire rope on the winding drum is wound around the upper guide pulley and connected to the purlin (2) through the hook, it can serve as the traction rope for the turning of the array semi-finished product to separate from the reversible array conveying frame (14), so that the array semi-finished product assembled in the conveying frame can be slowly turned and fallen on the translation rod (15) under the traction of the steel wire rope. When the steel wire rope on the winding drum is connected to the traction trolley (or traction chain) on the translation rod (15), it can provide traction force for the trolley.

[0098] The electric steel wire rope winding drum in the lower base of the reversible array conveying frame (14) is driven and controlled by an electric winch, which can serve as the traction power source of the trolley on the translation rod (15) (optional, when the translation rod is a hydraulic or electric multi-section telescopic type, the traction trolley is not needed), and when the traction steel wire rope of the trolley on the translation rod (15) is connected to the winding drum through the hook, the trolley can be tractioned to run on the translation rod (15).

[0099] The reversible array transfer frame (14) is a multi-section combined structure, and the reels in the base are connected by flexible couplings, facilitating processing, transportation and transfer on site. In actual application, the assembled photovoltaic array semi-finished product in the reversible array transfer frame can be directly laid on the pile head support to be installed under the traction of the steel wire rope, and then connected and fastened by the installation personnel. It can also be laid on the translation rod (15) and pulled to the array installation position at the distal end of the translation rod by the trolley (or chain) running on the translation rod, and then the inclination angle of the translation rod (15) is adjusted to make the array semi-finished product fall on the pile head support, and then the connection and fastening of the array semi-finished product and the pile head support are completed by the installation worker. The assembly section is provided with multiple workstations, which are connected and fastened workstations of components and purlins (2), structural member installation workstations such as reinforcing bars, wiring workstations, and grounding connection workstations. When a row of photovoltaic components (1) and purlins (2) enter the corresponding workstations in the reversible array transfer frame (14) in turn, the assembly workers complete the corresponding assembly work in turn.

[0100] In actual application, the translation rod (15) can be traction type or multi-section hydraulic telescopic type. When the traction type translation rod is adopted, the root of the translation rod is connected with the lower rotating shaft of the photovoltaic array transfer frame, and the upper part can be supported on the support by being attached to the pile head support. When the construction sequence of installing the pile head support after the photovoltaic array is in place is adopted, a hinge support can also be installed on the platform as the support of the translation rod (15). The positioning method of the photovoltaic array semi-finished product on the translation rod has two kinds, Figures 12-18 、 Figures 31-32 The direct positioning method of the translation rod (15) is shown in Figure 32 , in which (19) is a positioning clamp of the hinge support, and (20) is a steel wire rope. Figure 33 In the figure, the angle steel (22) is arranged on the trolley (21) and matched with the spatial position of the purlin (2), and the angle steel (22) is provided with a hook hole (23) matched with the steel wire rope hook. The trolleys (21) at the same spatial position are connected by a connecting rod (24), and the translation rods at the east and west ends are made into a sinkable structure in actual application, so that the relative position of the array semi-finished product on the trolley is maintained. Figure 34 In the figure, a spring (26) and a spring non-return mechanism (27) are further arranged and matched, which can prevent the trolley from sliding downward along the translation rod after the trolley stops running at the set position of the end of the translation rod.

[0101] Figures 3-11 、 The positioning method of the translation rod around the hinge support is shown in Figures 21-30 .

[0102] As shown in Figure 2As shown, the translation bar (15) is consistent with the number of pile head mounting bracket, so that the array structure stress state is consistent with the design. In actual application, the translation bar (15) can be similar to the telescopic multi-section of the car hoist arm, when using multi-section telescopic structure, the translation bar is provided with anti-skid baffle on the contact part with the array purlin. The translation bar (15) can also be composed of a straight bar and a trolley pulled by a steel wire rope connected with a winding drum in the base of the reversible array conveying frame (14). The root of the translation bar (15) is connected with the base of the reversible array conveying frame (14), which is convenient for disassembly and assembly.

[0103] As shown in Figure 1 , Figures 3-11 , the hinged support (16) mounted on the reversible array conveying frame (14) is used as the rotating support of the translation bar (15), which is used when the array is installed by turning.

[0104] Embodiment 1

[0105] This embodiment is a coastal beach fixed pile centralized photovoltaic project, each array is composed of 2 columns, each column is 26 pieces of 580-watt photovoltaic components with a size of 2278*1134 and two purlins with a length of 30.2 meters after lengthening, and the designed array layout is as shown in Figure 1 , the north-south spacing between the arrays is 6.4 meters, and the pile spacing is 4 meters. The designed array component bottom elevation is 7.9 meters, the designed highest tidal level during the rising tide is 5.31 meters, and the beach ground elevation is about 3 meters. We use the tool-type operation platform supported on the pile body, and due to the limitation of the allowable bearing capacity of the pile foundation, the raw materials cannot be concentrated on the platform in whole boxes and bundles, so we use the rising tide period to transport the photovoltaic components, supports, purlins and other raw materials from the wharf to the bottom of the pile of the array to be installed, and then use the lifting machine to lift the components and other materials onto the platform.

[0106] According to the method of the present application, the platform is moved once to complete the installation of two adjacent arrays, wherein the south array is installed by using the translation bar rotating around the hinged support, and the working mode of the translation bar rotating around the hinged support includes:

[0107] NS1, as shown in Figure 3 , the hinged support (16) and the translation bar (15) are installed on the platform near the south array pile head, and in this process, the position of the reversible array conveying frame (14) on the platform needs to be adjusted to meet the design requirements of the array installation position, and the hoop and the short column (5) of the pile head structure support are installed on the south array pile head according to the design.

[0108] NS2, as shown in Figure 4 , the first column in the south is assembled on the assembly section, and the assembly process includes:

[0109] NS20, lengthening the purlin on the platform and placing the purlin on the conveying line (13) and assembling the joint components;

[0110] NS21, using the photovoltaic module automatic lifting equipment installed on the platform to lift the module from the beach ground (water surface during high tide) to the pushing position on the platform, connect and fasten the end of the purlin with the first module;

[0111] NS22, starting the automatic pushing equipment to push the photovoltaic modules one by one into the upper and lower guide rails of the reversible array conveying frame (14) and drive the purlin to enter synchronously, and the assembly section successively performs the connection and fastening of the photovoltaic modules and the purlin, the direct current line wiring, the grounding connection, the installation of the reinforcing rib, and other work, until the assembly of the first column (26 photovoltaic modules) array semi-finished product on the south is completed and transported to the terminal of the reversible array conveying frame (14);

[0112] NS3, as Figure 5 , connect the steel wire rope hook with the array purlin in the conveying frame, release the constraint of the array by the guide rail side, and start the winch to put the first column on the south to the trolley of the translation rod;

[0113] As Figure 6 , the trolley drags the first column on the south to the position, places the first column on the translation rod temporarily, and retracts the trolley. The assembly of the second column on the south is completed on the reversible array conveying frame;

[0114] As Figure 7 , connect the steel wire rope hook with the purlin to put the second column on the south to the trolley of the translation rod;

[0115] As Figure 8 , the trolley drags the second column to the position, places the second column on the translation rod temporarily, and retracts the trolley. The specific operation process includes:

[0116] NS30, connect the drum steel wire rope hook at the lower part of the reversible array conveying frame (14) with the purlin, release the constraint of the array by the upper and lower groove-shaped guide rails of the reversible array conveying frame (14), make the array semi-finished product placed on the trolley on the translation rod under the traction of the drum steel wire rope, then remove the hook, and start the winch to drive the drum to recover the steel wire rope;

[0117] NS31, connect the steel wire rope between the trolley on the translation rod and the drum, and start the winch to make the trolley on the translation rod slowly translate to the front end design position of the translation rod under the traction of the steel wire rope.

[0118] NS32, release the constraint of the array by the trolley on the translation rod, make the array fall on the translation rod and temporarily fasten, and then retract the trolley.

[0119] NS4, repeat NS3 to complete the assembly of the second column on the south side (26 photovoltaic module arrays semi-finished products) and transport to the site.

[0120] NS5, as Figure 9 , connect the steel wire rope hook with the translation bar, rotate the entire array on the south side to the design angle, and rotate it by starting the winch at the lower part of the reversible array conveying frame, so that the translation bar slowly turns to the design angle under the traction of the steel wire rope;

[0121] NS6, as Figure 10 , install the structural support on the south pile head, tighten the connecting bolts between the south array semi-finished product purlin bracket and the structural support, supplement the reinforcement, wiring and other work, and complete the installation of the south (2*26 photovoltaic modules) array. Retrieve the steel wire rope hook on the translation bar;

[0122] NS7, as Figure 11 , remove the south translation bar and hinged support, and install the north translation bar to facilitate the installation of the north array.

[0123] Then install the north array, which uses the translation bar direct positioning method to complete the positioning and installation of the photovoltaic array semi-finished product. The working mode of the translation bar direct positioning method includes:

[0124] BS1, as Figure 12 , adjust the position of the reversible array conveying frame (14) on the platform and complete the assembly of the first column on the north side;

[0125] BS2, as Figure 13 , connect the hook on the steel wire rope with the north first column purlin in the reversible array conveying frame, place the north first column on the trolley of the translation bar, and retrieve the steel wire rope;

[0126] BS3, as Figure 14 , connect the hook on the steel wire rope with the trolley on the translation bar, and start the winch to pull the north first column to the installation position at the front end of the translation bar;

[0127] BS4, as Figure 15 , install the bracket on the structural support of the pile head, lower the front end of the translation bar to place the north first column on the structural support of the pile head, and connect and tighten the structural support of the pile head with the bracket. Complete the connection and tightening of the bracket and the north first column, then recover the steel wire rope and remove the translation bar;

[0128] BS5, as Figure 16 , complete the assembly of the second column on the north side on the assembly frame;

[0129] BS6, as Figure 17 , connect the steel wire rope hook with the north second column purlin, and place the north second column on the support inclined beam;

[0130] BS7, as Figure 18 , fasten the fastener between the fastener and the bracket inclined beam, complete the installation of the north array.

[0131] Embodiment 2

[0132] The installation steps of the water surface and flat ground high pile array are as follows:

[0133] S1, as Figure 21 , the platform moves to the intended installation position, and the platform is connected and fastened with the pile body by using the hoop after adjustment is completed;

[0134] S2, as Figure 22 , the hinged support is extended from the platform, and the hoop short column of the pile head installation structure support is installed;

[0135] S3, as Figure 23 , the translation rod is installed on the platform hinged support, and the small car on the translation rod is connected with the steel wire rope of the winch;

[0136] S4, as Figure 24 , the purlin and the assembly are placed on the small car of the translation rod, and the first column assembly is completed;

[0137] S5, as Figure 25 , the first column is pulled upward, and the second column is assembled;

[0138] S6, as Figure 26 , the inclined beam inclined support is installed on the array, and the pull bar and the wiring between the two columns are supplemented;

[0139] S7, as Figure 27 , the winch is started, and the two columns are pulled as a whole to the top of the translation rod and temporarily connected and fastened;

[0140] S8, as Figure 28 , the connection between the root of the translation rod and the platform is released, the steel wire rope is connected with the winch and the root of the translation rod, and the translation rod is pulled to flip to the designed inclination angle;

[0141] S9, as Figure 29 , the pile head short column and the inclined beam are connected, the inclined support and the hoop are connected, the hoop and the cross arm are locked, and the entire array installation is completed;

[0142] S10, as Figure 30 , the winch steel wire rope is released, the translation rod is removed, the hinged support is retracted, the connection between the platform and the pile body is released, and the platform is transported to the next intended installation array position.

[0143] The above scheme is only a description of a preferred example, but is not limited thereto. In the implementation of the present application, appropriate replacement and / or modification can be made according to the needs of the user.

[0144] While embodiments of the application have been disclosed in connection with the above specification, it will be apparent to those skilled in the art that numerous modifications can be made thereto without departing from the scope of the application as set forth in the claims and equivalents thereof. Accordingly, it is intended that all such modifications come within the scope of the claims and equivalents thereof.

Claims

1. A method for assembly and overall installation of a photovoltaic array, characterized in that: Build a mobile work platform based on a tractor or a tool-type work platform on the pile body of a fixed pile, arrange the photovoltaic array assembly line and array installation section, and complete the assembly and installation of the photovoltaic array on the work platform; The tool-type working platform can be dragged along the layout direction of the fixed piles; The feed end of the work platform is set as the raw material processing section, the side away from the feed end is set as the array installation section, and the area between the raw material processing section and the array installation section is set as the photovoltaic array assembly line; The raw material processing section is equipped with automatic pushing equipment, purlin extension and conveyor lines to complete the distribution, transportation, positioning and purlin extension of materials required for photovoltaic array assembly; The photovoltaic array assembly line is composed of a reversible array conveyor rack and an automatic pushing device that cooperate with the purlin extension and conveyor line to form an assembly production line. The photovoltaic modules are pushed one by one into the reversible array conveyor rack by the automatic pushing device to complete the connection and fastening operations between the purlins and the photovoltaic modules, the DC cable wiring operations, the grounding wire installation operations, and the tie rod installation operations to obtain a semi-finished photovoltaic array. In the array installation section, the installers flip the semi-finished photovoltaic array in the reversible array conveyor rack and place it on the translation rod used for photovoltaic array installation, so as to use the translation rod to send the semi-finished photovoltaic array to the predetermined installation position of the fixed pile, thereby completing the installation of the entire photovoltaic array.

2. The method for assembly and overall installation of a photovoltaic array according to claim 1, wherein: When the tool-type work platform is used for high-pile, mudflat or water projects on land, the raw material processing section is also equipped with automatic photovoltaic module lifting equipment that cooperates with the automatic pushing equipment. When the work platform is mobile, the front end of the automatic pushing equipment is fed manually or with an automatic reversing stepping feeder.

3. The method for assembly and overall installation of a photovoltaic array according to claim 2, wherein: The reversible array conveyor rack can be arranged vertically or horizontally; Among them, when the reversible array conveyor is arranged horizontally, the reversing mode of the automatic reversing stepping feeder is to rotate 180 degrees horizontally in situ, and the stepping pushing mode is that the photovoltaic module automatic lifting device lifts the photovoltaic modules one by one to the predetermined pushing station at a set frequency to complete the feeding operation; When the reversible array conveyor rack is arranged vertically, the reversing method of the automatic reversing stepping feeder is to rotate 180 degrees vertically in situ. The stepping pushing method is that the photovoltaic components are stacked under the constraints of the clamping conveyor belt in the equipment, and the photovoltaic components are pushed one by one to the predetermined pushing station at a set frequency to complete the feeding operation.

4. The method for assembly and overall installation of a photovoltaic array according to claim 3, wherein: At the corresponding position of the top end of the reversible array conveying rack and the translation rod, there are guide pulleys for pulling the photovoltaic array semi-finished products in the reversible array conveying rack and laying down the photovoltaic array semi-finished products; the upper and lower ends of the reversible array conveying rack are respectively provided with guide rail groups for the photovoltaic array to run therein, and the side edge of the guide rail group facing the purlin side is set as a movable edge that can move or rotate, so as to realize the switching of the photovoltaic array constraint state in the guide rail by adjusting the state of the movable edge.

5. The method for assembly and overall installation of a photovoltaic array according to claim 1, wherein: A matching winch and drum are provided in the lower base of the reversible array conveyor rack. When the steel wire rope on the drum is passed over the guide pulley on the upper part of the reversible array conveyor rack and then connected to the photovoltaic array semi-finished product through a hook, the photovoltaic array semi-finished product assembled in the reversible array conveyor rack can be flipped onto the translation rod under the traction of multiple steel wire ropes.

6. The method for assembly and overall installation of a photovoltaic array according to claim 1, wherein: The assembled photovoltaic array semi-finished product is moved from the assembly position to the pile top installation position by a translation rod; The number of translation rods is the same as the number of brackets on the top of the pile foundation; The translation rod can be of a multi-section hydraulic telescopic type or a traction type.

7. The method for assembly and overall installation of a photovoltaic array according to claim 6, wherein: When the translation rod is put into place by flipping, a traction type translation rod is selected, which includes: a straight rod, a traction rope, and a trolley and a limiter that moves linearly on the straight rod through the traction of the traction rope; After the photovoltaic array semi-finished product falls onto the trolley, the winch controls the traction of the wire rope, and the trolley carries the photovoltaic array semi-finished product to the set position on the straight pole and stops.

8. The method for assembly and overall installation of a photovoltaic array according to claim 1, wherein: After the installation of two adjacent photovoltaic arrays is completed in the array installation section, the work platform moves once; Among them, the south array adopts the method of flipping the semi-finished photovoltaic array around the hinge support to complete the installation of the photovoltaic array; The north array uses the translation rod direct positioning method to complete the installation of the photovoltaic array semi-finished products.

9. The method for assembly and overall installation of a photovoltaic array according to claim 8, wherein: The working method of the translation rod flipping around the hinge support includes: NS1. Adjust the position of the reversible array conveyor frame on the working platform and install the corresponding hinge support and translation rod near the pile head on the south side of the working platform; NS2, the first column on the south side, has completed assembly at the assembly position; NS3. Connect the wire rope hook to the semi-finished photovoltaic array in the reversible array conveyor rack, place the first row on the south side onto the trolley on the translation rod, start the winch to carry the photovoltaic array to the set position at the front end of the translation rod, release the trolley's restraint on the photovoltaic array on the translation rod, let the photovoltaic array fall onto the translation rod and temporarily fasten it, then retract the trolley; NS4, repeat NS2-NS3 to complete the assembly of the second column on the south side and transport it into place; NS5. After connecting the wire rope hook to the base of the translation rod, release the connection between the base of the translation rod and the working platform. Under the action of gravity and the traction of the wire rope, the translation rod and the photovoltaic array on it will rotate the entire photovoltaic array on the south side to the designed inclination angle; NS6. Install the bracket on the south pile head, tighten the connecting bolts between the purlins and purlin supports, complete the south array installation, and retract the wire rope hook on the translation rod; NS7. Remove the south translation rod and hinge support.

10. The method for assembly and overall installation of a photovoltaic array according to claim 8, wherein: The working mode of the translation rod direct placement method includes: BS1. Adjust the position of the reversible array conveyor frame on the work platform, install the translation rod, and complete the assembly of the first row on the north side; BS2. Connect the hook on the wire rope to the first column on the north side, place the first column on the horizontal rod trolley, and retract the wire rope; BS3. Connect the hook on the wire rope to the trolley on the translation rod, start the winch and move the first column on the north side to the set position at the front end of the translation rod; BS4. Install the purlin support on the support at the pile head, lower the translation rod, place the first column on the north side flat on the support diagonal beam and connect it to the purlin support and tighten it, then remove the translation rod; BS5. After the second row of the north side is assembled, connect the wire rope hook to the semi-finished photovoltaic array in the reversible array conveyor rack, start the winch to place the semi-finished photovoltaic array on the pile head bracket, complete the connection and tightening of the purlins, purlin supports and brackets, and complete the installation of the entire north array after installing other array parts.

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