Photovoltaic module connector testing device and testing method

Abstract

The invention provides a photovoltaic module connector testing device and method, and belongs to the technical field of photovoltaic module performance test.The photovoltaic module connector testing device comprises a testing water tank, a jacking support, an upper fixing piece and a lower fixing piece, and a temperature controller used for adjusting the water temperature is arranged in the testing water tank; the jacking support comprises lifting stand columns symmetrically arranged on the two sides of the testing water tank and a cross beam connected between the lifting stand columns. The cross beam is positioned right above the test water tank; the upper fixing piece is arranged on the cross beam and is used for fixing a positive electrode cable; the lower fixing piece is arranged at the bottom of the test water tank and used for fixing a cathode cable; the lower fixing piece is located under the upper fixing piece, so that the connecting line of the lower fixing piece and the upper fixing piece is perpendicular to the cross beam. The device can effectively simulate the insulation performance and the electric conduction capability of the photovoltaic module connector in the outdoor application environment process, and achieves the verification of the comprehensive performance of the photovoltaic module connector.

Description

Technical Field

[0001] The invention belongs to the technical field of photovoltaic module performance testing, and in particular relates to a photovoltaic module connector testing device and a photovoltaic module connector testing method. Background Art

[0002] PV panel connectors are devices used to establish safe and reliable electrical connections between PV panels and other electrical equipment. They also connect PV panels and other components of the PV system, such as inverters, charge controllers, and batteries. PV panel connectors ensure efficient energy transfer and minimize any power loss in the system. The main principle is to convert solar rays into DC electricity and transmit it to the inverter or grid for storage or use.

[0003] When using a PV module connector, the PV module converts solar light into DC power and transmits it to the connector's plug. The interlayer in the plug ensures that the current flows properly into the socket and connects to other electrical devices. Through the PV module connector, DC power can be converted by an inverter and transmitted to the grid for home or commercial use.

[0004] Photovoltaic module connectors play an important role in the entire electrical circuit. Their main functions include protection, current conversion, improving system safety and adapting to harsh environments. The performance of connectors will directly affect the transmission quality of power and signals.

[0005] In the field of photovoltaic power generation, due to long-term outdoor use, there are high requirements for the reliability and weather resistance of connectors. In order to reduce the impact of wind, rain and dust, connectors used in the photovoltaic field must usually have excellent insulation performance and electrical conductivity performance. Among them, insulation performance is mainly used to measure whether there is a leakage risk in the connector, and electrical conductivity performance is mainly used to measure whether the connector can be conductive. Therefore, during the production process of connectors, they must undergo strict insulation tests and electrical conductivity tests. Traditional connector insulation tests and electrical conductivity tests are performed separately, and it is impossible to comprehensively verify the performance of the connector. Summary of the invention

[0006] The embodiment of the present invention provides a photovoltaic module connector testing device and a testing method thereof, which effectively simulate the outdoor application environment of the photovoltaic module connector, and aim to comprehensively verify the insulation performance and electrical conductivity of the photovoltaic module connector.

[0007] In the first aspect, in order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: to provide a photovoltaic module connector testing device, including: a test water tank, a lifting bracket, an upper fixing part and a lower fixing part, the test water tank is provided with a thermostat for adjusting the water temperature; the lifting bracket includes lifting columns symmetrically arranged on both sides of the test water tank and a crossbeam connected between the lifting columns; the crossbeam is located directly above the test water tank; the upper fixing part is arranged on the crossbeam for fixing the positive cable; the lower fixing part is arranged at the bottom of the test water tank for fixing the negative cable; wherein the lower fixing part is located directly below the upper fixing part so that the connecting line between the two is perpendicular to the crossbeam.

[0008] In combination with the first aspect, in one feasible manner, the upper fixing member includes an upper fixing block and an upper clamping block fixed to the upper fixing block by bolts; the upper fixing block is fixed to the cross beam, and the upper clamping block clamps the positive cable; the structure of the lower fixing member is the same as that of the upper fixing member, and the lower fixing block of the lower fixing member is fixed to the bottom of the test water tank.

[0009] In combination with the first aspect, in one achievable manner, a liquid level scale is provided on the side wall of the test water tank to observe the depth of the photovoltaic module connector submerged in the water.

[0010] In combination with the first aspect, in one achievable manner, a pressure sensor is provided on the lifting column; and a temperature sensor is provided on the test water tank.

[0011] In a second aspect, an embodiment of the present invention further provides a method for testing a photovoltaic module connector. Using the photovoltaic module connector testing device, the testing method comprises the following steps:

[0012] Step 1: randomly select multiple positive connectors and the same number of negative connectors, arbitrarily match and dock them to form multiple photovoltaic module connector samples, and randomly number them as 1#, 2#, 3#...n#; n is a positive integer;

[0013] Step 2: Connect the positive cable to the positive connector, connect the negative cable to the negative connector, measure the contact resistance of the photovoltaic module connector, and record the initial resistance values ​​as R1, R2, R3...Rn;

[0014] Step 3: Use an insulation withstand voltage tester to test the wet leakage current of the photovoltaic module connector. The initial insulation resistance value of each photovoltaic module connector is not less than 400MΩ.

[0015] Step 4: Perform multiple plugging and unplugging operations on each PV module connector, with the positive connector or negative connector flipped 180 degrees each time for plugging and unplugging, to simulate the actual multiple plugging and unplugging scenario of the PV module connector;

[0016] Step 5: Fix the positive cable to the crossbeam using the upper fixing piece, and then apply clockwise and counterclockwise torsional forces to the negative cable in sequence, and repeat this process multiple times to simulate the environment in which the photovoltaic module connector is subjected to external wind and rain torsional forces.

[0017] Step 6: Fix the negative cable in the test water tank using the lower fixing piece, and ensure that the PV module connector is submerged below the water surface and the negative cable extends out of the test water tank;

[0018] Step 7: Connect the positive cable and the negative cable to the positive pole of the insulation withstand voltage tester, and connect the negative pole of the insulation withstand voltage tester to the water surface of the test water tank;

[0019] Step 8: The lifting column is raised to apply tension to the photovoltaic module connector, simulating an environment in which the photovoltaic module connector is artificially stretched by external wind and rain;

[0020] Step nine, adjust the water temperature in the test water tank, apply 1500-2000V voltage to the PV module connectors in turn to perform a wet leakage current test, and record the insulation resistance values ​​SR1, SR2, SR3...SRn;

[0021] Step 10, test the contact resistance value of the photovoltaic module connector and record it as R11, R21, R31...R3n;

[0022] Step 11, result processing, if the difference of contact resistance value R11-R1, R21-R2, R31-R3... and R3n-Rn are all less than 5mΩ, then the corresponding PV module connector contact resistance is qualified; if the insulation resistance value SR1, SR2, SR3...SRn are all not less than 400MΩ, then the wet leakage current test is qualified; if any one of them is unqualified, then the PV module connector is unqualified;

[0023] If one of the samples fails to meet the requirements, re-sampling and testing will be carried out; if two or more samples fail to meet the requirements, the batch of products will be deemed to be unqualified.

[0024] In combination with the second aspect, in one achievable method, in step five, a torsional force of 0.1±0.05Nm is applied to the negative cable clockwise and maintained for 0.5-1min; then a torsional force of 0.1±0.05Nm is applied to the negative cable counterclockwise and maintained for 0.5-1min; and this is repeated 6-10 times in each direction.

[0025] In combination with the second aspect, in one achievable manner, in step six, the upper edge of the photovoltaic module connector is at least 10 cm below the water surface.

[0026] In combination with the second aspect, in one achievable manner, in step eight, the pulling force applied to the photovoltaic module connector is 5N.

[0027] In combination with the second aspect, in one achievable manner, in step nine, the water temperature of the test water tank is controlled at 85±2° C., and the photovoltaic module connector is immersed in water for 30±5 min.

[0028] Compared with the prior art, the photovoltaic module connector testing device and testing method provided by the present invention have the following beneficial effects: by applying a torsional force to the negative cable connected to the photovoltaic module connector, the deformation caused by the torsional force applied to the photovoltaic module connector by outdoor wind and rain can be simulated; the tension applied to the photovoltaic module connector by the jacking bracket can simulate the influence of the tension applied by outdoor wind, rain, human factors, etc.; by adjusting the water temperature, the influence of the outdoor temperature environment on the photovoltaic module connector can be simulated; therefore, the use of this device can effectively simulate the insulation performance and electrical conductivity of the photovoltaic module connector in the outdoor application environment, thereby realizing the verification of the comprehensive performance of the photovoltaic module connector. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 A schematic diagram of the structure of a photovoltaic module connector testing device provided by an embodiment of the present invention;

[0030] Description of reference numerals:

[0031] 1. Lifting column; 2. PV panel connector; 3. Test water tank; 4. Negative cable; 5. Lower fixings; 6. Insulation withstand voltage tester; 7. Positive cable; 8. Upper fixings; 9. Crossbeam. DETAILED DESCRIPTION

[0032] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0033] See also Figure 1 , the photovoltaic module connector test device provided by the present invention is now described. The photovoltaic module connector test device comprises: a test water tank 3, a lifting bracket, an upper fixing member 8 and a lower fixing member 5, wherein the test water tank 3 is provided with a thermostat for adjusting the water temperature; the lifting bracket comprises lifting columns 1 symmetrically arranged on both sides of the test water tank 3 and a crossbeam 9 connected between the lifting columns 1; the crossbeam 9 is located directly above the test water tank 3; the upper fixing member 8 is arranged on the crossbeam 9 for fixing the positive cable 7; the lower fixing member 5 is arranged at the bottom of the test water tank 3 for fixing the negative cable 4; wherein the lower fixing member 5 is located directly below the upper fixing member 8 so that the connecting line between the two is perpendicular to the crossbeam 9.

[0034] The photovoltaic module connector testing device provided by the present invention has the following beneficial effects compared with the prior art: by applying a torsional force to the negative cable 4 connected to the photovoltaic module connector 2, the deformation caused by the torsional force applied to the photovoltaic module connector 2 by outdoor wind and rain can be simulated; the tension applied to the photovoltaic module connector 2 by the jacking bracket can simulate the influence of the tension applied by outdoor wind, rain, human factors, etc.; by adjusting the water temperature, the influence of the outdoor temperature environment on the photovoltaic module connector 2 can be simulated; therefore, the use of this device can effectively simulate the insulation performance and electrical conductivity of the photovoltaic module connector 2 in the outdoor application environment, and realize the verification of the comprehensive performance of the photovoltaic module connector 2.

[0035] It should be noted that the positive cable 7 and the negative cable 4 of the present application are named because of the positive and negative poles of the connected photovoltaic module connector 2, and there is no difference in the specifications of the cables themselves; at the same time, the negative cable 4 can be fixed on the crossbeam 9, so during testing, the negative connector is located above the positive connector, and the positive cable 7 is fixed in the test water tank 3; similarly, when a torsional force is applied to the photovoltaic module connector 2, the negative cable 4 can also be fixed and the positive cable 7 can be twisted.

[0036] The lifting column of the present application can adopt a common screw lifting mechanism, a worm gear lifting mechanism, or simply adopt an electric push rod, a cylinder, a hydraulic cylinder, a lifting slide rail, etc. to lift the beam 9, thereby driving the positive cable 7 to stretch upward through the lifting of the beam 9, thereby achieving the stretching of the photovoltaic module connector 2.

[0037] In some embodiments, see Figure 1 The upper fixing member 8 includes an upper fixing block and an upper clamping block fixed to the upper fixing block by bolts; the upper fixing block is fixed to the crossbeam 9, and the upper clamping block clamps the positive cable 7; the structure of the lower fixing member 5 is the same as that of the upper fixing member 8, and the lower fixing block of the lower fixing member 5 is fixed to the bottom of the test water tank 3. The lower fixing block can be fixed or bonded to the bottom of the test water tank 3 by screws. Among them, a groove for positioning the positive cable 7 is provided on the upper fixing block, but the depth of the groove is not greater than the diameter of the positive cable 7, so that the upper clamping block can clamp and fix the positive cable 7.

[0038] Optionally, the upper fixing member 8 may also be a suitable line card fixing device publicly sold in the market.

[0039] In some embodiments, see Figure 1 A liquid level scale is provided on the side wall of the test water tank 3 so that the depth of the photovoltaic module connector 2 submerged in the water can be observed intuitively.

[0040] In some embodiments, see Figure 1The lifting column 1 is provided with a pressure sensor for obtaining the tension applied to the photovoltaic module connector 2 during lifting; the test water tank 3 is provided with a temperature sensor for real-time detection of the water temperature in the test water tank 3.

[0041] The thermostat is used to adjust the water temperature of the test water tank 3. Through the change of water temperature, the insulation performance and electrical conductivity performance of the photovoltaic module connector 2 under different ambient temperatures can be obtained. The thermostat is a commonly used device for adjusting temperature. For example, the thermostat can be an electric heating wire arranged at the bottom or side of the test water tank 3.

[0042] In the above embodiments, the description of each embodiment has its own emphasis. For parts that are not described or recorded in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0043] Based on the same inventive concept, the embodiment of the present application also provides a method for testing a photovoltaic module connector. Using the photovoltaic module connector testing device, the testing method includes the following steps:

[0044] Step 1: randomly select 3 positive connectors and the same number of negative connectors, arbitrarily match and dock them to form 3 photovoltaic module connector samples, and randomly number them as 1#, 2#, and 3#;

[0045] Step 2: Peel off 1 cm of insulation at both ends of the positive and negative cables to ensure that the cable core is exposed for testing the contact resistance of the connector; connect the positive cable to the positive connector and the negative cable to the negative connector, measure the contact resistance of the PV module connector, and record the initial resistance values ​​of R1, R2, and R3; contact resistance can be measured with a multimeter, megohmmeter or other measuring instrument;

[0046] Step 3: Use the insulation withstand voltage tester 6 to test the wet leakage current of the photovoltaic module connector at 1500-2000V, and the initial insulation resistance value of each photovoltaic module connector is not less than 400MΩ;

[0047] Step 4: Perform 100 plugging and unplugging operations on each PV module connector, flipping the positive connector 180° each time to simulate multiple plugging and unplugging scenarios of the PV module connector;

[0048] Step 5: Fix the positive cable to the crossbeam using the upper fixings, then apply a torsional force of 0.1 Nm clockwise to the negative cable and maintain for 1 minute; then apply a torsional force of 0.1 Nm counterclockwise to the negative cable and maintain for 1 minute; repeat 10 times in each direction to simulate the environment where the photovoltaic module connector is twisted by external wind and rain;

[0049] Step 6: Fix the negative cable in the test water tank with the lower fixings, and ensure that the PV module connector is submerged 20 cm below the water surface, and the negative cable extends 10 cm outside the test water tank to connect the positive cable of the insulation tester;

[0050] Step 7: Connect the positive cable and the negative cable to the positive pole of the insulation withstand voltage tester, and connect the negative pole of the insulation withstand voltage tester to the water surface of the test water tank;

[0051] Step 8: The lifting column is raised to apply a 5N pulling force to the photovoltaic module connector, simulating an environment where the photovoltaic module connector is artificially stretched by external wind and rain;

[0052] Step nine, adjust the water temperature in the test water tank to 85±2℃, immerse the PV module connector in water for 30 minutes, apply 1500-2000V voltage to the PV module connector to perform a wet leakage current test, and record the insulation resistance values ​​SR1, SR2, and SR3;

[0053] Step 10, test the contact resistance values ​​of the photovoltaic module connectors and record them as R11, R21, and R31;

[0054] Step 11, result processing, if the difference of contact resistance value R11-R1, R21-R2, R31-R3 are all less than 5mΩ, the corresponding PV module connector contact resistance is qualified; if the insulation resistance value SR1, SR2, SR3 are all not less than 400MΩ, the wet leakage current test is qualified; if any one of them is unqualified, the PV module connector is unqualified;

[0055] If one of the samples fails to meet the requirements, re-sampling and testing will be carried out; if two or more samples fail to meet the requirements, the batch of products will be deemed to be unqualified.

[0056] Test data see the table below

[0057]

[0058] The change value is 0.62-0.58=0.04mΩ, which is less than 5mΩ, indicating that the resistance value change is within the qualified range, indicating that the contact resistance value of the photovoltaic module connector is qualified.

[0059] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A photovoltaic module connector testing device, characterized in that: include: A test water tank (3) is provided with a thermostat for adjusting the water temperature; A lifting bracket comprises lifting columns (1) symmetrically arranged on both sides of the test water tank (3) and a crossbeam (9) connected between the lifting columns (1); the crossbeam (9) is located directly above the test water tank (3); an upper fixing member (8), arranged on the crossbeam (9) and used for fixing the positive electrode cable (7); and A lower fixing member (5) is arranged at the bottom of the test water tank (3) and is used to fix the negative cable (4); wherein the lower fixing member (5) is located directly below the upper fixing member (8) so that the line connecting the two is perpendicular to the crossbeam (9).

2. The photovoltaic module connector testing device according to claim 1, characterized in that: The upper fixing member (8) comprises an upper fixing block and an upper clamping block fixed to the upper fixing block by bolts; the upper fixing block is fixed to the cross beam (9), and the upper clamping block clamps the positive cable (7); the structure of the lower fixing member (5) is the same as that of the upper fixing member (8), and the lower fixing block of the lower fixing member (5) is fixed to the bottom of the test water tank (3).

3. The photovoltaic module connector testing device according to claim 1, characterized in that: A liquid level scale is provided on the side wall of the test water tank (3) to observe the depth of the photovoltaic module connector (2) submerged in the water.

4. The photovoltaic module connector testing device according to claim 1, characterized in that: The lifting column (1) is provided with a pressure sensor; and the test water tank (3) is provided with a temperature sensor.

5. A method for testing a photovoltaic module connector, using the photovoltaic module connector testing device according to any one of claims 1 to 4, characterized in that: The test method comprises the following steps: Step 1: randomly select multiple positive connectors and the same number of negative connectors, arbitrarily match and dock them to form multiple photovoltaic module connector samples, and randomly number them as 1#, 2#, 3#...n#; n is a positive integer; Step 2: Connect the positive cable to the positive connector, connect the negative cable to the negative connector, measure the contact resistance of the photovoltaic module connector, and record the initial resistance values ​​as R1, R2, R3...Rn; Step 3: Use an insulation withstand voltage tester to test the wet leakage current of the photovoltaic module connector. The initial insulation resistance value of each photovoltaic module connector is not less than 400MΩ. Step 4: Perform multiple plugging and unplugging operations on each PV module connector, with the positive connector or negative connector flipped 180 degrees each time for plugging and unplugging, to simulate the actual multiple plugging and unplugging scenario of the PV module connector; Step 5: Fix the positive cable to the crossbeam using the upper fixing piece, and then apply clockwise and counterclockwise torsional forces to the negative cable in sequence, and repeat this process multiple times to simulate the environment in which the photovoltaic module connector is subjected to external wind and rain torsional forces. Step 6: Fix the negative cable in the test water tank using the lower fixing piece, and ensure that the PV module connector is submerged below the water surface and the negative cable extends out of the test water tank; Step 7: Connect the positive cable and the negative cable to the positive pole of the insulation withstand voltage tester, and connect the negative pole of the insulation withstand voltage tester to the water surface of the test water tank; Step 8: The lifting column is raised to apply tension to the photovoltaic module connector, simulating an environment in which the photovoltaic module connector is artificially stretched by external wind and rain; Step nine, adjust the water temperature in the test water tank, apply 1500-2000V voltage to the PV module connectors in turn to perform a wet leakage current test, and record the insulation resistance values ​​SR1, SR2, SR3...SRn; Step 10, test the contact resistance value of the photovoltaic module connector and record it as R11, R21, R31...R3n; Step 11, result processing, if the difference of contact resistance value R11-R1, R21-R2, R31-R3... and R3n-Rn are all less than 5mΩ, then the corresponding PV module connector contact resistance is qualified; if the insulation resistance value SR1, SR2, SR3...SRn are all not less than 400MΩ, then the wet leakage current test is qualified; if any one of them is unqualified, then the PV module connector is unqualified; If one of the samples fails to meet the requirements, re-sampling and testing will be carried out; if two or more samples fail to meet the requirements, the batch of products will be deemed to be unqualified.

6. The photovoltaic module connector testing method according to claim 5, characterized in that: In step five, apply a torsional force of 0.1±0.05Nm to the negative cable in a clockwise direction and maintain for 0.5-1min; then apply a torsional force of 0.1±0.05Nm to the negative cable in a counterclockwise direction and maintain for 0.5-1min; repeat 6-10 times in each direction.

7. The photovoltaic module connector testing method according to claim 5, characterized in that: In step six, the upper edge of the PV module connector is at least 10 cm below the water surface.

8. The photovoltaic module connector testing method according to claim 5, characterized in that: In step eight, the pulling force applied to the photovoltaic module connector is 5N.

9. The photovoltaic module connector testing method according to claim 5, characterized in that: In step nine, the water temperature of the test water tank is controlled at 85±2°C, and the PV module connector is immersed in water for 30±5 minutes.

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