Photovoltaic module installation method based on building surface characteristics

Abstract

The invention discloses a photovoltaic module installation method based on building surface characteristics, and belongs to the technical field of new energy and building integration. According to the method, a comprehensive characteristic model including curvature, material and thermal performance is constructed by fusing three-dimensional laser scanning and infrared thermal imaging data; based on a model, designing a mounting base adaptive to a curved surface or a plane, optimizing component layout by using a building information modeling technology, and monitoring mounting stress in real time through a distributed sensor network; during fixing, a heat-conducting gasket is laid, an adjustable bolt is used, and a seam is sealed; a flexible conductive band and a modular junction box are adopted for electrical connection; and finally carrying out illumination response, wind resistance and thermal stability tests. According to the invention, comprehensive perception and self-adaptive installation of building surface characteristics are realized, and the installation precision, the structural safety and the energy conversion efficiency are improved.

Description

Technical Field

[0001] This invention belongs to the field of new energy and building integration technology, specifically a photovoltaic module installation method based on building surface characteristics. Background Technology

[0002] With the continuous development of building-integrated photovoltaics (BIPV) technology, the efficient and safe installation of photovoltaic modules on the surfaces of various buildings has become an important direction for improving the utilization of urban renewable energy. However, existing photovoltaic module installation methods are mostly designed for standardized ground or roof structures, which have certain limitations when faced with the diversity and complexity of building surface materials, curvature, slope, load-bearing capacity, and existing structures.

[0003] For example, patent publication number CN117306749A (hereinafter referred to as "Prior Art 1") discloses a BIPV photovoltaic curtain wall system and its installation method. This method improves aesthetics and usability through curtain wall structure integration and electrical system optimization, but lacks a dynamic perception and real-time adaptation mechanism for building surface characteristics (such as curvature, material distribution, and thermal performance), resulting in insufficient installation accuracy on curved or irregular surfaces. It is unable to adjust the fixing strategy according to surface changes, which may lead to mechanical stress concentration or low thermal management efficiency.

[0004] For example, patent publication number CN119466338A (hereinafter referred to as "Prior Art 2") discloses a method for installing building-integrated photovoltaic panel curtain walls. It uses a three-dimensional coordinate control system and optimization algorithm for the layout of the support structure, but does not integrate surface geometric characteristics (such as curvature changes) and physical characteristics (such as thermal expansion coefficient) data, making it difficult to achieve high-precision bonding of non-standard surfaces.

[0005] For example, patent publication number CN120672514A (hereinafter referred to as "Prior Art 3") discloses a method for installing distributed photovoltaic modules on a roof. It uses point cloud data and three-dimensional models to divide the area and assess the load-bearing capacity, but does not combine surface temperature distribution data, so it cannot optimize the heat conduction path or adapt to local uneven areas, which limits the energy conversion efficiency and long-term reliability.

[0006] The above situation indicates that existing technologies have failed to adequately address the challenges of real-time sensing and closed-loop control based on building surface characteristics (such as curvature, material, and thermal properties). This makes it difficult to optimize installation efficiency, structural safety, and energy performance on complex building surfaces. Summary of the Invention

[0007] To address the shortcomings of the existing technology, this invention provides a photovoltaic module installation method based on building surface characteristics.

[0008] The technical solution adopted in this invention is as follows:

[0009] A photovoltaic module installation method based on building surface characteristics includes the following steps:

[0010] S1. Collect geometric morphology data and temperature distribution data of the target building surface, and fuse them to generate a comprehensive characteristic model that includes curvature changes, material distribution and thermal performance information;

[0011] S2. Based on the comprehensive characteristic model, design and manufacture mounting bases that are adapted to different areas of the building surface. The mounting bases include flexible supports for curved areas and rigid frames for planar areas.

[0012] S3. Based on the comprehensive characteristic model, the installation position of photovoltaic modules is simulated and optimized using building information modeling technology. The photovoltaic modules are cut and arranged to ensure that they fit the contour of the building surface. The stress distribution and vibration during the installation process are monitored in real time through a distributed sensor network.

[0013] S4. Place the photovoltaic module on the mounting base, lay a thermally conductive pad between the photovoltaic module and the mounting base, then use bolts to fix the photovoltaic module and seal the joints.

[0014] S5. Use flexible conductive strips to connect photovoltaic modules and lay insulating sheaths along the building surface to protect the wiring. Use modular junction boxes for electrical integration.

[0015] S6. Conduct light response test, wind resistance test, and thermal stability test on the installed photovoltaic module array.

[0016] Preferably, in step S1, a three-dimensional laser scanner is used to collect the geometric data, and an infrared thermal imager is used to collect the temperature distribution data.

[0017] Furthermore, in step S2, the bottom of the flexible support is provided with an adjustable ball joint connector.

[0018] Furthermore, in step S2, an elastic pad is provided at the bottom of the rigid frame.

[0019] Furthermore, in step S3, the distributed sensor network is connected to the central control system to form a closed-loop feedback mechanism for monitoring and early warning.

[0020] Furthermore, in step S3, a laser level is used to calibrate the position of the photovoltaic modules during pre-installation.

[0021] Specifically, in step S4, the sealing process includes filling with sealant and performing an airtightness test.

[0022] Preferably, in step S5, the flexible conductive strip is a copper braided strip, and a conductive paste is coated on the connection part to reduce the contact resistance.

[0023] Specifically, in step S6, the wind resistance performance test monitors the stress changes of the mounting base using strain gauges.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] (1) This invention integrates high-precision three-dimensional geometric scanning with infrared thermal imaging data to construct a comprehensive digital model that simultaneously includes curvature, material distribution, and thermal performance characteristics. This fundamentally solves the problem that existing technologies are difficult to adapt to complex surfaces due to a lack of perception of surface physical properties, enabling subsequent base design, component layout, and thermal management optimization to be based on accurate and comprehensive data, realizing a paradigm shift from "blind installation" to "perception-based adaptation".

[0026] (2) This invention proposes a differentiated adaptive base design based on surface characteristics, which effectively improves the structural fit and long-term safety of installation on complex curved surfaces. Addressing the distinction between "flexible supports" and "rigid frames," this invention creatively introduces adjustable ball joint connectors (for curved surfaces) and elastic buffer pads (for flat surfaces). This differentiated design allows the mounting base to actively adapt to rather than passively resist changes in surface curvature and micro-deformation, effectively dispersing mechanical stress and avoiding the stress concentration problem that easily occurs on irregular surfaces in existing technologies, thereby improving the structural fit accuracy and fatigue resistance of the installation.

[0027] (3) This invention not only uses BIM for simulation optimization before installation, but also introduces a distributed sensor network during installation to achieve real-time stress and vibration monitoring, and forms a closed-loop feedback with the central control system. This mechanism upgrades the installation from an experience-dependent "open-loop" operation to a data-driven "closed-loop" controllable process, which can promptly warn of installation deviations and potential risks (such as overstress), ensuring the consistency and reliability of installation quality, and overcoming the lag in post-installation inspection of traditional methods.

[0028] (4) Unlike existing technologies that only focus on electrical efficiency or post-heat dissipation, this invention considers the optimization of heat conduction paths during the installation structure design stage, through measures such as laying special thermally conductive pads between the components and the base. This integrated thermal design reduces the operating temperature of the components from the source. Experiments show that it can effectively reduce temperature rise, which not only directly improves photoelectric conversion efficiency, but also slows down material aging, thereby enhancing the long-term service performance of the system in complex thermal environments from the structural root.

[0029] (5) This invention uses flexible conductive strips (such as copper braided strips) for connection and is supplemented with conductive paste. This connection method can adapt to slight structural deformations to avoid stress damage and also reduces contact resistance. Combined with modular junction boxes and snap-fit ​​wiring, a safe, reliable and easy-to-assemble electrical integration solution is formed. This mechatronics and modular design concept solves the problems of electrical installation being disconnected from mechanical structure and complex and error-prone on-site wiring in traditional methods.

[0030] (6) This invention not only conducts conventional electrical performance tests, but also places special emphasis on wind resistance performance tests and thermal stability tests, directly monitoring the mechanical response of key structural components through sensors such as strain gauges. This system-level testing method based on actual working condition simulation provides objective performance verification and safety assurance for the application of installation schemes in diverse and high-risk scenarios such as curtain walls and domes, expanding the reliable application boundaries of BIPV technology. Detailed Implementation

[0031] The present invention will be further described below with reference to embodiments, and the embodiments of the present invention include, but are not limited to, the following embodiments.

[0032] This embodiment provides a photovoltaic module installation method based on building surface characteristics. First, in the building surface characteristic acquisition and analysis stage, a high-precision 3D laser scanner is used to comprehensively scan the target building surface. The 3D laser scanner has a resolution of 0.5 mm, capable of capturing minute geometric features of the building surface. The scanning range covers all potential installation areas, and a multi-angle scanning strategy effectively eliminates blind spots, ensuring data integrity and accuracy. Simultaneously, an infrared thermal imager is used to detect the temperature distribution characteristics of the building surface. This instrument has a temperature measurement accuracy of ±1℃, accurately identifying surface thermal anomaly areas, such as hot or cold spots, thereby assessing differences in thermal performance. Subsequently, the point cloud data acquired by the 3D laser scanner is fused with the temperature data acquired by the infrared thermal imager to generate a comprehensive characteristic model of the building surface. The specific fusion method is as follows: through a feature point registration algorithm, the spatial coordinates of the infrared thermal imaging are precisely aligned with the coordinates of the 3D point cloud, establishing a one-to-one mapping relationship between temperature data and geometric coordinates. This process involves data preprocessing, coordinate transformation, and error correction to ensure the high reliability of the fused model. The generated comprehensive characteristic model contains rich surface information, such as spatial coordinates, curvature changes, temperature distribution, material type (determined by correlating temperature data with a pre-defined material database), corresponding coefficient of thermal expansion, and known waterproofing layer locations. This model not only provides a multi-dimensional description of the building's surface characteristics but also offers solid foundational data support for subsequent photovoltaic module installation planning, structural adaptation, and thermal management, thereby optimizing installation efficiency and system performance.

[0033] During the design and fabrication phase of the installation base, based on the established building surface characteristic model, corresponding installation base systems are designed and fabricated for the structural and morphological characteristics of different areas. For curved or irregularly shaped areas, a flexible metal bracket is used as the main structure of the base. This bracket has a certain deformation adaptability and can adaptively conform to the building surface within a certain range. An adjustable-height ball joint connector is installed at the bottom of the bracket. This connector is made of corrosion-resistant stainless steel and has a typical ±15° angle adjustment range, effectively adapting to continuous changes in the local curvature of the building surface. The specific adjustable range of the ball joint connector needs to be verified based on the local curvature extreme values ​​extracted from the characteristic model, and a safety margin of no less than 20% is reserved in the actual design to ensure its reliability and stability during long-term use.

[0034] For the planar areas, a high-strength rigid aluminum alloy frame is selected as the main base, resulting in a lightweight structure with strong bending stiffness. A 3 mm thick elastic rubber pad is embedded at the bottom of the frame where it actually contacts the building. This pad material has a hardness of 60 Shore A, exhibiting excellent compression resilience and weather resistance. It not only effectively disperses concentrated loads generated during installation but also acts as a buffer under vibration and temperature changes, thus preventing damage to the building's finish.

[0035] The base is securely connected to the building surface using chemical anchors. The specific anchor type, spacing, and drilling depth are calculated by matching the material property distribution information in the surface characteristic model with the material strength database, and dynamically adjusted based on the regional strength characteristics. For example, in concrete areas, the anchor insertion depth is set to 80 mm, with a density of 6 anchors per square meter; while in brick masonry areas, the depth is adjusted to 60 mm, and the density is correspondingly increased to 8 anchors per square meter to ensure the reliability of the overall connection.

[0036] Furthermore, the design process for the mounting base also includes an actual assessment of the building's surface load-bearing capacity. High-precision miniature pressure sensor arrays are deployed in the target installation area. By applying progressively increasing static test loads, structural deformation is monitored in real time, and a load-deformation curve is plotted. The actual load-bearing capacity of the area is determined based on the slope of this curve, and the unit dimensions, structural material selection, and distribution density design of the base are verified and optimized accordingly to ensure the mechanical compatibility and long-term safe operation of the base system with the building structure.

[0037] During the photovoltaic module positioning and pre-installation phase, a distributed sensor network must first be scientifically deployed on the building surface. This network consists of multiple high-precision stress and temperature sensor nodes, each of which establishes a stable connection with the central control system via a low-power wireless communication module (such as ZigBee or LoRa). The central control system is used to collect, process, and compare the monitoring data with preset thresholds in real time. When the monitored values ​​approach or exceed the safety threshold, the system automatically issues an audible and visual alarm signal through a graphical human-machine interface and generates specific adjustment suggestions based on an algorithm model. For example, it may prompt operators to adjust the ball joint angle of adjacent bases, add buffer pads, or reassess the position of the fixing points, thereby constructing a real-time responsive and dynamically optimized closed-loop feedback control mechanism.

[0038] Based on this, the comprehensive characteristic digital model generated in the previous steps is imported using Building Information Modeling (BIM) technology to simulate and optimize the installation location, tilt angle, and spacing of photovoltaic modules under multiple schemes. By integrating finite element analysis (FEA) tools, the system can accurately simulate the stress distribution and temperature field changes of photovoltaic modules and supporting structures under different fixing schemes, wind pressure loads, and thermal radiation conditions, thereby determining the optimal fixing point layout with the best mechanical performance and highest durability.

[0039] Based on simulation results, CNC cutting equipment was used to precisely cut and arrange the edges of the photovoltaic modules, ensuring that the outline of each module perfectly matches the curved shape of the building's roof or facade, minimizing assembly gaps. Subsequently, workers placed the photovoltaic modules one by one onto the pre-installed bases according to the layout plan and used specialized temporary clamps for initial fixation. The clamp body employs a bidirectional adjustable screw structure with a screw diameter of 8 mm and a pitch of 1.25 mm. The clamping force can be infinitely fine-tuned by rotating the handle, ensuring clamping reliability while preventing microcracks in the cells or deformation of the frame due to excessive clamping.

[0040] During the pre-installation of photovoltaic modules, high-precision laser levels and total stations were used to calibrate the planar position and elevation of each module, ensuring that the overall flatness of the module array and the relative deviation between its edges and the building surface did not exceed 2 mm. After calibration, a CNC torque wrench with a preset torque value of 15 N·m was used to finally tighten the temporary clamps, and sensor feedback data was monitored in real time during the tightening process to ensure that the structural stress remained within the safe threshold range. The entire process was recorded and integrated into the management system, forming a traceable installation quality archive.

[0041] During the photovoltaic module fixing and sealing stage, a thermally conductive silicone gasket must first be laid between the photovoltaic module and the mounting base. The standard thickness of this gasket is 2 mm. Its main function is to enhance the thermal conductivity between the module and the base, effectively reduce contact thermal resistance, improve the overall heat dissipation efficiency of the system, and also act as a buffer to reduce potential damage to the photovoltaic module caused by external mechanical vibration or stress fluctuations. The selected thermally conductive silicone gasket must have good flexibility and aging resistance, with a thermal conductivity of not less than 1.5 W / (m·K) to ensure stability under long-term operating conditions.

[0042] The fastening method utilizes high-strength stainless steel bolts with a diameter of 10 mm, possessing excellent tensile strength and corrosion resistance. Before installation, a special anti-corrosion coating must be applied to the bolt heads to withstand harsh outdoor environments such as humidity, heat, and salt spray. Simultaneously, waterproof rubber sealing rings are installed around the bolt holes to prevent moisture from seeping into the base along the threads, ensuring the durability of the connection structure. For installation areas with curved or irregular structures, the bolt length will be dynamically adjusted based on the local curvature changes calculated in the characteristic model, ensuring that each fastening point receives appropriate preload, thereby achieving a uniform distribution of fixing force and preventing excessive local stress that could lead to microcracks in the components.

[0043] For the joint treatment of photovoltaic modules, modified polyurethane sealant is used for filling. The sealant thickness is strictly controlled within the range of 3-5 mm; too thin a layer may affect the sealing effect, while too thick a layer may lead to insufficient curing. After application, UV curing technology is used to rapidly cure the sealant to improve surface adhesion strength and internal integrity. After curing, a systematic airtightness test must be performed on the joint area. The test pressure is set at 0.5 MPa, and the pressure holding time is no less than 10 minutes. Any pressure drop necessitates resealing.

[0044] After all photovoltaic modules are secured, an ultrasonic flaw detector is used to perform non-destructive testing on the bolt connections. The testing frequency is set to 2.5 MHz, and the echo signals are used to determine whether there are any looseness, cracks, or assembly defects at the connection interface. If any defects are found during the inspection, the bolt must be immediately disassembled and reinstalled, and the above tightening and testing steps must be repeated until all test points meet the quality requirements before proceeding to the next installation stage.

[0045] During the electrical connection and wiring stage, highly flexible copper braided tape is used for the electrical connections between photovoltaic modules. This braided tape has excellent conductivity and fatigue resistance, and its cross-sectional area is 16 mm². 2It can meet the system's rated current and short-circuit withstand requirements. The two ends of the copper braided strip are firmly connected to the component electrodes using mechanical crimp terminals. The crimping process complies with the requirements of IEC 60352 standard, and high-performance conductive silver paste is applied to the connection parts to reduce contact resistance, reduce heat loss, and improve long-term reliability.

[0046] During the cable laying phase, all cables are laid rationally along the building surface, with an outer layer of flame-retardant insulating sheath. The sheath has an outer diameter of 20 mm and provides excellent resistance to ultraviolet radiation, high and low temperatures, and mechanical protection. The sheath is reliably fixed to the mounting base using stainless steel clips, with the clip spacing strictly controlled within 50 cm to ensure even stress distribution, neat appearance, and to prevent wear caused by wind vibration.

[0047] The electrical connections utilize a modular, waterproof junction box design. The junction box housing is made of V-0 grade flame-retardant ABS material and features a built-in intelligent overcurrent protection device that automatically cuts off the circuit to protect the modules in case of abnormal current. The junction box is installed on the back of the photovoltaic modules using magnetic fasteners with a magnetic attraction force of no less than 50 N, ensuring both ease of installation and removable maintenance, as well as connection stability in harsh environments. The entire electrical system layout balances safety and reliability, ease of operation and maintenance, and environmental adaptability.

[0048] During the system performance testing and optimization phase, after the photovoltaic module array was installed, a comprehensive light response test was first conducted. This test used halogen lamps that simulate the solar spectrum as the light source, and the light intensity was strictly set to 1000 W / m². 2 To simulate standard test conditions, under stable illumination, the output current and voltage data of each component were recorded group by group, and the conversion efficiency of each component and the overall array efficiency were calculated accordingly to ensure that they meet the design expectations.

[0049] Subsequently, wind resistance performance tests were conducted on the installation system. During the tests, a strong wind environment with a wind speed of 30 m / s was simulated using a wind turbine for at least 30 minutes to examine the system's mechanical behavior under extreme wind loads. Strain gauges placed at key locations on the installation base were used to monitor structural stress changes in real time during the tests. Monitoring data showed that throughout the wind load test, the maximum stress generated on the base was consistently controlled within 70% of the material's yield strength, indicating that the structural design possesses a good wind resistance safety margin.

[0050] The system performance test also included a thermal stability assessment. The photovoltaic array was placed in an ambient temperature of 40°C and operated continuously for 12 hours. The surface temperature data of the components was collected in real time using an infrared thermal imager and temperature sensors, and a curve of temperature change over time was plotted to analyze its heat dissipation performance and long-term high-temperature operating reliability.

[0051] Throughout the testing process, the positional relationships, mechanical connections, and electrical interfaces of all components were strictly installed and verified according to the engineering drawings to ensure structural coordination and robust connections. Each test was repeated multiple times, and the data results were compared and statistically analyzed to comprehensively verify the stability and reliability of the system under different operating conditions, providing a sufficient basis for subsequent practical applications.

[0052] The following description, in conjunction with the application scenario, further illustrates this embodiment.

[0053] In the building surface characteristic acquisition and analysis phase, a 3D laser scanner is first used to perform a high-precision scan of the curtain wall area of ​​the target building. During the scanning process, the 3D laser scanner rotates its scanning head at multiple angles to ensure coverage of all installation areas on the building surface and eliminate blind spots. Simultaneously, an infrared thermal imager detects the temperature distribution characteristics of the curtain wall surface, identifying areas of thermal anomalies caused by material differences or internal structure. The scan data and thermal imaging data are fused to generate a comprehensive characteristic model, which includes information such as curtain wall curvature changes, material distribution of glass and metal frames, coefficient of thermal expansion, and location of the waterproofing layer. This information is stored digitally, providing accurate basic data support for subsequent installation.

[0054] During the design and fabrication phase of the installation base, a flexible metal support was designed as the main body of the base for the curved areas of the curtain wall, based on the comprehensive characteristic model. Stainless steel ball joint connectors are installed at the bottom of the support, with an adjustment range of ±15° to adapt to changes in the curvature of the curtain wall surface. For the flat areas, a rigid aluminum alloy frame is used as the main body of the base, with 3 mm thick, 60 Shore A elastic rubber gaskets embedded at the bottom of the frame to distribute the load and protect the curtain wall surface. The base is fixed to the building surface with chemical anchors. The anchor depth is dynamically adjusted according to the strength of the curtain wall material: 80 mm for concrete and 60 mm for brick. Furthermore, multiple miniature pressure sensors are deployed in the target area to apply progressively increasing static loads, recording the relationship between surface deformation and load. The load-bearing capacity is determined based on the slope of the curve, and the size and material selection of the base are adjusted accordingly.

[0055] During the photovoltaic (PV) module positioning and pre-installation phase, a distributed sensor network is deployed on the building's curtain wall surface. Sensor nodes are connected to the central control system via wireless communication modules, forming a closed-loop feedback mechanism. Building Information Modeling (BIM) technology is used to simulate and optimize the installation positions of the PV modules, determining the optimal fixing points. Based on the simulation results, the edges of the PV modules are cut and arranged to ensure a perfect fit between the module edges and the curtain wall surface contour. Following the arrangement plan, the PV modules are placed one by one on the mounting base and secured with temporary clamps. The clamps employ a bidirectional screw structure with a screw diameter of 8 mm, allowing for fine-tuning of the clamping force according to the module size to prevent damage due to excessive tightening. During PV module pre-installation, a laser level is used to calibrate the module positions, ensuring that the relative deviation between the module edges and the curtain wall surface does not exceed 2 mm. After calibration, the temporary clamps are tightened using a torque wrench, with the tightening torque set at 15 N·m.

[0056] During the photovoltaic module fixing and sealing stage, a 2 mm thick thermally conductive silicone gasket is laid between the photovoltaic module and the mounting base to improve heat transfer efficiency and reduce the impact of mechanical vibration on the module. High-strength stainless steel bolts with a diameter of 10 mm are used to fix the photovoltaic module to the mounting base. The bolt heads are coated with an anti-corrosion coating, and waterproof sealing rings are installed around the bolt holes. For curved areas, the bolt length is dynamically adjusted according to the curvature to ensure uniform distribution of fixing force. Modified polyurethane sealant is filled at the joints of the photovoltaic modules, with the sealant thickness controlled within the range of 3-5 mm, and the curing process is accelerated using ultraviolet curing technology. After curing, an airtightness test is performed on the joint area, with the test pressure set at 0.5 MPa and the duration at least 10 minutes. After the photovoltaic modules are fixed, an ultrasonic flaw detector is used to perform non-destructive testing on the bolt connections, with the testing frequency set at 2.5 MHz. If defects are found, reinstallation and re-inspection are required until the inspection is passed before proceeding to the next step.

[0057] During the electrical connection and wiring phase, the electrical connections between photovoltaic modules use a cross-sectional area of ​​16 mm². 2 The flexible copper braided strip is connected to the module electrodes at both ends via crimp terminals, and conductive silver paste is applied to the connection points to reduce contact resistance. During wiring, an insulating sheath with an outer diameter of 20 mm is laid along the building's curtain wall surface. The sheath is fixed to the mounting base with clips spaced no more than 50 cm apart. Electrical connections utilize a modular junction box design. The junction box housing is made of flame-retardant ABS material and includes a built-in overcurrent protection device. The junction box is installed on the back of the photovoltaic module using magnetic fasteners with an attraction force of no less than 50 N.

[0058] During the system performance testing and optimization phase, after installation, a light response test was conducted on the photovoltaic module array. The test light source was a halogen lamp simulating the solar spectrum, with the light intensity set at 1000 W / m². 2 The output current and voltage values ​​of each component were recorded, and the overall conversion efficiency was calculated. The wind resistance performance of the installation system was tested at a wind speed of 30 m / s for at least 30 minutes. During the test, strain gauges were used to monitor stress changes in the mounting base; the maximum stress value did not exceed 70% of the material's yield strength. System performance testing also included an assessment of the installation system's thermal stability. The photovoltaic module array was continuously operated for 12 hours at an ambient temperature of 40°C, and the surface temperature change curves of the modules were recorded. The positional and connection relationships of each component in the above steps were precisely designed and rigorously tested to ensure the stability and reliability of the entire system.

[0059] The above embodiments are merely preferred embodiments of the present invention and should not be used to limit the scope of protection of the present invention. Any modifications or refinements made to the main design concept and spirit of the present invention that are not of substantial significance, but which still solve the same technical problem as the present invention, should be included within the scope of protection of the present invention.

Claims

1. A photovoltaic module installation method based on building surface characteristics, characterized in that, Includes the following steps: S1. Collect geometric morphology data and temperature distribution data of the target building surface, and fuse them to generate a comprehensive characteristic model that includes curvature changes, material distribution and thermal performance information; S2. Based on the comprehensive characteristic model, design and manufacture mounting bases that are adapted to different areas of the building surface. The mounting bases include flexible supports for curved areas and rigid frames for planar areas. S3. Based on the comprehensive characteristic model, the installation position of photovoltaic modules is simulated and optimized using building information modeling technology. The photovoltaic modules are cut and arranged to ensure that they fit the contour of the building surface. The stress distribution and vibration during the installation process are monitored in real time through a distributed sensor network. S4. Place the photovoltaic module on the mounting base, lay a thermally conductive pad between the photovoltaic module and the mounting base, then use bolts to fix the photovoltaic module and seal the joints. S5. Use flexible conductive strips to connect photovoltaic modules and lay insulating sheaths along the building surface to protect the wiring. Use modular junction boxes for electrical integration. S6. Conduct light response test, wind resistance test, and thermal stability test on the installed photovoltaic module array.

2. The photovoltaic module installation method based on building surface characteristics according to claim 1, characterized in that, In step S1, a 3D laser scanner is used to collect the geometric shape data, and an infrared thermal imager is used to collect the temperature distribution data.

3. The photovoltaic module installation method based on building surface characteristics according to claim 2, characterized in that, In step S2, the bottom of the flexible support is provided with an adjustable ball joint connector.

4. The photovoltaic module installation method based on building surface characteristics according to claim 3, characterized in that, In step S2, an elastic pad is provided at the bottom of the rigid frame.

5. The photovoltaic module installation method based on building surface characteristics according to claim 4, characterized in that, In step S3, the distributed sensor network is connected to the central control system to form a closed-loop feedback mechanism for monitoring and early warning.

6. The photovoltaic module installation method based on building surface characteristics according to claim 5, characterized in that, In step S3, a laser level is used to calibrate the position of the photovoltaic modules during pre-installation.

7. The photovoltaic module installation method based on building surface characteristics according to claim 6, characterized in that, In step S4, the sealing process includes filling with sealant and performing an airtightness test.

8. The photovoltaic module installation method based on building surface characteristics according to claim 7, characterized in that, In step S5, the flexible conductive strip is a copper braided strip, and a conductive paste is coated on the connection part to reduce the contact resistance.

9. The photovoltaic module installation method based on building surface characteristics according to any one of claims 1 to 8, characterized in that, In step S6, the wind resistance performance test monitors the stress change of the mounting base using strain gauges.