Modularized splicing installation method for photovoltaic modules of machine room

Abstract

The invention discloses a modular splicing and mounting method for photovoltaic modules of a machine room, relates to the technical field of photovoltaic power generation, and comprises a standardized interface design and assembly process for realizing rapid positioning, electrical connection and structure fixation. The invention discloses a modular splicing installation method for photovoltaic modules of a machine room, and aims to solve the problems of poor deployment flexibility, complex operation and maintenance and insufficient expandability caused by too tight coupling of structural support, electrical interconnection and function extension in the prior art. According to the method, a standardized photovoltaic module unit, an integrated edge positioning flange, a self-alignment electrical connector, a distributed heat conduction interface layer and a prestress self-locking splicing process are adopted, and a sliding guide rail and a central cooperative controller are matched, so that rapid positioning, rigid connection, electrical penetration and heat flow dredging of the module are realized. Through the scheme, system deployment agility, maintenance convenience and capacity expansion adaptability are remarkably improved, and the method is suitable for scenes such as communication machine rooms and data centers.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic power generation technology, and in particular to a modular splicing and installation method for photovoltaic modules in a computer room. Background Technology

[0002] With the deepening of the global energy structure transformation, the integrated application of distributed renewable energy systems in various infrastructures is becoming increasingly widespread. Among these, combining photovoltaic (PV) power generation systems with critical facilities such as communication equipment rooms and data centers has become an important technological path to improve energy self-sufficiency and reduce operational carbon emissions. As a core node of information and communication networks, the power supply stability and energy efficiency of equipment rooms directly affect the reliable operation of the entire system. PV modules, as key energy conversion units, are significantly impacted by their installation methods, which not only affect power generation efficiency but also profoundly constrain construction cycles, ease of operation and maintenance, and overall structural safety. Against this backdrop, how to achieve efficient, reliable, and scalable deployment of PV modules in limited spaces such as equipment room rooftops or facades has become a core issue in engineering practice in this field.

[0003] In current technological practices, the installation of photovoltaic (PV) systems in data centers generally adopts either traditional bracket-fixed or prefabricated solutions. The former typically relies on on-site welding and bolting to fix standard-sized PV panels one by one onto customized steel structure brackets; the latter involves pre-assembling large integrated PV curtain walls or roof units in a factory, which are then hoisted onto the surface of the data center building. In their early development stages, these two models did indeed meet basic installation requirements to some extent: the bracket-fixed solution offered strong adaptability, allowing for localized adjustments based on different roof structures; and the prefabricated solution demonstrated faster construction speeds in newly built data centers with higher levels of standardization. However, as data center construction evolves towards modularization, rapid deployment, and flexible expansion, and with higher demands for timely operation and maintenance response and lifecycle cost control, the inherent structural defects of these traditional installation methods at the theoretical level have gradually become apparent, leading to a series of irreconcilable technical contradictions in practical applications.

[0004] Specifically, while traditional fixed-mount installation offers flexibility, it is highly dependent on on-site operations, involving complex procedures, lengthy work hours, and requiring a high level of skill from construction personnel. This is particularly disadvantageous in remote or space-constrained data center scenarios. More importantly, the lack of standardized mechanical and electrical interfaces between components necessitates redesigning the support structure for later capacity expansion or partial replacement, hindering "plug-and-play" functional expansion. While prefabricated solutions offer improved initial installation efficiency, their rigid, integrated structure sacrifices necessary adaptability. Even minor deviations in the data center's shape or subsequent adjustments to the photovoltaic coverage area can render the entire unit unsuitable, leading to material waste and project delays. Furthermore, the large size of these units is highly dependent on logistics and lifting equipment during transportation and hoisting, significantly increasing overall implementation costs. Ultimately, neither of these two approaches effectively decouples the three core elements of "structural support," "electrical interconnection," and "functional expansion," leading to a trade-off between deployment flexibility, maintenance convenience, and cost-effectiveness: prioritizing structural stability often sacrifices scalability, while emphasizing rapid installation frequently comes at the cost of reduced compatibility accuracy. Especially in real-world scenarios involving the mixing of multiple batches and manufacturers of equipment, problems such as interface incompatibility, uneven stress distribution, and stress concentration due to thermal expansion and contraction frequently occur, not only affecting power generation performance but also posing potential structural safety hazards.

[0005] Therefore, how to construct a photovoltaic module installation method that can maintain the independence and standardization of modular units while achieving efficient coordination of mechanical, electrical and thermal management functions at the splicing interface, thereby significantly improving the deployment agility, operation and maintenance convenience and full life cycle scalability of the data center photovoltaic system while ensuring structural safety and power generation efficiency, has become a key challenge and an urgent technical problem for those skilled in the art. Summary of the Invention

[0006] This invention provides a modular splicing and installation method for photovoltaic modules in a data center, aiming to solve the technical problems of poor deployment flexibility, high operation and maintenance complexity, and insufficient scalability throughout the entire life cycle caused by the tight coupling of structural support, electrical interconnection, and functional expansion in existing technologies. To achieve the above-mentioned objectives, this invention constructs a modular photovoltaic unit system with standardized mechanical interfaces, self-aligning electrical connection mechanisms, and distributed thermal management channels. Combined with a splicing and installation process based on a prestressed self-locking mechanism, each photovoltaic module can be quickly positioned, rigidly connected, electrically connected, and heat dissipated in a deterministic manner within the roof or facade space of the data center. This significantly improves the system's deployment agility, maintenance convenience, and expansion adaptability while ensuring structural safety and power generation efficiency.

[0007] The core components of the modular splicing and installation method for photovoltaic modules in the computer room include: several standardized photovoltaic module units, mechanical connection components between modules, self-aligning electrical connectors, a distributed heat conduction interface layer, and a central collaborative controller. Each standardized photovoltaic module unit consists of a photovoltaic cell array, a rigid support substrate, an edge positioning flange, a bottom heat dissipation fin array, a top protective cover, and an embedded status monitoring unit. The rigid support substrate is integrally stamped from 6061-T6 aluminum alloy, with its four edges extending vertically to form a closed edge positioning flange. This flange has two sets of symmetrically distributed conical guide holes and one set of central positioning pin holes. The bottom heat dissipation fin array is welded to the bottom surface of the rigid support substrate in a parallel arrangement with equal spacing. The fins are 12mm high and 2.5mm thick, and the material is die-cast aluminum with a thermal conductivity of not less than 200W / (m·K). The top protective cover is a double-layer tempered glass structure with an outer layer thickness of 4mm and an inner layer thickness of 3.2mm. The middle layer is filled with dry nitrogen and equipped with a microporous pressure relief valve. The embedded status monitoring unit includes a temperature sensor, a voltage sampling circuit, and a wireless communication module. It is fixedly installed on the inner side of the rigid support substrate near the edge positioning flange. Its signal output terminal is electrically connected to the busbar of the photovoltaic cell array through a flexible printed circuit board.

[0008] The mechanical connection components between modules consist of prestressed locking bolts, elastic buffer washers, limit blocks, and sliding guide rails. The prestressed locking bolts are M8 grade stainless steel bolts with hexagonal drive grooves on their heads and preset torque release marks on the screw section. They automatically break and separate when the tightening torque reaches 15 N·m. The elastic buffer washers are molded from silicone rubber material with a Shore hardness of 60A. Their inner diameter matches that of the prestressed locking bolts, and their outer diameter covers the entire conical guide hole area. The limit blocks are L-shaped stainless steel components. One end is fixed to the inner side of the edge positioning flange by a countersunk screw, and the other end extends towards the adjacent module and has an arc-shaped contact surface. The sliding guide rails are U-shaped aluminum alloy profiles with a length equal to the side length of the photovoltaic module unit. They are fixed to the main load-bearing keel of the roof or facade of the equipment room by riveting, and their inner side has a groove that mates with the bottom of the edge positioning flange.

[0009] The self-aligning electrical connector includes a male plug, a female socket, a floating alignment sleeve, and a spring reset mechanism. The male plug consists of silver-plated brass contacts, an insulating shell, and a push rod. It has four contacts, corresponding to the positive, negative, ground, and communication signal lines, respectively. The contact tips have a tapered chamfered structure with a chamfer angle of 30°. The female socket is embedded inside the edge positioning flange of an adjacent photovoltaic module unit. Its cavity dimensions precisely match the insulating shell of the male plug, and an annular guide slope is provided at the cavity entrance. The floating alignment sleeve is a polytetrafluoroethylene cylinder with an inner diameter slightly larger than the outer diameter of the male plug by 0.2 mm. Both ends are connected to the cavity of the female socket and the outer wall of the edge positioning flange via snap-fit ​​connections. The spring reset mechanism consists of a compression spring and a limiting pin. The compression spring is sleeved outside the male plug push rod, with one end abutting against the rear end face of the insulating shell and the other end abutting against the limiting pin. The limiting pin is fixed in a mounting hole on the inner wall of the edge positioning flange.

[0010] The distributed thermal conductivity interface layer is laid below the splicing gap between adjacent photovoltaic module units and is formed by stacking and pressing graphene composite thermal conductive film and phase change thermal storage microcapsules. The graphene composite thermal conductive film has a thickness of 0.15 mm, an in-plane thermal conductivity of not less than 1500 W / (m·K), and an anti-oxidation nano-coating on its surface. The phase change thermal storage microcapsules have a diameter of 50 μm, are encapsulated with polymethyl methacrylate, have a core material of octadecane, and a phase change temperature range of 42°C to 48°C. This interface layer is bonded to the bottom edge area of ​​the rigid support substrate with high-temperature resistant acrylate adhesive and extends to cover the starting position of the bottom heat dissipation fin array.

[0011] The central coordinating controller is an embedded ARM Cortex-M7 architecture processor with a main frequency of 480MHz, equipped with 128MB DDR3 memory and 16GB eMMC storage. Its input interfaces include an RS485 bus, a CAN 2.0B interface, and a Wi-Fi 6 wireless module. The output end is connected to the data center energy management system. The controller periodically polls the temperature and voltage data collected by each embedded status monitoring unit through the RS485 bus, judges the module's working status based on preset thresholds, and triggers a local audible and visual alarm when it detects an abnormal temperature rise rate exceeding 3℃ / min or an open circuit voltage deviation greater than the nominal value ±5%, and sends a fault code to the remote operation and maintenance platform through the Wi-Fi 6 module.

[0012] When implementing the modular splicing installation method for photovoltaic modules in the computer room, firstly, the sliding guide rail is fixed to the main load-bearing keel along the predetermined installation path on the roof or facade of the computer room, ensuring that the horizontal error of the rail plane does not exceed ±1mm / m; then, the bottom of the edge positioning flange of the first standardized photovoltaic module unit is aligned with the groove of the sliding guide rail, and pushed in along the rail direction to the designed position. At this time, the center positioning pin hole on the edge positioning flange is automatically aligned with the positioning pin pre-embedded on the rail and inserted; next, the adjacent photovoltaic module unit is installed, so that the side of its edge positioning flange closest to the installed module fits against the edge positioning flange of the latter, using the tapered guide hole and prestressed locking bolt. The initial positioning is achieved through the cooperation of the components, and then the prestressed locking bolts are screwed in one by one and a torque of 15 N·m is applied to break the bolt head, thus completing the mechanical locking. During this process, the male plug is automatically inserted into the female socket as the module is pushed forward, the floating alignment sleeve compensates for the axial offset caused by manufacturing tolerances, and the spring reset mechanism ensures that the contact pressure at the contact point is not less than 8 N. At the same time, the distributed heat conduction interface layer is tightly attached to the bottom of the two modules under the action of module clamping, forming a continuous heat conduction path. After all modules are installed, the central coordinating controller establishes a communication link with each embedded status monitoring unit through the RS485 bus, performs initialization configuration, and begins real-time monitoring.

[0013] Furthermore, the standardized photovoltaic module unit has uniform dimensions of 1200mm×600mm×35mm and a weight controlled within 18kg, facilitating single-person handling and operation in confined spaces; its edge positioning flange has a height of 8mm and a width of 25mm, and its surface is anodized with a film thickness of not less than 15μm; the tapered guide hole has a major diameter of 10.5mm, a minor diameter of 8.2mm, a cone angle of 15°, and a central positioning pin hole diameter of 8H7 tolerance grade; the prestressed locking bolt has a pitch of 1.25mm and a breaking torque tolerance of ±0.5N·m; the male plug and female socket have a insertion and removal life of not less than 5000 cycles and a contact resistance of less than 0.5mΩ; the total thickness of the distributed heat conduction interface layer is 0.8mm, and it can maintain an interface temperature difference of less than 2℃ at an ambient temperature of 45℃.

[0014] In a preferred embodiment of the present invention, the inner wall of the sliding guide rail is provided with a grease injection port, one of which is set every 1.5m, for injecting lithium-based grease to reduce the sliding resistance of the module; the radius of the arc-shaped contact surface of the limiting block is R5, and the surface roughness Ra≤0.8μm; the temperature sensor of the embedded status monitoring unit is a PT1000 platinum resistance thermometer, with a temperature measurement range of -40℃ to +120℃ and an accuracy of ±0.3℃; the voltage sampling circuit adopts an isolated Hall sensor with a bandwidth of 100kHz and a nonlinearity of less than 0.1%; the wireless communication module supports the IEEE 802.11ax protocol, with a transmit power of 20dBm and a receive sensitivity of -92dBm.

[0015] The modular splicing installation method for photovoltaic modules in the computer room also includes a rapid replacement process for faulty modules: when the central coordinating controller determines that a photovoltaic module unit has failed, the maintenance personnel first disconnect the DC isolation switch of the branch where the module is located, then loosen the prestressed locking bolts of the adjacent two side modules (at this time the bolts have broken, only the remaining screws need to be removed), pull out the module to be replaced along the sliding guide rail in the opposite direction, insert the new module and re-tighten the connecting bolts on both sides, the self-aligning electrical connector automatically restores electrical connection, the central coordinating controller identifies the new module ID and updates the system topology in the next communication cycle, and the whole process does not require rewiring or adjustment of the support structure.

[0016] Furthermore, the method supports bidirectional expansion in both the horizontal and vertical directions: within the roof plane, multiple standardized photovoltaic module units can be connected end-to-end along sliding guide rails to form a photovoltaic array of arbitrary length; in the vertical direction of the facade, by setting transition connectors between the upper and lower sliding guide rails, the modules can be stacked and installed, and the transition connectors integrate waterproof sealing rings and gravity unloading springs to ensure that the vertical load is effectively transferred to the main load-bearing structure; all splicing interfaces meet the IP67 protection level and withstand level 8 wind pressure (0.5kN / m²) and temperature cycling tests from -30℃ to +70℃.

[0017] The central coordinating controller is also equipped with a thermal management coordination strategy: when the temperature of a photovoltaic module unit in a certain area is continuously higher than 55°C for more than 10 minutes, the controller sends a cooling request signal to the computer room air conditioning system through the CAN 2.0B interface and adjusts the local air supply volume accordingly; at the same time, if the phase change thermal storage microcapsule layer is in the phase change heat absorption stage, the controller records the power generation attenuation coefficient during that period and compensates and corrects it in the subsequent energy efficiency analysis.

[0018] The beneficial effects of this invention are:

[0019] This invention constructs a modular splicing and installation system for data center photovoltaic modules by integrating standardized photovoltaic module units, inter-module mechanical connection components, self-aligned electrical connectors, distributed heat conduction interface layers, and a central collaborative controller at the system level. This system features structural decoupling, unified interfaces, and coordinated functions. At the physical level, it achieves simultaneous completion of mechanical positioning, electrical connection, and heat flow dissipation. At the logical level, it realizes closed-loop control of state perception, fault diagnosis, and operation and maintenance response. This fundamentally solves the structural contradiction between deployment flexibility, maintenance convenience, and full lifecycle scalability in traditional installation methods, making it suitable for distributed photovoltaic integration scenarios in newly built and renovated communication data centers, edge data centers, and various critical infrastructures. Attached Figure Description

[0020] Figure 1 This is a flowchart of the modular splicing and installation method for photovoltaic modules in a computer room according to the present invention;

[0021] Figure 2 This is a schematic diagram of the connection between two adjacent standardized photovoltaic module units in the splicing area of ​​this invention. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. The illustrative embodiments and descriptions herein are used to explain the present invention, but are not intended to limit the present invention.

[0023] This invention provides a modular splicing and installation method for photovoltaic modules in a data center. Its core lies in the system integration of standardized photovoltaic module units, mechanical connection components between modules, self-aligning electrical connectors, a distributed heat conduction interface layer, and a central coordinating controller. This integration enables rapid deployment, rigid connection, electrical continuity, and heat dissipation of the photovoltaic system within the rooftop or facade space of the data center. The technical solution of this invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0024] The standardized photovoltaic module unit serves as the basic building block of this invention. Its overall dimensions are uniformly 1200mm × 600mm × 35mm, and its weight is controlled to within 18kg, meeting the requirements for single-person handling and operation in confined spaces. This unit consists of six parts: a photovoltaic cell array, a rigid support substrate, edge positioning flanges, a bottom heat dissipation fin array, a top protective cover, and an embedded status monitoring unit. The rigid support substrate is made of 6061-T6 aluminum alloy, manufactured using an integral stamping process, possessing excellent structural strength and fatigue resistance. Its four edges extend vertically to form closed edge positioning flanges, with a height of 8mm and a width of 25mm. The surface is anodized with a film thickness of not less than 15μm to improve corrosion resistance and wear resistance. The edge positioning flange is provided with two sets of symmetrically distributed tapered guide holes and one set of central positioning pin holes; the tapered guide holes have a major diameter of 10.5mm, a minor diameter of 8.2mm, and a cone angle of 15°, and are used to guide the initial alignment of adjacent modules; the central positioning pin holes have a diameter of 8H7 tolerance grade and are used to achieve high-precision positioning.

[0025] The photovoltaic array is fixedly mounted on the upper surface of a rigid support substrate. It consists of monocrystalline silicon cells connected in series and parallel, with a nominal open-circuit voltage of 48V and a maximum power point voltage of 40V. A top protective cover, a double-layered tempered glass structure, covers the photovoltaic array. The outer layer is 4mm thick, and the inner layer is 3.2mm thick. Dry nitrogen is filled between the two layers, and microporous pressure relief valves are installed at the edges to balance the internal and external pressure differences and prevent glass breakage due to temperature changes. The bottom heat dissipation fin array is welded to the bottom surface of the rigid support substrate, arranged in parallel at equal intervals. The fins are 12mm high and 2.5mm thick, made of die-cast aluminum with a thermal conductivity of not less than 200W / (m·K), effectively enhancing the natural convection heat dissipation capacity at the bottom of the module.

[0026] The embedded status monitoring unit is fixedly mounted on the inner side of a rigid support substrate near the edge positioning flange. It includes a PT1000 platinum resistance temperature sensor, an isolated Hall voltage sampling circuit, and a wireless communication module supporting the IEEE 802.11ax protocol. The temperature sensor has a measurement range of -40℃ to +120℃ and an accuracy of ±0.3℃. The voltage sampling circuit has a bandwidth of 100kHz and a nonlinearity of less than 0.1%. Its input is connected to the busbar of the photovoltaic array via an isolation transformer. The output signal is converted from analog to digital and then transmitted by the wireless communication module. The wireless communication module has a transmit power of 20dBm, a receive sensitivity of -92dBm, and operates in the 5GHz frequency band, ensuring stable communication even in a metal roof environment. This unit is electrically connected to the photovoltaic array via a flexible printed circuit board, achieving low-interference and highly reliable data acquisition and transmission.

[0027] The inter-module mechanical connection assembly is used to achieve rigid locking and stress buffering between adjacent photovoltaic module units. It consists of prestressed locking bolts, elastic buffer washers, limit blocks, and sliding guide rails. The prestressed locking bolts are M8 grade stainless steel bolts with a pitch of 1.25mm. Their heads have hexagonal drive grooves, and the screw portion has preset torque release marks. When the tightening torque reaches 15N·m (tolerance ±0.5N·m), controlled fracture occurs at the marks, and the bolt head automatically separates, leaving only the screw portion embedded in the connection hole, thus preventing overload damage to the structure. The elastic buffer washers are molded from silicone rubber material with a Shore hardness of 60A. Their inner diameter matches the bolt, and their outer diameter covers the entire tapered guide hole area. During bolt tightening, they provide axial elastic compression, absorbing micro-displacements caused by thermal expansion and contraction and wind vibration.

[0028] The limiting stop is an L-shaped stainless steel component. One end is fixed to the inner side of the edge positioning flange with a countersunk screw, and the other end extends towards the adjacent module. Its contact end face is machined into an arc-shaped surface with a radius of R5 and a surface roughness Ra≤0.8μm. This is used to limit excessive displacement of the module during lateral sliding and to provide lateral constraint after splicing. The sliding guide rail is a U-shaped aluminum alloy profile with a length equal to the side length of the photovoltaic module unit (i.e., 1200mm or 600mm). It is fixed to the main load-bearing keel of the roof or facade of the equipment room with stainless steel rivets. The inner side of the rail has a groove that mates with the bottom of the edge positioning flange. The groove is 10mm deep and 28mm wide to ensure that the module maintains a horizontal posture during the pushing process. A grease injection port is set every 1.5m on the inner wall of the groove for injecting lithium-based grease to reduce the sliding resistance of the module and extend the service life of the guide rail.

[0029] The self-aligning electrical connector is integrated into the splicing interface of adjacent photovoltaic module units to achieve automatic connection of DC power, grounding protection, and communication signals. The connector includes a male plug, a female socket, a floating alignment sleeve, and a spring-reset mechanism. The male plug consists of four silver-plated brass contacts, a polyimide insulating shell, and a push rod; the contacts correspond to the positive, negative, grounding, and communication signal lines, respectively, and the front end is machined with a 30° tapered chamfer for easy insertion guidance; the contact pressure is maintained by the spring-reset mechanism at no less than 8N, ensuring low contact resistance (less than 0.5mΩ) during long-term operation. The female socket is embedded inside the positioning flange on the edge of the adjacent module, and its cavity dimensions precisely match the insulating shell of the male plug. An annular guide ramp with a 20° angle is provided at the cavity entrance to further improve alignment tolerance.

[0030] The floating alignment sleeve is made of PTFE and has a cylindrical structure with an inner diameter 0.2mm larger than the outer diameter of the male plug. Both ends are connected to the female socket cavity and the outer wall of the edge positioning flange via snap-fit ​​structures, allowing the male plug to float radially within ±1.5mm to compensate for manufacturing tolerances and installation deviations. The spring reset mechanism consists of a compression spring and a limiting pin. The compression spring is sleeved outside the male plug push rod, with one end abutting against the rear end face of the insulating shell and the other end abutting against the limiting pin. The limiting pin is fixed in the mounting hole on the inner wall of the edge positioning flange, ensuring a spring pre-compression of 3mm, thus automatically ejecting the male plug when the module is separated, avoiding arcing damage. This connector has a mating life of no less than 5000 cycles, meeting the needs of maintenance and replacement throughout its entire lifecycle.

[0031] A distributed thermal conductivity interface layer is laid below the seam between adjacent photovoltaic module units to create a continuous bottom thermal conductivity path and suppress the formation of local hot spots. This interface layer is composed of a graphene composite thermal conductive film and phase change thermal storage microcapsules, with a total thickness of 0.8 mm. The graphene composite thermal conductive film is 0.15 mm thick, with an in-plane thermal conductivity of not less than 1500 W / (m·K), and its surface is coated with a 50 nm thick anti-oxidation nano-coating (mainly composed of Al2O3) to prevent thermal conductivity degradation caused by high-temperature oxidation. The phase change thermal storage microcapsules have a diameter of 50 μm, are encapsulated with polymethyl methacrylate (PMMA), and have a core material of octadecane (C2O3). 18 H 38 The phase transition temperature range is 42℃ to 48℃, and the latent heat of phase transition is approximately 240kJ / kg. This interface layer is bonded to the bottom edge of the rigid support substrate using a high-temperature resistant acrylic adhesive (temperature resistance ≥120℃), extending to cover the starting position of the bottom heat dissipation fin array, ensuring efficient heat transfer from the module center to the edge. At an ambient temperature of 45℃, this interface layer can maintain a temperature difference of less than 2℃ between the bottom contact areas of adjacent modules.

[0032] The central coordinating controller serves as the core of the system-level monitoring and scheduling, employing an embedded ARM Cortex-M7 processor with a 480MHz clock speed, equipped with 128MB of DDR3 memory and 16GB of eMMC storage. Its input interfaces include an RS485 bus, a CAN2.0B interface, and a Wi-Fi 6 wireless module; the output connects to the data center energy management system via Modbus TCP protocol. The controller periodically collects temperature and voltage data uploaded by each embedded status monitoring unit via the RS485 bus in a polling manner (with a period of 1 second). When a module's temperature rise rate exceeds 3℃ / min, or its open-circuit voltage deviation exceeds the nominal value ±5%, the controller immediately triggers a local audible and visual alarm and sends a fault code containing the module ID, fault type, and timestamp to the remote operation and maintenance platform via the Wi-Fi 6 module.

[0033] In addition, the central coordinating controller is equipped with a thermal management coordination strategy: when the temperature of a photovoltaic module unit in a certain area remains above 55℃ for more than 10 minutes, the controller sends a cooling request signal to the air conditioning system of the computer room through the CAN 2.0B interface, and adjusts the opening of the air valve of the air outlet in that area to increase the local air supply volume; at the same time, if the phase change thermal storage microcapsule layer is in the phase change heat absorption stage (i.e., the temperature is in the range of 42-48℃), the controller records the power generation attenuation coefficient of that period (defined as the ratio of the actual output power to the theoretical power under standard test conditions), and compensates and corrects the data for that period in the subsequent energy efficiency analysis report to ensure the accuracy of power generation statistics.

[0034] When implementing the modular splicing installation method for photovoltaic modules in the data center, firstly, based on the structural drawings of the data center roof or facade, a sliding guide rail is fixed on the main load-bearing keel along the predetermined installation path. A laser level is used to calibrate the track plane to ensure that the levelness error does not exceed ±1mm / m. Subsequently, the bottom of the edge positioning flange of the first standardized photovoltaic module unit is aligned with the groove of the sliding guide rail, and it is smoothly pushed into the designed starting position along the track direction. During this process, the bottom of the module and the track groove form a sliding pair, and the lubricant reduces frictional resistance. When the module is fully in place, the center positioning pin hole on the edge positioning flange automatically aligns with and inserts the stainless steel positioning pin (diameter 8h6) pre-embedded on the track, achieving initial precise positioning.

[0035] Next, install adjacent photovoltaic module units by pushing them in along the same sliding guide rail, ensuring that the edge positioning flange of the module closest to the installed module aligns with the latter's edge positioning flange. At this point, the tapered guide holes of the two modules are aligned, and the prestressed locking bolts pass through the two holes in sequence, are fitted with elastic buffer washers, and then screwed into the threaded holes. Apply a tightening torque of 15 N·m using a digital torque wrench, and the bolt head breaks off at the indentation, completing the mechanical locking. During this process, the male plug automatically inserts into the female socket as the module moves, the floating alignment sleeve absorbs manufacturing deviations within ±1 mm, and the spring reset mechanism ensures stable contact pressure. Simultaneously, the distributed heat conduction interface layer is compressed to a thickness of 0.75 mm under the pressure of the module, forming a low thermal resistance contact interface.

[0036] After all modules are installed, the central coordinating controller powers on and performs a self-test, broadcasting an initialization command via the RS485 bus. Each embedded status monitoring unit responds and reports a unique ID code, which the controller uses to construct a system topology diagram and begin real-time monitoring. The entire installation process requires no on-site drilling, soldering, or wiring, and the installation time for a single module is no more than 3 minutes.

[0037] In a preferred embodiment of the present invention, the method supports rapid replacement of faulty modules. When the central coordinating controller determines that a photovoltaic module unit has failed (e.g., the open-circuit voltage remains below 35V or the temperature rises abnormally), the maintenance personnel first disconnect the isolating switch of the branch where the module is located in the DC distribution cabinet to ensure operational safety. Then, using an Allen wrench, the remaining screws of the prestressed locking bolts on the adjacent modules are loosened (since the head is broken, only the screws need to be unscrewed in the reverse direction) to release the mechanical constraints. Next, the module to be replaced is smoothly pulled out along the sliding guide rail in the reverse direction, the new module is inserted, and the connecting bolts on both sides are retightened. The self-aligning electrical connector automatically restores electrical connection during the insertion process. The central coordinating controller identifies the new module ID in the next communication cycle (within 1 second), updates the topology diagram, and clears the original fault alarm. The entire process takes no more than 8 minutes and requires no rewiring or adjustment of the support structure.

[0038] Furthermore, this method supports bidirectional expansion both horizontally and vertically. Within the roof plane, multiple standardized photovoltaic module units can be connected end-to-end along sliding guide rails to form a linear photovoltaic array of arbitrary length, suitable for computer room roofs of different areas. In the vertical direction of the facade, the modules are stacked and installed by setting transition connectors between the upper and lower sliding guide rails. These transition connectors are high-strength engineering plastic injection molded parts, internally integrating a silicone waterproof sealing ring (compression set ≤15%) and a gravity unloading spring (stiffness 5N / mm). The upper end is fixed to the upper rail, and the lower end supports the positioning flange of the lower module edge, ensuring that the vertical load is effectively transferred to the main load-bearing structure while isolating vibration transmission. All splicing interfaces (including mechanical, electrical, and thermal interfaces) are certified to IP67 protection level and can maintain functional integrity after undergoing a wind pressure of level 8 (0.5kN / m²) and a temperature cycle test of -30℃ to +70℃ (50 cycles, 4 hours per cycle).

[0039] To verify the technical effect of the present invention, the following embodiments and comparative experiments were conducted.

[0040] In one specific embodiment, a 6m × 2.4m rooftop photovoltaic array consisting of 12 standardized photovoltaic module units was constructed and installed on the roof of a communication equipment room. Sliding guide rails were arranged along an east-west direction, and the modules were spliced ​​along the rails in a north-south direction. The ambient temperature was 32℃, and the solar irradiance was 950W / m². The system operated for 24 hours, with the central coordinating controller recording the temperature and voltage data of each module every second.

[0041] In the comparative example, the same number and model of photovoltaic modules were installed using traditional bolt fixing and manual wiring methods. The modules had no standardized interfaces, relied on natural convection for heat dissipation, and lacked condition monitoring functions. They were operated for 24 hours under the same conditions.

[0042] The experimental results are shown in the table below:

[0043] index Example (of the present invention) Comparative Example (Traditional Method) Average installation time per module 2.8 minutes 18.5 minutes Maximum overall array installation deviation ±1.2mm ±8.7mm Maximum module temperature (steady state) 58.3℃ 67.9℃ Temperature standard deviation (12 modules) 1.8℃ 5.6℃ Contact resistance (electrical interface) 0.32mΩ — (Manual crimping, no measurement) Replacement time of faulty module 7.2 minutes 42 minutes (including power outage, disconnection, and reconnection) Wind-induced displacement (0.5 kN / m²) <0.3mm 2.1mm Power generation interruption time during operation and maintenance 0 (Hot-swap) ≥15 minutes

[0044] Data shows that this invention is significantly superior to traditional methods in terms of installation efficiency, temperature uniformity, structural stability, and ease of operation and maintenance. In particular, in terms of temperature control, the synergistic effect of the distributed heat conduction interface layer and the bottom heat dissipation fin array reduces the module temperature rise by approximately 9.6°C, effectively delaying the degradation of photovoltaic cell efficiency (efficiency decreases by approximately 0.4% for every 1°C increase in temperature).

[0045] Furthermore, to assess the effectiveness of the thermal management coordination strategy, another set of experiments simulated localized hot spots by artificially blocking some modules. In the example system, the air conditioning was automatically triggered within 10 minutes after the temperature reached 56°C, increasing the local airflow by 30%, and the module temperature dropped back to 52°C within 15 minutes. In contrast, the comparative system lacked this function, and the temperature continued to rise to 71°C, triggering inverter power-limiting operation and reducing power generation efficiency by 12%.

[0046] In summary, this invention, through the deep integration of standardized design, self-aligned connection, distributed thermal management, and intelligent collaborative control, constructs a highly integrated, scalable, and easily maintainable modular splicing and installation system for photovoltaic modules in data centers. This system achieves simultaneous completion of mechanical, electrical, and thermal interfaces at the physical level, and realizes closed-loop control of sensing, diagnosis, and response at the logical level, providing a reliable technical path for green energy integration in critical infrastructure such as communication equipment rooms and edge data centers. Those skilled in the art can make various modifications and equivalent substitutions to the above embodiments without departing from the spirit and scope of this invention, but all such modifications and substitutions should fall within the protection scope defined by the claims of this invention.

[0047] The technical solutions of the present invention are not limited to the specific embodiments described above. Any technical modifications made in accordance with the technical solutions of the present invention fall within the protection scope of the present invention.

Claims

1. A method for modular splicing and installation of photovoltaic modules in a computer room, characterized in that, Includes the following steps: The sliding guide rail is fixed along the main load-bearing keel of the roof or facade of the machine room, and the horizontal error of the sliding guide rail does not exceed ±1mm / m. Align the bottom of the edge positioning flange of the first standardized photovoltaic module unit with the groove of the sliding guide rail, and push it into the designed position along the rail direction so that the center positioning pin hole on the edge positioning flange of the module is automatically aligned with the positioning pin pre-embedded on the rail and inserted. Push adjacent standardized photovoltaic module units along the same sliding guide rail so that their edge positioning flanges fit with the edge positioning flanges of the installed modules. After aligning the two modules using the symmetrically distributed tapered guide holes on their edge positioning flanges, insert the prestressed locking bolts and apply a torque of 15 N·m to break the bolt heads and complete the mechanical locking. During the module advancement process, the male plug automatically inserts into the female socket as the module moves, the floating alignment sleeve compensates for axial offset caused by manufacturing tolerances, and the spring reset mechanism maintains the contact pressure at the contact point at no less than 8N to achieve electrical connection. Meanwhile, the distributed heat conduction interface layer laid under the splicing gap of adjacent modules is tightly bonded under the compression of the modules, forming a continuous heat conduction path; After all modules are installed, the central coordinating controller establishes a communication link with each embedded status monitoring unit via the RS485 bus, performs initialization configuration, and begins real-time monitoring.

2. The modular splicing and installation method for photovoltaic modules in a computer room according to claim 1, characterized in that, The standardized photovoltaic module unit has an overall size of 1200mm×600mm×35mm and a weight of no more than 18kg; its edge positioning flange has a height of 8mm and a width of 25mm, and its surface is anodized with a film thickness of no less than 15μm; the tapered guide hole has a major diameter of 10.5mm, a minor diameter of 8.2mm, and a cone angle of 15°; the diameter of the center positioning pin hole is of tolerance grade 8H7.

3. The modular splicing and installation method for photovoltaic modules in a computer room according to claim 1, characterized in that, The prestressed locking bolt is an M8 grade stainless steel bolt with a pitch of 1.25 mm. The bolt has a preset torque release mark. When the tightening torque reaches 15 N·m ± 0.5 N·m, the bolt head breaks. The elastic buffer washer is made of silicone rubber with a Shore hardness of 60 A, and its outer diameter covers the entire tapered guide hole area. The limiting block is an L-shaped stainless steel component with an arc-shaped contact surface with a radius of R5 at one end facing the adjacent module, and a surface roughness Ra≤0.8 μm.

4. The modular splicing and installation method for photovoltaic modules in a computer room according to claim 1, characterized in that, The self-aligning electrical connector includes a male plug, a female socket, a floating alignment sleeve, and a spring reset mechanism. The male plug contains four silver-plated brass contacts, corresponding to the positive, negative, ground, and communication signal lines, respectively, with a 30° tapered chamfer at the front end. The female socket has an annular guide slope at its cavity entrance. The floating alignment sleeve is a polytetrafluoroethylene cylinder with an inner diameter 0.2 mm larger than the outer diameter of the male plug, allowing the male plug to float radially within a range of ±1.5 mm. The spring reset mechanism consists of a compression spring and a limiting pin, ensuring that the contact pressure is not less than 8 N, the contact resistance is less than 0.5 mΩ, and the mating life is not less than 5000 cycles.

5. The modular splicing and installation method for photovoltaic modules in a computer room according to claim 1, characterized in that, The distributed thermal conduction interface layer has a total thickness of 0.8 mm and is formed by stacking and pressing graphene composite thermal conductive film and phase change thermal storage microcapsules. The graphene composite thermal conductive film has a thickness of 0.15 mm, an in-plane thermal conductivity of not less than 1500 W / (m·K), and an anti-oxidation nano-coating on its surface. The phase change thermal storage microcapsules have a diameter of 50 μm, a core material of octadecane, and a phase change temperature range of 42°C to 48°C. This interface layer is bonded to the bottom edge area of ​​the rigid support substrate with high-temperature resistant acrylic adhesive and extends to cover the starting position of the bottom heat dissipation fin array, maintaining a temperature difference of less than 2°C between the bottom contact areas of adjacent modules at an ambient temperature of 45°C.

6. The modular splicing and installation method for photovoltaic modules in a computer room according to claim 1, characterized in that, The central coordinating controller uses an ARM Cortex-M7 architecture processor with a main frequency of 480MHz, equipped with 128MB DDR3 memory and 16GB eMMC storage; it polls the temperature and voltage data collected by each embedded status monitoring unit at a 1-second cycle via RS485 bus; when the temperature rise rate exceeds 3℃ / min or the open circuit voltage deviation is greater than the nominal value ±5%, it triggers a local audible and visual alarm and sends a fault code to the remote operation and maintenance platform via the Wi-Fi 6 module.

7. The modular splicing and installation method for photovoltaic modules in a computer room according to claim 1, characterized in that, It also includes a rapid replacement process for faulty modules: After the maintenance personnel disconnect the DC disconnect switch of the branch where the module to be replaced is located, they remove the remaining screws of the prestressed locking bolts of the modules on both sides, pull out the faulty module in the opposite direction along the sliding guide rail, insert the new module, and re-tighten the connecting bolts on both sides; the self-aligning electrical connector automatically restores electrical connection, and the central coordinating controller identifies the new module ID and updates the system topology in the next communication cycle. The entire process does not require rewiring or adjustment of the bracket structure.

8. The modular splicing and installation method for photovoltaic modules in a computer room according to claim 1, characterized in that, Supports both horizontal and vertical expansion: Within the roof plane, multiple standardized photovoltaic module units are connected end-to-end along sliding guide rails to form a photovoltaic array of arbitrary length; in the vertical direction of the facade, stacking installation is achieved through transition connectors between upper and lower sliding guide rails. The transition connectors integrate waterproof sealing rings and gravity unloading springs to ensure that vertical loads are transferred to the main load-bearing structure; all splicing interfaces meet the IP67 protection level and can withstand level 8 wind pressure (0.5kN / m²) and temperature cycling tests from -30℃ to +70℃.

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