Method, system and assembly mounting device for mounting photovoltaic assemblies

Abstract

The application discloses a kind of photovoltaic module installation method, system and module installation equipment, photovoltaic module installation method includes: determining component installation area;Take photovoltaic module, and adjust photovoltaic module to be parallel with the plane where component installation area is;According to the relative position of the installation structure of photovoltaic module and target installation area, photovoltaic module is moved to target installation area, wherein, target installation area is the current remaining area of component installation area;Along the first direction, photovoltaic module is moved to the junction with vacant connector on component installation support, to be connected with vacant connector, then photovoltaic module is placed.The photovoltaic module installation method realizes the automatic lifting, handling, positioning and installation of component, reduces the degree of manual participation, reduces the risk of component hidden crack, improves the component installation efficiency, to improve the power station quality and safety.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic power plant technology, and in particular to a method, system and equipment for installing photovoltaic modules. Background Technology

[0002] The construction of existing photovoltaic power plants requires manual lifting and handling of the modules, which are then secured to the mounting brackets using bolts and nuts. The entire installation process relies on manual labor, resulting in low efficiency and increasing the risk of microcracks in the modules during manual lifting and handling. Furthermore, the large number of bolts and nuts required for securing the modules makes quality control difficult and hazard identification challenging. Summary of the Invention

[0003] One objective of this invention is to provide a photovoltaic module installation method, system, and module installation equipment that can automatically lift, transport, position, and install the modules, reducing manual intervention, reducing the risk of microcracks in the modules, improving module installation efficiency, and thus enhancing the quality and safety of the power plant.

[0004] To achieve the above objectives, a first aspect of the present invention provides a method for installing a photovoltaic module, the method comprising: determining a module installation area; taking a photovoltaic module and adjusting the photovoltaic module to be parallel to the plane where the module installation area is located; moving the photovoltaic module to the target installation area according to the relative position of the installation structure of the photovoltaic module and the target installation area, wherein the target installation area is the current remaining area of ​​the module installation area; moving the photovoltaic module along a first direction to the connection point with an empty connector on the module installation bracket, so as to connect with the empty connector, and then placing the photovoltaic module.

[0005] In addition, the photovoltaic module installation method proposed in the above embodiments of the present invention may also have the following additional technical features:

[0006] According to one embodiment of the present invention, a photovoltaic power station is provided with multiple reference positions, and the module mounting bracket in the photovoltaic power station includes multiple purlins; determining the module installation area includes: for each reference position, receiving the transmission signals of at least four beacons through a beacon receiver placed at the reference position, and obtaining the distance between each beacon and the reference position based on the transmission signals, wherein the at least four beacons are located at both ends of at least two of the purlins; obtaining the height values ​​of the at least four beacons, and obtaining the position information of the at least four beacons based on the height values ​​of the at least four beacons, a first distance, and a second distance; and obtaining the module installation area based on the position information of the at least four beacons and the width of the at least two purlins where the at least four beacons are located.

[0007] According to one embodiment of the present invention, the number of reference positions and purlins are both two. The two reference positions are designated as a first reference position and a second reference position, respectively. The distance between each beacon and the first reference position is designated as a first distance, and the distance between each beacon and the second reference position is designated as a second distance. Obtaining the position information of the at least four beacons based on their height values, the first distance, and the second distance includes: obtaining a first elevation angle of each beacon relative to the first reference position based on its height value and the first distance; obtaining a second elevation angle of each beacon relative to the second reference position based on its height value and the second distance; obtaining a first projection distance of the corresponding first distance on a horizontal plane based on each first elevation angle; obtaining a second projection distance of the corresponding second distance on a horizontal plane based on each second elevation angle; obtaining coordinate information of each beacon on a horizontal plane based on each first projection distance and the corresponding second projection distance; and obtaining the position information of each beacon based on its coordinate information and the corresponding height value.

[0008] According to one embodiment of the present invention, obtaining the component installation area based on the location information of the at least four beacons and the width of the at least two purlins where the at least four beacons are located includes: obtaining the plane where the at least four beacons are located based on the location information of the at least four beacons; and determining at least two component installation areas from the plane where the at least four beacons are located based on the location information of the at least four beacons and the width of the at least two purlins where the at least four beacons are located.

[0009] According to one embodiment of the present invention, a photovoltaic module is picked up by a suction cup of a module mounting device. The step of adjusting the photovoltaic module to be parallel to the plane where the module mounting area is located includes: calculating the plane tilt angle between the plane containing at least four beacons and the horizontal plane; adjusting the tilt angle of the suction cup to the plane tilt angle; obtaining multiple distances between multiple positions on the suction cup and the plane where the module mounting area is located, thus obtaining multiple third distances, wherein the plane containing the multiple positions is parallel to the suction surface of the suction cup; calculating the difference between the maximum and minimum values ​​of the multiple third distances; if the difference is less than or equal to a first difference threshold, then determining that the photovoltaic module is parallel to the plane where the module mounting area is located; if the difference is greater than the first difference threshold, then adjusting the tilt angle of the suction cup according to the difference, and returning to the step of obtaining the multiple third distances.

[0010] According to an embodiment of the present invention, moving the photovoltaic module to the target installation area based on the relative position of the photovoltaic module's installation structure and the target installation area includes: receiving the transmission signals of at least four beacons through a beacon receiver placed on the module installation equipment, and obtaining the position information of the beacon receiver based on the transmission signals; obtaining the position information of the installation structure based on the position information of the beacon receiver, and obtaining a projection area composed of the projection positions of the installation structure in the target installation area based on the position information of the installation structure; if the area of ​​the projection area reaches a first area threshold, moving the suction cup along the normal vector direction of the plane where the at least four beacons are located to a preset distance from the target installation area; if the area of ​​the projection area does not reach the first area threshold, moving the suction cup according to the position information of the beacon receiver, and returning to the step of receiving the transmission signals of the at least four beacons through the beacon receiver placed on the module installation equipment.

[0011] According to one embodiment of the present invention, obtaining the location information of the installation structure based on the location information of the beacon receiver includes: obtaining the location information of the photovoltaic module center based on the location information of the beacon receiver; obtaining the positional relationship between the installation structure and the photovoltaic module center, and obtaining the location information of the installation structure based on the positional relationship and the location information of the photovoltaic module center.

[0012] According to an embodiment of the present invention, after placing the photovoltaic module, the method further includes: if the area of ​​the current remaining area of ​​the module installation area is greater than or equal to a second area threshold, then removing the next photovoltaic module and returning to the step of adjusting the photovoltaic module to be parallel to the plane where the module installation area is located; if the area of ​​the current remaining area of ​​the module installation area is less than the second area threshold, then determining that the current string installation is complete, wherein the second area threshold is greater than the first area threshold.

[0013] According to one embodiment of the present invention, the method further includes: after determining that the current string is installed, limiting the current string by means of the mounting protective plates on both sides of the component mounting bracket.

[0014] According to one embodiment of the present invention, the mounting structure includes: a first structural member, a second structural member, a movable bolt, a fixing member, a third structural member, a fourth structural member, a fifth structural member, and a connecting rod. The first structural member, the second structural member, and the movable bolt form a connecting member. The movable bolt is fixed by the fixing member. The connecting member is fixed to the frame of the photovoltaic module. The third structural member, the fourth structural member, and the fifth structural member form a module fixing leg. The connecting member is connected to the module fixing leg by the connecting rod. When the movable bolt on the connecting member is in a protruding state, the fourth structural member in the module fixing leg is compressed in the fifth structural member, and the photovoltaic module can move along a second direction in the module mounting bracket. When the connecting member is connected to other connecting members, the movable bolt falls, and the connecting rod drives the fourth structural member to move downward. The photovoltaic module can move along the first direction in the module mounting bracket, wherein the first direction is perpendicular to the second direction.

[0015] The photovoltaic module installation method of this invention first determines the module installation area, drives a suction cup to pick up the photovoltaic module and adjusts it to be parallel to the plane of the module installation area, then drives the suction cup to move the photovoltaic module to the target installation area, and finally moves the suction cup along a first direction to connect the photovoltaic module to the empty connector on the module installation bracket. After connection, the photovoltaic module is placed. This photovoltaic module installation method realizes automatic lifting, transportation, positioning and installation of the module, reduces manual intervention, reduces the risk of microcracks in the module, improves the module installation efficiency, and thus improves the quality and safety of the power station.

[0016] To achieve the above objectives, a second aspect of the present invention provides a component mounting device, the device comprising: a suction cup, a driving mechanism, and a controller, wherein the controller is configured to: determine a component mounting area; control the driving mechanism to drive the suction cup to pick up a photovoltaic component and adjust the photovoltaic component to be parallel to the plane of the component mounting area; control the driving mechanism to drive the suction cup to move the photovoltaic component to the target mounting area according to the relative position of the photovoltaic component's mounting structure and the target mounting area, wherein the target mounting area is the currently remaining area of ​​the component mounting area; control the driving mechanism to drive the suction cup to move the photovoltaic component along a first direction to the connection point with an empty connector on the component mounting bracket, so as to connect with the empty connector, and then place the photovoltaic component.

[0017] In addition, the component mounting device proposed according to the above embodiments of the present invention may also have the following additional technical features:

[0018] According to one embodiment of the present invention, a photovoltaic power station is provided with multiple reference positions, and the module mounting bracket in the photovoltaic power station includes multiple purlins; the device further includes a beacon receiver, and the controller is specifically configured to: for each reference position, control the drive mechanism to place the beacon receiver at the reference position, then receive the transmission signals of at least four beacons, and obtain the distance between each beacon and the reference position based on the transmission signals, wherein the at least four beacons are located at both ends of at least two of the purlins; obtain the height values ​​of the at least four beacons through position sensors at the locations of the at least four beacons, and obtain the position information of the at least four beacons based on the height values ​​of the at least four beacons, a first distance, and a second distance; and obtain the module mounting area based on the position information of the at least four beacons and the width of the at least two purlins where the at least four beacons are located.

[0019] According to one embodiment of the present invention, the device further includes a plurality of position sensors, which are placed on the suction cup and located on the same plane, and the plane is parallel to the suction surface of the suction cup. When the controller controls the driving mechanism to drive the suction cup to adjust the photovoltaic module to be parallel to the plane where the module is installed, it is specifically configured to: calculate the plane tilt angle between the plane where the at least four beacons are located and the horizontal plane; adjust the tilt angle of the suction cup to the plane tilt angle through the driving mechanism; obtain the distances between multiple positions on the suction cup and the plane where the module is installed through the plurality of position sensors to obtain a plurality of third distances; calculate the difference between the maximum and minimum values ​​of the plurality of third distances; if the difference is less than or equal to a first difference threshold, it is determined that the photovoltaic module is parallel to the plane where the module is installed; if the difference is greater than the first difference threshold, the tilt angle of the suction cup is adjusted by the driving mechanism according to the difference, and the process returns to the step of obtaining the plurality of third distances.

[0020] To achieve the above objectives, a third aspect of the present invention provides a photovoltaic module installation system, the system comprising: a photovoltaic module, a module mounting bracket, and module installation equipment according to the above.

[0021] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0022] Figure 1 This is a flowchart of a photovoltaic module installation method according to an embodiment of the present invention;

[0023] Figure 2 This is a flowchart illustrating the determination of a component installation area according to an embodiment of the present invention;

[0024] Figure 3 This is a schematic diagram showing the location of purlins in a photovoltaic power station according to an embodiment of the present invention;

[0025] Figure 4 This is a flowchart illustrating the process of obtaining the location information of at least four beacons according to an embodiment of the present invention;

[0026] Figure 5 This is a flowchart illustrating the process of obtaining the component installation area according to a specific embodiment of the present invention;

[0027] Figure 6 This is a flowchart of an embodiment of the present invention, showing how to adjust a photovoltaic module to be parallel to the plane where the module is installed.

[0028] Figure 7 This is a schematic diagram of a suction cup in a component mounting device according to an embodiment of the present invention;

[0029] Figure 8 This is a schematic diagram of the structure of a component installation device according to an embodiment of the present invention;

[0030] Figure 9 This is a flowchart illustrating how a photovoltaic module is moved to a target installation area according to an embodiment of the present invention;

[0031] Figure 10 This is a flowchart illustrating how the location information of an installation structure is obtained based on the location information of a beacon receiver, according to one embodiment of the present invention.

[0032] Figure 11 This is a flowchart illustrating the placement of photovoltaic modules according to one embodiment of the present invention;

[0033] Figure 12 This is a top view of a component mounting structure according to an embodiment of the present invention;

[0034] Figure 13 This is a schematic diagram of the structure after the components of one embodiment of the present invention have been installed;

[0035] Figure 14 This is a schematic diagram of the installation structure according to an embodiment of the present invention;

[0036] Figure 15 This is a schematic diagram of a photovoltaic module installation system according to an embodiment of the present invention. Detailed Implementation

[0037] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0038] The following describes in detail, with reference to the accompanying drawings, the photovoltaic module installation method, system, and module installation equipment according to embodiments of the present invention.

[0039] Figure 1 This is a flowchart of a photovoltaic module installation method according to an embodiment of the present invention.

[0040] In one embodiment of the present invention, such as Figure 1 As shown, the installation methods for photovoltaic modules include:

[0041] S1, Determine the component installation area.

[0042] Specifically, this invention uses a photovoltaic module installation machine to replace manual lifting and handling of modules, thus reducing the risk of microcracks in the modules. The installation of photovoltaic modules by the module installation machine first requires determining the module installation area. This invention uses a beacon and beacon receiver, along with a position sensor, to locate the modules, thereby determining the installation area.

[0043] In one embodiment of the present invention, a plurality of reference positions are provided within the photovoltaic power station, and the module mounting bracket within the photovoltaic power station includes a plurality of purlins, such as... Figure 2 As shown, the component installation area is defined, including:

[0044] S11, for each reference position, receive the transmission signals of at least four beacons by a beacon receiver placed at the reference position, and obtain the distance between each beacon and the reference position based on the transmission signals, wherein at least four beacons are located at both ends of at least two purlins.

[0045] Specifically, the present invention can set two reference positions within the photovoltaic power station, such as... Figure 3 The coordinate origin (denoted as the first reference position O1) and auxiliary reference point (denoted as the second reference position O2) are shown in the diagram. When the module installation area is obtained, beacon receivers are placed at both reference positions to receive beacon transmission signals. These beacon receivers can be those already on the module installation equipment or additionally installed beacon receivers. The module installation bracket within the photovoltaic power station includes multiple purlins, with a beacon placed at each end of each purlin. This invention uses an example with two purlins on the module installation bracket. Figure 3 As shown, the module mounting bracket in the photovoltaic power station has two purlins, and a beacon is placed at the end of each of the two purlins, for a total of four beacons, namely A1, A2, A3 and A4.

[0046] More specifically, beacon receivers at two reference locations receive signals transmitted by four beacons and determine the distance between each beacon and a reference location based on the transmitted signals. The beacon receivers at the reference locations receive signals from the beacons; due to the varying distances to the beacons, the signal strength received by each beacon receiver differs. Based on the received signal strength, the beacon receivers convert the signal strength into distance to obtain the distance between each beacon and the reference location.

[0047] S12, obtain the height values ​​of at least four beacons, and obtain the position information of at least four beacons based on the height values ​​of at least four beacons, the first distance, and the second distance.

[0048] Specifically, a position sensor is installed at the location of each beacon to obtain the height value of each beacon. Based on the height value of each beacon and the distance of each beacon from the two reference positions, the position information of each beacon is obtained. This position information includes the spatial position information of each beacon in the reference coordinate system.

[0049] In one embodiment of the present invention, such as Figure 3 As shown, the number of reference positions and purlins are both 2. The two reference positions are denoted as the first reference position 01 and the second reference position 02. The distance between each beacon and the first reference position is defined as the first distance, and the distance between each beacon and the second reference position is defined as the second distance. For example... Figure 4 As shown, the location information of at least four beacons is obtained based on their height values, a first distance, and a second distance, including:

[0050] S121, based on the height value of each beacon and the first distance, the first elevation angle of each beacon relative to the first reference position is obtained, and based on the height value of each beacon and the second distance, the second elevation angle of each beacon relative to the second reference position is obtained.

[0051] S122, based on each first elevation angle, obtain the first projected distance of the corresponding first distance on the horizontal plane, and based on each second elevation angle, obtain the second projected distance of the corresponding second distance on the horizontal plane.

[0052] S123, obtain the coordinate information of each beacon on the horizontal plane based on each first projection distance and the corresponding second projection distance, and obtain the position information of each beacon based on the coordinate information and the corresponding height value.

[0053] Specifically, the reference positions of the two reference frames receive the information transmitted by the beacons and obtain the distance between each beacon and the reference position. The distance between each beacon and the first reference position O1 is the first distance, and the distance between each beacon and the second reference position O2 is the second distance. By combining the height values ​​of the four beacons obtained by the position sensor, the first elevation angle β1_i of the four beacons relative to the first reference position O1 and the second elevation angle β2_i of the four beacons relative to the second reference position O2 can be obtained.

[0054] More specifically, based on the first elevation angle β1_i of the four beacons relative to the first reference position 01 and the second elevation angle β2_i of the four beacons relative to the second reference position 02, the first projected distance r1_i of the four first distances on the horizontal plane and the second projected distance r2_i of the four second distances on the horizontal plane are obtained through trigonometric functions. Then, based on the first projected distance r1_i and the second projected distance r2_i, combined with the elevation values ​​of the four beacons, the position information of the four beacons in the spatial reference coordinate system, that is, the spatial coordinates of the four beacons, are obtained.

[0055] S13, the component installation area is obtained based on the location information of at least four beacons and the width of at least two purlins where the at least four beacons are located.

[0056] Specifically, the plane where the beacons are located can be determined based on the location information of the four beacons, and the component installation area can be obtained by combining the width of the two purlins.

[0057] In one embodiment of the present invention, such as Figure 5 As shown, the component mounting area is obtained based on the location information of at least four beacons and the width of at least two purlins where the at least four beacons are located, including:

[0058] S131, obtain the plane containing at least four beacons based on the location information of at least four beacons.

[0059] S132, based on the location information of at least four beacons and the width of at least two purlins where the at least four beacons are located, determine at least two component installation areas from the plane where the at least four beacons are located.

[0060] Specifically, based on the spatial coordinates of the four beacons, the point normal method is used to calculate the normal vectors of the plane containing the four beacons, thereby obtaining the plane equations of the plane containing the four beacons. Combined with the width of the two purlins, two module installation areas are determined from the plane containing the four beacons; these determined module installation areas are two strip-shaped module installation areas. After determining the module installation areas, the photovoltaic modules are taken and aligned with the module installation plane for installation.

[0061] S2, Take the photovoltaic module and adjust it to be parallel to the plane where the module is installed.

[0062] Specifically, the module installation equipment is equipped with suction cups, which are used to pick up photovoltaic modules. The module installation equipment adjusts the photovoltaic modules to be parallel to the plane where the module installation area is located.

[0063] In one embodiment of the present invention, such as Figure 6 As shown, the photovoltaic module is picked up using the suction cup of the module mounting equipment, and then adjusted to be parallel to the plane of the module mounting area, including:

[0064] S21, calculate the plane inclination angle between the plane containing at least four beacons and the horizontal plane.

[0065] S22, adjust the suction cup tilt angle to the plane tilt angle.

[0066] S23, obtain the distances between multiple positions on the suction cup and the plane where the component is installed, and obtain multiple third distances, wherein the plane where the multiple positions are located is parallel to the suction surface of the suction cup.

[0067] S24, calculate the difference between the maximum and minimum values ​​among multiple third distances.

[0068] S25, if the difference is less than or equal to the first difference threshold, then the photovoltaic module is determined to be parallel to the plane where the module installation area is located.

[0069] S26, If the difference is greater than the first difference threshold, adjust the tilt angle of the suction cup according to the difference and return to the step of obtaining multiple third distances.

[0070] Specifically, such as Figure 7 The component mounting device shown has multiple suction cups 1, and four position sensors 2 are mounted on each suction cup 1. For example... Figure 8 As shown, the four position sensors 2 are arranged on the same plane, which is parallel to the adsorption plane of the photovoltaic module 8 adsorbed by the suction cup 1, and the distance between the two planes is h1. Figure 8 The cross-sectional diagram of the component installation equipment shown is as follows: 3 is a structural component, 4 is an electrical control box, 5 is a battery box, 6 is a beacon receiver, 7 is a three-degree-of-freedom drive mechanism, and 8 is a photovoltaic module. After the suction cup picks up the photovoltaic module 8, it is necessary to determine whether the plane of the photovoltaic module 8 is parallel to the plane of the module installation area.

[0071] More specifically, the normal vector of the horizontal plane is calculated, and combined with the normal vectors of the four beacon planes calculated above, the plane tilt angle between the four beacon planes and the horizontal plane is obtained. The drive mechanism 7 on the module mounting equipment drives the tilt angle of the suction cup to the plane tilt angle. Then, the distance from the four position sensors on the suction cup to the module mounting area is read, and this distance is recorded as the third distance d3-i. The third distances obtained by the four position sensors are inconsistent, and the maximum value max(d3-i) and minimum value min(d3-i) of the third distance are obtained. The difference between the maximum value and the minimum value of the third distance is calculated. If the difference is less than or equal to the first difference threshold, it is determined that the photovoltaic module is parallel to the plane where the module mounting area is located. If the difference is greater than the first difference threshold, it indicates that the photovoltaic module is not parallel to the plane where the module mounting area is located. The tilt angle of the suction cup is adjusted again until it is determined that the difference between the maximum value max(d3-i) and the minimum value min(d3-i) of the third distance is within the range of the first difference threshold. At this time, it is determined that the photovoltaic module is parallel to the plane where the module mounting area is located.

[0072] It should be noted that the lowest point of the suction cup should be above the plane where the component is mounted to prevent the component from hitting the purlin during movement. For example... Figure 8 As shown, the lowest point of the suction cup is at least h2 distances above the plane where the component is installed. If the distance between the purlin and the ground is h3, then the distance from the lowest point of the suction cup to the ground is h2+h3.

[0073] The purpose of adjusting the photovoltaic modules to be parallel through the above steps is to ensure that the photovoltaic modules and the module mounting brackets are on the same plane, so that the photovoltaic modules can be moved to the installation position by extending the robotic arm.

[0074] S3, based on the relative position of the photovoltaic module's installation structure and the target installation area, move the photovoltaic module to the target installation area, where the target installation area is the current remaining area of ​​the module installation area.

[0075] Specifically, after adjusting the photovoltaic module to be parallel to the plane where the module is installed, the photovoltaic module is moved to the target installation area by a drive mechanism according to the relative position of the photovoltaic module's installation structure and the target installation area. The target installation area is the current remaining area of ​​the module installation area.

[0076] In one embodiment of the present invention, such as Figure 9 As shown, based on the relative position of the photovoltaic module's mounting structure and the target mounting area, the photovoltaic module is moved to the target mounting area, including:

[0077] S31, receiving transmission signals from at least four beacons via a beacon receiver placed on the component mounting equipment, and obtaining the location information of the beacon receiver based on the transmission signals.

[0078] Specifically, the component mounting equipment is equipped with a beacon receiver, which can be a beacon receiver at a reference location or a beacon receiver configured on its own. The beacon receiver on the component mounting equipment receives signals emitted by four beacons on two purlins. The distance between the beacon receiver on the component mounting equipment and the beacons is determined according to the strength of the received beacon signals. The position information of the beacon receiver on the component mounting equipment, i.e., the spatial position coordinates of the beacon receiver on the component mounting equipment, is obtained by using the spatial four-point positioning method.

[0079] S32, obtain the location information of the installation structure based on the location information of the beacon receiver, and obtain the projection area composed of the projection position of the installation structure in the target installation area based on the location information of the installation structure.

[0080] Specifically, after obtaining the spatial coordinates of the beacon receiver on the component mounting device, the position information of the mounting structure can be obtained based on the mounting structure and the beacon receiver on the component mounting device. The position information of the mounting structure is then projected to obtain the projection area composed of the projected positions of the mounting structure in the target mounting area.

[0081] In one embodiment of the present invention, such as Figure 10 As shown, the location information of the installation structure is obtained based on the location information of the beacon receiver, including:

[0082] S321, obtain the location information of the photovoltaic module center based on the location information of the beacon receiver.

[0083] S322, obtain the positional relationship between the installation structure and the center of the photovoltaic module, and obtain the positional information of the installation structure based on the positional relationship and the positional information of the center of the photovoltaic module.

[0084] Specifically, the suction cup is used to attach the photovoltaic module to a fixed position. The position information of the center of the photovoltaic module and the module installation equipment is known. After obtaining the spatial position coordinates of the beacon receiver on the module installation equipment, the position information of the center of the photovoltaic module can be obtained, that is, the spatial position coordinates of the center of the photovoltaic module. Then, the positional relationship between the installation structure and the center of the photovoltaic module is obtained. Based on this positional relationship and the spatial position coordinates of the center of the photovoltaic module, the position information of the installation structure is obtained, that is, the coordinates of the four corners of the four installation structures.

[0085] More specifically, the projection method is used to calculate the projected coordinates of the four corner coordinates of the four mounting structures in the component mounting area, and the projected coordinates constitute the projection area.

[0086] S33, if the area of ​​the projection area reaches the first area threshold, then move the suction cup along the normal vector direction of the plane where at least four beacons are located to a preset distance from the target installation area.

[0087] S34, if the area of ​​the projection area does not reach the first area threshold, the suction cup is moved according to the position information of the beacon receiver, and the process returns to the step of receiving the transmission signals of at least four beacons through the beacon receiver placed on the component mounting device.

[0088] Specifically, the ratio of the projected area of ​​the rectangle formed by the installation structure to the area of ​​the component installation area is calculated. If the ratio reaches a preset value, the area of ​​the projected area reaches a first area threshold. The suction cup is then moved along the normal vector direction of the plane containing the four beacons to a preset distance from the target installation area. If the ratio does not reach the preset value, the area of ​​the projected area does not reach the first area threshold. The suction cup is then moved until the area of ​​the projected area reaches the first area threshold. Projecting the component installation structure and comparing the ratio of the component installation structure projection to the component installation area ensures that the component installation structure is within the mounting slot, making the installation positioning more accurate.

[0089] It should be noted that the preset ratio of the rectangular projected area of ​​the installation structure to the area of ​​the module installation area is a known quantity. Before moving the suction cup to a preset distance from the target installation area along the normal vector direction of the plane containing the four beacons, it is also necessary to determine whether the photovoltaic module is above the installation position.

[0090] S4, move the photovoltaic module along the first direction to the connection point with the empty connector on the module mounting bracket, connect with the empty connector, and then place the photovoltaic module.

[0091] Specifically, after moving the suction cup along the normal direction of the plane where the four beacons are located, the photovoltaic module is moved along its vertical direction to the connection point with the empty connector on the module mounting bracket and connected to the connector. Then the suction cup no longer adheres to the photovoltaic module, that is, the module is properly placed.

[0092] More specifically, after placing a set of photovoltaic modules, the above steps are repeated to pick up the next module. Before placing the next photovoltaic module, it is necessary to determine whether the remaining area is large enough to accommodate the next set of modules.

[0093] In one embodiment of the present invention, such as Figure 11 As shown, after placing the photovoltaic modules, the installation method also includes:

[0094] S41, if the area of ​​the current remaining area of ​​the module installation area is greater than or equal to the second area threshold, then take the next photovoltaic module and return to the step of adjusting the photovoltaic module to be parallel to the plane where the module installation area is located.

[0095] S42, if the area of ​​the current remaining area of ​​the component installation region is less than the second area threshold, then the current group string is determined to be installed. The second area threshold is greater than the first area threshold.

[0096] Specifically, if the area of ​​the remaining region in the module installation area is greater than or equal to the second area threshold, it indicates that the remaining region can accommodate the next group of modules. In this case, the next photovoltaic module is removed, and the process returns to the step of adjusting the photovoltaic module to be parallel to the plane where the module installation area is located. If the area of ​​the remaining region in the module installation area is less than the second area threshold, it indicates that the remaining region cannot accommodate the next group of modules, and the current string is considered to be installed successfully.

[0097] Figure 12 This is a schematic diagram of the assembly after the components of an embodiment of the present invention have been installed. Structural components 11, 15, 20, and 22 are linked structures. During the assembly process, structural component 11 protrudes. After the components are installed in place, structural component 11 falls, causing structural components 15 and 20 to extend, thereby fixing the clamping parts of structural component 20.

[0098] Figure 12 and Figure 13 This is a schematic diagram of the installation structure according to an embodiment of the present invention, as shown below. Figure 12 and Figure 13 As shown, the mounting structure includes: a first structural component 16, a second structural component 17, a movable bolt 18, a fixing component 19, a third structural component 20, a fourth structural component 21, a fifth structural component 22, and a connecting rod 15. The first structural component 16, the second structural component 17, and the movable bolt 18 form a connecting component 11. The movable bolt 18 is fixed by the fixing component 19. The connecting component 11 is fixed to the module frame 9 of the photovoltaic module. The third structural component 20, the fourth structural component 21, and the fifth structural component 22 form a module fixing leg 10. The connecting component 11 is connected to the module fixing leg 10 by the connecting rod 15. When the movable bolt 18 on the connecting component 11 is in a protruding state, the fourth structural component 21 in the module fixing leg 10 is compressed in the fifth structural component 22, and the photovoltaic module can move along the second direction in the module mounting bracket 13. When the connecting component is connected to other connecting components, the movable bolt 18 falls, and the connecting rod 15 drives the fourth structural component 21 to move downward, and the photovoltaic module can move along the first direction in the module mounting bracket 13, wherein the first direction is perpendicular to the second direction.

[0099] Specifically, the mounting structure includes a connector 11 composed of a first structural component 16, a second structural component 17, and a movable bolt 18. The movable bolt 18 is fixed by a fixing component 19, and the connector 11 is fixed to the component frame 9. A third structural component 20, a fourth structural component 21, and a fifth structural component 22 form a component fixing leg 10. The connector 11 is connected to the component fixing leg 10 via a connecting rod 15. The movable bolt 18 on the connector 11 is in a protruding state. At this time, the fourth structural component 21 in the component fixing leg 10 is compressed in the fifth structural component 22, and the component can move up and down in the component mounting bracket 13. When the left and right components 8 are connected hand in hand, the movable bolt 18 falls and becomes horizontal with the component surface. The connecting rod 15 drives the fourth structural component 21 to move down. At this time, the component can only move in the first direction in the component mounting bracket 13, that is, move left and right.

[0100] In one embodiment of the present invention, after determining that the current string is installed, the current string is limited by the mounting protective plates on both sides of the component mounting bracket 13.

[0101] Specifically, protective plates 14 are installed on the left and right sides of the component mounting bracket 13. The protective plates 14 on both sides limit the current entire string and achieve the function of fixing it.

[0102] The photovoltaic module installation method of this invention first determines the module installation area, drives a suction cup to pick up the photovoltaic module and adjusts it to be parallel to the plane of the module installation area, then drives the suction cup to move the photovoltaic module to the target installation area, and finally moves the suction cup along a first direction to connect the photovoltaic module to the empty connector on the module installation bracket. After connection, the photovoltaic module is placed. This photovoltaic module installation method realizes automatic lifting, transportation, positioning and installation of the module, reduces manual intervention, reduces the risk of microcracks in the module, improves the module installation efficiency, and thus improves the quality and safety of the power station.

[0103] The present invention also proposes a component mounting device.

[0104] In one embodiment of the present invention, such as Figure 8 As shown, the component mounting equipment includes: a suction cup 1, a drive mechanism 7, and a controller 4. The controller 4 is used to: determine the component mounting area; control the drive mechanism 7 to drive the suction cup 1 to pick up the photovoltaic component and adjust the photovoltaic component to be parallel to the plane where the component mounting area is located; according to the relative position of the photovoltaic component's mounting structure and the target mounting area, control the drive mechanism 7 to drive the suction cup 1 to move the photovoltaic component to the target mounting area, wherein the target mounting area is the current remaining area of ​​the component mounting area; control the drive mechanism 7 to drive the suction cup 1 to move the photovoltaic component along a first direction to the connection point with the empty connector on the component mounting bracket, so as to connect with the empty connector, and then place the photovoltaic component.

[0105] For other specific embodiments of the component installation equipment of the above embodiments of the present invention, please refer to the photovoltaic module installation method of the above embodiments of the present invention.

[0106] In one embodiment of the present invention, a photovoltaic power station is provided with multiple reference positions, and the module mounting bracket in the photovoltaic power station includes multiple purlins; the device also includes a beacon receiver, and the controller is specifically configured to: for each reference position, control the drive mechanism to place the beacon receiver at the reference position, then receive the transmission signals of at least four beacons, and obtain the distance between each beacon and the reference position based on the transmission signals, wherein at least four beacons are located at both ends of at least two purlins; obtain the height values ​​of at least four beacons through position sensors at the locations of at least four beacons, and obtain the position information of at least four beacons based on the height values ​​of at least four beacons, a first distance, and a second distance; and obtain the module mounting area based on the position information of at least four beacons and the width of the at least two purlins where the at least four beacons are located.

[0107] In one embodiment of the present invention, the component mounting device further includes multiple position sensors, which are placed on a suction cup and located on the same plane, and the plane is parallel to the suction surface of the suction cup. When the controller controls the drive mechanism to drive the suction cup to adjust the photovoltaic module to be parallel to the plane where the component mounting area is located, it is specifically used to: calculate the plane tilt angle between the plane where at least four beacons are located and the horizontal plane; adjust the tilt angle of the suction cup to the plane tilt angle through the drive mechanism; obtain multiple third distances by acquiring multiple distances between multiple positions on the suction cup and the plane where the component mounting area is located through multiple position sensors; calculate the difference between the maximum and minimum values ​​of the multiple third distances; if the difference is less than or equal to a first difference threshold, it is determined that the photovoltaic module is parallel to the plane where the component mounting area is located; if the difference is greater than the first difference threshold, the tilt angle of the suction cup is adjusted by the drive mechanism according to the difference, and the process returns to the step of obtaining multiple third distances.

[0108] The present invention also proposes an installation system for photovoltaic modules.

[0109] In one embodiment of the present invention, such as Figure 15 As shown, the photovoltaic module installation system 1000 includes: a photovoltaic module 8, a module mounting bracket 13, and a module installation device 400 according to the above.

[0110] The photovoltaic module installation method, system, and module installation equipment of this invention realize automatic lifting, handling, positioning, and installation of photovoltaic modules through control strategies, reducing manual intervention and the risk of microcracks in the modules. Furthermore, through the module installation bracket with guide rails and the mechanical interlock between modules and module installation brackets, the modules can be installed without bolts and nuts, improving module installation efficiency.

[0111] It should be noted that the logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any device that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device. More specific examples (a non-exhaustive list) of computer-readable media include: electrical connections having one or more wires (electronic devices), portable computer disk drives (magnetic devices), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Alternatively, the computer-readable medium may be paper or other suitable media on which the program can be printed, since the program can be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in a computer memory.

[0112] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0113] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0114] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0115] 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 indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0116] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0117] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0118] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A method for installing photovoltaic modules, characterized in that, The method includes: Determine the component installation area; Take the photovoltaic module and adjust it to be parallel to the plane where the module is installed; Based on the relative position of the photovoltaic module's installation structure and the target installation area, the photovoltaic module is moved to the target installation area, wherein the target installation area is the current remaining area of ​​the module's installation area; The photovoltaic module is moved along the first direction to the connection point with the empty connector on the module mounting bracket, so as to connect with the empty connector, and then the photovoltaic module is placed. The mounting structure includes: a first structural component, a second structural component, a movable bolt, a fixed component, a third structural component, a fourth structural component, a fifth structural component, and a connecting rod. The first structural component, the second structural component, and the movable bolt form a connecting component. The movable bolt is fixed by the fixed component. The connecting component is fixed to the frame of the photovoltaic module. The third structural component, the fourth structural component, and the fifth structural component form a module fixing leg. The connecting component is connected to the module fixing leg by the connecting rod. When the movable bolt on the connector is in a protruding state, the fourth structural member in the component fixing leg is compressed in the fifth structural member, and the photovoltaic module can move along the second direction in the component mounting bracket; when the connector is connected to other connectors, the movable bolt falls, the connecting rod drives the fourth structural member to move downward, and the photovoltaic module can move along the first direction in the component mounting bracket, wherein the first direction is perpendicular to the second direction.

2. The method according to claim 1, characterized in that, The photovoltaic power station has multiple reference locations, and the module mounting brackets within the photovoltaic power station include multiple purlins; determining the module installation area includes: For each of the reference locations, a beacon receiver placed at the reference location receives transmission signals from at least four beacons, and the distance between each beacon and the reference location is obtained based on the transmission signals, wherein the at least four beacons are located at both ends of at least two of the purlins; Obtain the height values ​​of the at least four beacons, and obtain the position information of the at least four beacons based on the height values ​​of the at least four beacons and the distances between them and the plurality of reference positions; The component installation area is obtained based on the location information of the at least four beacons and the width of the at least two purlins where the at least four beacons are located.

3. The method according to claim 2, characterized in that, The number of reference positions and purlins are both 2. The two reference positions are designated as the first reference position and the second reference position, respectively. The distance between each beacon and the first reference position is designated as the first distance, and the distance between each beacon and the second reference position is designated as the second distance. The step of obtaining the position information of the at least four beacons based on their height values ​​and their distances to the multiple reference positions includes: A first elevation angle of each beacon relative to the first reference position is obtained based on the elevation value of each beacon and the first distance, and a second elevation angle of each beacon relative to the second reference position is obtained based on the elevation value of each beacon and the second distance. The first projection distance of the corresponding first distance on the horizontal plane is obtained according to each of the first elevation angles, and the second projection distance of the corresponding second distance on the horizontal plane is obtained according to each of the second elevation angles; The coordinate information of each beacon on the horizontal plane is obtained based on the first projection distance and the corresponding second projection distance, and the position information of each beacon is obtained based on the coordinate information and the corresponding height value.

4. The method according to claim 2, characterized in that, The step of obtaining the component installation area based on the location information of the at least four beacons and the width of the at least two purlins where the at least four beacons are located includes: The plane containing the at least four beacons is obtained based on their location information; Based on the location information of the at least four beacons and the width of the at least two purlins where the at least four beacons are located, at least two component installation areas are determined from the plane where the at least four beacons are located.

5. The method according to claim 2, characterized in that, The photovoltaic module is picked up using a suction cup of a module mounting device, and the photovoltaic module is adjusted to be parallel to the plane where the module mounting area is located, including: Calculate the plane inclination angle between the plane containing the at least four beacons and the horizontal plane; Adjust the tilt angle of the suction cup to the tilt angle of the plane; The distances between multiple positions on the suction cup and the plane where the component mounting area is located are obtained to obtain multiple third distances, wherein the plane where the multiple positions are located is parallel to the suction surface of the suction cup; Calculate the difference between the maximum and minimum values ​​among the plurality of third distances; If the difference is less than or equal to the first difference threshold, then the photovoltaic module is determined to be parallel to the plane where the module installation area is located; If the difference is greater than the first difference threshold, the tilt angle of the suction cup is adjusted according to the difference, and the process returns to the step of obtaining multiple third distances.

6. The method according to claim 5, characterized in that, The step of moving the photovoltaic module to the target installation area based on the relative position of the photovoltaic module's installation structure and the target installation area includes: The system receives the transmission signals of the at least four beacons by placing a beacon receiver on the component mounting device, and obtains the location information of the beacon receiver based on the transmission signals. The location information of the installation structure is obtained based on the location information of the beacon receiver, and the projection area formed by the projection position of the installation structure in the target installation area is obtained based on the location information of the installation structure. If the area of ​​the projection area reaches the first area threshold, then the suction cup is moved along the normal vector direction of the plane where the at least four beacons are located to a preset distance from the target installation area; If the area of ​​the projection region does not reach the first area threshold, the suction cup is moved according to the position information of the beacon receiver, and the process returns to the step of receiving the transmission signals of the at least four beacons through the beacon receiver placed on the component mounting device.

7. The method according to claim 6, characterized in that, The step of obtaining the location information of the installation structure based on the location information of the beacon receiver includes: The location information of the center of the photovoltaic module is obtained based on the location information of the beacon receiver; The positional relationship between the installation structure and the center of the photovoltaic module is obtained, and the positional information of the installation structure is obtained based on the positional relationship and the positional information of the center of the photovoltaic module.

8. The method according to claim 6, characterized in that, After placing the photovoltaic module, the method further includes: If the area of ​​the current remaining area of ​​the component installation area is greater than or equal to the second area threshold, then remove the next photovoltaic module and return to the step of adjusting the photovoltaic module to be parallel to the plane where the component installation area is located; If the area of ​​the remaining area of ​​the component installation area is less than the second area threshold, then the current group string is determined to be installed. The second area threshold is greater than the first area threshold.

9. The method according to claim 8, characterized in that, The method further includes: After determining that the current string is installed, the current string is limited by the mounting protective plates on both sides of the component mounting bracket.

10. An installation device for photovoltaic modules, characterized in that, The device includes: a suction cup, a drive mechanism, and a controller, wherein the controller is used for: Determine the component installation area; The drive mechanism is controlled to drive the suction cup to pick up the photovoltaic module and adjust the photovoltaic module to be parallel to the plane where the module is installed. Based on the relative position of the photovoltaic module's installation structure and the target installation area, the drive mechanism is controlled to drive the suction cup to move the photovoltaic module to the target installation area, wherein the target installation area is the current remaining area of ​​the module installation area; The drive mechanism is controlled to drive the suction cup to move the photovoltaic module along the first direction to the connection point with the empty connector on the module mounting bracket, so as to connect with the empty connector, and then place the photovoltaic module; The mounting structure includes: a first structural component, a second structural component, a movable bolt, a fixed component, a third structural component, a fourth structural component, a fifth structural component, and a connecting rod. The first structural component, the second structural component, and the movable bolt form a connecting component. The movable bolt is fixed by the fixed component. The connecting component is fixed to the frame of the photovoltaic module. The third structural component, the fourth structural component, and the fifth structural component form a module fixing leg. The connecting component is connected to the module fixing leg by the connecting rod. When the movable bolt on the connector is in a protruding state, the fourth structural member in the component fixing leg is compressed in the fifth structural member, and the photovoltaic module can move along the second direction in the component mounting bracket; when the connector is connected to other connectors, the movable bolt falls, the connecting rod drives the fourth structural member to move downward, and the photovoltaic module can move along the first direction in the component mounting bracket, wherein the first direction is perpendicular to the second direction.

11. The device according to claim 10, characterized in that, The photovoltaic power station has multiple reference locations, and the module mounting brackets within the photovoltaic power station include multiple purlins; the equipment also includes a beacon receiver, and the controller is specifically used for: For each reference position, the drive mechanism is controlled to place the beacon receiver at that reference position, and then receives the transmission signals of at least four beacons. The distance between each beacon and the reference position is obtained based on the transmission signals, wherein the at least four beacons are located at both ends of at least two purlins. The height values ​​of the at least four beacons are obtained through position sensors at the locations of the at least four beacons, and the position information of the at least four beacons is obtained based on the height values ​​of the at least four beacons and the distances between them and the plurality of reference positions. The component installation area is obtained based on the position information of the at least four beacons and the width of the at least two purlins where the at least four beacons are located.

12. The device according to claim 11, characterized in that, The device also includes multiple position sensors, which are placed on the suction cup and located on the same plane, and this plane is parallel to the suction surface of the suction cup; when the controller controls the drive mechanism to drive the suction cup to adjust the photovoltaic module to be parallel to the plane where the module is installed, it is specifically used for: Calculate the plane inclination angle between the plane containing the at least four beacons and the horizontal plane; The tilt angle of the suction cup is adjusted to the tilt angle of the plane by the drive mechanism; Multiple third distances are obtained by acquiring the distances between multiple positions on the suction cup and the plane where the component mounting area is located using the multiple position sensors; Calculate the difference between the maximum and minimum values ​​among the plurality of third distances; If the difference is less than or equal to the first difference threshold, then the photovoltaic module is determined to be parallel to the plane where the module installation area is located; If the difference is greater than the first difference threshold, the tilt angle of the suction cup is adjusted by the drive mechanism according to the difference, and the process returns to the step of obtaining multiple third distances.

13. A photovoltaic module installation system, characterized in that, The system includes: a photovoltaic module, a module mounting bracket, and an installation device for the photovoltaic module according to any one of claims 10-12.

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