A photovoltaic module uneven load testing device

Abstract

This utility model discloses a photovoltaic module uneven load testing device, including a frame, a tension / compression assembly, and a control module. A module support frame is located below the frame, and the tension / compression assembly is mounted above the support frame. The tension / compression assembly includes multiple independently controlled cylinders, pressure sensors, and vacuum suction cups. The pressure sensors are located between the output shaft of the cylinders and the vacuum suction cups. Each cylinder is connected to an air source via an independent air path, and each air path is equipped with a proportional solenoid valve. The control module receives the pressure value measured by the pressure sensors and adjusts the airflow of each cylinder through the proportional solenoid valves. The cylinders in this utility model are equipped with independent proportional solenoid valves. The control module can precisely adjust the airflow of each cylinder according to requirements, thereby applying different levels of pressure to various parts of the photovoltaic module, completely replicating the stress state of the module during actual operation, and significantly improving the accuracy of the load test results.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic module testing technology, and in particular to a photovoltaic module non-uniform load testing device. Background Technology

[0002] Photovoltaic modules undergo load testing before leaving the factory to verify their load-bearing capacity. Load testing is divided into static load testing and dynamic load testing. Static load testing primarily verifies the module's ability to withstand long-term biased strong winds, assessing its reliability under constant pressure. Testing methods can include sand pressure, air pressure, or water pressure, and the pressure applied to the module must be uniform and sustained throughout the test (each test surface requires 1 hour of testing, with 3 cycles of forward and reverse testing). Dynamic load testing verifies the module's reliability under specific scenarios, such as airflow through a valley, assessing its ability to withstand alternating pressure in both directions and the vibration and shaking of its front and rear surfaces.

[0003] Traditional load testing methods involve placing photovoltaic (PV) modules on a mounting frame. Multiple cylinders equipped with vacuum suction cups are positioned above the PV modules, with the suction cups adhering to the module's surface. Forces are applied through tension and compression to load the PV modules. Currently, all cylinders are uniformly controlled, assuming a consistent external environment and uniform force applied to the module surface. However, in actual operating environments, the presence of purlins causes uneven stress distribution on the PV modules. The force applied to the top of the purlins, between purlins, and on the top of the purlins cannot be uniform, leading to inconsistent stress on the module's surface glass and increasing the risk of failure. Therefore, existing load testing methods have limitations, failing to fully replicate actual operating conditions and resulting in inaccurate test results. Utility Model Content

[0004] To address the aforementioned issues, this invention provides a photovoltaic module uneven load testing device that can apply different levels of pressure to various parts of the photovoltaic module, thereby improving the accuracy of load testing.

[0005] Therefore, the technical solution of this utility model is: a photovoltaic module uneven load testing device, including a frame, a tension-compression assembly, and a control module. A module support frame is provided below the frame, and the tension-compression assembly is installed above the module support frame. The tension-compression assembly includes multiple independently controlled cylinders, pressure sensors, and vacuum suction cups. The pressure sensors are located between the output shaft of the cylinders and the vacuum suction cups. Each cylinder is connected to a gas source through an independent air path, and each air path is equipped with a proportional solenoid valve. The control module receives the pressure value measured by the pressure sensor and adjusts the airflow of each cylinder through the proportional solenoid valve.

[0006] Based on the above scheme and as a preferred option: each cylinder is equipped with a cylinder descent control solenoid valve, and the control module controls the lifting and lowering of the cylinder through the cylinder descent control solenoid valve.

[0007] Based on the above scheme and as a preferred option: each vacuum suction cup is connected to a vacuum solenoid valve, and the control module controls the suction and release operations of the vacuum suction cup through the vacuum solenoid valve.

[0008] Based on the above scheme and as a preferred embodiment of the above scheme: several sliding rods and guide rails are provided above the frame, and the guide rails and sliding rods are perpendicular to each other; multiple sliding blocks are provided above the guide rails, and the sliding blocks are fitted on the sliding rods and can slide along the sliding rods; the cylinder is set upright, and its top is slidably mounted on the guide rail through a second sliding block and can move along the guide rail.

[0009] Based on the above scheme and as a preferred embodiment of the above scheme: the front side of the frame is also provided with a control area, which is equipped with a touch screen, operation buttons and status indicator lights. The touch screen is used to display the air volume and pressure value of each cylinder; the operation buttons include a power button, a start / stop button, an up button, a down button and an emergency stop button, which are used to control the operation of the cylinders.

[0010] Compared with the prior art, the beneficial effects of this utility model are: 1. Each cylinder is equipped with an independent proportional solenoid valve and a pressure sensor. The pressure sensor is located between the cylinder output shaft and the vacuum suction cup, which can collect the pressure value applied to the photovoltaic module by each cylinder in real time and transmit the data to the control module. The control module can accurately adjust the air volume of each cylinder through the proportional solenoid valve as needed, thereby applying different pressures to various parts of the photovoltaic module, completely replicating the stress state of the module when it is actually working, greatly improving the accuracy of the load test results, and providing a more realistic basis for judging the reliability of the photovoltaic module.

[0011] 2. Each cylinder is also equipped with an independent cylinder descent control solenoid valve and a vacuum suction solenoid valve. The control module can control the lifting and lowering status of a single cylinder and the vacuum suction cup operation, meeting the needs of different load tests for different areas of photovoltaic modules.

[0012] 3. The control area on the front side of the device frame is equipped with a touch screen, which can display key test data such as the air flow rate and pressure value of each cylinder in real time. The air flow rate of each cylinder can also be set through the touch screen. Operators can quickly and intuitively grasp the status of the entire test process through the screen, which is convenient for timely detection of abnormalities and improves the monitoring efficiency of the test process.

[0013] 4. The frame is equipped with mutually perpendicular sliding rods and guide rails. The top of the cylinder is slidably mounted on the guide rail via a sliding block, and the sliding block can slide along the sliding rod. The position of the cylinder can be flexibly adjusted according to the size of different specifications of photovoltaic modules and the requirements of the test area, so that the device can be adapted to the testing of photovoltaic modules of different lengths and widths. There is no need to customize a test device for specific specifications of modules, which expands the applicability of the device and reduces the investment cost of test equipment. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 for Figure 1 A magnified view of a portion of the image; Figure 3 This is a front view of the structure of this utility model; Figure 4 This is a side view of the structure of this utility model; Figure 5 This is a schematic diagram of the tension / compression assembly of this utility model; Figure 6 This is a circuit diagram of the microcontroller module and power supply module of this utility model; Figure 7 This is a circuit diagram of the component connection module of this utility model; Figure 8 This is a circuit diagram of the pressure detection module of this utility model (only including some pressure detection sensors). Figure 9 This is a circuit diagram of the cylinder airflow control module of this utility model (only including some proportional solenoid valves). Figure 10 This is a circuit diagram of the cylinder working control module of this utility model (only including part of the cylinder descent control solenoid valve and vacuum suction solenoid valve).

[0015] The components in the diagram are labeled as follows: frame 1, component support frame 11, slide bar 12, guide rail 13, sliding block 14, tension / compression assembly 2, cylinder 21, pressure sensor 22, vacuum suction cup 23, touch screen 31, and operation button 32. Detailed Implementation

[0016] In the description of this utility model, it should be noted that the directional terms such as "center", "horizontal (X)", "longitudinal (Y)", "vertical (Z)", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation and positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. They should not be construed as limiting the specific protection scope of this utility model.

[0017] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features. Thus, the use of "first" and "second" to define a feature may explicitly or implicitly include one or more of that feature. In the description of this utility model, "several" or "a number" means two or more, unless otherwise explicitly specified.

[0018] See the attached figures. The photovoltaic module uneven load testing device described in this embodiment includes a frame 1, a tension / compression assembly 2, and a control module. A module support frame 11 is located below the frame 1, and the tension / compression assembly 2 is mounted above the module support frame 11. Multiple sliding rods 12 and guide rails 13 are located above the frame 1, with the guide rails 13 perpendicular to the sliding rods 12. Multiple sliding blocks 14 are located above the guide rails 13, and the sliding blocks 14 are fitted onto the sliding rods 12 and can slide along the sliding rods 12. The cylinder 21 of the tension / compression assembly 2 is vertically mounted, and its top is slidably mounted on the guide rail 13 via a second sliding block, and can move along the guide rail 13. In use, the position of the cylinder can be flexibly adjusted according to the size of different specifications of photovoltaic modules and the requirements of the testing area, enabling the device to adapt to the testing of photovoltaic modules of different lengths and widths. This eliminates the need to customize a testing device for specific specifications of modules, expanding the applicability of the device.

[0019] The tension / compression assembly 2 includes 72 independently controlled cylinders 21, pressure sensors 22, and vacuum suction cups 23. The pressure sensors 22 are located between the output shaft of each cylinder 21 and the vacuum suction cup 23, and can collect the pressure value applied to the photovoltaic module by each cylinder 21 in real time and transmit the data to the control module. Each cylinder 21 is connected to an air source through an independent air path, and each air path is equipped with a proportional solenoid valve. The control module receives the pressure value measured by the pressure sensors and adjusts the airflow of each cylinder through the proportional solenoid valves. Simultaneously, each cylinder 21 is equipped with a cylinder descent control solenoid valve and a vacuum suction solenoid valve. The control module controls the lifting and lowering of the cylinder through the cylinder descent control solenoid valve, and controls the suction and release of the vacuum suction cup through the vacuum solenoid valve.

[0020] The front side of the frame 1 is also provided with a control area, which includes a touch screen 31, operation buttons 32 and status indicator lights. The touch screen 31 is used to display the air flow and pressure values ​​of each cylinder. At the same time, the operator can also set the air flow of each cylinder on the touch screen 31 to meet different testing requirements. The operation buttons 32 include a power button, a start / stop button, an up button, a down button and an emergency stop button, which are used to control the operation of the cylinders.

[0021] The control module includes a microcontroller module, a power supply module, a component connection module, a pressure detection module, a cylinder airflow control module, and a cylinder operation control module.

[0022] Power supply module (see) Figure 6 The circuit breaker F1 connects to the three-phase lines (L (live wire), N (neutral wire), and PE (ground wire) to provide AC220V main power input for the entire equipment. It serves as the main power supply entry point, ensuring the foundation for the overall electrical system's power supply. F1 acts as the main circuit breaker, providing overload and short-circuit protection for the entire equipment circuit, preventing equipment damage or safety accidents due to circuit faults. F3, F4, and F5 are three branch circuit breakers, providing overload and short-circuit protection for different branch circuits, protecting the electrical components of the corresponding branches from circuit abnormalities, and improving the safety and reliability of circuit operation.

[0023] Two AC contactors, KM1 and KM2 (model LC1 D09AM7C), control the start and stop of vacuum pump 1 (-M1) and vacuum pump 2 (-M2), respectively. The contactor coil voltage is DC24V. By controlling the opening and closing of the main contacts through the control of the coil, the power supply to the vacuum pumps is controlled to provide the power source for the vacuum adsorption function of the equipment.

[0024] Microcontroller module (see) Figure 6 The CPU is the control core of the entire device. It is powered by DC24V and has digital input (I0.0-I0.7, etc.) and digital output (Q0.0-Q0.5, etc.) interfaces. It can receive input signals from buttons, sensors (temperature, pressure, displacement, etc.) and output control signals to actuators such as contactors, solenoid valves, and indicator lights according to the preset control logic to realize the automated operation of the device.

[0025] The CPU interacts with the touchscreen via the HMI, allowing operators to set equipment parameters (such as pressure threshold, displacement range, operating speed, etc.), start / stop the equipment, view the equipment's operating status (temperature, pressure, displacement data) and fault alarm information, thus enabling visual operation and monitoring of the equipment.

[0026] Component connection module (see) Figure 7The system includes a 75mV signal acquisition (-ST3), which uses a KMB-30-9-G module in conjunction with a shunt (-R1, DC0-5A / 75mV). The shunt can convert the large current in the circuit into a standard 75mV voltage signal, which is then transmitted to the control system through the acquisition module. This enables the monitoring of the current in the main circuit or critical loads, allowing for real-time monitoring of the operating current status of the photovoltaic module ZJ and timely detection of current anomalies.

[0027] Pressure detection module (see) Figure 8 ), a total of 72 pressure sensors, Figure 8 The display shows some of the pressure sensors (-PS1 to -PS12), grouped by function to monitor the pressure status of components such as cylinders and vacuum systems. The sensor wiring uses four-color wires: red (positive power), green (signal), white (auxiliary signal), and black (negative power), with uniform wire diameters to ensure stable signal transmission. The pressure sensor output signals are connected to subsequent acquisition modules via J1-J6 interfaces, enabling real-time detection of whether the pressure reaches a set threshold, providing pressure feedback signals for the equipment's adsorption, lifting, and other actions.

[0028] Pressure transmitters (-PT1, -PT2) convert the pressure signals collected by pressure sensors into standard analog signals (such as 4-20mA or voltage signals), which are then transmitted to the microcontroller module via signal lines to achieve accurate acquisition and quantitative analysis of pressure data, providing a basis for the logical judgment of the control system.

[0029] Cylinder airflow control module (see) Figure 9 There are 72 proportional solenoid valves in total, each corresponding to a cylinder. Figure 9 This section only displays some proportional solenoid valves (-VP1 to -VP16, model ITV-1050). These valves adjust their opening by controlling current or voltage signals, thereby precisely controlling parameters such as the cylinder's air intake and the vacuum system's pressure, achieving accurate control of equipment actions (e.g., cylinder lifting speed, adsorption pressure adjustment). The proportional valve wiring includes a positive power supply (V+), a negative power supply (V-), and control signal terminals (interfaces 1, 2, 3, 4, etc.). It connects to the microcontroller's output terminals via -A7 and -A8 interface modules to receive control signals from the microcontroller and achieve proportional adjustment.

[0030] Cylinder working control module (see) Figure 10 This includes 72 vacuum suction solenoid valves (YAX series) and 72 cylinder lowering solenoid valves (YPX series). Figure 10Only some vacuum solenoid valves (-YA1 to -YA24) are displayed. They are used to control the on / off state of the vacuum system. When a control signal is received from the microcontroller, the valve opens or closes to realize the vacuum adsorption or vacuum breaking function, providing a control switch for the adsorption action of the equipment. Figure 10 Only some cylinder lowering solenoid valves (-YP1 to -YP32) are displayed. They control the lifting and lowering of the cylinders. By opening and closing the valves, they control the entry and exit of compressed air, driving the cylinder piston to move up and down, thus realizing the lifting and lowering function of the equipment.

[0031] The above description is merely a preferred embodiment of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions falling within the scope of this utility model's concept are protected. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of this utility model should also be considered within the protection scope of this utility model.

Claims

1. A photovoltaic module uneven load testing device, comprising a frame, a tension / compression module, and a control module, wherein a module support frame is provided below the frame, and the tension / compression module is mounted above the module support frame; characterized in that: The tension / compression assembly includes multiple independently controlled cylinders, pressure sensors, and vacuum suction cups. The pressure sensors are located between the output shaft of the cylinders and the vacuum suction cups. Each cylinder is connected to an air source through an independent air path, and each air path is equipped with a proportional solenoid valve. The control module receives the pressure value measured by the pressure sensor and adjusts the airflow of each cylinder through the proportional solenoid valve.

2. The photovoltaic module non-uniform load testing device as described in claim 1, characterized in that: Each cylinder is equipped with a cylinder descent control solenoid valve, and the control module controls the cylinder's lifting and lowering operations through the cylinder descent control solenoid valve.

3. The photovoltaic module non-uniform load testing device as described in claim 2, characterized in that: Each vacuum suction cup is connected to a vacuum solenoid valve, and the control module controls the suction and release operations of the vacuum suction cup through the vacuum solenoid valve.

4. The photovoltaic module non-uniform load testing device as described in claim 1, characterized in that: The frame is provided with several sliding rods and guide rails, with the guide rails perpendicular to the sliding rods; multiple sliding blocks are provided above the guide rails, with the sliding blocks fitted onto the sliding rods and able to slide along the sliding rods; the cylinder is set upright, with its top slidably mounted on the guide rail via a second sliding block, and can move along the guide rail.

5. A non-uniform load testing device for a photovoltaic module as defined in claim 1, wherein: The front side of the frame is also equipped with a control area, which includes a touch screen, operation buttons and status indicator lights. The touch screen is used to display the air volume and pressure value of each cylinder. The operation buttons include a power button, a start / stop button, an up button, a down button and an emergency stop button, which are used to control the operation of the cylinders.

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