Offshore photovoltaic module high-yield assembly line assembling method, offshore photovoltaic module and sliding device

Abstract

The invention discloses an offshore photovoltaic module high-yield assembly line assembling method, an offshore photovoltaic module and a sliding device, and belongs to the technical field of offshore photovoltaic power generation engineering. According to the method, sliding rails are laid on an assembly site, functional areas of a continuous truss assembly area, a continuous assembly installation area and a continuous finished product treatment area are defined, a special sliding device is used for bearing the offshore photovoltaic module, sliding circulation of the module between stations is achieved through manual pushing, and parallel operation of procedures is achieved. The offshore photovoltaic module comprises a load-bearing framework composed of a primary truss, a secondary truss and tie bars, C-shaped steel supports installed on the trusses and photovoltaic panels fixed through pressing blocks. The sliding device comprises a sliding steel plate, a low-friction rolling pair composed of a rail sliding rod and a pulley, a limiting bolt used for locking the rail and a modularized limiting base capable of being matched with different trusses. According to the method, discrete operation is changed into continuous flow line production, the splicing efficiency and safety are improved, and the construction cost is reduced.

Description

Technical Field

[0001] This invention belongs to the field of offshore photovoltaic power generation engineering technology, specifically relating to a high-volume assembly method for offshore photovoltaic modules, offshore photovoltaic modules manufactured by this method, and a dedicated sliding device for implementing this method. Background Technology

[0002] To achieve the strategic goal of "carbon peaking and carbon neutrality," the new energy industry has been vigorously developed. The open marine environment and long hours of sunshine have made offshore photovoltaic (PV) power generation a key renewable energy growth engine, following onshore PV and offshore wind power, leading to a surge in related projects. Among these, shallow-sea fixed offshore PV systems have attracted significant attention. Their technical principle involves rigidly fixing a photovoltaic array to the tidal flats or near-shore foundation using a pile foundation structure. The successful implementation of these projects highly depends on the large-scale, efficient, and high-quality manufacturing of their supporting structures.

[0003] A typical offshore solar PV project consists of hundreds or thousands of standardized solar arrays, each composed of multiple structurally similar, mass-producible offshore solar modules. Each module typically includes a load-bearing structure composed of primary and secondary trusses, a support system, solar panels, and electrical equipment. Despite their standardization and high reproducibility, these projects face a series of severe challenges during the onshore prefabrication and assembly phase due to their unique application scenarios and construction environment, significantly hindering their large-scale and rapid development.

[0004] 1. Due to the harsh sea conditions, onshore prefabrication became the only option, but the site conditions were demanding.

[0005] The harsh working environment at sea and the short window of opportunity make it impossible to install individual components. Therefore, the entire module must be fully assembled on land before being transported to sea for installation. This requires the assembly site to be located near a coastal dock and equipped with facilities for shipping large components, resulting in extremely limited suitable sites and high costs.

[0006] 2. The modules are extremely large, and traditional assembly methods are inefficient and cannot meet tight deadlines.

[0007] To reduce the workload of offshore connection and improve overall integrity, individual offshore photovoltaic modules are enormous (typically tens of meters long) and weigh over ten tons. The traditional discrete operation mode of "fixed-point assembly and crane relocation" has serious bottlenecks:

[0008] (1) Sequential process and serious waiting: All processes (truss → bracket → photovoltaic panel) are completed at the same work station. Large cranes are occupied for a long time to move modules, resulting in waiting between different types of work and processes. Daily output is extremely low, usually only 1-2 modules.

[0009] (2) High risk and high cost of hoisting and relocation: The modules need to be hoisted and relocated multiple times, which poses risks of high-altitude swinging and collision, and the hoisting stress may cause hidden damage to the un-tightened structure. Frequent hoisting also leads to high machine shift costs.

[0010] (3) The module has a complex structure and many parts and processes, which puts forward extremely high requirements for on-site organization and management.

[0011] A complete module comprises numerous components and fasteners, including trusses, tie rods, cantilever beams, steel columns, inclined beams, purlins, bracing, photovoltaic panels, and clamping blocks, making the assembly process complex. Traditional block-shaped assembly sites result in workers of different trades moving around, chaotic and overlapping logistics, high management difficulty, low space utilization, and further drag down overall efficiency.

[0012] (4) There are variations of the standard module, and the tooling needs to have a certain degree of universality and rapid adaptation capability.

[0013] Although the modules are highly standardized, there are various truss and support forms (such as different spans and different bottom support forms) in different specifications and sizes to adapt to different sea areas or functional requirements. This requires that the assembly tooling cannot be a "one-to-one" dedicated tool, but needs to have the ability to quickly adapt to different module specifications, otherwise it will lead to a sharp increase in tooling investment costs and efficiency losses when changing modules. Summary of the Invention

[0014] The purpose of this invention is to provide a high-volume assembly line method for offshore photovoltaic modules, offshore photovoltaic modules manufactured by this method, and a dedicated sliding device for implementing this method, so as to solve the technical problems of low assembly efficiency, poor process connection, and difficulty in module movement in the prior art.

[0015] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0016] A high-volume assembly method for offshore photovoltaic modules is characterized by the following steps: A sliding track is laid in the assembly area, and at least three continuous functional areas are demarcated along the sliding track: a truss assembly area, a module installation area, and a finished product processing area. Truss assembly is completed in the truss assembly area. The assembled truss is then slid along the sliding track using a sliding device, and moved as a whole to the module installation area. Photovoltaic system supports and photovoltaic panels are then installed on the truss to obtain the offshore photovoltaic module. Finally, the offshore photovoltaic module is moved to the finished product processing area.

[0017] Furthermore, the component installation area is divided into a bracket installation area and a photovoltaic panel installation area. The bracket and photovoltaic panel installation steps include: first, sliding the truss to the bracket installation area, installing the bracket on the truss, and then sliding the overall structure with the truss and bracket installed to the photovoltaic panel installation area, and installing the photovoltaic panels on the bracket.

[0018] Furthermore, several spaced columns are set up along the length of the sliding track in the assembly area. By measuring the elevation point by point and adjusting the height of the columns, the sliding track is fixed on the columns to ensure the overall level of the sliding track.

[0019] A marine photovoltaic module is characterized by being assembled using the aforementioned assembly line method.

[0020] Furthermore, the truss includes a main truss and a secondary truss. The length direction of the main truss is perpendicular to the length direction of the sliding track. The secondary truss is fixed between two adjacent main trusses. Tie rods are fixed between the main trusses and the secondary trusses, and between the secondary trusses.

[0021] Furthermore, the support structure includes steel columns, inclined beams, and purlins. The steel columns are fixed to the truss, and the inclined beams are fixed to the steel columns at an incline along the length of the main truss. The steel columns and inclined beams form a support unit. Several support units are set on the truss. The purlins are fixed to the inclined beams along the length of the secondary truss, and the photovoltaic panels are fixed to the purlins.

[0022] Furthermore, the truss also includes cantilevered members, which are fixed to the main truss along the length of the purlins and are used to support the installation of the unit.

[0023] Furthermore, the purlin is provided with a pressure block, and the pressure block is provided with a groove. The edge of the photovoltaic panel is embedded in the groove, so that the pressure block presses the photovoltaic panel tightly.

[0024] Furthermore, the pressure block is located on the top surface of the purlin, and the pressure block has a through hole one through which a screw rod passes. The screw rod has a pressure plate, and the screw rod passes through a through hole two on the pressure plate. The pressure plate is located on the bottom surface of the purlin, so that the pressure block and the pressure plate are fixed at the purlin.

[0025] A sliding device for implementing the above-mentioned assembly line method is characterized in that it includes a sliding steel plate, a limiting member, and a limiting seat. The sliding steel plate is provided with a downwardly extending connecting part, which is limited on the sliding track, so that the sliding steel plate moves directionally along the length direction of the sliding track. The limiting member is installed on the sliding steel plate and is used to press or release the sliding track. The limiting seat is used to limit the truss.

[0026] Furthermore, the sliding steel plate is provided with a track sliding assembly and a pulley assembly. The track sliding assembly includes a track sliding rod that rotates at the sliding steel plate and is attached to the top surface of the upper flange plate of the sliding track. The pulley assembly includes a pulley that rotates at the sliding steel plate and is attached to the bottom surface of the upper flange plate of the sliding track.

[0027] Furthermore, the track sliding rod has a rotating shaft at both ends, and a through hole 1 is provided at the connecting part. The rotating shaft passes through the through hole 1 and rotates in the through hole 1.

[0028] Furthermore, a fixing plate is fixed to the connecting part, and a fixing shaft is fixed to the fixing plate, with the pulley rotating on the fixing shaft.

[0029] Furthermore, the limiting component uses a limiting bolt, the sliding steel plate has a through hole two, the sliding steel plate is welded with a limiting nut, the limiting bolt is threaded into the limiting nut, and the limiting bolt passes through the through hole two.

[0030] Furthermore, the limiting seat adopts support one and / or support two. Support one is provided with a connecting pipe with a pipe hole, and the truss is provided with a vertical rod, which is limited in the pipe hole. Support two is provided with an adjusting column, and the lower chord of the truss is supported on the adjustable column with adjustable height. The adjusting column is provided with a limiting plate, which limits the lower chord in the direction of truss movement and in the direction perpendicular to the truss movement.

[0031] Furthermore, the top of the adjusting column is provided with a second connecting plate, and the bottom of the limiting plate is provided with a third connecting plate. The second connecting plate and the third connecting plate are connected by fixing bolts.

[0032] Furthermore, eccentric adjustment plate 1 is welded to support 1, eccentric adjustment plate 2 is welded to connecting plate 3, and the truss is supported on eccentric adjustment plate 1 and eccentric adjustment plate 2.

[0033] The present invention, by adopting the above-described technical solution, has the following beneficial effects:

[0034] 1. When the truss is assembled in the truss assembly area, the support frame can be installed simultaneously in the bracket installation area, and the photovoltaic panel can be installed simultaneously in the photovoltaic panel installation area, eliminating the turnaround and waiting time of large hoisting equipment between processes. Simultaneously, module station transitions can be achieved through manual sliding, with each sliding operation taking only a few minutes, while traditional crane lifting takes more than half an hour and requires coordination of crane resources. This invention breaks the traditional discrete operation mode of "fixed-point assembly and crane relocation," creating a continuous production line of "track flow and parallel processes." The construction efficiency of this invention is significantly improved; practical estimates show that the number of modules completed per day (24 hours) has increased dramatically from approximately 2 to 6-8.

[0035] 2. Linear functional zoning ensures that material storage areas are adjacent to work areas, resulting in the shortest and clearest logistics paths. Workers of each trade are assigned to their designated functional areas, avoiding the chaos and wasted non-working time caused by mobile operations, thus significantly improving management efficiency. Simultaneously, this method frees up the large overhead clearance required for traditional hoisting operations, and the estimated site space utilization rate can be increased by over 40%.

[0036] 3. The method of moving offshore photovoltaic modules is changed from "high-altitude hoisting" to "track sliding". The center of gravity is always stably supported by the sliding track and sliding device, and is in a controlled low position. With the quick mechanical locking of the limiting components (such as limiting bolts) and the limiting seat limiting the truss, there is no possibility of instability in the module in the moving and stationary states, which improves construction safety and eliminates the safety risks of "falling from height" and "swinging impact" of the module during frequent hoisting and moving.

[0037] 4. The sliding device adopts a double-sided rolling pair design of "track sliding rod - nylon pulley", which converts sliding friction into rolling friction, reducing frictional resistance by 80-90%. This allows the 15-ton module to be easily pushed by only 1-2 workers, eliminating the need for the entire electric drive system and energy consumption costs.

[0038] Meanwhile, the 25t truck crane only needs to be fixed in the truss assembly area for component assembly, without being responsible for module relocation, thus maximizing its utilization efficiency; the 150t crawler crane is only responsible for the final product hoisting, with extremely low utilization. Compared to the traditional solution where large cranes participate in every relocation, the mechanical operating costs are reduced by more than 50%.

[0039] 5. Using adjustable column leveling technology with point-to-point elevation measurement, a rigid, highly precise horizontal track hundreds of meters long was created on-site. This track ensures that all offshore photovoltaic modules are assembled on a uniform reference surface, avoiding internal forces and deformations caused by uneven site settlement. Furthermore, it enables the rapid establishment of a level assembly base on undulating sites with a certain slope.

[0040] The tie rods, bracing, and longitudinal stabilizer bars in the offshore photovoltaic module constitute a multi-stabilization system, connecting the individual components of the main and secondary trusses and supports into a high-rigidity and high-stability spatial integral structure. Its overall torsional and bending stiffness is significantly improved, which is sufficient to resist the inertial forces during the sliding process and the dynamic loads of offshore hoisting.

[0041] 6. The uprights are quickly connected through the pipe holes of support one, while the limiting plate of support two provides precise positioning of the lower chord of the truss from all four sides, ensuring the repeatability of the positioning accuracy of the connection between the offshore photovoltaic module and the sliding device. Combined with the height adjustment of the adjusting column, the offshore photovoltaic module can be stably positioned on the sliding device.

[0042] Furthermore, the sliding device of the present invention, through its unique limiting seat design, achieves wide adaptability to trusses of different specifications (sizes, cross-sectional forms), specifically:

[0043] (1) The vertical uprights of the truss are positioned by using a quick-connect plug-in limiting device with support one. During installation, the operator only needs to insert the upright of the truss into the pipe hole of this connecting pipe. This plug-in structure itself can achieve effective limiting in the horizontal plane.

[0044] (2) Limit the lower chord of the truss. By installing an adjustment column with a set height, the top surface elevation of support two can be adjusted to ensure that the lower chords of different specifications are stably and horizontally supported. Moreover, the limiting plate is designed in an L shape, and the four limiting plates form a cross-shaped groove. The four limiting plates constrain the lower chord in the front, back, left and right directions.

[0045] (3) Based on the structural characteristics of the actual truss, support one and support two can be installed on a sliding track at the same time. For example, support one can be used in the position where the truss has uprights, and support two can be used in the truss section without uprights, forming a hybrid support and limiting system.

[0046] This invention, through the combination of a universal insertion hole in support one and an adjustable, replaceable surrounding limiting plate in support two, constitutes a modular and configurable adaptation system. It requires no structural modifications to the sliding device; simply by selecting different limiting seat modules and making simple on-site adjustments, it can safely and accurately support and guide marine photovoltaic module trusses of different sizes. This greatly enhances the versatility and engineering application range of the sliding device, and significantly reduces the R&D and manufacturing costs of specialized tooling required for different projects.

[0047] 7. Eccentricity Adaptive Adjustment: Eccentricity adjustment plates made of PTFE are installed on the support surfaces of supports one and two. This design not only utilizes its low-friction characteristics to reduce resistance, but more importantly, it allows for slight sliding of the support surface when the module has cantilever eccentricity. This automatically adjusts the force on the sliding device to near its centerline, effectively solving the "rail jamming" problem caused by eccentric loads and ensuring smooth sliding and track life.

[0048] 8. All components of this invention are made of standard steel and can be disassembled and recycled after the project is completed, and reused in subsequent projects, realizing the recycling of resources and forming a recyclable, low-loss green construction system. Attached Figure Description

[0049] The present invention will be further described below with reference to the accompanying drawings:

[0050] Figure 1 This is a schematic diagram of a marine photovoltaic module without photovoltaic panels installed according to the present invention;

[0051] Figure 2 This is a schematic diagram of the truss structure in this invention;

[0052] Figure 3 This is a schematic diagram of the main truss structure in this invention;

[0053] Figure 4 This is a schematic diagram of the connection between two secondary trusses in this invention;

[0054] Figure 5 This is a schematic diagram of the support structure in this invention;

[0055] Figure 6 This is an exploded view of the pressure block assembly in this invention;

[0056] Figure 7 This is a schematic diagram of the connection between the sliding device and the sliding track in this invention;

[0057] Figure 8 This is a schematic diagram of the connection between the sliding steel plate, the limiting member, and the limiting seat in this invention;

[0058] Figure 9 This is a schematic diagram of the connection between the sliding steel plate, the limiting member, and the limiting seat in this invention;

[0059] Figure 10 This is a schematic diagram of the track sliding assembly in this invention;

[0060] Figure 11 This is a schematic diagram of the pulley assembly in this invention;

[0061] Figure 12 This is a schematic diagram of the structure of support one in this invention;

[0062] Figure 13 This is a schematic diagram of the structure of support two in this invention;

[0063] Figure 14 This is a schematic diagram of the structure of connecting plate three in this invention;

[0064] Figure 15 for Figure 8 A schematic diagram of another embodiment;

[0065] Figure 16 for Figure 9 A schematic diagram of another embodiment;

[0066] Figure 17 This is a plan view of a first embodiment of the truss of the present invention;

[0067] Figure 18 This is a plan view of the second embodiment of the truss of the present invention;

[0068] Figure 19 This is a plan view of the truss embodiment three of the present invention;

[0069] Figure 20 This is a schematic diagram of the structure of a marine photovoltaic module according to the present invention;

[0070] Figure 21 This is a structural diagram illustrating the functional areas defined in this invention;

[0071] Figure 22 This is a schematic diagram of the on-site sliding track structure;

[0072] Figure 23 This is a schematic diagram of the structure of the sliding steel plate on site.

[0073] In the diagram, 100 - column; 101 - column base plate; 102 - column top plate; 103 - column H-beam;

[0074] 200 - Sliding track; 201 - Upper flange; 202 - Web; 203 - Lower flange;

[0075] 300-Offshore photovoltaic module; 301-Main truss; 302-Secondary truss; 303-Tie rod; 304-Steel column; 305-Diagonal beam; 306-Diagonal support; 307-Cantilever rod; 308-Purlin; 309-Web member; 310-Horizontal support rod; 311-Inclined support rod; 312-Tie rod; 313-Pressure block; 314-Slot; 315-Screw rod; 316-Pressure plate; 317-Upper chord; 318-Lower chord; 319-Upright pole; 320-Photovoltaic panel;

[0076] 400-Sliding device; 401-Sliding steel plate; 402a-Support one; 402b-Support two; 403-Connecting part; 404-Limiting bolt; 405-Limiting nut; 406-Rail sliding assembly; 4061-Rail sliding rod; 4062-Limiting plate; 4063-Rotating shaft; 4064-Mounting nut; 407-Pulley assembly; 4071-Pulley; 4072-Fixed shaft; 4073-Fixed plate; 408-Connecting pipe; 409-Pipe hole; 410-Connecting plate one; 411-Adjusting column; 412-Reinforcing plate; 413-Connecting plate two; 414-Connecting plate three; 415-Limiting plate; 416a-Eccentric adjustment plate one; 416b-Eccentric adjustment plate two. Detailed Implementation

[0077] like Figures 1 to 23 As shown, the present invention provides a marine photovoltaic module assembly line system, which includes a dedicated sliding device 400, an assembly line assembly method using the sliding device 400, and a marine photovoltaic module 300 assembled by the method.

[0078] I. Specific Implementation Examples of Offshore Photovoltaic Modules:

[0079] The specific components and connections of the marine photovoltaic module 300 assembled using the above method are as follows:

[0080] 1. Truss: The truss adopts a main truss 301 and a secondary truss 302. The main truss 301 and the secondary truss 302 have the same structure, both including an upper chord 317, a lower chord 318, and a web member 309 welded between the upper chord 317 and the lower chord 318. The secondary truss 302 is connected to the main truss 301 by bolts.

[0081] Between the main truss 301 and the secondary truss 302, and between the secondary trusses 302, tie rods 303 made of round tubes are fixed by bolts. The tie rods 303 are installed at the level of the upper chord 317 and the lower chord 318, forming a double-layer tie rod structure, which greatly enhances the overall stiffness and stability of the truss.

[0082] A cantilever rod 307 is fixed to the upper chord 317 of the main truss 301 with bolts, and a horizontal auxiliary rod 310 is fixed between the cantilever rods 307 with bolts. An inclined auxiliary rod 311 is fixed between the cantilever rod 307 and the lower chord 318 of the main truss 301 with bolts, thus forming a stable external cantilever structure.

[0083] 2. Support Structure: The support structure includes steel columns 304, inclined beams 305, and purlins 308, all of which are C-shaped. The steel columns 304 and inclined beams 305 form a support unit. A portion of the steel columns 304 in this support unit are bolted to the upper chord 317 of the secondary truss 302, while the remaining portion are bolted to the cantilever beams 307, thus fully utilizing the truss structure. An inclined support 306 is bolted between the steel columns 304 and the inclined beams 305, and the purlins 308 are fixed to the inclined beams 305 along the length of the secondary truss 302.

[0084] 3. Photovoltaic Panel 320: The photovoltaic panel 320 is fixed to the purlin 308 by a dedicated clamping assembly, which includes a clamping block 313, a screw 315, and a pressure plate 316. The clamping block 313 is located on the top surface of the purlin 308 and has a slot 314; the edge of the photovoltaic panel 320 is embedded in this slot 314. The screw 315 passes through a through hole one in the clamping block 313 and a through hole two in the pressure plate 316. By tightening the locking nut, the clamping block 313 and the pressure plate 316 together clamp the upper and lower flanges of the purlin 308, thereby firmly pressing the photovoltaic panel 320.

[0085] Tie rods 312 are fixed between two adjacent steel columns 304, between two adjacent inclined beams 305, and between two adjacent purlins 308 to further enhance the stability of the support system.

[0086] II. Specific Implementation of Sliding Device 400:

[0087] To achieve efficient assembly line assembly of the aforementioned marine photovoltaic module 300, this invention specifically designs a sliding device 400, the specific structure of which is as follows:

[0088] The sliding device 400 includes a sliding steel plate 401, a moving mechanism, a limiting component, and a limiting seat.

[0089] 1. The sliding steel plate 401 is preferably made of Q235B steel plate, which is the main load-bearing component. The sliding steel plate 401 is provided with a downwardly extending connecting part 403. The sliding steel plate 401 and the connecting part 403 are integrally formed by stamping, so that the sliding steel is U-shaped.

[0090] 2. The moving mechanism includes a track sliding assembly 406 and a pulley assembly 407. The track sliding assembly 406 includes a track sliding rod 4061, which is made of round steel and surface-hardened to increase wear resistance. It is attached to the top surface of the upper flange plate 201 of the sliding track 200. The rotating shafts 4063 at both ends of the track sliding rod 4061 pass through the through holes of the connecting part 403 with clearance fit, allowing free rotation. A limiting plate 4062 is provided on the track sliding rod 4061, and a mounting nut 4064 is threadedly connected to the rotating shaft 4063. The connecting part 403 is located between the limiting plate 4062 and the mounting nut 4064. The force on the track sliding rod 4061 is transmitted to the sliding steel plate 401 through the limiting plate 4062 and the mounting nut 4064, forming a force transmission path in the axial direction of the track sliding rod 4061. The vertical load and impact force borne by the track sliding rod 4061 are directly transmitted to the connecting part 403 through the end face of the limiting plate 4062. Simultaneously, the mounting nut 4064 provides preload from the other side, ensuring smooth and direct force transmission and avoiding uncontrollable gaps and impact loads. Furthermore, the mounting nut 4064 provides adjustable preload, completely eliminating any axial movement gap of the track sliding rod 4061 (i.e., in the axial direction of the rotating shaft 4063). This prevents the sliding device 400 from wobbling or knocking during startup and braking, ensuring smooth sliding of the marine photovoltaic module and effectively protecting the delicate upper marine photovoltaic module from bolt loosening or structural damage caused by shaking.

[0091] The pulley assembly 407 includes a pulley 4071 made of nylon. A fixing plate 4073 is bolted to the connecting part 403, and a fixing shaft 4072 is welded to the fixing plate 4073. The pulley 4071 is fitted onto the fixing shaft 4072 and can rotate. The pulley 4071 is attached to the bottom surface of the upper flange plate 201 of the sliding track 200. The nylon pulley 4071 and the steel sliding track 200 generate rolling friction, with a coefficient of friction lower than the sliding friction between steel structures. This is a key technological guarantee that the sliding power of the offshore photovoltaic module, weighing over ten tons, requires only manual pushing. Furthermore, the pulley 4071 attaches to and hooks onto the upper flange plate 201 from below, forming a closed rolling pair with the upper track sliding rod 4061. This design ensures that the sliding device 400 cannot detach from the track, guaranteeing the safety and reliability of the construction process.

[0092] 3. The limiting component uses a limiting bolt 404. The sliding steel plate 401 has a through hole two, and a limiting nut 405 is welded to the sliding steel plate 401. The limiting bolt 404 is threaded into the limiting nut 405, and the limiting bolt 404 passes through the through hole two, making operation more convenient. Tightening it will cause its end to press against the upper flange plate 201 of the sliding track 200, achieving reliable mechanical locking. The adjustment method of the limiting bolt 404 can also be designed as follows: the sliding steel plate 401 has a through hole two, the limiting bolt 404 passes through the through hole two of the sliding steel plate 401, and the limiting nut 405 is threaded into the limiting bolt 404, using two limiting nuts 405 to lock onto the sliding steel plate 401. However, this method of adjusting the limiting bolt 404 is time-consuming.

[0093] 4. The limiting seat adopts support 1 402a and support 2 402b. When limiting the truss, support 1 402a and support 2 402b can be used alone, or support 1 402a and support 2 402b can be used simultaneously.

[0094] Support 402a is welded with a vertical connecting pipe 408, which has a pipe hole 409. The truss has a vertical pole 319, which is confined within the pipe hole 409. To prevent the truss from becoming eccentric, another embodiment of support 402a is designed based on this embodiment. An eccentric adjustment plate 416a is intermittently welded to support 402a. The connecting pipe 408 passes through the hole in the eccentric adjustment plate 416a. When the vertical pole 319 is inserted into the pipe hole 409, the lower chord 318 is supported on the eccentric adjustment plate 416a, which can control the force on the sliding device 400 to be on the center line of the sliding device 400, thus solving the problem of track jamming caused by the eccentricity of the cantilever structure.

[0095] Support 2 402b is welded with an adjusting column 411. A reinforcing plate 412 is welded between the adjusting column 411 and support 2 402b to improve the load-bearing capacity of the adjusting column 411. A connecting plate 2 413 is welded to the top of the adjusting column 411. The connecting plate 3 414 is specifically designed. In embodiment one, four L-shaped limiting plates 415 are directly welded to the connecting plate 3 414. The lower chord 318 of the truss is supported on the connecting plate 3 414. The limiting plates 415 precisely limit the lower chord 318 in four directions: front, back, left, and right. To prevent the truss from becoming eccentric, another embodiment of support 402b is designed based on the previous embodiment. An eccentric adjustment plate 416b is intermittently welded onto the connecting plate 414. The eccentric adjustment plate 416b is located in the area between the four limiting plates 415. When the lower chord 318 is supported on the connecting plate 414, the lower chord 318 is supported on the eccentric adjustment plate 416b, which can control the force on the sliding device 400 to be on the center line of the sliding device 400, thus solving the problem of track jamming caused by the eccentricity of the cantilever structure.

[0096] Both the eccentric adjustment plate 416a and the eccentric adjustment plate 416b are made of PTFE. By utilizing the low coefficient of friction and self-lubricating properties of PTFE, the sliding friction resistance can be reduced during the sliding of the module. At the same time, it allows the truss to undergo adaptive sliding fine-tuning when there are slight installation deviations, effectively avoiding additional horizontal constraint forces caused by jamming.

[0097] Connecting plate 2 413 and connecting plate 3 414 are connected by fixing bolts, allowing the adjusting column 411 to be detachably connected between the sliding steel plate 401 and the limiting plate 415. The adjusting column 411 can be selected with a set height according to construction requirements, and its height can be adjusted as needed. The sliding steel plate 401 is equipped with connecting plate 1 410, and supports 1 402a and 2 402b are both connected to connecting plate 1 410 by fixing bolts.

[0098] The upright 319 is quickly connected to the tube hole 409 of the support 402a, while the limiting plate 415 of the support 402b provides precise positioning of the lower chord 318 of the truss in a four-sided surround manner, ensuring the repeatability of the positioning accuracy of the connection between the marine photovoltaic module 300 and the sliding device 400. With the height adjustment of the adjusting column 411, the marine photovoltaic module 300 can be stably positioned on the sliding device 400.

[0099] Furthermore, the sliding device 400 of the present invention, through its unique limiting seat design, achieves wide adaptability to trusses of different specifications (sizes and forms), such as... Figures 17 to 19 Specifically:

[0100] (1) The vertical uprights 319 of the truss are positioned by using a quick-connect fitting of support 402a. During installation, the operator only needs to insert the uprights 319 of the truss into the pipe hole 409 of this connecting pipe 408. This plug-in structure itself can achieve effective positioning in the horizontal plane.

[0101] (2) The lower chord 318 of the truss is limited. The top surface elevation of the support 402b can be adjusted by installing the adjusting column 411 with a set height to ensure that the lower chord 318 of different specifications of the truss is stably and horizontally supported. Moreover, the limiting plate 415 is designed in an L shape, and the four limiting plates 415 form a cross-shaped groove. The four limiting plates 415 constrain the lower chord 318 in the front, back, left and right directions.

[0102] (3) Based on the structural characteristics of the actual truss, support 402a and support 402b can be installed simultaneously on a sliding track 200. For example, support 402a can be used at the position where the truss has uprights 319, and support 402b can be used in the truss section without uprights 319, forming a hybrid support and limiting system.

[0103] This invention, through the combination of the universal insertion hole of support 402a and the adjustable and replaceable surrounding limiting plate 415 of support 402b, constitutes a modular and configurable adaptation system. It requires no structural modifications to the sliding device 400; simply by selecting different limiting seat modules and making simple on-site adjustments, it can safely and accurately support and guide marine photovoltaic module 300 trusses of different sizes, improving the versatility and engineering application range of the sliding device 400 and reducing the R&D and manufacturing costs of specialized tooling required for different projects.

[0104] III. Specific Implementation Examples of High-Production Assembly Line Method for Offshore Photovoltaic Modules:

[0105] The high-volume assembly line method for offshore photovoltaic modules is the core of the assembly system, and its specific steps are as follows:

[0106] 1. Functional area delineation and overall layout planning:

[0107] like Figure 21 As shown in the diagram, based on the overall construction plan, a production line is planned along a predetermined direction within the assembly area, and the following functional areas are delineated in sequence:

[0108] (1) Truss assembly area: The truss assembly area serves as the beginning of the assembly line and is used for assembling the main truss 301 and the secondary truss 302.

[0109] A truss storage area is set up adjacent to the truss assembly area, and the trusses are stored in the truss storage area after they are assembled.

[0110] Two tie rod installation areas are set up adjacent to the truss assembly area: the tie rod installation area is used for the manual installation of double-layer tie rods 303 in the truss, and also for the installation of cantilever rods 307.

[0111] (2) A component installation area is set up adjacent to the tie rod installation area, which is divided into the following sections:

[0112] Two bracket installation areas: The bracket installation area is used to install steel columns 304, inclined beams 305 and purlins 308.

[0113] Two photovoltaic panel installation areas: The photovoltaic panel installation area is used to install the tie rod 312, the pressure block 313 and the photovoltaic panel 320.

[0114] (3) A finished product processing area is set up adjacent to the photovoltaic panel installation area, which is divided into the following sections:

[0115] An additional process area: This area is used for bolt re-tightening, touch-up painting, and wiring installation for the 320 photovoltaic panels.

[0116] Three finished product storage areas: The finished product storage area is used for temporary storage of finished marine photovoltaic modules, and the finished product storage area serves as the end of the production line.

[0117] Material stacking plan: An assembly area is set up near the beginning of the assembly line, a truss material storage area is set up near the assembly area, and a support material storage area and a photovoltaic panel storage area are set up near the truss material storage area. The support material storage area is used to store support materials, and the photovoltaic panel storage area is used to store photovoltaic panels 320.

[0118] Positioning of hoisting equipment: Plan a position for a 25-ton truck crane between the assembly area and the truss assembly area. The truck crane is preferred to be a 25-ton truck crane and will be used to hoist the truss materials.

[0119] A crawler crane station is planned between the outermost finished product stacking area and the hoisting dock area. The crawler crane is to be set up here. The preferred crawler crane is a 150-ton crawler crane. The 150-ton crawler crane will be used to hoist the finished marine photovoltaic modules 300 out to sea.

[0120] A vehicle transport channel is set up on the outside of the entire production line for vehicles to transport bracket materials and photovoltaic panels 320 to the corresponding bracket installation area and photovoltaic panel installation area.

[0121] 2. On-site preparation and installation of the 200mm sliding rail:

[0122] Based on the delineation of functional areas, the site is leveled and compacted. Then, along the center line of the production line, two parallel sliding tracks 200 are laid in the truss assembly area, component installation area, and finished product processing area. The sliding tracks 200 are 273m long and include an upper flange plate 201, a lower flange plate 203, and a web plate 202. The web plate 202 is fixed between the upper flange plate 201 and the lower flange plate 203.

[0123] Along the length of the sliding track 200, install the columns 100 at 3m intervals in the assembly area. Each column 100 comprises a base plate 101, an H-beam 103, and a top plate 102, with the H-beam 103 welded between the base plate 101 and the top plate 102. Use a level to measure the target elevation of the top of each column 100 point by point, and calculate the precise height of each column 100, with an allowable error of ±2mm. Vertically fix all columns 100 to the concrete foundation of the assembly area with bolts, and then weld the sliding track 200 to the top plate 102 of each column 100.

[0124] After the sliding rail 200 is installed, a total station is used to re-measure to ensure that the horizontal elevation error of the two sliding rails 200 is less than 5 mm.

[0125] 3. Modular assembly line assembly operation:

[0126] Step 1: Truss Installation

[0127] A truck crane lifts two main trusses 301 and several secondary trusses 302 to the truss assembly area, ensuring the length of the main trusses 301 is perpendicular to the sliding rails 200. Workers then use high-strength bolts to secure the connections. Simultaneously, two sets of sliding devices 400 on each sliding rail 200 are pushed to their designated positions below the trusses. For truss support points at the uprights 319, operators insert the uprights 319 into the connecting pipes 408 of the supports 402a of the sliding devices 400. For support points at the lower chords 318, operators install adjustable columns 411 at the set height using bolts, then install limiting plates 415 using bolts, and finally place the lower chords 318 between the four limiting plates 415, ensuring they are tightly against the limiting plates 415. Then, use fixing bolts to fasten the support 402a and the connecting plate 410 of the sliding device 400 together, and at the same time use fixing bolts to fasten the support 402b and the connecting plate 410 of the sliding device 400 together.

[0128] After the truss is fixed, the operator uses a wrench to rotate the limiting bolt 404 counterclockwise, causing the end of the limiting bolt 404 to disengage from the upper flange plate 201 of the sliding track 200. The operator then pushes the truss, at which point the track sliding rod 4061 (round steel) and pulley 4071 (nylon material) of the sliding device 400 roll on the upper flange plate of the sliding track 200, smoothly sliding the entire truss.

[0129] The operator slides the assembled truss to the truss storage area for temporary storage. Once another truss is assembled, it is pushed from the storage area to the tie rod installation area. The limiting bolt 404 is rotated clockwise, firmly locking the end of the bolt against the upper flange plate 201 of the track. Tie rods 303 are fixed between the main truss 301 and secondary trusses 302, and between secondary trusses 302, using bolts. The tie rods 303 are arranged in two layers within the truss. Simultaneously, cantilever rods 307 are fixed to the upper chord 317 of the main truss 301 using bolts. Horizontal auxiliary rods 310 are then fixed between the cantilever rods 307 using bolts. Inclined auxiliary rods 311 are fixed between the cantilever rods 307 and the lower chord 318 of the main truss 301 using bolts.

[0130] Step 2: Bracket Installation

[0131] The operator uses a wrench to rotate the limiting bolt 404 counterclockwise, so that the end of the limiting bolt 404 is out of contact with the upper flange plate 201 of the sliding track 200. The operator pushes the truss to the bracket installation area, and then rotates the limiting bolt 404 clockwise, so that the end of the limiting bolt 404 presses against the upper flange plate 201 of the track.

[0132] With the lock in place, workers begin installing C-shaped steel columns 304, C-shaped inclined beams 305, and C-shaped purlins 308. The steel columns 304 and inclined beams 305 form a support unit. A portion of the steel columns 304 in the support unit are bolted to the upper chord 317 of the secondary truss 302, while the other portion of the steel columns 304 in the support unit are bolted to the cantilever beams 307. An inclined support 306 is bolted between the steel columns 304 and the inclined beams 305. The purlins 308 are fixed to the inclined beams 305 along the length of the secondary truss 302.

[0133] Step 3, Installation of 320 Solar Panels:

[0134] After the bracket is installed and passes inspection, the operator uses a wrench to rotate the limiting bolt 404 counterclockwise, so that the end of the limiting bolt 404 is out of contact with the upper flange plate 201 of the sliding track 200. The operator pushes the truss to the photovoltaic panel installation area, and then rotates the limiting bolt 404 clockwise, so that the end of the limiting bolt 404 presses against the upper flange plate 201 of the track.

[0135] In the locked state, a photovoltaic panel 320 is placed on the purlin 308, and a pressure block assembly is fixed on the purlin 308. The edge of the photovoltaic panel 320 is embedded in the groove 314 of the pressure block 313. Then, tie rods 312 are fixed between two adjacent steel columns 304, between two adjacent inclined beams 305, and between two adjacent purlins 308.

[0136] Step 4: Finished Product Processing

[0137] After the photovoltaic panel 320 is installed and passes inspection, the operator uses a wrench to rotate the limiting bolt 404 counterclockwise, so that the end of the limiting bolt 404 is out of contact with the upper flange plate 201 of the sliding track 200. The operator pushes the truss to other process areas, and then rotates the limiting bolt 404 clockwise, so that the end of the limiting bolt 404 presses against the upper flange plate 201 of the track.

[0138] While locked, bolts are tightened, paint is applied to the trusses and supports, and wiring is installed on the photovoltaic panels 320. At the same time, other auxiliary components are installed to obtain the finished marine photovoltaic module.

[0139] After the finished marine photovoltaic modules pass inspection, the operator uses a wrench to rotate the limiting bolt 404 counterclockwise, so that the end of the limiting bolt 404 is out of contact with the upper flange plate 201 of the sliding track 200. The operator then pushes the finished marine photovoltaic modules to the finished product stacking area.

[0140] Ultimately, the finished offshore photovoltaic modules can be hoisted and shipped out to sea using a 150-ton crawler crane.

[0141] Through the above specific implementation, this invention successfully transforms traditional discrete operations into efficient assembly line production. The assembly cycle of a single module is shortened from the traditional 12 hours to approximately 3-4 hours, the space utilization rate is increased by more than 40%, and the safety risks associated with high-altitude hoisting and relocation are completely eliminated.

[0142] The above are merely specific embodiments of the present invention, but the technical features of the present invention are not limited thereto. Any simple changes, equivalent substitutions, or modifications made based on the present invention to solve essentially the same technical problems and achieve essentially the same technical effects are all covered within the protection scope of the present invention.

Claims

1. A high-volume assembly method for offshore photovoltaic modules, characterized in that, The process includes the following steps: laying sliding tracks at the assembly site and delineating at least three continuous functional areas along the sliding tracks: a truss assembly area, a component installation area, and a finished product processing area; assembling the truss in the truss assembly area; sliding the assembled truss along the sliding tracks using a sliding device to move it as a whole to the component installation area, then installing the photovoltaic system brackets and photovoltaic panels on the truss to obtain the offshore photovoltaic module; and finally, sliding the offshore photovoltaic module to the finished product processing area.

2. The high-yield assembly method for offshore photovoltaic modules according to claim 1, characterized in that: The component installation area is divided into a bracket installation area and a photovoltaic panel installation area. The bracket and photovoltaic panel installation steps include: first, sliding the truss to the bracket installation area and installing the bracket on the truss; then, sliding the overall structure with the truss and bracket installed to the photovoltaic panel installation area and installing the photovoltaic panel on the bracket.

3. The high-yield assembly method for offshore photovoltaic modules according to claim 1, characterized in that: Several spaced columns are set up along the length of the sliding track in the assembly site. The elevation is measured point by point and the height of the columns is adjusted. The sliding track is fixed on the columns to ensure that the overall level of the sliding track is maintained.

4. A marine photovoltaic module, characterized in that: It is assembled by the assembly method of any one of claims 1-3.

5. A marine photovoltaic module according to claim 4, characterized in that: The truss includes a main truss and a secondary truss. The length direction of the main truss is perpendicular to the length direction of the sliding track. The secondary truss is fixed between two adjacent main trusses. Tie rods are fixed between the main trusses and the secondary trusses, and between the secondary trusses.

6. A marine photovoltaic module according to claim 4, characterized in that: The support structure includes steel columns, inclined beams, and purlins. The steel columns are fixed to the truss, and the inclined beams are fixed to the steel columns at an incline along the length of the main truss. The steel columns and the inclined beams form a support unit. Several support units are provided on the truss. The purlins are fixed to the inclined beams along the length of the secondary truss, and the photovoltaic panels are fixed to the purlins.

7. A marine photovoltaic module according to claim 6, characterized in that: The truss also includes cantilever rods, which are fixed to the main truss along the length of the purlins and are used for the installation of the support unit.

8. A marine photovoltaic module according to claim 7, characterized in that: The purlin is provided with a pressure block, the pressure block is provided with a groove, and the edge of the photovoltaic panel is embedded in the groove, so that the pressure block presses the photovoltaic panel tightly.

9. A marine photovoltaic module according to claim 8, characterized in that: The pressure block is located on the top surface of the purlin. The pressure block has a through hole one, through which a screw rod passes. The screw rod has a pressure plate, and the screw rod passes through a through hole two of the pressure plate. The pressure plate is located on the bottom surface of the purlin, so that the pressure block and the pressure plate are fixed at the purlin.

10. A sliding device for implementing the assembly line method according to any one of claims 1-3, characterized in that: It includes a sliding steel plate, a limiting member, and a limiting seat. The sliding steel plate has a downwardly extending connecting part, which is limited on the sliding track, so that the sliding steel plate can move in a directional manner along the length direction of the sliding track. The limiting member is installed on the sliding steel plate and is used to press or release the sliding track. The limiting seat is used to limit the truss.

11. A sliding device according to claim 10, characterized in that: The sliding steel plate is provided with a track sliding assembly and a pulley assembly. The track sliding assembly includes a track sliding rod, which rotates at the sliding steel plate and is attached to the top surface of the upper flange plate of the sliding track. The pulley assembly includes a pulley, which rotates at the sliding steel plate and is attached to the bottom surface of the upper flange plate of the sliding track.

12. A sliding device according to claim 11, characterized in that: The track sliding rod has a rotating shaft at both ends, and the connecting part has a through hole. The rotating shaft passes through the through hole and rotates in the through hole.

13. A sliding device according to claim 11, characterized in that: The connecting part is fixed with a fixing plate, the fixing plate is fixed with a fixing shaft, and the pulley rotates on the fixing shaft.

14. A sliding device according to claim 10, characterized in that: The limiting component is a limiting bolt, the sliding steel plate is provided with a second through hole, the sliding steel plate is welded with a limiting nut, the limiting bolt is threaded into the limiting nut, and the limiting bolt passes through the second through hole.

15. A sliding device according to claim 10, characterized in that: The limiting seat adopts support one and / or support two; support one is provided with a connecting pipe, the connecting pipe is provided with a pipe hole, the truss is provided with a vertical rod, and the vertical rod is limited in the pipe hole; support two is provided with an adjusting column, the lower chord of the truss is supported on the adjustable column with adjustable height, the adjusting column is provided with a limiting plate, and the limiting plate limits the lower chord in the truss movement direction and perpendicular to the truss movement direction.

16. A sliding device according to claim 15, characterized in that: The top of the adjusting column is provided with a second connecting plate, and the bottom of the limiting plate is provided with a third connecting plate. The second connecting plate and the third connecting plate are connected by fixing bolts.

17. A sliding device according to claim 16, characterized in that: The support is welded with an eccentric adjustment plate, the connecting plate is welded with an eccentric adjustment plate, and the truss is supported on the eccentric adjustment plate and the eccentric adjustment plate.

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