Photovoltaic module glass self-explosion detection system and detection method
Through the thermal gradient loading system, stress monitoring system and digital twin verification system, the accuracy and efficiency issues of photovoltaic module glass self-explosion detection are solved, and fast and accurate self-explosion detection is achieved.
Patent Information
- Application Number
- CN202510817874.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-18
- Publication Date
- 2025-09-23
AI Technical Summary
The existing photovoltaic module glass self-explosion detection system cannot accurately simulate the local thermal gradient in actual working conditions. The monitoring method is single, the test cycle is lengthy, and the failure mechanism differs from the actual situation.
Adopting a thermal gradient loading system, a stress monitoring system and a digital twin verification system, through locally controllable large temperature differences and diversified monitoring methods, combined with finite element simulation and machine learning, fast and accurate glass self-explosion detection can be achieved.
It achieves accurate local thermal gradient simulation and multi-dimensional stress monitoring, shortens the test cycle, and improves the accuracy and efficiency of fracture prediction.
Smart Images
Figure CN120688322A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the technical field of detection systems, specifically relates to detection system technology for photovoltaic modules, and more specifically relates to a photovoltaic module glass self-explosion detection system and detection method. Background Art
[0002] With the market penetration of double-glass photovoltaic modules exceeding 40%, the problem of glass spontaneous explosion has become a pain point in the industry. Specific scenarios for spontaneous explosion caused by uneven thermal stress include: hot spot effects causing localized temperature surges (150-200°C), shadows / contamination causing regional temperature differences (20-100°C), and differential thermal expansion between the edge and center of the glass. Therefore, it is crucial to perform pre-shipment inspections on the glass surface of double-glass photovoltaic modules. The current solutions are:
[0003] Traditional thermal cycling testing (IEC 61215 standard): only applies uniform temperature changes (-40°C to 85°C cycling), which cannot simulate the local thermal gradients in actual operating conditions.
[0004] Finite element simulation analysis: relies on idealized boundary conditions and lacks the ability to correct the results based on real material defects (such as microcracks);
[0005] Destructive sampling: The strength of glass is judged by mechanical impact testing (such as the steel ball drop method), which is not related to the thermal stress failure mechanism.
[0006] However, the current detection system has the following technical defects:
[0007] Distorted thermal loading: Uniform heating cannot reproduce the local hot spots in actual photovoltaic systems;
[0008] Single monitoring method: relying on static strain gauges or theoretical calculations, unable to capture transient stress fields;
[0009] Lengthy testing cycles: Traditional methods require months of outdoor testing to accumulate failure cases;
[0010] Failure mechanism deviation: There are essential differences between mechanical impact testing and real thermal stress fracture modes.
[0011] Therefore, in response to the above technical problems, the industry lacks photovoltaic module detection system technology that can solve the above problems.
[0012] The information disclosed in this background technology section is only intended to enhance understanding of the overall background of the invention and should not be regarded as an admission or any form of suggestion that the information constitutes the prior art already known to a person skilled in the art. Summary of the Invention
[0013] The purpose of the present invention is to provide an accelerated detection system and method for the self-explosion phenomenon of the glass surface of a photovoltaic module, which can achieve a locally controllable large temperature difference on the glass panel of the module, accelerate the test through short-term and rapid temperature difference changes, accelerate stress changes, and observe whether the glass has self-explosion.
[0014] In order to achieve the above object, a specific embodiment of the present invention provides the following technical solutions:
[0015] A photovoltaic module glass surface self-explosion phenomenon accelerated detection system, comprising:
[0016] Thermal gradient loading system to generate local gradient temperature field;
[0017] Stress monitoring system;
[0018] The digital twin verification system includes a thermal-mechanical coupling simulation module and a failure prediction module.
[0019] In one or more embodiments of the present invention, the thermal gradient loading system includes a laser scanning heating module.
[0020] In one or more embodiments of the present invention, the laser scanning heating module uses a semiconductor laser to perform local lattice heating.
[0021] In one or more embodiments of the present invention, the thermal gradient loading system further includes a partitioned temperature control array module and a dynamic thermal shock module. The partitioned temperature control array module generates a temperature field of arbitrary shape, and the dynamic thermal shock module simulates an actual lighting scene.
[0022] In one or more embodiments of the present invention, the zoned temperature control array module includes a programmable infrared lamp matrix and a thermoelectric cooling sheet.
[0023] In one or more embodiments of the present invention, the stress monitoring system includes a surface strain field monitoring module and an internal stress sensing module. The stress monitoring system also includes a nanoparticle tracing module and a terahertz imaging module. The nanoparticle tracing module coats thermochromic nanoparticles on the glass surface and inverts stress through spectral analysis. The terahertz imaging module detects the birefringence effect induced by stress inside the glass.
[0024] In one or more embodiments of the present invention, the stress monitoring system further includes a crack propagation tracking module.
[0025] In one or more embodiments of the present invention, the surface strain field monitoring module includes a camera using digital imaging technology, and the internal stress sensing module includes at least two distributed fiber Bragg grating sensors.
[0026] In one or more embodiments of the present invention, the spacing distance between the distributed fiber grating sensors is 5 mm per sensor.
[0027] In one or more embodiments of the present invention, the crack growth tracking module includes an acoustic emission sensor.
[0028] In one or more embodiments of the present invention, the thermal-mechanical coupling simulation engine module uses an accelerated finite element calculation method.
[0029] In one or more embodiments of the present invention, the failure prediction module uses a fusion of Griffith crack theory and proper orthogonal decomposition method.
[0030] A method for detecting a photovoltaic module glass surface self-explosion phenomenon accelerated detection system includes the following steps:
[0031] S1, thermal field loading: Generate a gradient temperature field in the target area through the infrared matrix;
[0032] S2. Dynamic monitoring: synchronously collect DIC strain field, optical fiber stress data, and acoustic emission signals;
[0033] S3, simulation calibration: input experimental data into the digital twin system and iteratively modify the material constitutive model;
[0034] S4, threshold determination: when any of the following signals is detected, it is determined to be the critical point of self-destruction;
[0035] Among them, the surface principal strain exceeded 0.15%, the acoustic emission energy increased 10 times and lasted for 3 seconds, and the simulation predicted rupture probability was >95%.
[0036] Compared with the prior art, the photovoltaic module glass surface self-explosion phenomenon accelerated detection system and detection method of the present invention has the following advantages:
[0037] 1) Accurate thermal loading method: Accurately generate an adjustable local thermal gradient field (ΔT = 20-200°C);
[0038] 2) Diversified monitoring methods: real-time dynamic monitoring of the three-dimensional stress distribution on the glass surface / interior;
[0039] 3) Establish a quantitative prediction model for thermal stress accumulation and glass cracking;
[0040] 4) Short test cycle: shorten the self-explosion risk assessment cycle from several months to within 2 weeks; BRIEF DESCRIPTION OF THE DRAWINGS
[0041] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.
[0042] Figure 1 This is a comparison diagram of the technical effects of a traditional method and the present invention in an accelerated detection system for the self-explosion phenomenon of a photovoltaic module glass surface in one embodiment of the present invention. DETAILED DESCRIPTION
[0043] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of the present invention.
[0044] In one embodiment of the present invention, a photovoltaic module glass surface self-explosion phenomenon accelerated detection system includes an intelligent thermal gradient loading system, a multi-dimensional stress monitoring system and a digital twin verification system, thereby providing a method that can simulate the stress unevenness caused by such thermal temperature difference in advance in the laboratory, thereby judging the possibility of self-explosion of the double-glass module glass.
[0045] The intelligent thermal gradient loading system generates a local gradient temperature field. The intelligent thermal gradient loading system includes a partitioned temperature control array module and a dynamic thermal shock module. The partitioned temperature control array module generates a temperature field of any shape on the glass surface.
[0046] The zone temperature control array module includes a programmable infrared lamp matrix and a thermoelectric cooling chip, that is, the zone temperature control array module can be 2 The glass surface generates a temperature field (accuracy ±1.5°C) of arbitrary shape (for example, simulating hot spots, bird droppings, etc.). The dynamic thermal shock module simulates actual lighting scenes. The dynamic thermal shock module achieves rapid temperature changes of 0-200°C / min, simulating day and night alternation or cloud cover scenes.
[0047] It should be noted that the wavelength of the programmable infrared light matrix is 2-5μm.
[0048] The multi-dimensional stress monitoring system utilizes multi-source data fusion, synchronized temporal and spatial acquisition, and correlation analysis of DIC, FBG (a multi-functional sensing system), and acoustic emission. Specifically, the system includes a surface strain field monitoring module, an internal stress sensing module, and a crack growth tracking module.
[0049] The surface strain field monitoring module uses a camera with digital image correlation technology (DIC) and a high-speed camera (a camera with a selection parameter of 1000 frames) to capture the micro strain of the glass surface (with a resolution of 0.5με).
[0050] The internal stress sensing module monitors the propagation of stress waves inside the glass in real time by implanting multiple distributed fiber Bragg grating (FBG) sensors. The internal stress sensing module contains at least two distributed fiber Bragg grating (FBG) sensors, each separated by 5 mm.
[0051] The crack growth tracking module locates the initiation of microcracks using an integrated acoustic emission sensor with a frequency range of 50-400kHz.
[0052] The digital twin verification system includes a thermal-mechanical coupling simulation engine module and a failure prediction model. The thermal-mechanical coupling simulation engine module uses an accelerated finite element calculation method, and the failure prediction model is based on a fracture criterion driven by a hybrid of physical mechanisms and machine learning.
[0053] Specifically, the thermal-mechanical coupling simulation engine module is based on measured temperature field data and uses AI to accelerate finite element calculations (using artificial intelligence technology to optimize and accelerate the calculation process of finite element analysis (FEA)). The failure prediction model integrates Griffith's crack theory (Griffith's crack theory: under the action of external force, stress concentration will occur near these cracks and defects. When the stress reaches a certain level, the cracks begin to expand and cause fracture) and the intrinsic orthogonal decomposition method (POD-is a mathematical method for extracting characteristic information of discrete data) to output a fracture probability curve.
[0054] It should be noted that the thermal-mechanical coupling simulation engine uses AI to accelerate finite element calculations, taking less than 5 minutes per time.
[0055] A method for detecting a photovoltaic module glass surface self-explosion phenomenon accelerated detection system includes the following steps:
[0056] S1. Thermal field loading: Generate a gradient temperature field in the target area through an infrared matrix (e.g., 150°C in the center / 70°C at the edge);
[0057] S2. Dynamic monitoring: synchronously collect DIC strain field, optical fiber stress data, and acoustic emission signals;
[0058] S3, simulation calibration: input experimental data into the digital twin system and iteratively modify the material constitutive model;
[0059] S4. Threshold determination: When any of the following signals is detected, it is determined to be the critical point of self-destruction.
[0060] Among them, the surface principal strain exceeded 0.15%, the acoustic emission energy increased 10 times and lasted for 3 seconds, and the simulation predicted rupture probability was >95%.
[0061] like Figure 1 As shown, after testing, it is known that the thermal field simulation accuracy, stress monitoring dimension, test cycle, fracture prediction accuracy, fracture prediction accuracy and multi-factor coupling capability of the present invention are significantly higher than those of the existing detection systems, especially the test cycle is shortened to 14 days, which greatly shortens the existing long cycle of 6-12 months. The fracture prediction accuracy is as high as 92%, and the accuracy has a great leap compared with the existing detection system. The present detection system realizes local controllable large temperature difference, accelerates the test (similar to accelerated aging) through short-term and rapid temperature difference changes, accelerates stress changes, and observes whether the glass explodes.
[0062] Example 2
[0063] The intelligent thermal gradient loading system includes a laser scanning heating module, which uses a 980nm semiconductor laser for local dot heating and is suitable for small areas (<1cm 2 )Precise temperature control.
[0064] The multi-dimensional stress monitoring system includes a nanoparticle tracing module and a terahertz imaging module. The nanoparticle tracing module coats thermochromic nanoparticles (such as vanadium dioxide) on the glass surface and inverts stress through spectral analysis. The terahertz imaging module uses the 0.1-1THz band to detect the birefringence effect induced by stress inside the glass.
[0065] The difference between Example 1 and Example 2 is that the intelligent thermal gradient loading system and the multi-dimensional stress monitoring system used in Example 2 have different compositions, but can achieve the same technical effect. Different embodiments can be selected according to actual needs and technical requirements to determine the possibility of self-explosion of the double-glass component glass.
[0066] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.
[0067] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.
Claims
1. A photovoltaic module glass self-explosion detection system, characterized in that: Includes: Thermal gradient loading system to generate local gradient temperature field; Stress monitoring system; The digital twin verification system includes a thermal-mechanical coupling simulation module and a failure prediction module.
2. The photovoltaic module glass self-explosion detection system according to claim 1, characterized in that: The thermal gradient loading system includes a laser scanning heating module.
3. The photovoltaic module glass self-explosion detection system according to claim 2, characterized in that: The laser scanning heating module uses a semiconductor laser to perform local dot matrix heating.
4. The photovoltaic module glass self-explosion detection system according to claim 1, characterized in that: The thermal gradient loading system further includes a partitioned temperature control array module and a dynamic thermal shock module. The partitioned temperature control array module generates a temperature field of arbitrary shape, and the dynamic thermal shock module simulates an actual lighting scene.
5. The photovoltaic module glass self-explosion detection system according to claim 4, characterized in that: The zoned temperature control array module includes a programmable infrared lamp matrix and a thermoelectric cooling sheet.
6. The photovoltaic module glass self-explosion detection system according to claim 1, characterized in that: The stress monitoring system includes a surface strain field monitoring module and an internal stress sensing module; The stress monitoring system also includes a nanoparticle tracing module and a terahertz imaging module. The nanoparticle tracing module coats thermochromic nanoparticles on the glass surface and inverts stress through spectral analysis. The terahertz imaging module detects the birefringence effect induced by stress inside the glass.
7. The photovoltaic module glass self-explosion detection system according to claim 6, characterized in that: The stress monitoring system further includes a crack propagation tracking module.
8. The photovoltaic module glass self-explosion detection system according to claim 6, characterized in that: The surface strain field monitoring module includes a camera using digital imaging technology, and the internal stress sensing module includes at least two distributed fiber grating sensors.
9. The photovoltaic module glass self-explosion detection system according to claim 8, characterized in that: The spacing between the distributed fiber grating sensors is 5 mm per sensor.
10. The photovoltaic module glass self-explosion detection system according to claim 7, characterized in that: The crack growth tracking module contains an acoustic emission sensor.
11. The photovoltaic module glass self-explosion detection system according to claim 1, characterized in that: The thermal-mechanical coupling simulation engine module uses an accelerated finite element calculation method.
12. The photovoltaic module glass self-explosion detection system according to claim 1, characterized in that: The failure prediction module uses a fusion of Griffith crack theory and proper orthogonal decomposition method.
13. A detection method for a photovoltaic module glass surface self-explosion accelerated detection system, applied to the photovoltaic module glass surface self-explosion accelerated detection system according to any one of claims 1 to 12, characterized in that: The steps include: S1, thermal field loading: Generate a gradient temperature field in the target area through the infrared matrix; S2. Dynamic monitoring: synchronously collect DIC strain field, optical fiber stress data, and acoustic emission signals; S3, simulation calibration: input experimental data into the digital twin system and iteratively modify the material constitutive model; S4, threshold determination: when any of the following signals is detected, it is determined to be the critical point of self-destruction; Among them, the surface principal strain exceeded 0.15%, the acoustic emission energy increased 10 times and lasted for 3 seconds, and the simulation predicted rupture probability was >95%.