Matching test method for different types of photovoltaic module connectors

Abstract

The invention provides a matching test method for different types of photovoltaic module connectors, which belongs to the technical field of photovoltaic module manufacturing, and is characterized in that different types of positive and negative electrode connectors are randomly matched, and an accelerated aging test, a temperature shock test, a temperature rise test, a composite illumination test and a saline corrosion test are sequentially carried out in a simulated environment. Contact resistance measurement and wet leakage current test are carried out on each connector, and contact resistance values and insulation resistance values are recorded one by one; a contact resistance value obtained by testing is compared with an initial resistance value, an insulation resistance value of the connector after testing is obtained, and whether a product is qualified or not is judged through comparison, so that the matching performance and the safety performance of mixed insertion of connectors of different models can be effectively verified, unqualified products are removed in time, the unqualified products are prevented from being applied to a photovoltaic power station, and the quality of the photovoltaic power station is improved. And safety guarantee is provided for operation of the photovoltaic power station.

Description

Technical Field

[0001] The invention belongs to the technical field of photovoltaic assembly manufacturing, and in particular relates to a matching test method for connectors of photovoltaic assemblies of different models. Background Art

[0002] Connectors are important components widely used in various industrial fields. They are mainly used to establish electrical connections between different electrical components to realize signal and power transmission functions. As a transmission medium, connectors play an important role in the entire electrical circuit. The performance of connectors will directly affect the transmission quality of power and signals.

[0003] The actual phenomenon that may exist in photovoltaic power stations is that the connection box connectors of different manufacturers are paired, and the thermal, mechanical and electrical properties of different connectors after pairing, as well as the outdoor environment affecting their appearance and contact resistance changes, are likely to cause safety accidents such as connector deformation and burning. At present, relevant tests only conduct independent tests on the performance of the same type of connectors, and cannot meet the performance test of different types of connectors from different manufacturers after pairing. Summary of the invention

[0004] The embodiment of the present invention provides a method for testing the matching of connectors of photovoltaic modules of different models, aiming to verify the matching of connectors of different models and the safety performance of mixed insertion of connectors of different models.

[0005] To achieve the above object, the technical solution adopted by the present invention is: to provide a method for testing the matching of connectors of photovoltaic modules of different models, the method comprising the following steps: Step 1: Sample preparation Randomly select multiple positive connectors from the A model connector, and randomly select the same number of negative connectors from the B model connector, and arbitrarily form multiple matching connectors, and randomly number them as 1#, 2#, 3#...n#; n is a positive integer; Step 2: Initial value measurement Measure the contact resistance of the matching connectors and record the initial contact resistance values ​​as R1, R2, R3, ..., Rn; Perform a 1500-2000V wet leakage current test on the matching connectors, and record the insulation resistance values ​​as JY1, JY2...JYn. The insulation resistance value of each connector shall not be less than 400MΩ; Apply 310N pulling force to each mating connector and it still remains interlocked; Step 3: Environmental simulation test The connectors that have passed the test in step 2 are divided into five groups in order of number, each group includes at least two connectors, and the accelerated aging test, temperature shock test, temperature rise test, composite illumination test and salt water corrosion test are carried out in turn. Each connector is subjected to contact resistance measurement and wet leakage current test, and the contact resistance value and insulation resistance value are recorded one by one; Step 4: Result processing Compare the contact resistance value obtained by the test in step 3 with the initial resistance value obtained in step 2. If the contact resistance value of the matched connector is less than 0.5Ω, the contact resistance value of the matched connector is qualified. If the insulation resistance value of each matching connector tested in step 3 is not less than 400 MΩ, the insulation resistance value of the matching connector is qualified; Apply 310N pulling force to each tested mating connector. If the connector remains interlocked, it is considered as qualified. If any of the contact resistance value, insulation resistance value and tensile test fails, the matching connector fails and re-samples shall be tested; If two or more connectors fail to meet the standards, the batch of products is deemed to be mismatched.

[0006] In one achievable manner, in step 3, the accelerated aging test includes: Take the first group of 1# and 2# connectors and place them in an environment with a temperature of 105-121°C and a humidity of 100%RH for 48-96 hours; Measure the contact resistance of connectors 1# and 2#, and record them as R11 and R21; Conduct 1500-2000V wet leakage current test on 1# and 2# connectors and record the insulation resistance values ​​JY11 and JY21.

[0007] In one achievable manner, in step 3, the temperature shock test includes: Place the second group of 3# and 4# connectors in an environment of 200℃-105℃ for 48-96 hours, then quickly reduce the temperature to -40±5℃ within 15-20 minutes, and place them in an environment of -40±5℃ for 48-96 hours; Measure the contact resistance of connectors 3# and 4#, and record them as R31 and R41; Conduct 1500-2000V wet leakage current test on 3# and 4# connectors and record the insulation resistance values ​​JY31 and JY41.

[0008] In one achievable method, the 3# and 4# connectors are first placed in an environment of 105°C for 96 hours, then rapidly dropped to -40°C within 15 minutes, and placed in an environment of -40°C for 96 hours.

[0009] In one achievable manner, in step 3, the temperature rise test includes: Take the third group of 5# and 6# connectors and apply 1.2-1.35 times the designed short-circuit current respectively for 1.5-2 hours; Measure the contact resistance of connectors 5# and 6#, and record them as R51 and R61; Conduct 1500-2000V wet leakage current test on 5# and 6# connectors and record the insulation resistance values ​​JY51 and JY61.

[0010] In one achievable method, 1.35 times the designed short-circuit current is applied to the 5# and 6# connectors respectively, and the power-on time is 2 hours.

[0011] In one achievable manner, in step 3, the composite illumination test includes: Lay outdoor soil at the bottom of the composite test box, take the fourth group of 7# and 8# connectors and place them on the soil surface without the two connectors touching; the humidity in the box is controlled at 70-85%; Use 800-1000W / m 2 The light source irradiates the two connectors at the same time, the ambient temperature is controlled at 75±5℃, and the cumulative irradiation is 120kWh / m 2 ; Measure the contact resistance of connectors 7# and 8#, and record them as R71 and R81; Perform 1500-2000V wet leakage current test on the two connectors and record the insulation resistance values ​​JY71 and JY81.

[0012] In one achievable manner, the thickness of the outdoor soil laid on the bottom of the composite test box is 0.4-0.5 m.

[0013] In one achievable manner, in step 3, the salt water corrosion test includes: Take the fifth group of 9# and 10# connectors and soak them in salt water with a mass ratio of 3-8% and a temperature of 60-70℃ for 48 hours; Measure the contact resistance of the 9# and 10# connectors and record them as R91 and R101; Perform 1500-2000V wet leakage current test on both connectors and record the insulation resistance values ​​as JY91 and JY101.

[0014] In a feasible manner, the mass ratio of the salt water is 5%.

[0015] Compared with the prior art, the matching test method for different types of photovoltaic module connectors provided by the present invention has the beneficial effects of simulating the environment in which the connectors are used, and conducting accelerated aging tests, temperature shock tests, temperature rise tests, composite illumination tests and salt water corrosion tests on mixed-insertion connectors of different types, which can effectively verify the matching performance and safety performance of mixed-insertion connectors of different types, remove unqualified products in time, prevent unqualified products from being used in photovoltaic power stations, and provide safety guarantees for the operation of photovoltaic power stations. DETAILED DESCRIPTION

[0016] 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 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.

[0017] The matching test method of different types of photovoltaic module connectors provided by the present invention is now described. The test method comprises the following steps: Step 1: Sample preparation Randomly select 10 positive connectors from the A type connector, and randomly select 10 negative connectors from the B type connector. The length of the positive and negative connector cables should not be less than 60cm. Arbitrarily form multiple matching connectors and randomly number them as 1#, 2#, 3#...10#; Peel off 1 cm of insulation at both ends of the positive and negative cables to expose the cable core for testing the contact resistance of the connector.

[0018] Step 2: Initial value measurement (1) Measure the contact resistance of all matching connectors and record the initial resistance values ​​as R1, R2, R3, ... R10; (2) Initial test of insulation resistance value Perform a 1500-2000V wet leakage current test on the matching connectors, and record the insulation resistance values ​​as JY1, JY2...JY10. The insulation resistance value of each connector shall not be less than 400MΩ; (3) Matching connector tensile test Apply 310N pulling force to each mating connector and it still remains interlocked; Step 3: Environmental simulation test The 10 mixed-insertion connectors were divided into five groups, and then subjected to accelerated aging test, temperature shock test, temperature rise test, composite illumination test and salt water corrosion test. Each connector was subjected to contact resistance measurement and wet leakage current test, and the contact resistance and insulation resistance values ​​were recorded one by one. In real environments, connectors are often exposed to high temperatures, which accelerates aging and can be exposed to large temperature differences. (1) Accelerated aging tests include: Take connectors 1# and 2# and place them in an environment with a temperature of 121°C and a humidity of 100%RH for 96 hours. Measure the contact resistance of connectors 1# and 2#, and record them as R11 and R21; Conduct 1500-2000V wet leakage current test on 1# and 2# connectors and record the insulation resistance values ​​JY11 and JY21.

[0019] In real-world environments, connectors are often exposed to high temperatures, which accelerates aging. This test tests the performance of contact resistance and insulation resistance when the connector is exposed to high temperatures for a long time, in order to determine its service life while maintaining safe performance at high temperatures, and to provide a test basis for its application in real-world environments.

[0020] (2) The temperature shock test includes: Place the 3# and 4# connectors in a 105°C environment for 96 hours, then quickly drop the temperature to -40°C within 15 minutes and place them in a -40°C environment for 96 hours; Measure the contact resistance of connectors 3# and 4#, and record them as R31 and R41; Conduct 1500-2000V wet leakage current test on 3# and 4# connectors and record the insulation resistance values ​​JY31 and JY41.

[0021] The purpose of the temperature shock test is to verify the use and storage conditions of the sample under high and low temperature changes, and to examine the product's adaptability to rapid changes in ambient temperature.

[0022] ‌Test principle‌: When the temperature changes rapidly, the alternating stress caused by the thermal expansion and contraction effect may lead to material cracking, poor contact, performance changes, etc.‌ The temperature shock test of the connector can be effectively carried out to evaluate its performance under extreme temperature conditions.

[0023] (3) The temperature rise test includes: Take 5# and 6# connectors, apply 1.35 times the designed short-circuit current respectively, and power on for 2 hours; Measure the contact resistance of connectors 5# and 6#, and record them as R51 and R61; Conduct 1500-2000V wet leakage current test on 5# and 6# connectors and record the insulation resistance values ​​JY51 and JY61.

[0024] The purpose of the connector temperature rise test is to verify the temperature rise of the sample under conditions higher than the normal use current, and to examine the product's adaptability to the temperature rise caused by current heating.

[0025] ‌Test principle‌: When the temperature changes, the alternating stress caused by the thermal expansion and contraction effect may lead to material cracking, poor contact, performance changes, etc.‌ The temperature shock test of the connector can be effectively carried out to evaluate its performance under extreme temperature conditions.

[0026] (4) The composite illumination test includes: Lay 0.5m of outdoor soil at the bottom of the composite test box to simulate the outdoor environment, take the 7# and 8# connectors and place them on the surface of the soil layer without the two connectors touching; the humidity in the box is controlled at 70-85%; Use 800-1000W / m 2 The light source irradiates the two connectors at the same time, the ambient temperature is controlled at 75±5℃, and the cumulative irradiation is 120kWh / m 2 ; Measure the contact resistance of connectors 7# and 8#, and record them as R71 and R81; Perform 1500-2000V wet leakage current test on the two connectors and record the insulation resistance values ​​JY71 and JY81.

[0027] The main purpose of the connector lighting test is to evaluate the performance changes of the connector under lighting environment and ensure its stability and reliability under different lighting conditions.

[0028] Verify the performance changes of the connector under lighting environment: By simulating different lighting conditions, the performance changes of the connector under the influence of lighting are detected to ensure that it can work normally in various lighting environments.

[0029] ‌Evaluating the weather resistance of connectors‌: Light testing can help evaluate the weather resistance of connectors under different lighting conditions, ensuring that they can maintain stable performance after long-term exposure to light environments.

[0030] ‌Ensure the service life of the connector‌: Through lighting tests, the service life of the connector under different lighting conditions can be predicted, thereby optimizing the design and material selection to extend its service life.

[0031] Lighting tests are widely used in various connector products that need to be exposed to light environments, such as outdoor equipment, solar equipment, etc. Through lighting tests, it can be ensured that these products will not experience performance degradation or failure due to the influence of light during long-term use, thereby improving product reliability and user satisfaction.

[0032] (5) The salt water corrosion test includes: Take 9# and 10# connectors and soak them in salt water with a mass ratio of 5% and a temperature of 60-70℃ for 48 hours; Measure the contact resistance of the 9# and 10# connectors and record them as R91 and R101; Perform 1500-2000V wet leakage current test on both connectors and record the insulation resistance values ​​as JY91 and JY101.

[0033] Used to test the stability and reliability of connectors in salt spray environments.

[0034] Salt spray corrosion is a common but most destructive atmospheric corrosion. Salt spray mainly refers to a gas environment with a high concentration of chloride salt (sodium chloride) in the ocean. It is mainly distributed in coastal areas and inland saline-alkali areas. Through salt water testing, it can be verified that the performance of the connector will deteriorate or fail in a long-term salt spray corrosion environment, thereby improving product reliability and user satisfaction.

[0035] Step 6: Result processing (1) Compare the contact resistance value obtained by the test with the initial resistance value obtained. If the contact resistance value of the matching connector is less than 0.5Ω, that is, R11-R1, R21-R2, R31-R3...R101-R10 are all less than 0.5Ω, then the contact resistance value of the matching connector is qualified; (2) Wet leakage current test: if the insulation resistance values ​​of JY11, JY21, JY31, ... JY101 are not less than 400MΩ, the insulation resistance values ​​of the matching connectors are qualified; (3) A tensile force of 310N is applied to each mating connector after the test. If the connector remains interlocked, the tensile force is qualified. (4) Result judgment After the test, all connectors should not have any cracks or deformation on their appearance, otherwise they will be deemed unqualified; If any of the contact resistance value, insulation resistance value and tensile test fails, the matching connector fails and re-samples shall be tested; If two or more connectors fail to meet the standards, the batch of products is deemed to be mismatched.

[0036] Test data see the table below

[0037] The comparison average value 0.62-0.574=0.046 is less than 5mΩ, indicating that the resistance value change is within the qualified range, indicating that the contact resistance value of the connectors for mixed-insertion photovoltaic modules of different models is qualified.

[0038] 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.

[0039] 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 method for testing the matching of connectors of photovoltaic modules of different models, characterized in that: The method comprises the following steps: Step 1: Sample preparation Randomly select multiple positive connectors from the A model connector, and randomly select the same number of negative connectors from the B model connector, and arbitrarily form multiple matching connectors, and randomly number them as 1#, 2#, 3#...n#, where n is a positive integer; Step 2: Initial value measurement Measure the contact resistance of the matching connectors and record the initial contact resistance values ​​as R1, R2, R3, ..., Rn; Perform a 1500-2000V wet leakage current test on the matching connectors, and record the insulation resistance values ​​as JY1, JY2...JYn. The insulation resistance value of each connector shall not be less than 400MΩ; Apply 310N pulling force to each mating connector and it still remains interlocked; Step 3: Environmental simulation test The connectors that have passed the test in step 2 are divided into five groups in order of number, each group includes at least two connectors, and the accelerated aging test, temperature shock test, temperature rise test, composite illumination test and salt water corrosion test are carried out in turn. Each connector is subjected to contact resistance measurement and wet leakage current test, and the contact resistance value and insulation resistance value are recorded one by one; Step 4: Result processing Compare the contact resistance value obtained by the test in step 3 with the initial resistance value obtained in step 2. If the contact resistance value of the matched connector is less than 0.5Ω, the contact resistance value of the matched connector is qualified. If the insulation resistance value of each matching connector tested in step 3 is not less than 400 MΩ, the insulation resistance value of the matching connector is qualified; Apply 310N pulling force to each matched connector after the test, if it still remains in the interlocked state, it is considered as qualified; If any of the contact resistance value, insulation resistance value and tensile test fails, the matching connector fails and re-samples shall be tested; If two or more connectors fail to meet the standards, the batch of products is deemed to be mismatched.

2. The method for testing the matching of connectors of photovoltaic modules of different models as claimed in claim 1, characterized in that: In step 3, the accelerated aging test includes: Take the first group of 1# and 2# connectors and place them in an environment with a temperature of 105-121°C and a humidity of 100%RH for 48-96 hours; Measure the contact resistance of connectors 1# and 2#, and record them as R11 and R21; Conduct 1500-2000V wet leakage current test on 1# and 2# connectors and record the insulation resistance values ​​JY11 and JY21.

3. The method for testing the matching of connectors of photovoltaic modules of different models as claimed in claim 1, characterized in that: In step 3, the temperature shock test includes: Place the second group of 3# and 4# connectors in an environment of 200℃-105℃ for 48-96 hours, then quickly reduce the temperature to -40±5℃ within 15-20 minutes, and place them in an environment of -40±5℃ for 48-96 hours; Measure the contact resistance of connectors 3# and 4#, and record them as R31 and R41; Conduct 1500-2000V wet leakage current test on 3# and 4# connectors and record the insulation resistance values ​​JY31 and JY41.

4. The method for testing the matching of connectors of photovoltaic modules of different models as claimed in claim 3, characterized in that: The 3# and 4# connectors were first placed in an environment of 105°C for 96 hours, then rapidly cooled to -40°C within 15 minutes, and then placed in an environment of -40°C for 96 hours.

5. The method for testing the matching of connectors of photovoltaic modules of different models as claimed in claim 1, characterized in that: In step 3, the temperature rise test includes: Take the third group of 5# and 6# connectors and apply 1.2-1.35 times the designed short-circuit current respectively for 1.5-2 hours; Measure the contact resistance of connectors 5# and 6#, and record them as R51 and R61; Conduct 1500-2000V wet leakage current test on 5# and 6# connectors and record the insulation resistance values ​​JY51 and JY61.

6. The method for testing the compatibility of connectors of photovoltaic modules of different models as claimed in claim 5, characterized in that: Apply 1.35 times the designed short-circuit current to the 5# and 6# connectors respectively, and keep the power on for 2 hours.

7. The method for testing the matching of connectors of photovoltaic modules of different models according to claim 1, characterized in that: In step 3, the composite illumination test includes: Lay outdoor soil at the bottom of the composite test box, take the fourth group of 7# and 8# connectors and place them on the soil surface without the two connectors touching; the humidity in the box is controlled at 70-85%; Use 800-1000W / m 2 The light source irradiates the two connectors at the same time, the ambient temperature is controlled at 75±5℃, and the cumulative irradiation is 120kWh / m 2 ; Measure the contact resistance of connectors 7# and 8#, and record them as R71 and R81; Perform 1500-2000V wet leakage current test on the two connectors and record the insulation resistance values ​​JY71 and JY81.

8. The method for testing the matching of connectors of photovoltaic modules of different models as claimed in claim 7, characterized in that: The thickness of the outdoor soil laid on the bottom of the composite test box is 0.4-0.5m.

9. The method for testing the compatibility of connectors of photovoltaic modules of different models as claimed in claim 1, characterized in that: In step 3, the salt water corrosion test includes: Take the fifth group of 9# and 10# connectors and soak them in salt water with a mass ratio of 3-8% and a temperature of 60-70℃ for 48 hours; Measure the contact resistance of the 9# and 10# connectors and record them as R91 and R101; Perform 1500-2000V wet leakage current test on both connectors and record the insulation resistance values ​​as JY91 and JY101.

10. The method for testing the matching of connectors of photovoltaic modules of different models as claimed in claim 9, characterized in that: The mass ratio of brine is 5%.

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