Photovoltaic module puncture positioning bearing plate and integrated installation system thereof

Abstract

The invention provides a photovoltaic module puncture positioning bearing plate and an integrated installation system thereof. The photovoltaic module puncture positioning bearing plate comprises a substrate made of a zinc-aluminum-magnesium steel plate; an inverted conical puncture tooth array is arranged on the surface of the base plate; puncture grooves complementary with the puncture teeth are formed in the bottom surface of the base plate, the depth of the grooves is 0.8 + / -0.05 mm, the width of the grooves and the width of the roots of the puncture teeth are in interference fit, and the magnitude of interference is 0.1-0.2 mm; threaded mounting holes are formed in the two ends of the base plate and used for being fixed to a purline through self-tapping screws. The device integrates the functions of positioning, conducting and pressing, and is suitable for rapid installation and efficient conductive connection of the photovoltaic module.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic power generation, in particular to a piercing positioning carrier plate for photovoltaic modules and its integrated installation system. Background Art

[0002] The current BIPV system adopts a four-component split installation structure (positioning carrier plate, conductive piercing piece, photovoltaic module, pressing block), and there are the following problems:

[0003] Low electrical conductivity reliability: The independent conductive piercing piece is prone to insufficient contact area due to installation deviation (the measured contact resistance fluctuates by ±30%);

[0004] Low construction efficiency: It is necessary to install 4 components step by step, and the average time-consuming for a single module is 25 minutes (construction data of China Power Construction Group in 2022);

[0005] Too high cost: Each group of modules needs to use 4 piercing pieces (unit price ￥8.5 / piece), and the annual operation and maintenance replacement rate ≥ 15%. Summary of the Invention

[0006] To overcome the above problems, the purpose of the present invention is to provide a piercing positioning carrier plate for photovoltaic modules and its integrated installation system that integrates the functions of positioning, electrical conductivity, and pressing, and is suitable for the rapid installation and efficient electrical connection of photovoltaic modules.

[0007] The present invention is implemented as follows: A piercing positioning carrier plate for photovoltaic modules, including a substrate made of zinc-aluminum-magnesium steel plate; an array of inverted conical piercing teeth is provided on the surface of the substrate; a piercing groove complementary to the piercing teeth is provided on the bottom surface of the substrate, with a groove depth of 0.8 ± 0.05 mm, and the groove width forms an interference fit with the root width of the piercing teeth, with an interference amount of 0.1 - 0.2 mm; threaded mounting holes are provided at both ends of the substrate for fixing to the purlin through self-tapping screws.

[0008] Further, the zinc-aluminum-magnesium steel plate is S350GD-Z275 zinc-aluminum-magnesium steel plate, with a thickness of 2.0 ± 0.1 mm and a yield strength ≥ 350 MPa; the height of a single piercing tooth of the inverted conical piercing teeth is 1.5 ± 0.1 mm, the adjacent tooth spacing is 5 ± 0.2 mm, the tooth apex angle is 60° ± 5°, and the root width of the tooth is 1.2 ± 0.1 mm.

[0009] Further, the tip thickness of the inverted conical piercing teeth is 0.3 ± 0.05 mm, the surface roughness Ra of the tooth tip ≤ 3.2 μm, and the inclination angle of the tooth side wall is 15° ± 2°.

[0010] Further, the bottom of the piercing groove is provided with a fillet with a radius of 0.2 mm, and the gap between the groove wall and the side wall of the piercing tooth ≤ 0.05 mm.

[0011] An integrated installation system for the photovoltaic module piercing positioning carrier plate described above includes a piercing press block. The bottom of the piercing press block is provided with a copper alloy conductive layer (copper content ≥ 99%), the thickness of the conductive layer is 0.5 mm, and the interference amount in the pressing area with interference fit with the piercing teeth is 0.15 ± 0.05 mm. The piercing press block applies a vertical pressure through an M8 bolt, and the pressure value is 3000 - 5000 N, so that the piercing teeth pierce the oxide layer of the photovoltaic module frame to form a conductive path with a contact resistance ≤ 0.1 Ω.

[0012] Furthermore, the surface of the copper alloy conductive layer of the piercing press block is provided with a V-shaped current guiding groove with a groove depth of 0.3 mm and a groove spacing of 2 mm, which is used to increase the contact area and guide the current distribution.

[0013] The beneficial effects of the present invention are as follows: Through the collaborative innovation of structure, material and process, the present invention realizes the high efficiency, low cost and long life of the photovoltaic installation system, and is applicable to distributed photovoltaic power stations and BIPV scenarios; it solves the three major technical pain points of unstable electrical conductivity, complex installation process and high operation and maintenance cost caused by the traditional split structure; through the interference fit of the inverted cone teeth + piercing groove, the mechanical locking and conductivity are integrated, and no additional conductive medium is required; the three-stage progressive stamping solves the problem of tooth shape cracking of 2 mm thick high-strength steel, and the die life reaches 550,000 times; it reduces the conductive sheet and installation steps, and the cost of a single MW photovoltaic power station is reduced by about 120,000 yuan. Description of the Drawings

[0014] Figure 1 It is the assembly schematic diagram of the first state of the present invention.

[0015] Figure 2 It is the assembly schematic diagram of the second state of the present invention.

[0016] In the figure: substrate - 1, piercing teeth - 2, piercing groove - 3, threaded installation hole - 4, screw - 5, piercing press block - 6, V-shaped current guiding groove - 7. Detailed Embodiments

[0017] The present invention will be further described below with reference to the drawings.

[0018] Example 1: Processing and Testing of the Piercing Positioning Carrier Plate

[0019] Material Preparation:

[0020] Select S350GD-Z275 zinc-aluminum-magnesium steel plate with a thickness of 2.0 mm, and cut it into a 600 mm × 200 mm substrate by laser cutting, with a cutting accuracy of ±0.15 mm.

[0021] Stamping and Forming:

[0022] Use a three-stage progressive die (die number PM-2023-ZM) to stamp on a 200-ton hydraulic press:

[0023] The first working station: Pre-punch a circular pit at the root of the piercing tooth. The diameter of the punch is 1.2 mm and the depth of the pit is 0.3 mm.

[0024] The second working station: Form an inverted conical tooth through three times of stretching (each feed is 0.5 mm), and the stretching speed is 10 mm / s.

[0025] The third working station: Finish the tooth profile and punch the piercing groove on the bottom surface. The finishing pressure is 200 kN and the pressure holding time is 0.5 s.

[0026] After forming, the tooth height is 1.5 mm, the tooth tip angle is 58°, and the surface roughness Ra = 2.8 μm.

[0027] Surface treatment:

[0028] After the substrate is coated with zinc-aluminum-magnesium, it is subjected to a salt spray test according to ASTM B117 standard, and no red rust is generated after 3500 h.

[0029] Performance test:

[0030] Conductivity: Mate the piercing pressure block (copper layer thickness 0.5 mm) with the carrier plate. After applying a pressure of 4000 N, the contact resistance is 0.08 Ω (tested by KEITHLEY 2450).

[0031] Tensile pull-out force: Tested according to IEC 61215 standard, the vertical pull-out force ≥ 5200 N (Instron 5982 testing machine).

[0032] Example 2: On-site application of the integrated installation system

[0033] Installation steps:

[0034] Fix the piercing positioning carrier plate to the C-shaped steel purlin through self-tapping screws (torque 18 N·m), and the purlin spacing is 1.2 m.

[0035] Directly lay 60 photovoltaic modules (size 1750 mm × 990 mm), and cancel the traditional conductive sheet.

[0036] Use an electric wrench to install the piercing pressure block, apply a torque of 25 N·m (corresponding pressure 4500 N) to make the tooth tip pierce the oxide layer of the module frame.

[0037] Effect verification:

[0038] Installation efficiency: The installation time of a single module is shortened from the traditional 15 minutes to 5 minutes.

[0039] System resistance: The loop resistance of the whole string of modules ≤ 1.2 Ω, which is 40% lower than the traditional scheme.

[0040] Weather resistance: After 12 months of outdoor operation, there is no corrosion or loosening at the puncture connection (verified by visual inspection and re-measurement of resistance).

[0041] The above are only the preferred embodiments of the present invention, and all equivalent changes and modifications made according to the scope of the patent application of the present invention shall fall within the scope of the present invention.

Claims

1. A puncture positioning carrier plate for a photovoltaic module, characterized in that: It includes a substrate made of zinc-aluminum-magnesium steel plate; an array of inverted conical piercing teeth is provided on the surface of the substrate; piercing grooves complementary to the piercing teeth are provided on the bottom surface of the substrate, with a groove depth of 0.8 ± 0.05 mm, and the groove width forms an interference fit with the root width of the piercing teeth, and the interference amount is 0.1 - 0.2 mm; threaded mounting holes are provided at both ends of the substrate for fixing to the purlin through self-tapping screws.

2. The puncture positioning carrier plate of a photovoltaic module according to claim 1, characterized in that: The zinc-aluminum-magnesium steel plate is S350GD-Z275 zinc-aluminum-magnesium steel plate, with a thickness of 2.0 ± 0.1 mm and a yield strength ≥ 350 MPa; the height of a single piercing tooth of the inverted conical piercing teeth is 1.5 ± 0.1 mm, the adjacent tooth spacing is 5 ± 0.2 mm, the tooth apex angle is 60° ± 5°, and the root width of the tooth is 1.2 ± 0.1 mm.

3. The puncture positioning carrier plate of a photovoltaic module according to claim 1, characterized in that: The tip thickness of the inverted conical piercing teeth is 0.3 ± 0.05 mm, the surface roughness Ra of the tooth tip ≤ 3.2 μm, and the inclination angle of the tooth side wall is 15° ± 2°.

4. A photovoltaic module puncture positioning carrier plate according to claim 1, characterized in that: The bottom of the piercing groove is provided with a fillet with a radius of 0.2 mm, and the gap between the groove wall and the side wall of the piercing tooth ≤ 0.05 mm.

5. An integrated installation system for a puncture positioning carrier plate of a photovoltaic module according to any one of claims 1-3, characterized in that: It includes a piercing press block, and a copper alloy conductive layer (copper content ≥ 99%) is provided at the bottom of it, with a conductive layer thickness of 0.5 mm, and the interference amount in the pressing area with an interference fit with the piercing teeth is 0.15 ± 0.05 mm; the piercing press block applies a vertical pressure through an M8 bolt, and the pressure value is 3000 - 5000 N, so that the piercing teeth pierce the oxide layer of the photovoltaic module frame to form a conductive path with a contact resistance ≤ 0.1 Ω.

6. The integrated installation system of the photovoltaic module puncture positioning carrier plate according to claim 5, characterized in that: The surface of the copper alloy conductive layer of the piercing press block is provided with V-shaped diversion grooves, with a groove depth of 0.3 mm and a groove spacing of 2 mm, for increasing the contact area and guiding the current distribution.

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