A final testing method and automated testing device for intelligent photovoltaic modules

Abstract

The present invention relates to a method for testing photovoltaic modules, and more particularly to a final testing method and automated testing device for intelligent photovoltaic modules, belonging to the field of solar photovoltaic technology. The invention relates to an automated testing device for intelligent photovoltaic modules, comprising a voltage detection device, a computer, a test box capable of blocking light, and an assembly line with a correction mechanism for conveying the intelligent photovoltaic modules to be tested. The test box has a built-in simulated light source simulating sunlight, an intelligent photovoltaic junction box integrated with an intelligent semiconductor chip, and a conduction test fixture. The conduction test fixture achieves electrical connection between the intelligent photovoltaic junction box and the voltage detection device during testing. The voltage detection device tests the voltage at the output end of the intelligent photovoltaic module to be tested and inputs the real-time test data into the computer through the computer data port. The device can realize automated functional testing of intelligent photovoltaic modules, save manpower, and improve the accuracy and efficiency of module testing.

Description

Technical Field

[0001] The present invention relates to a photovoltaic module detection method, in particular to a final detection method and an automated detection device for an intelligent photovoltaic module, and belongs to the technical field of solar photovoltaics. Background Art

[0002] Based on traditional photovoltaic modules, smart photovoltaic modules encapsulate intelligent semiconductor chips inside the photovoltaic modules to optimize the battery string-level MPPT, thereby increasing the maximum power output of the modules when shaded and improving the reliability of the modules.

[0003] Smart PV panels have an MPPT (maximum power point tracking) power optimization function. However, because the smart PV junction box has a built-in DC-DC (direct current-direct current) synchronous buck converter, it affects the power tester's measurement, calculation and simulation of the IV (I: current, V: voltage) curve. Current power testing methods are unable to perform power testing on smart panels, especially those with a voltage-limiting function. Currently, power testing of smart panels all uses a shielding optimization module.

[0004] In each link of component production, the EL (electroluminescence) testing process and the installation process of the junction box may cause damage to the junction box chip in the component. In addition, there is no functional testing of the components in the subsequent processes. If unqualified components are delivered to customers, it will cause serious customer complaints and affect the company's quality reputation. Summary of the Invention

[0005] The present invention provides a final testing method for intelligent photovoltaic modules, which can realize functional testing of intelligent modules and prevent unqualified photovoltaic modules from reaching customers.

[0006] The present invention also provides an automated detection device for intelligent photovoltaic modules, which can realize automated detection of intelligent photovoltaic module functions, save manpower, and improve module detection accuracy and efficiency.

[0007] The technical solution adopted by the present invention to solve its technical problem is:

[0008] An automated testing device for intelligent photovoltaic components, comprising a voltage detection device, a computer, a test box capable of blocking light, and an assembly line with a correction mechanism for conveying intelligent photovoltaic components to be tested. The test box has a built-in simulated light source simulating sunlight, an intelligent photovoltaic junction box integrated with an intelligent semiconductor chip, and a conduction test tool. The conduction test tool realizes electrical connection between the intelligent photovoltaic junction box and the voltage detection device during testing. The voltage detection device tests the voltage at the output end of the intelligent photovoltaic component to be tested, and inputs the real-time test data into the computer through the computer data port. The test box is used to block the light generated during testing, thereby protecting the eyes of employees. The main function of the intelligent photovoltaic junction box is to connect the power at the positive and negative ends of the intelligent photovoltaic component array to an external load. The conduction test tool is used in the curing and cleaning process (see for details). Figure 1 Flowchart of the installation process) is installed in a fixed position on the smart PV panel.

[0009] Solar photovoltaic modules are priced based on their power. PV module power testing methods measure the module's voltage-current characteristics under STC (standard test conditions) to calculate the module's rated power. Smart photovoltaic modules contain intelligent semiconductor chips. The active feedback mechanism of their DC-DC synchronous buck converters can affect the power tester's ability to measure the module's voltage-current characteristics, making it impossible to properly measure the module's rated power. This is especially true for smart photovoltaic modules with voltage limiting. Current power testing of smart photovoltaic modules utilizes optimized modules that shield the module, making existing testing methods unable to detect the module's intelligent semiconductor chips. Furthermore, various steps in the production of smart photovoltaic modules, such as EL testing and junction box installation, can damage the module's intelligent semiconductor chips. Current module production processes lack functional testing for smart photovoltaic modules.

[0010] This invention utilizes the photovoltaic effect of crystalline silicon semiconductors to generate photoelectromotive force. The intelligent photovoltaic junction box, integrated with an intelligent semiconductor chip, outputs a rated output voltage Un under a certain voltage input from the solar cell array. Using a voltage detection device (voltmeter or multimeter), the module voltage is tested to assess the functional integrity of the intelligent photovoltaic module. This allows for comprehensive functional inspection of the intelligent photovoltaic module, preventing substandard products from reaching customers and safeguarding the company's reputation. The automated testing device provided by this invention automates the functional testing of intelligent photovoltaic modules, saving manpower and improving module testing accuracy and efficiency.

[0011] Preferably, the continuity test fixture includes a conductive sheet, a conductive ejector pin, and a lifting cylinder. The conductive sheet is electrically connected to the smart photovoltaic junction box and the inside of the smart photovoltaic module. The lifting cylinder is connected to the conductive ejector pin and is used to control the connection between the conductive ejector pin and the conductive sheet. During testing, one end of the conductive ejector pin is connected to the conductive sheet and the other end is connected to the input of a voltage detection device, forming a voltage for automatically testing the smart photovoltaic module. The conductive ejector pin is connected to the input of the voltage detection device via a cable to achieve electrical continuity between the smart photovoltaic module and the voltage detection device during testing. The smart photovoltaic module outputs electrical energy through the smart photovoltaic junction box, and the voltage monitoring device is directly connected to the smart photovoltaic junction box and is electrically connected to the smart photovoltaic module.

[0012] Preferably, a plurality of ventilation and heat dissipation holes are provided on the test box, and a heat dissipation fan is installed in the ventilation and heat dissipation holes.

[0013] Preferably, the simulated light source includes one or more constantly lit lights. Another preferred solution is that the simulated light source is a touch-sensitive type, whereby when the smart photovoltaic module to be tested enters the testing station, a trigger switch lights up the simulated light source, and when the smart photovoltaic module leaves, the simulated light source is turned off.

[0014] Preferably, the conductive sheet is connected to a cable, the other end of the cable is connected to a connector, and the connector is connected to the connector of the smart photovoltaic junction box, thereby forming internal conduction between the conductive sheet and the smart photovoltaic junction box and the smart photovoltaic module.

[0015] Preferably, the irradiance of the simulated light source is not less than 400W / m 2 , and make the light evenly and directly enter the smart photovoltaic module. Under this irradiance, a certain value of electromotive force is generated at the positive and negative ends of the smart photovoltaic module.

[0016] Preferably, the smart photovoltaic junction box is adhered to the back of the smart photovoltaic component through silica gel.

[0017] A final testing method for smart photovoltaic modules using the above-mentioned automated testing device for smart photovoltaic modules is provided. This method utilizes the photovoltaic effect of crystalline silicon semiconductors to generate photoelectromotive force, and uses a voltage detection device to test the voltage of the smart photovoltaic modules to assess the functional integrity of the smart photovoltaic modules. Figure 1 The final function test process is set between the EL test process and the FI appearance inspection process based on the current production process of photovoltaic modules. It is used for functional testing of smart photovoltaic modules. The production process flow chart of the improved smart photovoltaic modules is as follows: Figure 1 shown.

[0018] Preferably, the smart photovoltaic junction box outputs a rated output voltage Un under a certain voltage input of the solar cell array; if the actual measured voltage value U satisfies Un-4≤U≤Un, it can be determined that the function of the smart photovoltaic junction box inside the smart photovoltaic module is intact, otherwise it is defective.

[0019] Due to the semiconductor photovoltaic effect, crystalline silicon solar cells generate a photoelectric potential difference across the PN junction of the photovoltaic cell under illumination. Under a certain voltage input, the output terminal of the intelligent semiconductor chip will output a certain voltage. The intelligent semiconductor chip is typically integrated within an intelligent photovoltaic junction box, and the functional integrity of the intelligent semiconductor chip within the photovoltaic module is assessed by testing the positive and negative voltage values ​​of the photovoltaic module. The present invention uses a voltage detection device with a DC voltage range to test the voltage across the junction box connector. If the actual measured voltage value U satisfies Un-4≤U≤Un, it can be determined that the integrated circuit function of the intelligent photovoltaic junction box within the intelligent photovoltaic module is intact, and thus the intelligent photovoltaic junction box function of the intelligent photovoltaic module can be determined to be qualified. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a production process flow chart of the smart photovoltaic module of the present invention;

[0021] Figure 2 This is a schematic structural diagram of the final testing device of the intelligent photovoltaic module of the present invention;

[0022] Figure 3 This is a partial schematic diagram of the final test of the intelligent photovoltaic module of the present invention;

[0023] Explanation of reference numerals: smart photovoltaic module 1, smart photovoltaic junction box 2, continuity test tooling 3, conductive sheet 4, conductive thimble 5, lifting cylinder 6, multimeter 7, computer 8, test box 9, simulated light source 10, ventilation and heat dissipation holes 11, assembly line 12. DETAILED DESCRIPTION

[0024] The technical solution of the present invention is further described in detail below through specific examples. It should be understood that the implementation of the present invention is not limited to the following examples, and any form of modification and / or change made to the present invention will fall within the scope of protection of the present invention.

[0025] Unless otherwise specified, the components or devices in the following embodiments are all universal standard parts or components known to those skilled in the art, and their structures and principles can be known to those skilled in the art through technical manuals or conventional experimental methods.

[0026] Example:

[0027] like Figure 2 and Figure 3The illustrated device is an automated testing device for smart photovoltaic modules. It primarily consists of a voltage detector, a computer 8, a light-blocking test box 9, and an assembly line 12 with a rectifier for conveying the smart photovoltaic modules 1 under test. The test box 9 includes a built-in simulated sunlight light source 10, a smart photovoltaic junction box 2 integrated with a smart semiconductor chip, and a continuity test fixture 3. The smart photovoltaic junction box is attached to the back of the smart photovoltaic module 1 under test using silicone. In this embodiment, the voltage detector is a multimeter 7, which measures the voltage at the output of the smart photovoltaic module 1 under test and inputs the real-time test data into the computer 8 via the computer data port.

[0028] The continuity test fixture 3 ensures electrical connection between the smart photovoltaic junction box 2 and the multimeter 7 during testing. It consists of a conductive sheet 4, a conductive ejector pin 5, and a lifting cylinder 6. The conductive sheet 4 is connected to a cable, the other end of which is connected to a connector that connects to the connector of the smart photovoltaic junction box. This creates internal continuity between the conductive sheet 4, the smart photovoltaic junction box 2, and the smart photovoltaic module 1. The lifting cylinder 6 is connected to the conductive ejector pin 5 and controls the connection between the conductive ejector pin 5 and the conductive sheet 4. During testing, one end of the conductive ejector pin is connected to the conductive sheet, and the other end is connected to the input of the multimeter, generating a voltage that automatically tests the smart photovoltaic module. The conductive ejector pin 5 is connected to the input of the multimeter 7 via a cable, ensuring continuity between the smart photovoltaic module 1 and the multimeter 7 during testing.

[0029] In order to ensure accurate test results and good ventilation, a plurality of ventilation and heat dissipation holes 11 are provided on the test box 9 , and a heat dissipation fan is installed in the ventilation and heat dissipation holes 11 .

[0030] The simulated light source 10 is composed of one or more constantly lit lights. In addition, the simulated light source 10 can be configured to be touch-activated, that is, when the smart photovoltaic module 1 to be tested enters the testing station, a trigger switch lights up the simulated light source, and turns off the simulated light source when the smart photovoltaic module leaves.

[0031] The irradiance of the simulated light source is not less than 400W / m 2 , and make the light evenly and directly enter the smart photovoltaic component. Under this irradiance, a certain value of electromotive force is generated at the positive and negative ends of the smart photovoltaic component 1.

[0032] A final test method for smart photovoltaic modules implemented using the above-mentioned smart photovoltaic module automatic detection device utilizes the photovoltaic effect of crystalline silicon semiconductors to generate photoelectromotive force, and uses a multimeter to test the voltage of the smart photovoltaic modules to evaluate the functional integrity of the smart photovoltaic modules. The final test method for smart photovoltaic modules of the present invention ( Figure 1The final function test process is set between the EL test process and the FI appearance inspection process based on the current production process of photovoltaic modules. It is used for functional testing of smart photovoltaic modules. The production process flow chart of the improved smart photovoltaic modules is as follows: Figure 1 The smart PV junction box outputs a rated output voltage Un under a certain voltage input of the solar cell array. If the actual measured voltage value U satisfies Un-4≤U≤Un, it can be determined that the smart PV junction box inside the smart PV module is functioning properly; otherwise, it is defective.

[0033] When a smart photovoltaic module 1 reaches the testing station of the automated testing system, the alignment mechanism of assembly line 12 precisely aligns the module 1, ensuring that it remains in the fixed position for testing. Once the module 1 is aligned, the lifting cylinder 6 rises, and the conductive ejector pin 5 contacts the conductive pad 4 on the continuity test fixture 3. A multimeter 7 measures the voltage at the output of the smart photovoltaic module 1 and transmits the real-time test data to computer 8 via the computer data port.

[0034] The multimeter measures the voltage at the output of the smart photovoltaic module under test and inputs the real-time test data into the computer through the computer data port. Based on the rated output voltage Un of the smart photovoltaic junction box, a qualified voltage range is pre-set on the computer 8 before the test. If the tested voltage falls within the qualified voltage range, the indicator light turns green, indicating that the test has passed. Otherwise, the indicator light turns red, a buzzer sounds, indicating that the test has failed, and the test results are displayed on the computer interface. The identity code of the component corresponding to the test data is also stored on the computer for easy subsequent query.

[0035] The embodiment described above is only a preferred solution of the present invention and does not limit the present invention in any form. Other variations and modifications are possible without exceeding the technical solution described in the claims.

Claims

1. An intelligent photovoltaic module automatic detection device, characterized by: The intelligent photovoltaic component automatic detection device comprises a voltage detection device (7), a computer (8), a test box (9) capable of blocking light, and an assembly line (12) with a correction mechanism for conveying the intelligent photovoltaic components to be tested. The test box (9) has a built-in simulated light source (10) for simulating sunlight, an intelligent photovoltaic junction box (2) integrated with an intelligent semiconductor chip, and a conduction test tool (3). The conduction test fixture (3) realizes the electrical connection between the intelligent photovoltaic junction box (2) and the voltage detection device (7) during the test. The voltage detection device (7) tests the voltage at the output end of the tested intelligent photovoltaic component (1), and inputs the real-time data of the test into the computer (8) through the computer data port; The irradiance of the simulated light source is not less than 400W / m 2 , and make the light evenly and directly enter the smart photovoltaic module. Under this irradiance, a certain value of electromotive force is generated at the positive and negative ends of the smart photovoltaic module (1); The conduction test fixture (3) comprises a conductive sheet (4) having a conduction function, a conductive ejector pin (5) and a lifting cylinder (6), wherein the conductive sheet (4) is internally connected to the smart photovoltaic junction box (2) and the smart photovoltaic module (1); The lifting cylinder (6) is connected to the conductive ejector pin (5) and is used to control the connection state between the conductive ejector pin (5) and the conductive sheet (4). During testing, one end of the conductive ejector pin is connected to the conductive sheet, and the other end is connected to the input end of the voltage detection device to form a voltage for automatically testing the intelligent photovoltaic module. The conductive pin (5) is connected to the input end of the voltage detection device (7) through a cable to achieve conduction between the smart photovoltaic component (1) and the voltage detection device (7) during detection; the smart photovoltaic junction box (2) has a built-in DC-DC synchronous buck converter and a smart semiconductor chip with an active feedback mechanism, and the smart photovoltaic junction box outputs a rated output voltage Un under a certain voltage input of the solar cell array; the computer (8) automatically determines whether the function of the smart photovoltaic junction box is intact based on the received voltage test data, and if the actual measured voltage value U satisfies Un-4≤U≤Un, the computer determines that the function of the smart photovoltaic junction box inside the smart photovoltaic component is intact, otherwise it is defective, and stores the judgment result on the computer; The test box (9) is provided with a plurality of ventilation and heat dissipation holes (11), and the ventilation and heat dissipation holes (11) are equipped with a heat dissipation fan; the simulation light source (10) includes one or more lights that are always on; the simulation light source (10) is a touch type, when the smart photovoltaic component (1) to be tested enters the detection station, the touch switch lights up the simulation light source, and when the smart photovoltaic component leaves the detection station, the simulation light source is turned off; The conductive sheet (4) is connected to a cable, the other end of the cable is connected to a connector, and the connector is connected to a connector of the smart photovoltaic junction box; the smart photovoltaic junction box (2) is adhered to the back of the smart photovoltaic component through silicone.

2. A final testing method for smart photovoltaic modules using the smart photovoltaic module automated testing device according to claim 1, characterized in that: The photovoltaic effect of crystalline silicon semiconductors is used to generate photoelectric potential, and the voltage of the smart photovoltaic module is tested with the help of a voltage detection device to judge the functional integrity of the smart photovoltaic module.

3. The final testing method according to claim 2, wherein: The intelligent photovoltaic junction box (2) has a built-in DC-DC synchronous buck converter and an intelligent semiconductor chip with an active feedback mechanism. The intelligent photovoltaic junction box outputs a rated output voltage Un under a certain voltage input of the solar cell array; if the actual measured voltage value U satisfies Un-4≤U≤Un, it can be determined that the function of the intelligent photovoltaic junction box inside the intelligent photovoltaic component is intact, otherwise it is defective.

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