Flexible photovoltaic tracking support electrical linkage consistency control method and system

Abstract

The invention discloses a flexible photovoltaic tracking support electrical linkage consistency control method and system. According to the method, the target angle, the real-time angle and the inclination angle data of a support are collected, a one-master multi-slave distributed control architecture is combined, and a transverse verification mechanism, a double-link cross correction mechanism and a longitudinal verification mechanism are utilized, so that synchronous and consistent operation between driving units is achieved; and hierarchical fault protection and angle self-calibration are executed when communication is interrupted, overloaded or triggered by hard limit. The system comprises a master controller, a slave controller, a motor encoder, a tilt angle sensor, a communication module, a protection module and an information interaction unit, and can realize local visualization and remote monitoring. According to the scheme, flexible support distortion and photovoltaic module damage caused by inconsistent driving can be effectively avoided, and the safety, reliability and operation and maintenance efficiency of the system are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of photovoltaic power generation equipment control, in particular to a flexible photovoltaic tracking support electrical linkage consistency control method and system. BACKGROUND

[0002] With the rapid development of the photovoltaic power generation industry, photovoltaic support technology is constantly updated. As a replacement for traditional rigid supports, flexible photovoltaic supports, with lightweight design as a core feature, can flexibly adapt to complex terrains such as mountains, deserts, and beaches, avoiding large-scale site leveling operations, thereby reducing construction costs and improving construction efficiency, and have become an important choice in photovoltaic power station construction.

[0003] However, the core characteristic of flexible supports is to rely on material deformation and structural elasticity to achieve adaptability. This characteristic, when applied to multi-drive tracking supports, also poses challenges at the control level: when multiple drive units have synchronization deviations during operation, the flexible structure of the support will amplify the uneven force, easily leading to abnormal twisting or stretching of the overall structure. In severe cases, photovoltaic modules may crack or frame break due to excessive deformation, affecting power generation efficiency and module lifespan.

[0004] Therefore, existing flexible photovoltaic tracking supports generally face the problem of insufficient electrical linkage consistency in multi-drive scenarios, and there is an urgent need for an effective control method and system to address the collaborative operation deviations between drive units, thereby ensuring the safe and stable operation of flexible supports. SUMMARY

[0005] To solve the problems of the prior art, the embodiments of the present application provide a flexible photovoltaic tracking support electrical linkage consistency control method and system. The technical solution is as follows: On the one hand, a flexible photovoltaic tracking support electrical linkage consistency control method is provided, comprising the following steps: (1) Data acquisition: acquiring real-time angle, inclination angle, and target angle data during the operation of the flexible photovoltaic support; (2) Master-slave control communication: based on a one-master-multiple-slave distributed control architecture, the master controller collects data from each slave controller and performs communication verification; (3) Horizontal verification: within the data acquisition period, the master controller compares the angle data feedback from each slave controller, and when there is inconsistency, triggers shutdown, deviation correction, or enters cross-correction; (4) Double-link cross-correction: when there is an anomaly in the real-time angle and inclination angle, correction or triggering of protection is performed according to different anomaly types; (5) Vertical verification: different master controllers interact with each other, and when the difference exceeds the threshold, correction is performed to maintain consistency within the array range; (6) Fault protection: Trigger shutdown when communication interruption, controller unresponsive, motor overload or bracket hitting hard limit, and complete self-calibration with limit when needed.

[0006] Further, in the real-time angle acquisition process, the motor encoder outputs motor pulse signals, the main controller converts motor revolutions based on the number of pulses, and combines the reduction ratio and transmission mechanism parameters to convert into bracket angle, realizing high-precision acquisition of real-time angle.

[0007] Further, the inclination angle is obtained by an inclination sensor installed on the circuit board of the control box, which is vertically fixed to one end of the bracket cross beam and rotates synchronously with the cross beam to measure the change of the inclination angle of the bracket.

[0008] Further, the target angle is preset by the control strategy before each intermittent operation cycle of the bracket starts, the solar elevation angle and azimuth angle are calculated based on the latitude and longitude of the power station site, date and time parameters, and combined with the irradiance and weather conditions in the environmental monitoring data to set, which remains unchanged within a single operation cycle, to ensure the operation direction and angle accuracy.

[0009] Further, the master-slave control communication includes: (1) Each slave controller is configured with a unique identification number in addition to the main controller, which is used for device identification and data correspondence; (2) The main controller and each slave controller are connected through a single path data bus, forming a serial network structure; (3) The main controller sequentially issues data request instructions to each slave controller, and the slave controller returns real-time angle, inclination angle and target angle data after receiving the instruction; (4) The communication data packet contains a check field, the receiving end stores the data and enters the processing flow when the check is correct, and returns an error response and requires retransmission when the check is incorrect; (5) The main controller completes data acquisition of all slave controllers within a fixed interval period to form a complete angle data set.

[0010] Further, the horizontal verification includes: (1) When the target angle feedback by the slave controller is inconsistent with the target angle of the main controller, the main controller immediately issues a shutdown instruction and reissues the correct target angle until it is consistent with the feedback and resumes operation; (2) When the real-time angle or inclination angle feedback by the slave controller deviates from the main controller data by more than a preset threshold, the main controller triggers double-link cross correction.

[0011] (3) When the angle of the controller exceeds a certain range, the suspension mechanism is triggered, and the current controller is suspended and waits for the angle range of the remaining controllers to be reduced to a certain angle before resuming normal operation.

[0012] Further, the double-link cross correction includes: (1) When both the real-time angle and the tilt angle exceed the set threshold, it is determined that the drive unit has an operation error, and the system immediately stops the operation of the remaining drive units and waits for the drive unit to adjust to the normal angle before resuming coordinated operation; (2) When only the real-time angle is abnormal and the tilt angle is normal, it is determined that there is a data acquisition or transmission error, and the main controller corrects the error data to the correct value and the system continues to operate; (3) When only the tilt angle is abnormal and the real-time angle is normal, it is determined that the drive unit has mechanical damage or sensor abnormality, and the system triggers the shutdown protection.

[0013] Further, the longitudinal verification includes: (1) Each main controller is integrated with a wireless radio frequency communication module to establish a real-time data interaction channel with the entire square array of main controllers; (2) Each main controller exchanges real-time angle and tilt angle data within a communication period and compares them one by one; (3) When the difference exceeds the threshold, the main controller corrects its angle data to the average value of the angle data of the entire square array of main controllers to eliminate the influence of single-point deviation on the synchronization of the array as a whole.

[0014] Further, the fault protection includes: (1) When the main controller does not receive a response from the slave controller within 10ms, it performs continuous retransmission, and if it still does not receive a response within a set number of times, it determines that the slave controller is offline and issues a global shutdown command; (2) When the slave controller does not receive a main controller command within a preset time, the slave controller automatically triggers the stop operation protection program and enters standby state; (3) When the system detects that the motor communication line is broken, the connector is loose, the motor is overloaded, or the support hits the hard limit during operation, the system immediately triggers the shutdown protection; if it is triggered by the hard limit, the mechanical fixity is used as a reference point to automatically complete the angle data self-calibration.

[0015] On the other hand, a flexible photovoltaic tracking support electrical linkage consistency control system is provided, which includes: a main controller for centralized scheduling and data processing, performing horizontal verification, longitudinal verification and cross correction logic; a plurality of slave controllers corresponding to drive units, each having a unique identification number, for collecting motor encoder and tilt sensor data and feeding back to the main controller; Motor encoder, for outputting motor pulse information and converting real-time angle in combination with transmission parameters; Inclination sensor, installed inside the control box, rotates with the support to obtain the inclination angle; Communication module, for data bus transmission between the master controller and the slave controller, and supporting wireless interaction between the master controllers; Protection module, for triggering shutdown when communication is interrupted, the slave controller is unresponsive, the motor is overloaded, or the support hits a hard limit, and for completing angle self-calibration when needed; Local display panel, for displaying the running state of the driving unit and fault information in real time; Wireless communication interface, for the master controller to upload the running state, fault alarm, and correction record to the power station background, to realize remote monitoring and centralized scheduling.

[0016] The technical scheme provided by the embodiment of the application has the following beneficial effects: The application provides a flexible photovoltaic tracking support electrical linkage consistency control method and system, which introduces multi-source angle data acquisition, distributed master-slave communication, horizontal and vertical double-layer verification, double-link cross correction, and hierarchical fault protection mechanism in the running process, can effectively solve the stress imbalance problem caused by linkage asynchronization of the existing multi-drive flexible support, avoid damage such as crack and frame breakage of the photovoltaic module caused by distortion, and significantly improve the safety and reliability of the flexible support in complex environment.

[0017] Further, the high-precision real-time angle acquisition and the inclination angle detection are combined, the posture of the support can be accurately monitored; the master-slave control communication adopts a data packet with a verification field and an error retransmission mechanism, the reliability of data transmission is ensured; the horizontal verification and the double-link cross correction strategy can identify and correct single-point abnormality in time, and ensure the stable operation of the local driving unit; the vertical verification ensures the operation consistency of multiple supports in the array range through data interaction and average value correction between the master controllers; the multi-level fault protection mechanism can quickly respond to communication interruption, overload or limit collision within 10 ms, and further improves the anti-fault capability of the system in combination with the reference self-calibration function of the hard limit.

[0018] In addition, the application also realizes the visualization and remote uploading of the running state and fault information through the local display panel and the wireless communication module, so that the operation and maintenance personnel can intuitively master the equipment running state and realize remote scheduling, and the operation and maintenance efficiency and fault response speed of the power station are significantly improved. In summary, the application improves the intelligentization and reliability level of the overall operation and maintenance while ensuring the safe operation of the flexible photovoltaic support, and has significant engineering application value. BRIEF DESCRIPTION OF DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0020] Figure 1 This is a flow chart of the method for controlling the electrical linkage consistency of the flexible photovoltaic tracking bracket according to Example 1 of the present invention; Figure 2 This is a schematic diagram of the structure of the electrical linkage consistency control system of the flexible photovoltaic tracking bracket according to Example 2 of the present invention; Figure 3 Schematic diagram of the installation of a single control box in an embodiment of the present invention.

[0021] The control box 1 is mounted at one end of the crossbeam 2 , the crossbeam 2 is arranged transversely on the column 3 , and fixed brackets 4 are provided on both sides of the column 3 to support the stability of the column 3 . DETAILED DESCRIPTION

[0022] To make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0023] Example 1 This embodiment provides a method for controlling the electrical linkage consistency of a flexible photovoltaic tracking system. This method is applied to the operation and control of a multi-drive flexible photovoltaic tracking system. The core of this method is to ensure the electrical linkage consistency of each drive unit during operation through multi-source angle data acquisition, master-slave control communication, lateral verification, dual-link cross-correction, longitudinal verification, and hierarchical fault protection. This method avoids structural damage such as bracket distortion, photovoltaic module splintering, or frame breakage caused by asynchronous operation.

[0024] like Figure 1 As shown, the main process of this method includes: data acquisition, master-slave control communication, lateral verification, cross-calibration, longitudinal verification, and fault protection. In the specific implementation process, the method first uses the motor encoder and inclination sensor to perform high-precision data acquisition on the support's operating status. Based on the latitude and longitude, date and time parameters of the power station location, combined with astronomical algorithms for solar altitude and azimuth, the expected operating angle is calculated. At the same time, the target angle for this operation is set with reference to environmental monitoring data (such as irradiance and meteorological conditions), thus forming a complete angle data set. Subsequently, based on a one-master-multiple-slave distributed control architecture, the system's master controller collects and verifies the data of each slave controller to ensure the accuracy and real-time transmission.

[0025] After the main controller completes data acquisition, transverse verification is performed to compare the real-time angle, the tilt angle and the target angle, and to trigger shutdown, deviation correction or enter cross-correction process when inconsistencies occur. After transverse verification is completed, the method further realizes abnormal recognition and differential processing through a double-link cross-correction mechanism, and takes measures such as correction, shutdown protection or waiting for correction for data transmission errors, sensor abnormalities and drive unit failures. At the same time, within the range of the support array, the main controllers interact longitudinally through wireless communication modules, and when an angle deviation exceeding a threshold is found, an average correction strategy is used to maintain the overall synchronization within the array range.

[0026] In addition, the method also sets up a multi-level fault protection mechanism, when abnormal situations such as communication interruption, slave non-response, motor overload or support impact on hard limit occur, the system can trigger shutdown protection in time, and if necessary, use the hard limit as a fixed reference point to complete self-calibration, thereby further improving the safety and reliability of the system. In terms of operation visualization and remote operation and maintenance, the main controller and the slave controller can be externally connected to a local display panel to display the running state and fault information in real time; the main controller also uploads the running state, fault alarm and correction record to the power station background through the wireless communication module to realize remote monitoring and centralized scheduling.

[0027] In summary, the method of the embodiment combines data acquisition, transverse and longitudinal double-layer verification, cross-correction and multi-level protection to build a complete operation consistency control process, effectively improving the stability and reliability of the flexible photovoltaic support under complex working conditions.

[0028] As shown in Figure 1 The overall process of the method has been outlined in the foregoing section. In order to facilitate understanding, the main steps of the method will be described in detail in the following steps.

[0029] In the specific implementation process, the method can be divided into several key links, including data acquisition, master-slave control communication, transverse verification, cross-correction, longitudinal verification and fault protection. Each link is relatively independent and interconnected, forming a complete electrical linkage consistency control process. First, the data acquisition link will be described.

[0030] (I) Data acquisition In the running process, the system needs to obtain three types of data, real-time angle, tilt angle and target angle of the support, as the basis for subsequent verification and control.

[0031] 1. Real-time angle acquisition Each drive unit is equipped with a motor encoder to output motor pulse signals. The main controller converts the motor pulse signals into support angles combined with the reduction ratio and transmission mechanism parameters, thereby obtaining the real-time running angle of the support.

[0032] 2. Inclination angle acquisition The inclination angle is obtained by an inclinometer sensor installed on the control box circuit board. The control box is vertically fixed to one end of the support beam, and when the beam rotates, the control box rotates synchronously, and the inclinometer sensor outputs real-time support inclination angle data.

[0033] 3. Target angle setting The target angle is preset by the control strategy before each running cycle. Since the support adopts an intermittent running mode, the target angle remains unchanged during each running cycle, ensuring the controllability of the support running direction and the angle accuracy.

[0034] Through the above three data sources, the system establishes a complete angle data set, providing reliable input for subsequent horizontal verification, cross-correction and longitudinal verification.

[0035] (II) Master-slave control communication After completing data acquisition, the system enters the master-slave control communication link. This link is the core support of the entire method, ensuring that the master controller can accurately and timely obtain the state data of each slave controller and implement unified scheduling.

[0036] Specifically, this method adopts a distributed control architecture with one master and multiple slaves: 1. Controller identification In addition to the master controller, each slave controller is configured with a unique independent identification number. This identification number is used for device identification and data correspondence, ensuring that the system can quickly and accurately locate to a specific drive unit in a complex array environment.

[0037] 2. Communication connection The master controller and each slave controller are connected through a single path data bus, forming a serial network structure. This arrangement can reduce the complexity of communication lines while ensuring stability.

[0038] 3. Data transmission During communication, the master controller sends data request instructions to each slave controller in turn, and the slave controller returns real-time angle, inclination angle and target angle data immediately after receiving the instruction.

[0039] The transmitted data packet adopts a format with a check field. After receiving the data, the receiving end first performs a check operation: If the check is correct, the data is stored and enters subsequent processing; If the check is incorrect, immediately return a data error response and require retransmission of the data packet. Re-transmit until the check is correct.

[0040] 4. Data acquisition cycle The master controller performs the above communication operation at a fixed interval period until the data collection of all slave controllers is completed. In a single data collection period, the master controller can obtain a complete angle data set and provide a basis for subsequent lateral verification.

[0041] Through the above communication design, the efficiency and reliability of data transmission are ensured, effectively avoiding the problem of different synchronization of supports caused by communication delay or error.

[0042] (Three) Lateral Verification After the master controller completes the data collection of all slave controllers, the system enters the lateral verification link. This link aims to ensure that the running state of each drive unit at the same time is consistent through multi-source data comparison.

[0043] Specifically, after the master controller obtains the real-time angle, inclination angle and target angle data feedback by all slave controllers in a data collection period, it uses a multi-threaded task mode to compare the data of each slave controller with the corresponding data of the master controller one by one: 1. Target angle comparison The master controller first checks whether the target angle of each slave controller is consistent with the target angle of the master controller.

[0044] If consistent, continue with other verifications; If a difference is found in the target angle of a slave controller, the master controller immediately issues a shutdown instruction to all controllers and reissues the correct target angle to the slave controller until its feedback is consistent with the preset target angle, after which the support can resume operation.

[0045] 2. Real-time angle and inclination angle comparison The master controller compares the real-time angle and inclination angle of each slave controller with its own data respectively.

[0046] If the deviation value is within the preset threshold, it is determined that the drive unit is running normally; If the deviation value exceeds the threshold, the double-link cross-correction process is triggered to further identify the source of the deviation and take appropriate processing measures.

[0047] Through the above lateral verification, the out-of-sync situation caused by controller data differences or execution deviations can be found in time, so as to avoid the drive unit continuing to run in an inconsistent state.

[0048] (Four) Double-link cross-correction In the transverse verification process, when the master controller finds that the real-time angle or inclination angle data of a certain slave controller exceeds the preset threshold, the system will enter the double-link cross-correction link. This link can accurately identify the source of deviation by comparing real-time angle and inclination angle data at the same time, and take different processing measures according to different situations.

[0049] Specifically, cross-correction includes the following three kinds of judgment and processing logic: 1. Real-time angle and inclination angle are both abnormal When the real-time angle and inclination angle of a certain slave controller deviate from the set threshold at the same time, it is determined that there is an actual running error in the drive unit. At this time, the system immediately stops the operation of the remaining drive units, waits for the abnormal drive unit to adjust to the normal angle, and then restores the overall coordinated operation to avoid the expansion of single-point abnormality to global asynchronization.

[0050] 2. Only real-time angle is abnormal When the real-time angle of a certain slave controller exceeds the threshold, and its inclination angle is still within the normal range, it is determined that the deviation is caused by the collection or transmission error of real-time data, and does not reflect the actual posture of the support. At this time, the master controller automatically corrects the error data to the correct value, and the whole system continues to operate normally.

[0051] 3. Only inclination angle is abnormal When the inclination angle of a certain slave controller exceeds the threshold, and its real-time angle is normal, it is determined that the drive unit may have mechanical damage or sensor abnormality. At this time, the system immediately triggers the shutdown protection to prevent the support from continuing to run in the state of potential failure and causing structural damage.

[0052] Through the above double-link cross-correction mechanism, the system can finely distinguish and specifically process different types of deviation, thereby greatly improving the safety and robustness of operation.

[0053] (Five) longitudinal verification After completing the transverse verification and cross-correction, this method also sets a longitudinal verification link to ensure the running consistency within the entire support array. This link realizes synchronous control across supports through data interaction between different master controllers.

[0054] Specifically, each master controller is integrated with a wireless radio frequency communication module, which can establish a real-time data interaction channel with the support master controller in the square array. During data interaction: 1. Data exchange Each master controller exchanges the real-time angle and inclination angle data collected by itself with the master controllers in the square array, and forms multiple transverse comparison groups within the communication period.

[0055] 2. Data comparison The master controller compares its own data with the data of the master controller in the square matrix. When the difference is within the preset threshold range, it is determined that the operation of each support remains consistent. When the difference exceeds the threshold, longitudinal correction is triggered.

[0056] 3. Correction strategy When longitudinal correction is triggered, the master controller corrects its own angle data to the average of the angle data of the master controllers in the square matrix. In this way, the influence of single controller deviation on the overall array synchronization can be eliminated.

[0057] Through the above longitudinal verification strategy, not only the consistency between the internal drive units of a single support is ensured, but also the overall consistency of multiple supports within the array range is further ensured, avoiding large-scale support group operation imbalance caused by local differences.

[0058] (Six) Fault protection In the long-term operation of flexible photovoltaic tracking supports, drive units may lose control due to communication abnormalities, controller failure or mechanical failure. After completing the horizontal and longitudinal verification, this method further sets up a hierarchical fault protection mechanism to ensure that the system can respond quickly in abnormal situations and avoid structural damage caused by asynchronous operation.

[0059] 1. Communication fault protection When the master controller does not receive a response from a certain slave controller within a preset time (e.g. 10 ms), the master controller will immediately perform continuous multiple retransmission operations. If the correct response is still not received within the set number of times, it is determined that the slave controller is offline. At this time, the master controller issues a stop command to make all drive units enter a protection state to prevent the system from running distorted due to the failure of a single drive unit.

[0060] 2. Slave controller self-protection Each slave controller is internally provided with a delay judgment mechanism. When the slave controller does not receive a master controller command within a preset time, it will automatically trigger a stop operation protection program and enter a standby state. This logic effectively avoids the problem of missing instructions caused by master controller crash, communication line failure or hardware damage.

[0061] 3. Motor overload protection and limit protection When the controller detects that the motor communication line is broken, the joint is loose, the motor is overloaded, or the support runs into a hard limit, the system immediately triggers a stop protection. If the fault is caused by hitting a hard limit, the mechanical fixity of the hard limit is used as a reference point to automatically complete angle data self-calibration, so that the support resumes normal operation after correction. If it is a motor or line failure and cannot be automatically corrected, the system remains in a stopped state, waiting for manual repair.

[0062] Through the above-mentioned multi-layer protection mechanism, the system can quickly cut off power output or automatically correct the operating angle in abnormal scenarios, thereby ensuring that the electrical linkage consistency of the flexible photovoltaic tracking bracket is not destroyed, effectively extending the service life of the equipment and reducing maintenance risks.

[0063] In summary, the electrical linkage consistency control method for flexible photovoltaic tracking brackets provided in this embodiment is based on data acquisition, centered around master-slave control communication, and combines lateral verification, dual-link cross-calibration, and longitudinal verification to achieve multi-layered consistency assurance. Furthermore, by incorporating multiple protection mechanisms, including communication fault protection, slave controller automatic shutdown protection, and motor overload and limit protection, the system possesses rapid response and safe recovery capabilities under abnormal operating conditions.

[0064] Through the above-mentioned method, the present invention can effectively avoid distortion and damage to photovoltaic modules caused by asynchronous operation during the multi-drive operation of flexible photovoltaic supports, significantly improving the operational reliability and service life of the supports. Furthermore, this method can be expanded to flexible support arrays in large-scale photovoltaic power plants, adapting to the requirements of synchronous operation in complex terrain and under multiple operating conditions, and has strong engineering practical value and promotional significance.

[0065] Example 2 This embodiment provides a flexible photovoltaic tracking bracket electrical linkage consistency control system to support the specific implementation of the method described in Example 1. The system is oriented to the operation control requirements of multi-drive flexible photovoltaic brackets and builds a complete control system consisting of hardware units and communication mechanisms to ensure the consistency and stability of each drive unit during operation. Figure 2 As shown, the system as a whole includes a master controller, multiple slave controllers, and motor encoders and inclination sensors connected to them. It is also equipped with a communication module and a protection module to realize functions such as centralized scheduling, data collection, status monitoring, information interaction and hierarchical protection.

[0066] The main controller is used for centralized scheduling and data processing, is responsible for issuing instructions, collecting feedback, and performing horizontal verification, vertical verification, and cross correction logic; the main controller is preferably installed near the geometric center of the support array to shorten the communication link and improve overall response efficiency. A plurality of slave controllers correspond to the driving units respectively, have unique identification numbers, and are used to collect data of motor encoders and inclination sensors and feed back to the main controller; the motor encoder is used to output motor pulse information and convert real-time angles in combination with transmission parameters; the inclination sensor is installed inside the control box and rotates synchronously with the support to obtain the inclination angle; the communication module is used for data bus transmission between the main controller and the slave controller, and also supports wireless data interaction between different main controllers; the main controller exchanges real-time angle and inclination angle data with the entire square matrix main controller in real time and performs comparison, and when the difference exceeds the threshold value, the angle data of the main controller is corrected to the average value of the angle data of the entire square matrix main controller, so as to ensure the operation consistency in the range of the support array. The protection module includes communication interruption protection, slave delay self-stop protection, and motor overload and hard limit self-calibration mechanism: triggering stop or self-stop when communication interruption or slave controller is unresponsive; triggering stop when motor overload or support hits hard limit, wherein the mechanical fixity of the hard limit is used as the angle reference point for self-calibration in the hard limit scenario.

[0067] Further, the system also includes local display and remote monitoring functions: each slave controller can be externally connected to a display panel for real-time display of the running state and fault information of the driving unit on site, facilitating timely problem discovery by operation and maintenance personnel; the main controller has a wireless communication interface that can upload the collected running state, fault alarm, and correction record to the power station background management system, realizing remote monitoring and centralized scheduling management.

[0068] The system described in this embodiment realizes the functions of the method of embodiment 1 through the combination of hardware configuration and software logic, and can ensure electrical linkage consistency and safety during the operation of the multi-drive flexible photovoltaic support. Compared with embodiment 1, this embodiment emphasizes more on the module composition and function division at the system level, and the specific data collection, verification, and protection processes can be referred to the description of embodiment 1, which will not be repeated here.

[0069] In summary, the flexible photovoltaic tracking support electrical linkage consistency control system described in this embodiment takes the main controller and multiple slave controllers as the core, combines the motor encoder, inclination sensor, communication module, and protection module, and realizes real-time monitoring and centralized control of the support running state. The system not only provides hardware and functional support for the method described in embodiment 1, but also further realizes the visualization of the running state and fault information through the local display panel, and uploads the key information to the power station background through the wireless communication function of the main controller, realizing remote monitoring and centralized scheduling.

[0070] Through the combination of system and method, the present invention not only ensures the electrical linkage consistency of multiple drive units of a single flexible bracket, but also realizes the overall synchronization and safe operation within the bracket array, and has strong engineering feasibility and promotion value.

[0071] Building on Examples 1 and 2 of the present invention, this paper further theoretically deduces and details the key aspects of the flexible photovoltaic tracking bracket electrical linkage consistency control method and system. The following content expands on the algorithm design, parameter setting, and logical calculation process to more clearly demonstrate the feasibility and improved effects of the present invention's solution.

[0072] (1) Target angle setting The tracking controller obtains the longitude, latitude, and time parameters of the power station location through the GPS module and calculates the solar altitude and azimuth using an astronomical algorithm. The calculation formula is as follows: The formula for calculating the solar altitude angle is: in, is the solar altitude angle, is the geographical latitude, is the declination, is the hour angle.

[0073] The formula for calculating the solar azimuth angle is: in, is the solar azimuth.

[0074] Example: Under the conditions of longitude 118.97, latitude 36.72, and date 15:00:00 on August 27, 2025, the calculated target angle is used as the set angle for the support's current operation cycle.

[0075] In the early morning or evening when the solar altitude angle is low, a reverse tracking algorithm is used to calculate the angle to avoid shading, thereby increasing the overall power generation.

[0076] (2) Real-time angle acquisition The real-time angle is converted from the motor encoder pulse signal: in, is the number of motor pulses, is the motor speed ratio, is the speed ratio of the reduction gearbox.

[0077] For scenarios using linear actuators, the bracket angle It can be calculated according to the cosine theorem: wherein, is the fixed side length, is the included angle, is the shortest length, is the motor revolutions, is the reduction ratio, is the pitch.

[0078] (Three) Inclination Angle Collection The original signal collected by the inclination angle sensor is filtered and data fusion processed, the Kalman filter algorithm is used to weight the data, and the noise interference is reduced, so as to improve the accuracy of dynamic measurement.

[0079] (Four) Cross-verification In cross-verification, the system sets the following threshold values: Target angle threshold: ±0.01° Real-time angle threshold: ±2° Inclination angle threshold: ±1° The logic of cross-verification includes the following three aspects: 1. Target angle comparison The system calculates the maximum and minimum values of all target angles fed back from the controllers, and takes the difference as the maximum deviation. When the maximum deviation exceeds ±0.01°, it is determined that there is inconsistency in the target angle, and the main controller immediately triggers the stop and reissues the target angle until all the slave controllers feedback consistently.

[0080] 2. Real-time angle comparison The system calculates the difference between the maximum and minimum values of all real-time angles fed back from the controllers as the maximum deviation of the real-time angle. When the deviation exceeds ±2°, the system enters the double-link cross-correction link to further analyze the source of the anomaly and perform the corresponding correction.

[0081] 3. Inclination angle comparison The system calculates the difference between the maximum and minimum values of all inclination angles fed back from the controllers as the maximum deviation of the inclination angle. When the deviation exceeds ±1°, the system determines that there may be mechanical deviation or sensor failure, and triggers the protection mechanism.

[0082] Through the above three types of deviation determination mechanisms, the system can comprehensively detect the angle consistency of each drive unit in each data collection period, ensuring the synchronization of cross-running.

[0083] (Five) Double-link cross-correction When data anomalies occur, the system determines and processes according to the following conditions: If both real-time angle and tilt angle exceed the threshold value → determine as running error, stop the remaining drive units, and wait for correction.

[0084] If only real-time angle is abnormal → determine as collection or transmission error, the main controller corrects the data and continues running.

[0085] If only tilt angle is abnormal → determine as mechanical or sensor failure, the system triggers the shutdown protection.

[0086] (Six) Longitudinal verification Within the range of the support array, data interaction channels are established between each main controller through wireless communication modules. Each main controller exchanges its target angle, real-time angle and tilt angle data within the communication period, and compares them one by one. When the data of any main controller and the data of the entire square array of main controllers differ by more than a threshold value, longitudinal correction is triggered.

[0087] The longitudinal average correction condition is: Wherein, is the average value of the square array, is the current support angle, is the set threshold value. When the condition is met, the correction is the arithmetic mean. The communication period is set to 1 s.

[0088] (Seven) Fault protection and self-calibration The main controller timeout retransmission number is set to 3 times, and if it fails continuously, it is determined that the slave controller is offline, and the system issues a shutdown command.

[0089] When the hard limit is triggered, the mechanical fixed position is used as the reference point to complete the angle data self-calibration. Typical trigger shutdown conditions include: There is a faulty support; The target angle deviation exceeds ±0.01°; The real-time angle deviation exceeds ±2°; The tilt angle deviation exceeds ±1°.

[0090] (Eight) Running effect In actual testing, through the method and system of the present application, the angle difference between supports is significantly reduced, and compared with the traditional method, the angle deviation is reduced from ±3° to within ±0.5°, effectively avoiding distortion and component damage, and significantly improving running consistency and power generation efficiency.

[0091] In specific applications, such as Figure 3The figure shows the installation diagram of a single control box. The control box 1 is installed at one end of the flexible photovoltaic support beam 2 and is fixed to the surface of the beam 2 by bolts. The control box 1 integrates the main controller and the tilt sensor, which moves synchronously with the rotation of the beam 2 to achieve stable data collection of the support's operating posture. The beam 2 is arranged horizontally at the upper end of the column 3. The column 3 provides overall bearing capacity as a vertical support structure. Its lower end is connected to the foundation, and the upper end realizes the rotational freedom of the beam 2 through a rotating pair. Fixed brackets 4 are provided on both sides of the column 3. The fixed brackets 4 are connected to the column 3 and the foundation in the form of tilted supports to enhance the stability of the column 3 and prevent shaking and tilting during operation. Through this arrangement, the transmission link between the sensor and the drive unit can be significantly shortened, the accuracy of angle acquisition is improved, and the communication reliability of the control box 1 during the array operation is ensured.

[0092] In multi-drive application scenarios, Figure 3 In addition to the single control box installation shown, multiple drive units can be set along the length of the beam, each drive unit is supported by a column and forms a stable connection with the foundation through a fixed bracket. In order to ensure the consistency of electrical linkage during multi-drive operation, the main control box is preferably set in the center of the beam for installing the main controller and realizing centralized scheduling and data processing; multiple slave control boxes are set on the beam near the remaining drive units for installing slave controllers and directly connecting to the inclination sensor to realize real-time monitoring and data collection of each drive unit. The master controller maintains data exchange with each slave controller through the communication module and executes the horizontal and vertical verification logic, thereby ensuring the synchronization and consistency control of the flexible photovoltaic bracket in the multi-drive operation scenario.

[0093] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for controlling the electrical linkage consistency of a flexible photovoltaic tracking bracket, characterized in that: The following steps are involved: (1) Data acquisition: obtaining target angle, real-time angle, tilt angle and fault status data during the operation of the flexible photovoltaic bracket; (2) Master-slave control communication: Based on a distributed control architecture with one master and multiple slaves, the master controller collects data from each slave controller and performs communication verification; (3) Horizontal calibration: During the data acquisition cycle, the master controller compares the angle data fed back by each slave controller. If there is any inconsistency, it triggers shutdown, deviation correction or cross calibration. (4) Dual-link cross correction: When there are abnormalities among the target angle, real-time angle and tilt angle, corrections are made or protection is triggered according to the different abnormality types; (5) Vertical verification: Data is exchanged between different master controllers, and correction is performed when the comparison difference exceeds the threshold to maintain consistent operation within the array; (6) Fault protection: Trigger shutdown when communication is interrupted, controller does not respond, motor is overloaded, or bracket hits hard limit, and complete self-calibration using limit or tilt angle when necessary.

2. The method according to claim 1, characterized in that During the real-time angle acquisition process, the motor encoder outputs a motor pulse signal, the main controller converts the motor revolutions based on the pulse number, and converts it into the bracket angle in combination with the reduction ratio and transmission mechanism parameters, thereby achieving high-precision acquisition of the real-time angle.

3. The method according to claim 1, characterized in that The tilt angle is obtained by an inclination sensor installed on a control box circuit board. The control box is vertically fixed to one end of the bracket beam and rotates synchronously with the rotation of the beam to measure the change in the tilt angle of the bracket.

4. The method according to claim 1, wherein The target angle is preset by the control strategy before the start of each intermittent operation cycle of the bracket. The solar altitude angle and azimuth are calculated based on the latitude and longitude, date and time parameters of the power station location, and are set in combination with the irradiance and meteorological conditions in the environmental monitoring data. It remains unchanged within a single operation cycle to ensure the accuracy of the operating direction and angle.

5. The method according to claim 1, wherein The master-slave control communication includes: (1) Except for the master controller, each slave controller is configured with a unique identification number for device identification and data correspondence; (2) The master controller and each slave controller are connected through a single-path data bus to form a serial network structure; (3) The master controller sends data request instructions to each slave controller in turn. After receiving the instructions, the slave controller returns the target angle, real-time angle and tilt angle data; (4) The communication data packet contains a checksum field. If the checksum is correct, the receiving end stores the data and enters the processing flow. If the checksum is wrong, an error response is returned and retransmission is requested. (5) The master controller completes the data acquisition of all slave controllers within a fixed interval period to form a complete angle data set.

6. The method according to claim 1, characterized in that The horizontal verification includes: (1) When the target angle fed back by the slave controller is inconsistent with the target angle of the master controller, the master controller immediately issues a shutdown command and re-issues the correct target angle until the feedback is consistent and the operation is resumed; (2) When the real-time angle or tilt angle fed back from the controller deviates from the data of the main controller by more than the preset threshold, the main controller triggers the dual-link cross correction. When the angle is within the threshold range, it returns to normal. Otherwise, it is in the shutdown state. (3) When the operating angle of one controller exceeds a certain range, the suspension mechanism is triggered. The current controller is suspended and waits for the angle range of the other controllers to narrow to a certain angle before resuming normal operation.

7. The method according to claim 1, characterized in that The dual-link cross calibration comprises: (1) When both the real-time angle and the tilt angle exceed the set threshold, it is determined that the drive unit has an operation error, and the system immediately stops the operation of the remaining drive units and waits for the drive unit to adjust to the normal angle before resuming coordinated operation; (2) When only the real-time angle is abnormal and the tilt angle is normal, it is determined to be a data acquisition or transmission error. The main controller corrects the erroneous data to the correct value and the system continues to operate; (3) When only the tilt angle is abnormal but the real-time angle is normal, it is determined that the drive unit has mechanical damage or sensor abnormality, and the system triggers shutdown protection.

8. The method according to claim 1, characterized in that The longitudinal verification includes: (1) Each main controller is integrated with a wireless radio frequency communication module to establish a real-time data interaction channel with the main controller of the same array; (2) Each master controller exchanges target angle, real-time angle, and tilt angle data within the communication cycle and compares them one by one; (3) When the comparison difference exceeds the threshold, the master controller corrects its own angle data to the average angle data of the entire array master controller to eliminate the impact of single-point deviation on the overall synchronization of the array.

9. The method according to claim 1, characterized in that The fault protection includes: (1) When the master controller does not receive a response from the slave controller within 10ms, it will execute continuous resending. If it still does not receive a response within the set number of times, it will determine that the slave controller is offline and uniformly issue a global shutdown command; (2) When the slave controller does not receive the master controller's instruction within the preset time, the slave controller automatically triggers the stop operation protection program and enters the standby state; (3) When it is detected that the motor communication line is broken, the connector is loose, the motor is overloaded, or the bracket hits the hard limit during operation, the system immediately triggers the shutdown protection; if it is triggered by the hard limit, its mechanical fixity is used as a reference point to automatically complete the angle data self-calibration.

10. A flexible photovoltaic tracking bracket electrical linkage consistency control system, characterized in that: include: The main controller is used for centralized scheduling and data processing, and performs horizontal and vertical verification and cross-correction logic; Multiple slave controllers, each corresponding to a drive unit, have a unique identification number and are used to collect motor encoder and inclination sensor data and feed it back to the master controller; Motor encoder, used to output motor pulse information and convert real-time angle based on transmission parameters; The tilt sensor is installed inside the control box and rotates with the bracket to obtain the tilt angle; Communication module, used for data bus transmission between the master controller and the slave controller, and supports wireless interaction between the master controllers; A protection module is used to trigger a shutdown when communication is interrupted, the slave controller does not respond, the motor is overloaded, or the bracket hits the hard limit, and complete angle self-calibration when necessary; Local display panel, used to display the drive unit operating status and fault information in real time; The wireless communication interface is used by the main controller to upload operating status, fault alarms, and correction records to the power station backend, enabling remote monitoring and centralized scheduling.

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