Assembly line type assembly and overall installation method of photovoltaic array

Abstract

The invention discloses an assembly line type assembly and integral installation method of a photovoltaic array, which comprises the following steps: based on a mobile work platform or a tool type work platform, arranging a raw material processing section at the feed end of the work platform, arranging an array installation section at one side far away from the feed end, and arranging an assembly section between the raw material processing section and the array installation section; in a photovoltaic array assembly line, assembly personnel successively complete assembly operation beside a turnover array conveying frame according to a line production mode; and in the array mounting section, mounting personnel turn over the photovoltaic array semi-finished product in the turnover array conveying frame and place the photovoltaic array semi-finished product on a translation rod for array mounting, the photovoltaic array semi-finished product is conveyed to a preset mounting position through the translation rod, and mounting of the whole photovoltaic array is completed. According to the assembly line type assembly and overall installation method of the photovoltaic array, due to the fact that assembly of the semi-finished photovoltaic array products is completed on the installation site, the assembled semi-finished array products do not need to be transported, and factory-like assembly becomes feasible.

Description

Technical Field

[0001] The present invention relates to the field of photovoltaic array installation, and more specifically, to a method for assembly and overall installation of a photovoltaic array in an assembly line. Background Art

[0002] During the construction of large-scale centralized photovoltaic power station sites, the main work includes piling, setting up mounting brackets on the top of the piles, installing purlins on the mounting brackets, connecting photovoltaic modules through purlins and other structural parts such as tie bars to form a photovoltaic array, and then collecting the current generated by the photovoltaic modules through the collector line. The most labor-intensive part is the installation and wiring of purlins and modules. The commonly used method is still pure manual work. Workers stand on the scaffolding, first install the mounting bracket on the pile head, then place the purlin on the mounting bracket and complete the extension and adjustment of the purlin, then place the modules, tie bars and other structural materials on the purlin one by one and complete the adjustment and tightening connection, and finally complete the grounding and wiring.

[0003] The problem with this traditional manual operation method is that, first, the labor intensity is high, as all equipment and materials are manually transferred to the installation height by multiple people. Secondly, the working conditions are poor, as workers spend a long time in a working state that is like "standing on a scaffold and looking up to complete a lift." This is not only extremely easy to get tired but also very unsafe, which inevitably leads to low efficiency.

[0004] Another major reason for the low installation efficiency is that the photovoltaic array is installed on the pile foundation, and the positioning error of the pile foundation is usually about 50 mm (the specification stipulates that it should not exceed 50 mm), while the allowable error of the installation hole on the purlin required by the module installation is only 2.5 mm in the east-west direction and 0.5 mm in the north-south direction. It is necessary to adjust the position of the bracket diagonal beam (6) relative to the pile foundation and the bracket diagonal beam (6) relative to the purlin during the installation of the bracket on the top of the pile and the purlin, so that the positioning error of the installed purlin meets the requirements of the module installation. This adjustment process requires workers to have corresponding knowledge and experience accumulation. However, due to the rapid development of the photovoltaic industry, the labor market cannot provide enough skilled workers. Most of the workers entering the industry are transferred from other types of work in the construction industry and do not have the corresponding knowledge and experience of photovoltaic installation, which leads to overall low efficiency. Usually, completing the installation of 5 2*26 arrays is the efficiency limit that can be achieved by an installation team composed of 6 skilled workers working 8 hours a day. An installation team composed of 2 experienced workers and 4 new workers usually cannot complete the installation of 3 2*26 arrays in 8 hours a day.

[0005] The installation method designed by me and patented (patent number 202310917066.6) has been used to show that this method does improve the working conditions of workers, freeing the operators from the working state of "standing on the scaffolding and looking up to complete the snatch". At the same time, the workers complete the connection between the components and the purlins on the pre-installed rack with positioning spacers, thereby eliminating the factors that affect the installation efficiency due to the positioning error of the purlins, thereby effectively improving the work efficiency. Using this method, with the cooperation of a car crane, 2 skilled workers and 4 general workers can complete the installation of 8 2*26 arrays in 8 hours a day. However, this method has poor scene adaptability. First of all, because most of my country's large-scale photovoltaic base projects are built in "sand, Go, and wasteland" areas, most of these areas have frequent strong winds, which have great restrictions on hoisting operations. Secondly, it cannot adapt to the recent construction needs of photovoltaic field projects at sea, on mudflats, and on large water surfaces.

[0006] The patent (patent number 202410775372.5) "Photovoltaic array semi-finished product assembly method" applied by Shanghai Bogao Robot Co., Ltd. uses a factory-based assembly line to complete the assembly of photovoltaic array semi-finished products. The use of manipulators to replace the manual placement of photovoltaic components and other materials, and the use of assembly lines to complete the transfer of materials and semi-finished products can effectively reduce the labor in the material processing stage and thus improve labor productivity. However, in the critical assembly stage, this method still uses the traditional method of workers standing under the photovoltaic components on the assembly line to complete the connection and locking of the components and purlins. The operator needs to be in a working state of raising his hands and looking up for a long time. Workers in this state are very prone to fatigue, which will inevitably lead to overall low efficiency. On the other hand, a common photovoltaic power station site is composed of several square arrays, each of which is composed of several rows of parallel photovoltaic arrays. The spacing between the parallel arrays is usually no more than 14 meters. It is difficult for a material transport truck with a length of 13 meters to turn around at the installation site. The semi-finished photovoltaic arrays are large pieces with a length of more than 30 meters and a width of more than 2.3 meters. To transport such large pieces from the semi-finished product production workshop to the installation site to complete the installation of the semi-finished products, the installation cost will inevitably be high, so the application limitations of this method are very high.

[0007] Given the above background, the problems we need to solve are:

[0008] 1. How to efficiently assemble semi-finished array products at the installation site;

[0009] 2. How to safely and efficiently install the semi-finished photovoltaic array on the pile top bracket on site. Summary of the invention

[0010] An object of the present invention is to solve at least the above problems and / or disadvantages and to provide at least the advantages which will be described hereinafter.

[0011] In order to achieve these purposes and other advantages of the present invention, a method for assembly and overall installation of a photovoltaic array is provided, wherein a mobile working platform is built on a tractor or a tool-type working platform is built on a pile body, and a photovoltaic array assembly line and an array installation section are arranged, so that the assembly and installation operations of the photovoltaic array are completed on the working platform;

[0012] The tool-type working platform can be dragged along the layout direction of the fixed piles;

[0013] The feed end of the work platform is set as the raw material processing section, the side away from the feed end is set as the array installation section, and the area between the raw material processing section and the array installation section is set as the photovoltaic array assembly line;

[0014] Among them, the distribution, transportation, positioning and purlin extension of materials required for photovoltaic array assembly are completed in the raw material processing section;

[0015] In the photovoltaic array assembly line, the photovoltaic modules are pushed one by one into the reversible array conveyor rack by the automatic pushing device and the automatic reversing stepping feeder. The assemblers complete the assembly work in a flow-line manner next to the reversible array conveyor rack.

[0016] In the array installation section, the installers flip the semi-finished photovoltaic array in the flippable array conveyor rack and place it on the translation rod for array installation, so as to deliver the semi-finished photovoltaic array to the predetermined installation position through the translation rod, thereby completing the installation of the entire photovoltaic array.

[0017] Preferably, the raw material processing section is provided with automatic pushing equipment, purlin extension and conveyor line. When the tool-type working platform is applied to land high piles, tidal flats and water surface projects, the raw material processing section is also provided with photovoltaic module automatic lifting equipment matched with the automatic pushing equipment. When the working platform is mobile, the front end of the automatic pushing equipment is fed manually or by an automatic reversing stepping feeder.

[0018] The photovoltaic array assembly line is composed of a reversible array conveying frame and an automatic pushing device that cooperate with the purlin conveying line to form an assembly production line, so that the photovoltaic components are pushed one by one into the reversible array conveying frame through the automatic pushing device, and the connection and tightening operations of the purlins and photovoltaic components, the DC cable wiring operations, the grounding wire installation operations, and the tensioning installation operations are completed to obtain a semi-finished photovoltaic array.

[0019] Preferably, the reversible array conveyor rack can be arranged vertically or horizontally;

[0020] Among them, when the reversible array conveyor frame is arranged horizontally, the reversing mode of the automatic reversing stepping feeder is to rotate 180 degrees horizontally in situ, and the stepping pushing mode is that the photovoltaic module automatic lifting device lifts the photovoltaic modules to the predetermined pushing station one by one at a set frequency to complete the feeding operation;

[0021] When the reversible array conveyor rack is arranged vertically, the reversing method of the automatic reversing stepping feeder is to rotate 180 degrees vertically on the spot. The stepping pushing method is that the photovoltaic components are stacked under the constraints of the clamping conveyor belt in the equipment, and the photovoltaic components are pushed one by one to the predetermined pushing station at a set frequency to complete the feeding operation.

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

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

[0024] Preferably, a matching winch and drum are provided in the lower base of the reversible array conveyor rack. When the steel wire rope on the drum is passed around the guide pulley on the upper part of the reversible array conveyor rack and then connected to the array semi-finished product through a hook, the photovoltaic array semi-finished product assembled in the array conveyor rack can be flipped onto the translation rod under the traction of multiple steel wire ropes.

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

[0026] Among them, the number of translation rods is consistent with the number of brackets on the top of the pile foundation;

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

[0028] Preferably, when the translation rod needs to be flipped into place, a traction type can be selected, wherein the traction type translation rod comprises: a straight rod, a traction rope, and a trolley and a stopper that moves linearly on the straight rod through the traction of the traction rope;

[0029] After the semi-finished array falls onto the trolley, the winch controls the traction of the wire rope, and the trolley carries the semi-finished photovoltaic array to the set position on the straight pole and stops.

[0030] Preferably, after the array installation section completes the installation of two adjacent photovoltaic arrays at the same time, the work platform moves once;

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

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

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

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

[0035] NS2, the first train on the south side, has completed assembly at the assembly section;

[0036] NS3. Connect the wire rope hook to the semi-finished array in the conveyor frame, place the first row on the south side on the trolley of the translation rod, start the winch to carry the trolley to the front end of the translation rod, release the constraint of the trolley on the translation rod on the photovoltaic array, let the photovoltaic array fall on the translation rod and temporarily fasten it, and then retract the trolley;

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

[0038] NS5. After the wire rope hook is connected to the root of the translation rod, the connection between the root of the translation rod and the platform is released. Under the action of gravity and the traction of the wire rope, the translation rod and the array on it rotate the entire array on the south side to the designed inclination angle;

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

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

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

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

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

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

[0045] BS4. Install the purlin support on the bracket of the pile head, lower the translation rod, place the first row on the north side flat on the bracket diagonal beam and connect and tighten it with the purlin support, then remove the translation rod;

[0046] BS5. After the second row of the north side is assembled, connect the wire rope hook to the semi-finished photovoltaic array in the conveyor frame, start the winch to place the semi-finished array on the pile head bracket, complete the connection and tightening of the purlins, purlin supports and brackets, and complete the installation of the entire north array after installing other array parts such as tie rods.

[0047] The present invention includes at least the following beneficial effects: First, because the assembly of the photovoltaic array semi-finished products is completed at the installation site, the assembled array semi-finished products do not need to be transported, making factory assembly feasible. Secondly, by organizing an assembly line-type work method on the work platform to complete the assembly of the photovoltaic array semi-finished products, not only the assembly operation of the photovoltaic array semi-finished products is standardized and orderly, thereby improving the assembly quality and overall efficiency, but also the installation workers are transformed from the working state of "standing on the scaffolding and looking up to complete the snatch" to standing next to the assembly line to screw in, which completely changes the workers' working conditions. Thirdly, since the corresponding mechanical equipment is used in the main process, the labor intensity of the workers is greatly reduced. Finally, since the assembly work is all carried out in the conveyor rack, the assembly process does not need to consider and adjust the installation error, which makes the assembly work a simple repetitive labor, thereby reducing the requirements for the workers' relevant experience and knowledge.

[0048] Other advantages, objectives and features of the present invention will be embodied in part through the following description, and in part will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 This is a schematic diagram of the process plan in which two north and south arrays of the tidal flat project share one platform in an embodiment of the present invention;

[0050] Figure 2 This is a schematic diagram of the longitudinal section of the process in which the two north and south arrays of the tidal flat project share a platform in an embodiment of the present invention.

[0051] Figure 3 This is a schematic diagram of the installation step NS1 of the south array of the tidal flat project in an embodiment of the present invention;

[0052] Figure 4 This is a schematic diagram of the installation step NS2 of the south array of the tidal flat project in an embodiment of the present invention;

[0053] Figure 5 This is a schematic diagram of one of the steps NS3 of installing the south array of the tidal flat project in an embodiment of the present invention;

[0054] Figure 6 Another schematic diagram of the south array installation step NS3 of the tidal flat project in an embodiment of the present invention;

[0055] Figure 7 Another schematic diagram of the south array installation step NS3 of the tidal flat project in an embodiment of the present invention;

[0056] Figure 8 Another schematic diagram of the south array installation step NS3 of the tidal flat project in an embodiment of the present invention;

[0057] Fig. 9 This is a schematic diagram of the installation step NS5 of the south array of the tidal flat project in an embodiment of the present invention;

[0058] Fig.10 This is a schematic diagram of the installation step NS6 of the south array of the tidal flat project in an embodiment of the present invention;

[0059] Fig.11 This is a schematic diagram of the south array installation step NS7 of the tidal flat project in an embodiment of the present invention;

[0060] Fig.12 This is a schematic diagram of the installation step BS1 of the north array of the tidal flat project in an embodiment of the present invention;

[0061] Fig.13 This is a schematic diagram of the installation step BS2 of the north array of the tidal flat project in an embodiment of the present invention;

[0062] Fig.14 This is a schematic diagram of step BS3 of installing the north array of the tidal flat project in an embodiment of the present invention;

[0063] Fig.15 This is a schematic diagram of step BS4 of installing the north array of the tidal flat project in an embodiment of the present invention;

[0064] Fig.16 This is a schematic diagram of step BS5 of installing the north array of the tidal flat project in an embodiment of the present invention;

[0065] Fig.17 This is a schematic diagram of step BS6 of installing the north array of the tidal flat project in an embodiment of the present invention;

[0066] Fig.18 It is a schematic diagram of the installation step NS7 of the north array of the tidal flat project in an embodiment of the present invention;

[0067] Fig.19 This is a schematic diagram of a process plan of a vehicle-mounted mobile work platform in an embodiment of the present invention;

[0068] Fig. 20 This is a schematic longitudinal section diagram of a vehicle-mounted mobile work platform in an embodiment of the present invention;

[0069] Fig.21 This is an installation schematic diagram of S1 in an installation method of assembling a semi-finished array product directly on a translation rod in an embodiment of the present invention;

[0070] Fig. 22 This is a schematic diagram of the installation of S2 in an installation method of directly assembling a semi-finished array product on a translation rod in an embodiment of the present invention;

[0071] Fig.23 This is an installation schematic diagram of S3 when the installation method of directly assembling the semi-finished array product on the translation rod in an embodiment of the present invention;

[0072] Fig.24 This is an installation schematic diagram of S4 in an installation method of assembling a semi-finished array product directly on a translation rod in an embodiment of the present invention;

[0073] Fig.25 This is an installation schematic diagram of S5 when the installation method of assembling the semi-finished array product directly on the translation rod in an embodiment of the present invention;

[0074] Fig.26 This is a schematic diagram of the installation of S6 in an installation method of assembling a semi-finished array product directly on a translation rod in an embodiment of the present invention;

[0075] Fig. 27 This is an installation schematic diagram of S7 in an installation method of assembling a semi-finished array product directly on a translation rod in an embodiment of the present invention;

[0076] Fig.28 This is an installation schematic diagram of S8 in an installation method of assembling a semi-finished array product directly on a translation rod in an embodiment of the present invention;

[0077] Fig.29 This is a schematic diagram of the installation of S9 when the installation method of assembling the semi-finished array product directly on the translation rod in an embodiment of the present invention;

[0078] Fig.30 This is an installation schematic diagram of S10 when the installation method of directly assembling the semi-finished array product on the translation rod in an embodiment of the present invention;

[0079] Fig.31 This is a cross-sectional schematic diagram of a vehicle-mounted mobile work platform in an embodiment of the present invention;

[0080] Fig.32 This is a diagram of a translation rod assembly with a traction trolley in an embodiment of the present invention;

[0081] Fig.33 for Fig.32 The enlarged schematic diagram of the middle A part;

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

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

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

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

[0086] For specific engineering projects, the assembly method or installation method of the present invention can also be used separately. For example, in the construction of land projects, the installation method of the present invention can be used alone to drag the pre-assembled array semi-finished products onto the bracket for installation. In the construction of projects with good transportation conditions, the assembly method of the present invention can be used separately to first assemble the photovoltaic array semi-finished products in the workshop, transport the semi-finished products to the installation site, and then use the installation method of the present invention to install the semi-finished products on the bracket.

[0087] like Figure 1-Figure 2 As shown, in the raw material processing section, a purlin extension and conveyor line (13) is provided, and the conveyor line, the reversible array conveyor frame and the automatic pushing device constitute an assembly production line. The photovoltaic modules (1) are pushed into the reversible array conveyor frame one by one by the automatic pushing device to be connected and fastened with the purlins (2). The assembly workers stand beside the production line to complete the connection and fastening between the purlins (2) and the modules and other assembly work. The purlin extension and conveyor line can be a simple bracket unpowered roller line, and the roller surface height is consistent with the height and plane position of the purlin (2) in the reversible array conveyor frame (14). The purlin (2) is assembled with purlin joints and extended at this station. The extended purlin (2) enters the reversible array conveyor frame (14) along with the semi-finished array products assembled at the front end.

[0088] like Figure 1-Figure 2 As shown, when a high-pile tool-type mobile platform is used in land high-pile and tidal flat projects, a photovoltaic component automatic lifting device (11) is used to feed materials in the material processing section to lift the photovoltaic component (1) from the bottom of the platform to the assembly station. The photovoltaic component automatic lifting device (11) can be linked with the automatic pushing device (12). When the photovoltaic component (1) is lifted to a set height, the automatic pushing device (12) is triggered to start, and the photovoltaic component (1) is pushed into the flip array conveyor (14). The photovoltaic component automatic lifting device (11) can be a simple lifting machine. The main raw materials such as the photovoltaic component (1) for assembling the array are lifted from the bottom of the pile (ground or water surface) to the working platform through the lifting and conveying device. The lifting machine can be linked with the automatic pushing device (12). When the photovoltaic component (1) is lifted to a set height, the automatic pushing device (12) is triggered to push the photovoltaic component (1) into the flip array conveyor (14). When used to lift other materials such as support materials, tie bars, cables, etc., when it is lifted to a set parking position, the stop switch is triggered to stop and unload. The photovoltaic module automatic lifting device (11) can be telescopic, and its length can be adjusted to change with the tidal water level.

[0089] Furthermore, an automatic pushing device (12) is arranged on the upper part of the raw material processing section platform. When used as a mobile working platform mounted on a land vehicle, the pushing device moves at the same frequency as the automatic reversing stepping feeder (17) according to a set frequency; when used for land high piles, tidal flats and water surface projects, it can be linked with the (12) photovoltaic module automatic lifting device (11).

[0090] like Fig.19 As shown, when the raw material processing section is arranged on a mobile work platform, the front end of the automatic push device can be a manual placement of components, or an automatic reversing stepping feeder (17) can be set to feed it. The device and the automatic push device (12) operate at the same frequency. After the current photovoltaic component (1) enters the reversible array conveyor (14), the components in the automatic reversing stepping feeder (17) will send the photovoltaic components (1) one by one to the workstation between the automatic push device (12) and the reversible array conveyor (14) under the action of the clamping transmission belt. When it is necessary to change the direction of the positive and negative poles of the component in the array according to the designed string wiring requirements, the reversing motor of the component automatic reversing feeder can be started to realize the component reversal. Specifically, the reversing method of the automatic reversing stepping feeder (17) is to rotate 180 degrees vertically in situ, and the stepping pushing method is that the photovoltaic components are stacked under the constraint of the clamping conveyor belt in the equipment, and the photovoltaic components (1) are pushed to the pushing station one by one at a set frequency.

[0091] In another possible application scenario, Fig.19 As shown, when the array can be flipped and the array conveyor is arranged horizontally, the reversing method of the automatic reversing step feeder (17) is to rotate 180 degrees horizontally in situ. At this time, the step feeding method is that the lifting platform lifts the photovoltaic components (1) one by one to the height of the component pushing device at a set frequency.

[0092] like Fig. 20 As shown, a photovoltaic module component box flipping mechanism (18) is arranged on the upper part of the raw material processing section platform (the photovoltaic module component box flipping mechanism is mainly used for the mobile working platform and is optional). The unopened photovoltaic module raw material box (3) is flipped from a flat position to a vertical position through the device and then pushed into the automatic reversing stepping feeder (17).

[0093] like Figure 2 , Fig. 20 As shown, a reversible array conveyor frame (14) is provided in the assembly section. The reversible array conveyor frame can be arranged vertically or horizontally. When arranged vertically, the upper and lower ends of the reversible array conveyor frame are provided with a grooved guide rail group for the photovoltaic array to run therein, and the photovoltaic component array is pulsatingly conveyed in the grooved guide rail group.

[0094] The same side of the grooved guide rail group (towards the purlin (2)) is a movable edge that can be moved or rotated. By controlling the movable edge, the photovoltaic array in the guide rail can be constrained or released on the side (that is, by moving the side, the constraint on the array semi-finished product in the guide rail is released, so that the array semi-finished product can be separated from the reversible array conveying rack (14)).

[0095] At the same time, the lower roller of the lower grooved guide rail is rotatable. When the array semi-finished product is flipped and separated from the flippable array conveyor frame (14), the lower roller rotates with the array, that is, the lower grooved guide rail can rotate 90 degrees outside the axial plane. When the photovoltaic array in the guide rail is flipped, the entire lower grooved guide rail can rotate accordingly with the photovoltaic array.

[0096] In addition, the grooved rail group can be arranged on one side of the reversible array conveyor frame, or on both sides of the reversible array conveyor frame at the same time, so that the installation of photovoltaic arrays on both sides can be completed by using one reversible array conveyor frame.

[0097] A reel driven by a winch is arranged in the lower base of the reversible array conveying frame (14), and a plurality of guide pulleys (25) (such as Fig.34 ), and the guide pulley cooperates with each other. When it is necessary to flip the photovoltaic array in the flippable array conveying frame to the translation rod outside the plane of the flippable array conveying frame, the steel wire rope connected to the drum and passing through the guide wheel provides traction for the flipping of the photovoltaic array. That is, when the steel wire rope on the drum is passed around the upper guide pulley and connected to the purlin (2) through the hook, it can be used as a traction rope for flipping the array semi-finished product off the flippable array conveying frame (14), so that the array semi-finished product assembled in the conveying frame slowly flips and falls on the translation rod (15) under the traction of multiple steel wire ropes. When the steel wire rope on the drum is connected to the traction trolley (or traction chain) on the translation rod (15), it can provide traction.

[0098] The electric wire rope drum in the lower base of the flippable array conveyor frame (14) is driven and controlled by an electric winch and can serve as a traction power source for the trolley on the translation rod (15) (optionally, when the translation rod is a hydraulic or electric multi-section telescopic type, there is no need to traction the trolley). When the traction wire rope of the trolley on the translation rod (15) is connected to the drum through a hook, the trolley can be towed to run on the translation rod (15).

[0099] The reversible array conveyor (14) is a multi-section combined structure, and the reels in the base are connected by a flexible coupling, which is convenient for processing, transportation and transfer when used on site. In actual application, the photovoltaic array semi-finished products that have been assembled in the reversible array conveyor can be directly placed flat on the pile head bracket to be installed under the traction of the wire rope, and then the installation personnel can complete the connection and tightening. It can also be placed flat on the translation rod (15) and pulled to the array installation position at the far end of the translation rod by a trolley (or chain) running on the translation rod (15), and then the inclination of the translation rod (15) is adjusted to make the array semi-finished product fall on the pile head bracket, and then the installation workers can complete the connection and tightening of the array semi-finished product and the pile head bracket. The assembly section is equipped with multiple stations, which are: the assembly and purlin (2) connection and tightening station, the reinforcement and other structural components installation station, the wiring station, and the grounding connection station. When a row of photovoltaic modules (1) and purlins (2) are pulsed into corresponding workstations in the reversible array conveyor frame (14) in sequence, the assembling workers complete the corresponding assembly work in sequence.

[0100] In actual application, the translation rod (15) can be a traction type or a multi-section hydraulic telescopic type. When a traction type translation rod is used, the root of the translation rod is connected to the lower rotating shaft of the photovoltaic array conveyor frame, and the upper part can be supported on the bracket by being attached to the pile head bracket. When the construction sequence of installing the pile head bracket after the photovoltaic array is in place is adopted, a hinge support can be installed on the platform as a support for the translation rod (15). There are two methods for placing the semi-finished photovoltaic array on the translation rod: Figure 12-Figure 18 , Figure 31-Figure 32 For the direct positioning method using the translation rod (15) ( Fig.32 In the figure, (19) is a positioning clip of the hinge support, and (20) is a steel wire rope). Fig.33 In the embodiment, the angle steel (22) is arranged on the trolley (21) and matches the spatial position of the sandalwood bar (2), and a hook hole (23) matching the wire rope hook is arranged on the angle steel (22), and the trolleys (21) at the same spatial position are connected as a whole through a connecting rod (24), and the translation rods at the east and west ends are made into a sinking structure in actual application, so that the array semi-finished product on the trolley maintains a relative position with the trolley. Fig.34 A spring (26) and a spring check mechanism (27) are also provided, and their function is that when the trolley runs to the set position at the end of the translation rod and triggers the limiter to stop, the check mechanism can prevent the trolley from sliding down along the translation rod.

[0101] Figure 3-Figure 11 , Figure 21-Figure 30 It is a method of flipping the translation rod around the hinge support into position.

[0102] like Figure 2As shown, the number of the translation rod (15) and the pile head mounting bracket is consistent so that the structural stress state of the array is consistent with the design. In actual application, the translation rod (15) can be a multi-section telescopic type similar to the automobile crane arm. When a multi-section telescopic structure is adopted, an anti-slip baffle is provided on the translation rod where it contacts the array purlin. The translation rod (15) can also be composed of a straight rod and a trolley pulled by a steel wire rope on the straight rod connected to a drum in the base of the flip array conveyor frame (14). The root of the translation rod (15) is connected to the base of the flip array conveyor frame (14) for easy disassembly and assembly.

[0103] like Figure 1 , Figure 3-Figure 11 As shown, the hinge support (16) installed on the flippable array conveyor frame (14) serves as a rotating support for the translation rod (15) when the array is flipped in place for installation.

[0104] Example 1

[0105] This embodiment is a centralized photovoltaic project with fixed piles on coastal beaches. Each array consists of 2 columns, each column consists of 26 580-watt photovoltaic modules with a size of 2278*1134 and two purlins with a length of 30.2 meters after extension. The designed array layout is shown in the figure below. Figure 1 As shown, the north-south spacing between arrays is 6.4 meters, and the pile spacing is 4 meters. The designed bottom elevation of the array components is 7.9 meters, the designed highest tide level is 5.31 meters, and the tidal flat ground elevation is about 3 meters. We use a tool-type work platform supported by the pile body of the engineering pile. Due to the bearing capacity limit of the pile foundation, the raw materials cannot be piled up in boxes or bundles on the platform. Therefore, we use the high tide period to transport the photovoltaic components, brackets, purlins and other raw materials from the dock to the bottom of the pile where the array is to be installed, and then use the hoist to lift the components and other materials onto the platform.

[0106] According to the method of the present invention, the platform is moved once to complete the installation of two adjacent arrays, wherein the south array adopts the method of turning the semi-finished array around the hinge support to complete the installation of the array. The working mode of the method of turning the semi-finished array around the hinge support includes:

[0107] NS1, such as Figure 3 , the hinge support (16) and the translation rod (15) of the translation rod are installed at the position of the south side of the platform near the south array pile head. In this process, the position of the flippable array conveyor frame (14) on the platform needs to be adjusted to meet the design requirements of the array installation position. The hoop and short column (5) of the pile head structure support are installed at the south array pile head according to the design.

[0108] NS2, such as Figure 4 The first row on the south side is assembled in the assembly section. The assembly process includes:

[0109] NS20, placing purlins on the platform purlin extension and conveyor line (13) and assembling joint parts;

[0110] NS21. Use the photovoltaic module automatic lifting equipment installed on the platform to lift the module from the beach ground (water surface at high tide) to the pushing position on the platform, and connect and tighten the purlin end to the first module;

[0111] NS22, start the automatic pushing device to push the photovoltaic modules one by one into the upper and lower guide rails of the reversible array conveyor frame (14) and drive the purlins to enter synchronously. Each workstation in the assembly section successively performs the connection and fastening of the photovoltaic modules and the purlins, DC line wiring, grounding connection, and reinforcement installation, until the assembly of the semi-finished array of the first row (26 photovoltaic modules) on the south side is completed and transported to the terminal of the reversible array conveyor frame (14);

[0112] NS3, such as Figure 5 , connect the wire rope hook to the array purlin in the conveyor frame, release the constraint of the guide rail edge on the array, start the winch to put the first row on the south side onto the trolley of the translation rod;

[0113] like Figure 6 , the trolley drags the first row on the south side into place, places the first row on the south side flat on the translation rod and temporarily fixes it, retracts the trolley, and assembles the second row on the south side on the flip array conveyor rack;

[0114] like Figure 7 , connect the wire rope hook and the purlin to put the second row on the south side onto the translation rod trolley;

[0115] like Figure 8 , the trolley drags the second column into place, places the second column flat on the translation rod and temporarily fastens it, and retracts the trolley; the specific operation process includes:

[0116] NS30, connect the reel wire rope hook at the bottom of the reversible array conveyor frame (14) to the purlin, release the constraints of the upper and lower grooved guide rails of the reversible array conveyor frame (14) on the array, so that the array semi-finished product is placed flat on the trolley on the translation rod under the traction of the reel wire rope, then remove the hook, start the winch to drive the reel to recycle the wire rope;

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

[0118] NS32. Release the constraints of the trolley on the translation rod on the array, allow the array to fall on the translation rod and temporarily fasten it, and then retract the trolley.

[0119] NS4. Repeat NS3 to complete the assembly of the second row on the south side (26 semi-finished photovoltaic module arrays) and transport them to their destination.

[0120] NS5, such as Fig. 9 , connect the wire rope hook to the translation rod, and rotate the entire array on the south side to the designed inclination angle. The rotation is achieved by starting the winch at the bottom of the flippable array conveyor frame, so that the translation rod is slowly flipped to the designed inclination angle under the traction of the wire rope;

[0121] NS6, such as Fig.10 , install the structural support on the pile head on the south side, tighten the connecting bolts between the purlin purlin support and the structural support on the semi-finished south array, install the reinforcement and wiring, and complete the installation of the south array (2*26 photovoltaic modules). Retract the wire rope hook on the translation rod;

[0122] NS7, such as Fig.11 , remove the south translation rod and hinge support, and install the north translation rod to facilitate the installation of the north array.

[0123] Then the north array is installed. The north array uses the translation rod direct placement method to complete the installation of the semi-finished photovoltaic array. The working method of the translation rod direct placement method includes:

[0124] BS1, such as Fig.12 , adjust the position of the flippable array conveyor frame (14) on the platform and complete the assembly of the first row on the north side;

[0125] BS2, such as Fig.13 , connect the hook on the wire rope to the first row of purlins on the north side of the reversible array conveyor frame, place the first row on the north side flat on the trolley of the translation rod, and retract the wire rope;

[0126] BS3, such as Fig.14 , connect the hook on the wire rope to the trolley on the translation rod, start the winch to drag the first column on the north side to the installation position at the front end of the translation rod;

[0127] BS4, such as Fig.15 , install the purlin support on the structural support of the pile head, lower the front end of the translation rod so that the first row on the north side is placed flat on the pile head structural support, and connect and tighten the pile head structural support with the purlin support, complete the connection and tightening of the support and the first row on the north side, then retract the wire rope and remove the translation rod;

[0128] BS5, such as Fig.16 , complete the assembly of the second column on the north side on the assembly rack;

[0129] BS6, such as Fig.17 , connect the wire rope hook to the second row of purlins on the north side, and send the second row on the north side horizontally to the inclined beam of the bracket;

[0130] BS7, such as Fig.18 , tighten the fasteners between the purlins and the purlin brackets on the bracket diagonal beam to complete the north array installation.

[0131] Example 2

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

[0133] S1, such as Fig.21 , the platform is moved to the intended installation position, and after adjustment, the platform is connected and fastened to the pile body using a clamp;

[0134] S2, such as Fig. 22 , the hinged support extends from the platform, and the hoop short column of the structural support is installed at the pile head;

[0135] S3, such as Fig.23 , install the translation rod on the platform hinge support, and connect the drum wire rope with the trolley on the translation rod;

[0136] S4, such as Fig.24 , place the purlins and components on the trolley of the translation rod to complete the first row assembly;

[0137] S5, such as Fig.25 , drag the first column upwards and assemble the second column;

[0138] S6, such as Fig.26 , install the diagonal beams and braces on the array, and install the tie bars and connections between the two columns;

[0139] S7, such as Fig. 27 , start the winch, drag the two columns as a whole to the designed position on the top of the translation rod and temporarily connect and tighten them;

[0140] S8, such as Fig.28 , release the connection between the root of the translation rod and the platform, connect the drum and the root of the translation rod with a steel wire rope, and pull the translation rod to flip to the designed inclination angle;

[0141] S9, such as Fig.29 , connect the pile head short column and the inclined beam, the diagonal brace and the clamp; lock the clamp and the cross arm to complete the installation of the entire array;

[0142] S10, such as Fig.30 , release the drum wire rope and dismantle the translation rod; after retracting the hinged support, release the connection between the platform and the pile body, and transport the platform to the next array installation location.

[0143] The above solution is only an illustration of a preferred embodiment, but is not limited thereto. When implementing the present invention, appropriate replacement and / or modification can be performed according to user needs.

[0144] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and the embodiments. It can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily realized. Therefore, without departing from the general concept defined by the claims and equivalent scope, the present invention is not limited to the specific details and the illustrations shown and described here.

Claims

1. A method for assembly and overall installation of a photovoltaic array, characterized in that: A mobile work platform is built based on a tractor or a tool-type work platform is built on the pile body, and the photovoltaic array assembly line and array installation section are arranged, so that the assembly and installation of the photovoltaic array can be completed on the work platform; The tool-type working platform can be dragged along the layout direction of the fixed piles; The feed end of the work platform is set as the raw material processing section, the side away from the feed end is set as the array installation section, and the area between the raw material processing section and the array installation section is set as the photovoltaic array assembly line; Among them, the distribution, transportation, positioning and purlin extension of materials required for photovoltaic array assembly are completed in the raw material processing section; In the photovoltaic array assembly line, the photovoltaic modules are pushed one by one into the reversible array conveyor rack by the automatic pushing device and the automatic reversing stepping feeder. The assemblers complete the assembly work in a flow-line manner next to the reversible array conveyor rack. In the array installation section, the installers flip the semi-finished photovoltaic array in the flippable array conveyor rack and place it on the translation rod for array installation, so as to deliver the semi-finished photovoltaic array to the predetermined installation position through the translation rod, thereby completing the installation of the entire photovoltaic array.

2. The method for assembly line and overall installation of a photovoltaic array according to claim 1, characterized in that: The raw material processing section is provided with automatic pushing equipment, purlin extension and conveyor line. When the tool-type working platform is applied to land high piles, tidal flats and water surface projects, the raw material processing section is also provided with photovoltaic module automatic lifting equipment matched with the automatic pushing equipment. When the working platform is mobile, the front end of the automatic pushing equipment is fed manually or by an automatic reversing stepping feeder. The photovoltaic array assembly line is composed of a reversible array conveying frame and an automatic pushing device that cooperate with the purlin conveying line to form an assembly production line, so that the photovoltaic components are pushed one by one into the reversible array conveying frame through the automatic pushing device, and the connection and tightening operations of the purlins and photovoltaic components, the DC cable wiring operations, the grounding wire installation operations, and the tensioning installation operations are completed to obtain a semi-finished photovoltaic array.

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

4. The reversible array conveyor as claimed in claim 3, characterized in that: A guide pulley is provided at the top of the reversible array conveying frame and at the corresponding position of the translation rod, which is used to pull the semi-finished photovoltaic array in the reversible array conveying frame and lay down the semi-finished photovoltaic array; the upper and lower ends of the reversible array conveying frame are respectively provided with a guide rail group for the photovoltaic array to run therein, and the side edge of the guide rail group facing the purlin side is set as a movable edge that can move or rotate, so as to realize the switching of the constraint state of the photovoltaic array in the guide rail by adjusting the state of the movable edge; The guide rail group may be arranged on both sides of the reversible array conveying rack, so as to complete the installation of two adjacent photovoltaic arrays using one reversible array conveying rack.

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

6. The photovoltaic array assembly line and overall installation method according to claim 1, characterized in that: The semi-finished photovoltaic arrays assembled in the assembly section are moved from the assembly position to the pile top installation position by means of translation rods; Among them, the number of translation rods is consistent with the number of brackets on the top of the pile foundation; The translation rod can be a multi-section hydraulic telescopic type, or a traction type.

7. The photovoltaic array assembly line and overall installation method as claimed in claim 6, characterized in that: When the translation rod needs to be flipped into place, a traction type can be selected, wherein the traction type translation rod comprises: a straight rod, a traction rope, and a trolley and a stopper that moves linearly on the straight rod through the traction of the traction rope; After the semi-finished array falls onto the trolley, the winch controls the traction of the wire rope, and the trolley carries the semi-finished photovoltaic array to the set position on the straight pole and stops.

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

9. The overall installation method of a photovoltaic array according to claim 8, characterized in that: The working method of the translation rod flipping around the hinge support includes: NS1. Adjust the position of the flip array conveyor frame on the platform, and install the hinge support and the translation rod that match the translation rod at the position of the array near the pile head on the south side of the platform; NS2, the first train on the south side, has completed assembly at the assembly section; NS3. Connect the wire rope hook to the semi-finished array in the conveyor frame, place the first row on the south side on the trolley of the translation rod, start the winch to carry the trolley to the front end of the translation rod, release the constraint of the trolley on the translation rod on the photovoltaic array, let the photovoltaic array fall on the translation rod and temporarily fasten it, and then retract the trolley; NS4, repeat NS3 to complete the assembly of the second column on the south side and transport it to its place; NS5. After the wire rope hook is connected to the root of the translation rod, the connection between the root of the translation rod and the platform is released. Under the action of gravity and the traction of the wire rope, the translation rod and the array on it rotate the entire array on the south side to the designed inclination angle; NS6. Install the bracket on the south pile head, tighten the connecting bolts between the purlin and the purlin bracket, complete the south array installation, and retract the wire rope hook on the translation rod; NS7, remove the south translation rod and hinge support.

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

Images