A method and system for detecting and controlling microcracks in photovoltaic module installations.

Abstract

This invention provides a method and system for detecting and controlling microcracks in photovoltaic module installations, relating to the field of photovoltaic module microcrack detection technology. The method includes: acquiring the contact pressure between each pressure block and the photovoltaic module using a pressure sensor; acquiring the connection friction coefficient, installation position information, and tightening torque of each pressure block; acquiring module specification parameters; determining the dynamic risk coefficient of each pressure block based on the contact pressure and installation position information; determining the torque-pressure consistency coefficient based on the connection friction coefficient, contact pressure, and tightening torque; determining the pressure unevenness risk coefficient based on the installation position information, module specification parameters, and contact pressure; and generating a detection report and control scheme based on the dynamic risk coefficient, torque-pressure consistency coefficient, and pressure unevenness risk coefficient. According to this invention, the comprehensiveness and accuracy of microcrack detection in photovoltaic module installations can be improved, reducing the possibility of microcracks occurring.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module microcrack detection technology, and in particular to a method and system for detecting and controlling microcracks in photovoltaic module installation. Background Technology

[0002] In related technologies, installation cracks in photovoltaic modules can be detected and controlled by professionals using testing instruments. In other words, it mainly relies on human factors. However, excessive reliance on human factors may make it difficult to guarantee the accuracy of detection and control of installation cracks in photovoltaic modules.

[0003] The information disclosed in the background section of this application is intended only to enhance the understanding of the general background of this application and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0004] This invention provides a method and system for detecting and controlling microcracks in photovoltaic module installations, which can solve the technical problem that related technologies cannot guarantee the accuracy of microcrack detection and control in photovoltaic module installations.

[0005] According to a first aspect of the present invention, a method for detecting and controlling microcracks in photovoltaic module installation is provided, comprising: acquiring contact pressure between each pressure block and the photovoltaic module at multiple moments during a detection cycle using a pressure sensor; acquiring the connection friction coefficient, installation position information, and tightening torque of each pressure block; acquiring module specification parameters, wherein the module specification parameters include: module diagonal length and the number of module pressure blocks; determining a dynamic risk coefficient for each pressure block based on the contact pressure and the installation position information; determining a torque-pressure consistency coefficient based on the connection friction coefficient, the contact pressure, and the tightening torque; determining a pressure non-uniformity risk coefficient based on the installation position information, the module specification parameters, and the contact pressure; and generating a detection report and a control scheme based on the dynamic risk coefficient, the torque-pressure consistency coefficient, and the pressure non-uniformity risk coefficient.

[0006] According to the present invention, determining the dynamic risk coefficient of each pressure block based on the contact pressure and the installation position information includes: determining a preset weight for each pressure block based on the installation position information; determining the contact pressure change rate based on the contact pressure; obtaining the target pressure and the maximum allowable pressure; and determining the dynamic risk coefficient of each pressure block based on the contact pressure, the contact pressure change rate, the preset weight, the target pressure, and the maximum allowable pressure.

[0007] According to the present invention, determining the preset weight of each pressure block based on the installation position information includes: determining the corner recognition result, the center area recognition result, and the midpoint recognition result of the long side of each pressure block based on the installation position information; and determining the preset weight of each pressure block based on the corner recognition result, the center area recognition result, and the midpoint recognition result of the long side.

[0008] According to the present invention, the dynamic risk coefficient of each pressure block is determined based on the contact pressure, the contact pressure change rate, the preset weight, the target pressure, and the maximum allowable pressure, including: according to the formula: Determine the dynamic risk coefficient of the i-th pressure block at the j-th moment of the detection cycle. Where, if is a conditional function, Let be the preset weight of the i-th block. Let be the contact pressure of the i-th pressure block at the j-th moment of the detection cycle. The target pressure for the i-th pressure block is... For the maximum allowable pressure, Let be the rate of change of contact pressure of the i-th pressure block at the j-th moment of the detection cycle. For the j-th moment of the detection period, Let be the contact pressure of the i-th pressure block at the t-th moment of the detection cycle. The time it takes for the contact pressure to first reach the target pressure.

[0009] According to the present invention, determining a torque-pressure consistency coefficient based on the connection friction coefficient, the contact pressure, and the fastening torque includes: obtaining historical connection friction coefficients, historical contact pressures, and historical fastening torques of multiple historical pressure blocks in multiple historical installation cycles; determining a torque-pressure relationship function based on the historical connection friction coefficients, the historical contact pressures, and the historical fastening torques; and determining a torque-pressure consistency coefficient based on the torque-pressure relationship function, the connection friction coefficient, the contact pressure, and the fastening torque.

[0010] According to the present invention, determining the torque-pressure relationship function based on the historical connection friction coefficient, the historical contact pressure, and the historical fastening torque includes: according to the formula: Determine the equation to be fitted for the torque-pressure relationship function, where, The historical contact pressure of the e-th historical pressure block at the r-th moment of the k-th historical installation cycle. To preset the historical contact pressure threshold, The historical tightening torque of the historical clamping block at the r-th moment of the k-th historical installation cycle is given. To preset the historical tightening torque threshold, Let be the historical connection friction coefficient of the historical pressure block at the r-th moment of the k-th historical installation cycle. , , , and The coefficients to be fitted are: the historical connection friction coefficient, the historical contact pressure, and the historical fastening torque are used to solve for the coefficients to be fitted, and the solution values ​​of the coefficients to be fitted are obtained; based on the solution values ​​of the coefficients to be fitted and the equation to be fitted, the torque-pressure relationship function is determined.

[0011] According to the present invention, determining the pressure unevenness risk coefficient based on the installation location information, the component specification parameters, and the contact pressure includes: determining the maximum contact pressure location information and the minimum contact pressure location information based on the contact pressure and the installation location information; determining the maximum pressure difference distance based on the maximum contact pressure location information and the minimum contact pressure location information; determining the weighted average pressure based on the contact pressure and the preset weight; obtaining a preset pressure amplification coefficient; and determining the pressure unevenness risk coefficient based on the preset pressure amplification coefficient, the contact pressure, the maximum pressure difference distance, the weighted average pressure, and the component diagonal length.

[0012] According to the present invention, a pressure non-uniformity risk coefficient is determined based on the preset pressure amplification factor, the contact pressure, the maximum pressure difference distance, the weighted average pressure, and the component diagonal length, including: according to the formula: Determine the pressure non-uniformity risk coefficient at time j of the detection cycle. ,in, Let be the contact pressure of the i-th pressure block at the j-th moment of the detection cycle. For the j-th moment of the detection period, The weighted average pressure at time j of the detection period. Let be the preset weight of the i-th block. The maximum pressure difference distance is the distance at the j-th moment of the detection cycle. The length of the component's diagonal. The preset pressure amplification factor is n, where n is the number of pressure blocks, i ≤ n, and i and n are both positive integers.

[0013] According to a second aspect of the present invention, a photovoltaic module installation microcrack detection and control system is provided, comprising: a contact pressure module for acquiring contact pressure between each pressure block and the photovoltaic module at multiple moments during a detection cycle via a pressure sensor; a pressure block data module for acquiring the connection friction coefficient, installation position information, and tightening torque of each pressure block; a specification parameter module for acquiring module specification parameters, wherein the module specification parameters include: module diagonal length and the number of module pressure blocks; a dynamic risk module for determining a dynamic risk coefficient for each pressure block based on the contact pressure and the installation position information; a consistency coefficient module for determining a torque-pressure consistency coefficient based on the connection friction coefficient, the contact pressure, and the tightening torque; a non-uniformity risk module for determining a pressure non-uniformity risk coefficient based on the installation position information, the module specification parameters, and the contact pressure; and a detection control module for generating a detection report and a control scheme based on the dynamic risk coefficient, the torque-pressure consistency coefficient, and the pressure non-uniformity risk coefficient.

[0014] Technical Effects: According to this invention, the contact pressure between the clamping block and the photovoltaic module, the installation position information and tightening torque of the clamping block, and the module specification parameters of the photovoltaic module can be accurately collected. The dynamic impact risk, torque-pressure consistency, and pressure unevenness risk during the photovoltaic module installation process are assessed, generating dynamic risk coefficients, torque-pressure consistency coefficients, and pressure unevenness risk coefficients. Furthermore, corresponding inspection reports and control schemes are generated, improving the comprehensiveness and accuracy of microcrack detection in photovoltaic module installation and reducing the possibility of microcracks. When determining the dynamic risk coefficient, the dynamic risk coefficient of each clamping block can be determined based on the contact pressure, contact pressure change rate, preset weight, target pressure, and maximum allowable pressure. During the calculation process, the sources of microcrack risk in the photovoltaic module during the clamping stage and the fixed stage can be accurately analyzed, and the influence of the clamping block position on the degree of microcrack risk in the photovoltaic module can be fully considered, improving the comprehensiveness and accuracy of the dynamic risk coefficient. When determining the torque-pressure relationship function, the torque-pressure relationship function can be determined based on historical connection friction coefficients, historical contact pressures, and historical tightening torques. The relationship between tightening torque, connection friction coefficient, and contact pressure can be accurately analyzed, improving the accuracy of the torque-pressure relationship function. When determining the pressure unevenness risk coefficient, the pressure unevenness risk coefficient can be determined based on the preset pressure amplification factor, contact pressure, maximum pressure difference distance, weighted average pressure, and module diagonal length. During the calculation process, the overall torsional load risk caused by pressure unevenness and spatial distribution on the photovoltaic module and the comprehensive dispersion of the contact pressure of all pressure blocks on the entire photovoltaic module can be accurately analyzed, thus improving the comprehensiveness and accuracy of the pressure unevenness risk coefficient.

[0015] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only, and are not intended to limit the invention. Other features and aspects of the invention will become clearer from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0017] Figure 1 An exemplary flowchart of a photovoltaic module installation microcrack detection and control method according to an embodiment of the present invention is shown.

[0018] Figure 2 An exemplary schematic diagram illustrating the determination of the dynamic risk coefficient of each pressure block according to an embodiment of the present invention is shown;

[0019] Figure 3 An exemplary schematic diagram illustrating the determination of the torque-pressure consistency coefficient according to an embodiment of the present invention is shown;

[0020] Figure 4 An exemplary schematic diagram illustrating the determination of the pressure non-uniformity risk coefficient according to an embodiment of the present invention is shown;

[0021] Figure 5 A block diagram of a photovoltaic module installation microcrack detection and control system according to an embodiment of the present invention is shown as an example. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] The technical solution of the present invention will be described in detail below with reference to specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments.

[0024] Figure 1An exemplary flowchart of a photovoltaic module installation microcrack detection and control method according to an embodiment of the present invention is shown. The method includes: Step S1, acquiring the contact pressure between each pressure block and the photovoltaic module at multiple moments during the detection cycle using a pressure sensor; Step S2, acquiring the connection friction coefficient, installation position information, and tightening torque of each pressure block; Step S3, acquiring module specification parameters, wherein the module specification parameters include: module diagonal length and the number of module pressure blocks; Step S4, determining the dynamic risk coefficient of each pressure block based on the contact pressure and the installation position information; Step S5, determining the torque-pressure consistency coefficient based on the connection friction coefficient, the contact pressure, and the tightening torque; Step S6, determining the pressure non-uniformity risk coefficient based on the installation position information, the module specification parameters, and the contact pressure; Step S7, generating a detection report and a control scheme based on the dynamic risk coefficient, the torque-pressure consistency coefficient, and the pressure non-uniformity risk coefficient.

[0025] The photovoltaic module installation microcrack detection and control method according to embodiments of the present invention can accurately collect the contact pressure between the clamping block and the photovoltaic module, the installation position information and fastening torque of the clamping block, and the module specification parameters of the photovoltaic module. It can also assess the dynamic impact risk, torque-pressure consistency, and pressure unevenness risk during the photovoltaic module installation process, and generate dynamic risk coefficients, torque-pressure consistency coefficients, and pressure unevenness risk coefficients. Furthermore, it generates corresponding detection reports and control schemes, thereby improving the comprehensiveness and accuracy of photovoltaic module installation microcrack detection and reducing the possibility of microcracks occurring.

[0026] According to one embodiment of the present invention, in step S1, at multiple moments during the detection cycle, the contact pressure between each pressure block and the photovoltaic module is obtained by a pressure sensor.

[0027] For example, the contact pressure between the pressure block and the photovoltaic module backsheet can be measured in real time by using a pressure sensor module integrated inside the pressure block.

[0028] According to one embodiment of the present invention, in step S2, the connection friction coefficient, installation position information and fastening torque of each pressure block are obtained.

[0029] For example, by using a smart wrench that can record torque values, the tightening torque during the construction of the pressure block bolts can be recorded. With the centroid of the photovoltaic module backsheet as the origin of the coordinate system and the photovoltaic module backsheet as the xoy plane of the coordinate system, the installation position information of each pressure block in the coordinate system can be determined, the friction coefficient of the pressure block bolts can be detected, and the connection friction coefficient can be determined.

[0030] According to an embodiment of the present invention, in step S3, component specification parameters are obtained, wherein the component specification parameters include: component diagonal length and component pressing block quantity.

[0031] For example, based on the photovoltaic module's factory documentation, determine the module's specifications, such as the module's diagonal length and the number of module clamping blocks.

[0032] According to one embodiment of the present invention, in step S4, the dynamic risk coefficient of each pressure block is determined based on the contact pressure and the installation position information.

[0033] Figure 2 An exemplary schematic diagram illustrating the determination of the dynamic risk coefficient of each pressure block according to an embodiment of the present invention is shown.

[0034] According to an embodiment of the present invention, step S4 includes: step S41, determining the preset weight of each pressure block according to the installation position information; step S42, determining the contact pressure change rate according to the contact pressure; step S43, obtaining the target pressure and the maximum allowable pressure; step S44, determining the dynamic risk coefficient of each pressure block according to the contact pressure, the contact pressure change rate, the preset weight, the target pressure and the maximum allowable pressure.

[0035] For example, certain locations on photovoltaic (PV) modules are weak points in terms of bending resistance, and impacts can easily lead to stress concentration, causing microcracks in the PV modules. Based on the installation location information, the preset weights of each pressure block are determined; the contact pressure and the time points in the testing cycle are fitted to obtain a contact pressure function that describes the change of contact pressure over time during the testing cycle; based on the contact pressure function, the derivative function of the contact pressure is determined; based on the derivative function, the rate of change of contact pressure is determined; relevant structural strength data of the PV modules are obtained from the PV module manufacturer to determine the ultimate pressure value; based on the ultimate pressure value divided by the first safety factor (which can be set to 2), the maximum allowable... The allowable pressure and target pressure are the contact pressures that ensure the photovoltaic modules remain in a stable and ideal condition after fastening. The specifications of photovoltaic modules will clearly indicate their mechanical load capacity, for example, "front wind pressure: 2400Pa". The total force is determined by multiplying the front wind pressure and the area of ​​the photovoltaic module. The target pressure of each pressure block is determined by (total force * second safety factor) / number of pressure blocks. The second safety factor can be set to 1.5. The risk of microcracks caused by instantaneous impacts during installation is assessed based on the contact pressure, contact pressure change rate, preset weight, target pressure and maximum allowable pressure, and the dynamic risk coefficient of each pressure block is determined.

[0036] According to an embodiment of the present invention, step S41 includes: step S411, determining the corner identification result, the center area identification result, and the midpoint identification result of the long side of each pressure block according to the installation position information; step S412, determining the preset weight of each pressure block according to the corner identification result, the center area identification result, and the midpoint identification result of the long side.

[0037] For example, the midpoint and corners of the long side of a component are weak points in terms of bending resistance, and impacts can easily lead to stress concentration. The central area, on the other hand, has stronger bending resistance. Based on the installation location information of each pressure block, the corner identification result, central area identification result, and long side midpoint identification result of each pressure block are determined. For instance, if the pressure block is located at the midpoint of the long side of the component, the long side midpoint identification result is 2, and otherwise it is 0. If the pressure block is located at the corner of the component, the corner identification result is 2, and otherwise it is 0. If the pressure block is located in the central area of ​​the component, the central area identification result is 1, and otherwise it is 0. Based on the corner identification result, central area identification result, and long side midpoint identification result, a preset weight value is determined for each pressure block. The larger the preset weight value, the weaker the bending resistance of the pressure block's location, and the more likely it is to lead to stress concentration.

[0038] According to an embodiment of the present invention, step S44 includes: determining the dynamic risk coefficient of the i-th pressing block at the j-th moment of the detection cycle according to formula (1). , (1)

[0039] Where if is a conditional function. Let be the preset weight of the i-th block. Let be the contact pressure of the i-th pressure block at the j-th moment of the detection cycle. The target pressure for the i-th pressure block is... For the maximum allowable pressure, Let be the rate of change of contact pressure of the i-th pressure block at the j-th moment of the detection cycle. For the j-th moment of the detection period, Let be the contact pressure of the i-th pressure block at the t-th moment of the detection cycle. The time it takes for the contact pressure to first reach the target pressure.

[0040] According to an embodiment of the present invention, in formula (1), the condition function The value includes the following two cases, when the following conditions are met: When the condition is met, it means that the contact pressure of the i-th pressure block at the j-th moment of the detection cycle has not reached the target pressure. The pressure block is still in the transition period from a free state to initial fixation. The risk of microcracks mainly comes from severe and instantaneous external impact forces. The value of the condition function is... , Let be the ratio of the absolute value of the rate of change of contact pressure of the i-th pressure block at the j-th moment of the detection cycle to the maximum allowable pressure. This represents the dimensionless instantaneous impact intensity. The larger this ratio, the faster the contact pressure increases, and the greater the instantaneous impact intensity. The ratio represents the relative difference between the contact pressure and the target pressure of the i-th pressure block at the j-th moment of the detection cycle. The larger this ratio, the greater the distance between the current contact pressure and the safe and stable target state (i.e., the target pressure), indicating that it is in a high-risk and unstable transition process. This ratio represents the relative risk exposure to pressure; the larger the ratio, the greater the relative risk exposure to pressure. This represents the dynamic risk coefficient determined during the fastening phase based on the relative risk exposure to instantaneous impact intensity and contact pressure, provided that the following conditions are not met. When the condition is met, it means that the contact pressure of the i-th pressure block exceeds the target pressure at the j-th moment of the detection cycle. The pressure block has been fixed, and prestress already exists inside the corresponding location of the photovoltaic module. The risk of microcracks mainly stems from the contact pressure's inability to stabilize near the target pressure, i.e., continuous oscillation around the target pressure (potentially caused by uneven support, loose bolts, or mechanical interference). The value of the conditional function is... , Represents the dimensionless instantaneous impact intensity. The time from the contact pressure to the target pressure. up to the current moment The cumulative undershoot / overshoot area, i.e., the cumulative oscillation energy. The larger the value, the greater the accumulated oscillation energy, and the more severe the oscillation. The ratio of accumulated oscillation energy to target pressure represents the dimensionless oscillation intensity. The larger this ratio, the longer and more significant the pressure value fluctuates after reaching the target, making it difficult to stabilize. This continuous instability will apply alternating stress to the component, greatly increasing the risk of fatigue damage and microcracks. This represents the dynamic risk coefficient determined based on the instantaneous impact intensity and oscillation intensity at a fixed stage.

[0041] According to one embodiment of the present invention, Let be the preset weight of the i-th block. The larger the value, the weaker the bending resistance at the corresponding location of the block, and the higher the risk of microcracks. This represents the dynamic risk coefficient considering the location of the briquettes.

[0042] In this way, the dynamic risk coefficient of each pressure block can be determined based on the contact pressure, the rate of change of contact pressure, the preset weight, the target pressure, and the maximum allowable pressure. During the calculation process, the sources of hidden crack risk in photovoltaic modules during the pressure block fastening stage and the fixed stage can be accurately analyzed, and the influence of the pressure block position on the degree of hidden crack risk in photovoltaic modules can be fully considered, thus improving the comprehensiveness and accuracy of the dynamic risk coefficient.

[0043] According to one embodiment of the present invention, in step S5, a torque-pressure consistency coefficient is determined based on the connection friction coefficient, the contact pressure, and the fastening torque.

[0044] Figure 3 A schematic diagram illustrating the determination of the torque-pressure consistency coefficient according to an embodiment of the present invention is shown.

[0045] According to an embodiment of the present invention, step S5 includes: step S51, obtaining the historical connection friction coefficient, historical contact pressure, and historical fastening torque of multiple historical pressure blocks in multiple historical installation cycles; step S52, determining a torque-pressure relationship function based on the historical connection friction coefficient, the historical contact pressure, and the historical fastening torque; and step S53, determining a torque-pressure consistency coefficient based on the torque-pressure relationship function, the connection friction coefficient, the contact pressure, and the fastening torque.

[0046] For example, a construction period in which installation has been completed without any hidden cracks is taken as a historical installation period. The historical connection friction coefficient, historical contact pressure, and historical tightening torque of multiple historical pressure blocks in multiple historical installation periods are obtained. Friction and torque both affect contact pressure to some extent; for example, the greater the torque, the greater the converted contact pressure. Based on the correlation of the above data, a torque-pressure relationship function can be determined between the historical connection friction coefficient, historical contact pressure, and historical tightening torque. Substituting the connection friction coefficient and tightening torque into the torque-pressure relationship function, the predicted contact pressure is obtained. The contact pressure difference is determined based on the absolute value of the difference between the predicted and actual contact pressures. The contact pressure difference ratio is determined based on the ratio of the contact pressure difference to the predicted contact pressure. If the contact pressure difference ratio is greater than or equal to 0.15, it indicates that the torque-pressure consistency is unqualified, and the torque-pressure consistency coefficient is 0; conversely, it indicates that the torque-pressure consistency is qualified, and the torque-pressure consistency coefficient is 1.

[0047] According to an embodiment of the present invention, step S52 includes: determining the equation to be fitted for the torque-pressure relationship function according to formula (2). (2)

[0048] in, The historical contact pressure of the e-th historical pressure block at the r-th moment of the k-th historical installation cycle. To preset the historical contact pressure threshold, The historical tightening torque of the historical clamping block at the r-th moment of the k-th historical installation cycle is given. To preset the historical tightening torque threshold, Let be the historical connection friction coefficient of the historical pressure block at the r-th moment of the k-th historical installation cycle. , , , and The coefficients to be fitted are: the historical connection friction coefficient, the historical contact pressure, and the historical fastening torque are used to solve for the coefficients to be fitted, and the solution values ​​of the coefficients to be fitted are obtained; based on the solution values ​​of the coefficients to be fitted and the equation to be fitted, the torque-pressure relationship function is determined.

[0049] According to one embodiment of the present invention, This is the ratio of the historical contact pressure of the e-th historical pressure block at the r-th moment of the k-th historical installation cycle to the preset historical contact pressure threshold. It represents the dimensionless historical contact pressure, and the preset historical contact pressure threshold can be set to 1 Pa. This is the ratio of the historical tightening torque of the e-th historical clamping block at the r-th moment of the k-th historical installation cycle to the preset historical tightening torque threshold. It represents the dimensionless historical tightening torque, and the preset historical tightening torque threshold can be set to 1 N·m. This indicates a positive correlation between the historical contact pressure of the e-th historical clamping block at the r-th moment of the k-th historical installation cycle and the historical tightening torque of the e-th historical clamping block at the r-th moment of the k-th historical installation cycle. For example, torque is converted into axial clamping force in the bolt, and axial clamping force is converted into contact pressure. Therefore, the greater the historical tightening torque, the greater the historical contact pressure. This indicates a negative correlation between the historical contact pressure and the historical connection friction coefficient of the historical pressure block at the r-th moment of the k-th historical installation cycle. For example, the larger the friction coefficient, the more torque is consumed by friction, the smaller the torque converted into contact pressure, and the smaller the historical contact pressure. Based on the above relationship, the equation to be fitted for the torque-pressure relationship function can be determined.

[0050] According to one embodiment of the present invention, fitting can be performed based on multiple parameters involved in the above-mentioned equation to be fitted, that is, fitting can be performed based on historical connection friction coefficient, historical contact pressure, and historical fastening torque, and the above-mentioned multiple coefficients to be fitted can be solved. There are 5 coefficients to be fitted, namely, , , , and Based on the historical connection friction coefficient, historical contact pressure, and historical fastening torque from at least five historical installation cycles, the five coefficients to be fitted are solved to obtain the solution values ​​of the five coefficients to be fitted. The solution values ​​of the five coefficients to be fitted are then substituted into the equation to be fitted to determine the torque-pressure relationship function.

[0051] In this way, the torque-pressure relationship function can be determined based on historical connection friction coefficient, historical contact pressure, and historical tightening torque. This allows for accurate analysis of the relationship between tightening torque, connection friction coefficient, and contact pressure, thus improving the accuracy of the torque-pressure relationship function.

[0052] According to an embodiment of the present invention, in step S6, a pressure non-uniformity risk coefficient is determined based on the installation location information, the component specification parameters, and the contact pressure.

[0053] Figure 4 A schematic diagram illustrating the determination of the pressure non-uniformity risk factor according to an embodiment of the present invention is shown.

[0054] According to an embodiment of the present invention, step S6 includes: step S61, determining the maximum contact pressure location information and the minimum contact pressure location information based on the contact pressure and the installation location information; step S62, determining the maximum pressure difference distance based on the maximum contact pressure location information and the minimum contact pressure location information; step S63, determining the weighted average pressure based on the contact pressure and the preset weight; step S64, obtaining a preset pressure amplification coefficient; and step S65, determining the pressure non-uniformity risk coefficient based on the preset pressure amplification coefficient, the contact pressure, the maximum pressure difference distance, the weighted average pressure, and the diagonal length of the component.

[0055] For example, based on contact pressure and installation location information, the location of the pressure block with the highest contact pressure at the same time is determined, i.e., the location information of the pressure block with the lowest contact pressure, i.e., the location information of the pressure block with the lowest contact pressure is determined; based on the location information of the highest and lowest contact pressure, the distance between the pressure block with the highest and lowest contact pressure is determined, i.e., the maximum pressure difference distance; based on the product of the contact pressure of each pressure block and the corresponding preset weight of the pressure block, the weighted pressure is obtained, and the average of multiple weighted pressures is calculated to determine the weighted average pressure; the preset pressure amplification factor is a dimensionless empirical coefficient, representing the torsional load risk to the module caused by the uneven spatial distribution of pressure, and the amplification factor that should be applied relative to the pure pressure numerical unevenness risk. The preset pressure amplification factor can be set to 1.5; based on the preset pressure amplification factor, contact pressure, maximum pressure difference distance, weighted average pressure, and the diagonal length of the module, the risk of microcracks in the photovoltaic module caused by uneven pressure distribution is assessed, and the pressure unevenness risk coefficient is determined.

[0056] According to an embodiment of the present invention, step S65 includes: determining the pressure non-uniformity risk coefficient at the j-th moment of the detection cycle according to formula (3). , (3)

[0057] in, Let be the contact pressure of the i-th pressure block at the j-th moment of the detection cycle. For the j-th moment of the detection period, The weighted average pressure at time j of the detection period. Let be the preset weight of the i-th block. The maximum pressure difference distance is the distance at the j-th moment of the detection cycle. The length of the component's diagonal. The preset pressure amplification factor is n, where n is the number of pressure blocks, i ≤ n, and i and n are both positive integers.

[0058] According to one embodiment of the present invention, This is the ratio of the maximum pressure difference distance at time j of the detection cycle to the diagonal length of the module. It represents the ratio of the actual uneven lever arm occupying the maximum possible size of the module. When this ratio is close to 1, it indicates that the maximum and minimum pressure points are almost located on the diagonal of the module, causing the greatest damage to the photovoltaic module. This represents the risk of torsional load on the component after considering the effects of uneven pressure and spatial distribution; that is, the additional torsional risk. In the text, "1" represents the basic risk caused by uneven pressure values. This indicates the overall risk determined based on the basic risk and the additional tortuosity risk.

[0059] According to one embodiment of the present invention, This represents the relative error between the contact pressure of the i-th pressure block at time j of the detection cycle and the weighted average pressure. The larger this ratio, the greater the deviation between the contact pressure of the i-th pressure block at time j of the detection cycle and the weighted overall average contact pressure. The "standard deviation" represents the bending resistance at different locations on the photovoltaic module, and it represents the overall dispersion of the contact pressure of all pressure blocks on the entire photovoltaic module. The larger the value, the more uneven the pressure distribution, and the more often the uneven pattern appears in high-risk critical locations, thus the higher the overall risk of microcracks in photovoltaic modules. The pressure unevenness risk coefficient is determined based on the overall torsional load risk of the photovoltaic module caused by uneven pressure and spatial distribution, and the comprehensive dispersion of the contact pressure of all pressure blocks on the entire photovoltaic module.

[0060] In this way, the pressure unevenness risk coefficient can be determined based on the preset pressure amplification factor, contact pressure, maximum pressure difference distance, weighted average pressure, and module diagonal length. During the calculation process, the overall torsional load risk caused by pressure unevenness and spatial distribution on the photovoltaic module and the comprehensive dispersion of the contact pressure of all pressure blocks on the entire photovoltaic module can be accurately analyzed, thus improving the comprehensiveness and accuracy of the pressure unevenness risk coefficient.

[0061] According to an embodiment of the present invention, in step S7, a detection report and a control scheme are generated based on the dynamic risk coefficient, the torque-pressure consistency coefficient, and the pressure non-uniformity risk coefficient.

[0062] For example, when the torque-pressure consistency coefficient is 0, it indicates that the torque and pressure of the pressure block are inconsistent, generating corresponding detection information (e.g., there is a situation where the torque and pressure of the pressure block are inconsistent). A feeler gauge or long straightedge is used to check the flatness of the guide rail under the pressure block. If unevenness is confirmed, the relevant pressure block must be loosened, the bracket height adjusted, and the mounting surface ensured to be flat before retightening. If the torque-pressure consistency coefficient is 1, it indicates that the torque and pressure of the pressure block are consistent, generating corresponding detection information (e.g., there is no situation where the torque and pressure of the pressure block are inconsistent). When the pressure unevenness risk coefficient is greater than or equal to the preset pressure unevenness risk coefficient threshold (which can be set to 2), it indicates that the incidence of microcracks will significantly increase, generating corresponding detection information (e.g., there is a situation where pressure is uneven), and checking for pressure anomalies (pressure too high or too low). Clean the contact surfaces of the pressure blocks, bolts, and washers, or replace any defective bolts, washers, or pressure blocks, and retighten them. If the pressure unevenness risk coefficient is less than the preset pressure unevenness risk coefficient threshold, it indicates that the incidence of microcracks is extremely low, and corresponding detection information is generated (e.g., there is no pressure unevenness). If the dynamic risk coefficient is greater than or equal to the preset dynamic risk coefficient threshold (which can be set to 0.33), it indicates that the impact force is too large and may cause microcracks, and corresponding detection information is generated (e.g., there is excessive impact). Immediately stop the installation operation, loosen the pressure block that was impacted, check whether the bolt threads are damaged and whether there are foreign objects on the contact surface, clean it, and put it back. If the dynamic risk coefficient is less than the preset dynamic risk coefficient threshold, corresponding detection information is generated (e.g., there is no excessive impact).

[0063] The photovoltaic module installation microcrack detection and control method according to embodiments of the present invention can accurately collect the contact pressure between the clamping block and the photovoltaic module, the installation position information and tightening torque of the clamping block, and the module specification parameters of the photovoltaic module. It also assesses the dynamic impact risk, torque-pressure consistency, and pressure unevenness risk during the photovoltaic module installation process, generating dynamic risk coefficients, torque-pressure consistency coefficients, and pressure unevenness risk coefficients. Furthermore, it generates corresponding detection reports and control schemes, improving the comprehensiveness and accuracy of photovoltaic module installation microcrack detection and reducing the possibility of microcracks. When determining the dynamic risk coefficient, the dynamic risk coefficient of each clamping block can be determined based on the contact pressure, contact pressure change rate, preset weight, target pressure, and maximum allowable pressure. During the calculation process, the sources of photovoltaic module microcrack risk during the clamping block tightening stage and the fixed stage can be accurately analyzed, and the influence of the clamping block position on the degree of photovoltaic module microcrack risk is fully considered, improving the comprehensiveness and accuracy of the dynamic risk coefficient. When determining the torque-pressure relationship function, it can be based on historical connection friction coefficients, historical contact pressures, and historical tightening torques. This allows for accurate analysis of the relationship between tightening torque, connection friction coefficients, and contact pressures, improving the accuracy of the torque-pressure relationship function. When determining the pressure unevenness risk coefficient, it can be based on preset pressure amplification factors, contact pressures, maximum pressure difference distances, weighted average pressures, and the module diagonal length. During the calculation process, it allows for accurate analysis of the overall torsional load risk to the photovoltaic module caused by pressure unevenness and spatial distribution, as well as the comprehensive dispersion of the contact pressure of all pressure blocks on the entire photovoltaic module, improving the comprehensiveness and accuracy of the pressure unevenness risk coefficient.

[0064] Figure 5 An exemplary block diagram of a photovoltaic module installation microcrack detection and control system according to an embodiment of the present invention is shown. The system includes: a contact pressure module, used to acquire the contact pressure between each pressure block and the photovoltaic module at multiple moments during the detection cycle via a pressure sensor; a pressure block data module, used to acquire the connection friction coefficient, installation position information, and tightening torque of each pressure block; a specification parameter module, used to acquire module specification parameters, wherein the module specification parameters include: module diagonal length and the number of module pressure blocks; a dynamic risk module, used to determine the dynamic risk coefficient of each pressure block based on the contact pressure and the installation position information; a consistency coefficient module, used to determine the torque-pressure consistency coefficient based on the connection friction coefficient, the contact pressure, and the tightening torque; an unevenness risk module, used to determine the pressure unevenness risk coefficient based on the installation position information, the module specification parameters, and the contact pressure; and a detection control module, used to generate a detection report and a control scheme based on the dynamic risk coefficient, the torque-pressure consistency coefficient, and the pressure unevenness risk coefficient.

[0065] This invention can be a method, apparatus, system, and / or computer program product. The computer program product may include a computer-readable storage medium having computer-readable program instructions loaded thereon for performing various aspects of the invention.

[0066] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are merely examples and do not limit the present invention. The objectives of the present invention have been fully and effectively achieved. The functions and structural principles of the present invention have been demonstrated and explained in the embodiments, and any variations or modifications may be made to the implementation of the present invention without departing from the stated principles.

Claims

1. A method for photovoltaic module installation hidden crack detection and control, characterized in that, The method comprises the following steps: At multiple moments of a detection period, the contact pressure between each pressing block and photovoltaic module is obtained by a pressure sensor; The connection friction coefficient, installation position information and fastening torque of each pressing block are obtained; The module specification parameters are obtained, wherein the module specification parameters include the module diagonal length and the number of pressing blocks; the dynamic risk coefficient of each pressing block is determined according to the contact pressure and the installation position information; the torque pressure consistency coefficient is determined according to the connection friction coefficient, the contact pressure and the fastening torque; the pressure uneven risk coefficient is determined according to the installation position information, the module specification parameters and the contact pressure; the detection report and the control scheme are generated according to the dynamic risk coefficient, the torque pressure consistency coefficient and the pressure uneven risk coefficient; the dynamic risk coefficient of each pressing block is determined according to the contact pressure and the installation position information, which comprises the following steps: the preset weight of each pressing block is determined according to the installation position information; the contact pressure change rate is determined according to the contact pressure; the target pressure and the maximum allowable pressure are obtained; the dynamic risk coefficient of each pressing block is determined according to the contact pressure, the contact pressure change rate, the preset weight, the target pressure and the maximum allowable pressure; the torque pressure consistency coefficient is determined according to the connection friction coefficient, the contact pressure and the fastening torque, which comprises the following steps: the historical connection friction coefficient, the historical contact pressure and the historical fastening torque of a plurality of historical pressing blocks in a plurality of historical installation periods are obtained; the torque pressure relationship function is determined according to the historical connection friction coefficient, the historical contact pressure and the historical fastening torque; the torque pressure consistency coefficient is determined according to the torque pressure relationship function, the connection friction coefficient, the contact pressure and the fastening torque; the pressure uneven risk coefficient is determined according to the installation position information, the module specification parameters and the contact pressure, which comprises the following steps: the maximum contact pressure position information and the minimum contact pressure position information are determined according to the contact pressure and the installation position information; the maximum pressure difference distance is determined according to the maximum contact pressure position information and the minimum contact pressure position information; the weighted average pressure is determined according to the contact pressure and the preset weight; the preset pressure amplification coefficient is obtained; the pressure uneven risk coefficient is determined according to the preset pressure amplification coefficient, the contact pressure, the maximum pressure difference distance, the weighted average pressure and the module diagonal length.

2. The photovoltaic module installation crack detection and control method of claim 1, wherein, The preset weight of each pressing block is determined according to the installation position information, which comprises the following steps: the corner recognition result, the center area recognition result and the long side midpoint recognition result of each pressing block are determined according to the installation position information; the preset weight of each pressing block is determined according to the corner recognition result, the center area recognition result and the long side midpoint recognition result.

3. The photovoltaic module installation crack detection and control method of claim 1, wherein, According to the contact pressure, the contact pressure rate of change, the preset weight value, the target pressure and the maximum allowable pressure, a dynamic risk coefficient of each briquetting is determined, including: according to formula: Determination of the dynamic risk coefficient of the i th briquetting at the j th moment of the detection period Wherein, if is a conditional function, is the preset weight value of the i th briquetting, is the contact pressure of the i th briquetting at the j th moment of the detection period, is the target pressure of the i th briquetting, is the maximum allowable pressure, is the contact pressure rate of change of the i th briquetting at the j th moment of the detection period, is the j th moment of the detection period, is the contact pressure of the i th briquetting at the t th moment of the detection period, is the time when the contact pressure reaches the target pressure for the first time.

4. The photovoltaic module installation crack detection and control method according to claim 1, wherein, According to the historical connection friction coefficient, the historical contact pressure and the historical fastening torque, a torque-pressure relationship function is determined, comprising: according to the formula: determining a to-be-fitted equation of the torque-pressure relationship function, wherein, is a historical contact pressure of an e-th historical pressure block at an r-th moment of a k-th historical installation cycle, is a preset historical contact pressure threshold, is a historical fastening torque of the e-th historical pressure block at the r-th moment of the k-th historical installation cycle, is a preset historical fastening torque threshold, is a historical connection friction coefficient of the e-th historical pressure block at the r-th moment of the k-th historical installation cycle, , , , and are to-be-fitted coefficients; the to-be-fitted coefficients are solved according to the historical connection friction coefficient, the historical contact pressure and the historical fastening torque, to obtain a solving value of the to-be-fitted coefficients; and the torque-pressure relationship function is determined according to the solving value of the to-be-fitted coefficients and the to-be-fitted equation.

5. The photovoltaic module installation crack detection and control method according to claim 1, wherein, According to the preset pressure amplification coefficient, the contact pressure, the maximum pressure difference distance, the weighted average pressure and the assembly diagonal length, a pressure unevenness risk coefficient is determined, including: according to the formula: determining the pressure unevenness risk coefficient at the jth moment of the detection period , wherein, is the contact pressure of the ith pressure block at the jth moment of the detection period, is the jth moment of the detection period, is the weighted average pressure at the jth moment of the detection period, is the preset weight value of the ith pressure block, is the maximum pressure difference distance at the jth moment of the detection period, is the assembly diagonal length, is the preset pressure amplification coefficient, n is the number of pressure blocks, i≤n, i and n are both positive integers.

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