Photovoltaic module construction method suitable for complex building structure

Abstract

The invention discloses a photovoltaic module construction method suitable for a complex building structure, belongs to the technical field of photovoltaic building integration, and aims to solve the problems of assembly clearance, stress concentration, electrical mismatch and the like caused by the fact that an existing rigid connection system is difficult to adapt to curved surface, special-shaped and multi-directional bevel structures. According to the method, on the basis of a flexible self-adaptive supporting unit, a dynamic pose correction mechanism and a BIM-driven field assembly control three-in-one framework, high-precision fitting of components is achieved through a three-dimensional adjustable hinge mechanism, an elastic buffer layer and a non-uniform layout strategy; performing submillimeter attitude correction by combining laser tracking and a six-degree-of-freedom fine tuning platform, and dynamically matching electrical parameter similar components according to a BIM model to reduce string mismatch; meanwhile, a strain sensing network and a sealed water guide structure are integrated, and the long-term reliability of the system is improved. According to the invention, the installation adaptability, the structural stability and the power generation efficiency of the photovoltaic module on the complex building surface are obviously enhanced.

Description

Technical Field

[0001] This invention relates to the field of building-integrated photovoltaics (BIPV) technology, and in particular to a method for constructing photovoltaic modules suitable for complex building structures. Background Technology

[0002] With the deepening of global energy structure transformation and the "dual-carbon" strategic goals, building-integrated photovoltaics (BIPV) technology, as a key carrier of renewable energy in urban spaces, is increasingly becoming an important component of green building and near-zero energy building design. In this context, integrating photovoltaic modules into the building envelope not only enables on-site power generation and reduces transmission losses, but also enhances the aesthetic value and functional complexity of buildings through modular design. However, as photovoltaic systems expand from conventional flat roofs or simple pitched roofs to complex building structures with curved surfaces, irregular shapes, multi-directional angles, cantilevered structures, or irregular geometric forms, the technical challenges of their construction methods increase exponentially. Traditional photovoltaic installation processes are mainly optimized for standardized and modular scenarios. Their core idea lies in achieving rapid positioning and fixing of components through a pre-set support system. This method offers high construction efficiency and cost control on regular geometric surfaces. Specifically, existing technologies typically rely on standardized keel systems prefabricated in factories, combined with on-site bolting or welding processes, to rigidly anchor photovoltaic modules to the main building structure. In this process, parameters such as module tilt angle, orientation, and spacing are all pre-set according to a unified design module, and the construction process is highly dependent on the flatness and geometric consistency of the structural surface.

[0003] However, with the continuous development of related technologies and the increasingly stringent performance requirements of application scenarios, some inherent characteristics of the aforementioned technical solutions at the principle level have gradually revealed their limitations in addressing new challenges. The reason for this lies in the fact that complex building structures often lack continuous, regular load-bearing planes. Their surface curvature changes drastically, local structural nodes are densely packed, and there is often a coupling effect between dynamic loads (such as wind vibration and thermal expansion and contraction) and static loads (such as self-weight and snow load). Under such conditions, if rigid connections and standardized support systems are still used, the following deep-seated contradictions will inevitably arise: On the one hand, to ensure structural safety, independent stress analysis and customized support design must be performed for each installation point, which greatly weakens the efficiency advantages brought by standardized construction; on the other hand, if a universal support is forcibly applied to maintain the construction rhythm, uncontrollable assembly gaps or stress concentrations will inevitably occur between the components and the substrate, leading to secondary risks such as sealing failure, hot spot effects, and even structural fatigue fracture. Furthermore, existing construction methods generally lack the ability to adapt to micro-deformations of the building skin. Under the influence of diurnal temperature differences or seasonal climate effects, the relative displacement between the building body and photovoltaic modules caused by the difference in the coefficients of thermal expansion of the materials cannot be effectively absorbed. Over the long term, this will lead to loosening of connectors, glass breakage, or backsheet delamination, seriously threatening the reliability and safety of the system throughout its entire life cycle. In addition, the arrangement of modules on complex curved surfaces makes it difficult to meet the consistency requirements of electrical series and parallel connections. Local shading and tilt deviations will significantly reduce the overall power generation efficiency. Moreover, the existing construction process lacks a dynamic on-site adjustment mechanism that is deeply integrated with the BIM model, resulting in a discrepancy that is difficult to bridge between the design intent and the actual installation result.

[0004] Therefore, how to construct a photovoltaic module construction method that can adapt to complex building geometry, accommodate multi-scale deformation, and support high-precision on-site assembly, while ensuring structural safety and electrical performance, has become a key challenge and an urgent technical problem for those skilled in the art. Summary of the Invention

[0005] This invention provides a photovoltaic module construction method suitable for complex building structures, aiming to solve the technical problems in existing technologies, such as assembly gaps, stress concentration, sealing failure, hot spot effects, structural fatigue fracture, and degraded electrical performance, caused by the inability of rigid connection systems and standardized supports to adapt to irregular geometric shapes such as curved surfaces, irregular shapes, and multi-directional angles. To achieve the above-mentioned objectives, this invention proposes a systematic construction method based on a flexible adaptive support unit, a dynamic posture correction mechanism, and BIM-driven on-site assembly control. Its core lies in enabling high-precision bonding, uniform stress distribution, and long-term operational stability of photovoltaic modules on any complex building surface through modular flexible nodes, multi-degree-of-freedom adjustment mechanisms, and real-time feedback closed-loop control.

[0006] The construction method includes the following steps: First, several flexible adaptive support units are arranged on the surface of the main building structure. Each flexible adaptive support unit consists of a base anchor, a three-dimensional adjustable hinge mechanism, and an elastic buffer layer. The base anchor is reliably connected to the building structure by chemical anchoring or pre-embedded bolts, and its top is provided with a spherical groove. The three-dimensional adjustable hinge mechanism includes a ball-head connecting rod, a radial locking ring, and an axial limiting sleeve. The bottom of the ball-head connecting rod is embedded in the spherical groove to form a universal rotating pair, and the top is connected to the photovoltaic module frame by threads. The elastic buffer layer is set between the ball-head connecting rod and the photovoltaic module backsheet. It is made of silicone rubber composite material with a thickness of three to five millimeters and has shear deformation capability to absorb relative displacement caused by thermal expansion differences.

[0007] Furthermore, the flexible adaptive support units are arranged along the building skin at a non-uniform density, and their spatial coordinates are determined by the curvature gradient field in the building information model. In areas with drastic curvature changes, the spacing between support units is no more than 600 mm; in areas with gentle curvature, the spacing between support units is no more than 1,200 mm. The position data of all support units are pre-imported into the on-site construction control system and registered and aligned with the total station measurement point cloud.

[0008] In a preferred embodiment of the present invention, the construction method further includes a dynamic pose correction mechanism, which consists of a laser tracking positioning system, a six-degree-of-freedom fine-tuning platform, and a central collaborative controller. The laser tracking positioning system acquires the actual spatial pose of the installed photovoltaic modules in real time and transmits the deviation data to the central collaborative controller. The six-degree-of-freedom fine-tuning platform is integrated on the end effector of the hoisting equipment and includes three translational degrees of freedom and three rotational degrees of freedom. Its motion commands are generated by the central collaborative controller based on the preset BIM model and the measured deviation. During the module placement process, the six-degree-of-freedom fine-tuning platform adjusts the module's posture at the sub-millimeter level based on the closed-loop feedback signal to ensure that its alignment error with the edge of adjacent modules does not exceed 0.5 mm, and that the overall surface continuity satisfies the C1 continuity condition.

[0009] The central collaborative controller has a built-in micro-deformation prediction module for the building skin. Based on historical meteorological data and a material thermal expansion coefficient database, this module calculates the expected deformation of the building structure due to temperature changes in the next 24 hours and adjusts the initial preload of each flexible adaptive support unit accordingly. The preload is applied to the radial locking ring by an electric torque wrench, and its value is dynamically set according to the local radius of curvature and wind load level, ranging from 15 Nm to 25 Nm.

[0010] Furthermore, the construction method also includes an electrical series-parallel consistency assurance process; before module installation, each photovoltaic module undergoes spectral response testing and maximum power point calibration, and its electrical parameters are entered into the BIM database; during the on-site assembly stage, the central coordinating controller automatically matches modules with similar output characteristics to form the same electrical series based on the actual installation tilt angle, orientation, and surrounding shading conditions of the modules; the matching logic follows the principle that the open-circuit voltage deviation does not exceed 2% and the short-circuit current deviation does not exceed 1.5%, in order to minimize string mismatch losses.

[0011] As another key feature of the present invention, the elastic buffer layer in the flexible adaptive support unit is embedded with a strain sensing network. This network consists of distributed fiber optic grating sensors arranged along the three orthogonal directions of X, Y, and Z, and is used to monitor the shear force and compressive stress on the back plate of the component in real time. When any sensor detects that the local stress exceeds the threshold, the central coordinating controller immediately triggers an early warning signal and records the spatial coordinates of the location for later maintenance. At the same time, the data stream of the strain sensing network is processed by edge computing nodes and uploaded to the cloud operation and maintenance platform to build a digital twin model of the structural health status.

[0012] The construction method also includes an integrated sealing and waterproofing process; at the joint between the photovoltaic module frame and the building skin, a two-component polyurethane sealant is used for filling, and its injection path is automatically completed by the robot end effector according to a preset trajectory; before the sealant cures, it is locally heated to 45 degrees Celsius by an infrared heating device to accelerate the cross-linking reaction and improve the bonding strength; in addition, a water guide channel structure is set around the flexible adaptive support unit. The water guide channel is stamped from weather-resistant aluminum alloy and fixed to the outer edge of the base anchor by a snap-fit ​​method to guide rainwater to flow out along a predetermined direction and prevent water from seeping into the connection interface.

[0013] Furthermore, the axial limiting sleeve in the three-dimensional adjustable hinge mechanism is equipped with an axial displacement scale mark with a minimum resolution of 0.1 mm. After the component is installed, the construction personnel can visually read the axial compression of each support point to assess the tightness of the fit between the component and the substrate. If the compression of a certain point exceeds the design allowable range, the preload of that point needs to be readjusted until it meets the requirements.

[0014] As a system-level innovation of this invention, the construction method deeply integrates the BIM model, the on-site sensing system, and the execution mechanism to form an integrated control loop of "perception-decision-execution-feedback". The BIM model not only contains geometric information but also integrates structural mechanical properties, electrical topology relationships, and climate response characteristics. During on-site construction, the total station, laser tracker, and strain sensor network together constitute a multi-source sensing layer to collect the state of the physical world in real time. The central collaborative controller acts as the decision-making hub, running a deterministic scheduling algorithm to coordinate the action sequences of hoisting equipment, six-degree-of-freedom fine-tuning platform, and electric torque tools. Finally, all operation results are fed back to the BIM model for version updates, ensuring that the digital model and the physical project remain synchronized at all times.

[0015] The construction method described herein is applicable to various complex building structures, including but not limited to hyperbolic paraboloid roofs, spiral curtain walls, folded-plate facades, and cantilever truss systems. Regardless of the geometric shape of the building skin, this invention can maximize the solar radiation capture efficiency by ensuring that the normal direction of the photovoltaic module surface is consistent with the ideal receiving surface through the local independent adjustment capability of the flexible adaptive support unit. At the same time, since each support point has an independent displacement compensation function, the entire system can effectively isolate the micro-vibrations of the building body caused by wind vibration, earthquake, or temperature changes, avoiding resonance amplification effects.

[0016] The beneficial effects of this invention are:

[0017] This invention achieves local geometric adaptation by introducing flexible adaptive support units, ensures global assembly accuracy through a dynamic pose correction mechanism, and guarantees the traceability and repeatability of the construction process through a BIM-driven closed-loop control system. It fundamentally solves the structural contradictions and functional defects faced by photovoltaic module installation on complex building structures. This method not only improves construction efficiency and installation quality but also significantly enhances the long-term reliability and power generation performance stability of the photovoltaic system in extreme environments, providing solid technical support for the large-scale application of building-integrated photovoltaics (BIPV) technology in challenging scenarios. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall system structure of a photovoltaic module construction method applicable to complex building structures according to the present invention. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. The illustrative embodiments and descriptions herein are used to explain the present invention, but are not intended to limit the present invention.

[0020] This invention provides a photovoltaic module construction method suitable for complex building structures. The technical solution achieves high-precision bonding and installation of photovoltaic modules on irregular geometric building surfaces through the synergistic effect of flexible adaptive support units, dynamic posture correction mechanisms, and BIM-driven on-site assembly control. The technical solution of this invention will be described in detail below with reference to the accompanying drawings and specific engineering implementation scenarios.

[0021] Before implementing the construction method described in this invention, the construction and refinement of the Building Information Model (BIM) must first be completed. This BIM model not only contains the three-dimensional geometric data of the building skin but also integrates multi-dimensional information such as structural mechanical properties, material thermal expansion coefficients, wind load distribution maps, solar radiation trajectory simulation results, and electrical topology planning. Based on this model, the system automatically calculates the curvature gradient field of each region of the building skin and generates a spatial layout strategy for flexible adaptive support units accordingly. In areas with drastic curvature changes, such as near the saddle point of a hyperbolic paraboloid roof or the torsional transition section of a spiral curtain wall, the spacing between support units is set to no more than 600 mm; in areas with gentle curvature, such as the central plane section of a large-span folded plate facade, the spacing between support units can be relaxed to no more than 1200 mm. The theoretical coordinates of all support units are embedded into the BIM model in point cloud form and exported in a format recognizable by the construction control system.

[0022] The first step in on-site construction is to deploy flexible adaptive support units on the surface of the main building structure. Each flexible adaptive support unit consists of a base anchor, a three-dimensional adjustable hinge mechanism, and an elastic buffer layer. The base anchor is made of stainless steel, and its bottom is reliably connected to the building's concrete or steel structure via chemical anchoring or pre-embedded bolts, ensuring that the pull-out and shear forces meet the design specifications. The top of the base anchor is machined with a spherical groove, the inner diameter of which forms a precise fit clearance with the outer diameter of the ball head of the ball-head connecting rod, allowing the ball head to rotate freely in any direction. The three-dimensional adjustable hinge mechanism includes a ball head connecting rod, a radial locking ring, and an axial limiting sleeve. The ball head connecting rod is made of high-strength alloy steel, and its bottom ball head is embedded in the spherical groove of the base anchor, forming a universal joint; the top has external threads for connection with the internal threaded holes on the photovoltaic module frame. The radial locking ring is fitted around the outer circumference of the ball head connecting rod, located at the top opening of the base anchor. By rotating, radial pressure is applied, thereby restricting the rotational freedom of the ball head within the groove and achieving position locking. An axial limiting sleeve is coaxially fitted onto the ball joint connecting rod, with its lower end abutting against the top surface of the base anchor and its upper end contacting the elastic buffer layer. This sleeve is used to limit excessive axial displacement of the ball joint connecting rod. The outer wall of the axial limiting sleeve is marked with an axial displacement scale, with a minimum resolution of 0.1 millimeters, facilitating visual reading of the compression amount after component installation by construction personnel.

[0023] An elastic buffer layer, molded from silicone rubber composite material with a thickness of three to five millimeters, is positioned between the top of the ball-joint connecting rod and the backsheet of the photovoltaic module. This material possesses excellent shear deformation capacity and compressive resilience, absorbing the relative displacement between the photovoltaic module and the building structure when thermal expansion occurs due to temperature changes, thus preventing stress concentration caused by rigid constraints. Furthermore, a strain sensing network is embedded within the elastic buffer layer. This network consists of distributed fiber Bragg grating sensors arranged along the X, Y, and Z orthogonal directions to form a three-dimensional stress sensing array. The center wavelength of each fiber Bragg grating sensor is calibrated to correspond to a specific strain value. When the module backsheet deforms under stress, the reflected wavelength of the grating shifts. By acquiring the wavelength change in real time using a demodulator, the magnitude and direction of the local shear force and compressive stress can be determined.

[0024] After all flexible adaptive support units are installed, the photovoltaic module hoisting and dynamic pose correction phase begins. This phase relies on a closed-loop control system consisting of a laser tracking and positioning system, a six-degree-of-freedom fine-tuning platform, and a central coordinating controller. The laser tracking and positioning system is deployed at fixed reference points on the construction site. Its emitted laser beam tracks retroreflector targets installed at the four corners of the photovoltaic module in real time, acquiring the module's six-degree-of-freedom pose data in space (including three translational coordinates and three Euler angles). This data is transmitted to the central coordinating controller in real time via industrial Ethernet.

[0025] The central collaborative controller incorporates a BIM model parsing engine and a pose deviation calculation module. The controller compares the measured pose with the ideal installation pose of the component in the BIM model to calculate the position deviation vector. With attitude deviation angle Subsequently, the controller runs a deterministic scheduling algorithm to generate a sequence of motion commands for the six-DOF fine-tuning platform. Integrated into the end effector of the hoisting equipment, the six-DOF fine-tuning platform, composed of three linear motors and three rotary motors, forms a Stewart platform configuration, possessing sub-millimeter positioning accuracy and milliradian-level attitude adjustment capability. As the component slowly descends towards its installation position, the fine-tuning platform continuously corrects the component's attitude based on closed-loop feedback signals until the alignment error between its edge and adjacent installed components does not exceed 0.5 mm, and the overall surface continuity satisfies the C1 continuity condition (i.e., first derivative continuity, no sharp angles).

[0026] The central collaborative controller also integrates a building skin micro-deformation prediction module. This module calls upon parameters such as daily temperature difference, wind speed, and radiation intensity from a historical meteorological database, and combines them with the linear expansion coefficient α and elastic modulus E of the building structural materials to predict the expected deformation of various points on the building skin over the next 24 hours using a thermo-mechanical coupled finite element model. The prediction formula is as follows:

[0027]

[0028] in, For position At any moment Temperature change This is the skin normal vector at that point. Based on this prediction, the controller adjusts the initial preload of each flexible adaptive support unit in advance. The preload is applied to the radial locking ring via an electric torque wrench, with a target torque value... Dynamically set by the following formula:

[0029]

[0030] in, For the local radius of curvature, The standard value of the design wind load for this area is given. and This is an empirical coefficient, determined after calibration. The preload is controlled between 15 Nm and 25 Nm to ensure that, under extreme conditions, the support unit is neither too loose, causing component swaying, nor too tight, causing local stress exceeding limits.

[0031] After the mechanical installation of the modules is completed, an electrical series-parallel consistency assurance process is executed. Each photovoltaic module has undergone spectral response testing and maximum power point (MPP) calibration before leaving the factory, and its open-circuit voltage... Short-circuit current Key electrical parameters such as fill factor (FF) and temperature coefficient are entered into the BIM database, forming the component's "electrical ID card." During the on-site assembly phase, the central coordinating controller calculates the expected output characteristics of the component based on the actual installation tilt angle (θ), azimuth angle (ϕ), and projection analysis results of surrounding obstructions. Subsequently, the controller runs a matching algorithm to assign components with similar output characteristics to the same electrical series. The matching logic strictly follows: any two components within the same series... The deviation is no more than two percent. The deviation is no more than 1.5%. This strategy effectively suppresses string mismatch losses and improves the overall power generation efficiency of the system.

[0032] Sealing and waterproofing processes are integrated and carried out simultaneously. A two-component polyurethane sealant is used to fill the joint between the photovoltaic module frame and the building skin. This sealant is a 1:1 mass mixture of component A (isocyanate prepolymer) and component B (a mixture of polyols and fillers), automatically injected into the joint along a preset trajectory using a dual-channel injection head of a robotic end effector. The injection path is generated from the joint centerline exported from the BIM model, ensuring uniform and complete coverage. Before the sealant cures, an infrared heating device locally heats the joint area to 45 degrees Celsius for 15 minutes to accelerate the cross-linking reaction between the isocyanate and hydroxyl groups, improving the final bond strength and weather resistance. Simultaneously, a water-guiding channel structure is installed around each flexible adaptive support unit. This channel is stamped from weather-resistant aluminum alloy sheet, forming a ring-shaped groove, and is fixed to the outer edge of the base anchor using a snap-fit ​​method. Drainage holes are located at the bottom of the channel, connecting to the building's rainwater drainage system to guide rainwater out along a predetermined flow direction, preventing water accumulation and seepage at the joint interface.

[0033] The entire construction process achieves closed-loop data flow management. Total stations periodically scan the installed area, generating high-density point clouds, which are then registered with the BIM model via ICP (Iterative Closest Point) to verify overall installation accuracy. Stress data collected by the strain sensor network is filtered, denoised, and feature-extracted through edge computing nodes before being uploaded to the cloud-based operation and maintenance platform. This platform constructs a digital twin model of the structural health status based on long-term monitoring data, predicting potential fatigue damage locations and generating preventative maintenance recommendations. All operation records, including torque values, pose deviations, electrical matching results, and sealant injection parameters, are automatically written to the construction log layer of the BIM model, achieving version synchronization between the digital model and the physical project.

[0034] To verify the technical effect of the present invention, a specific embodiment and a comparative example are provided for comparison and explanation.

[0035] In one specific embodiment, the roof of a cultural center building adopts a hyperbolic paraboloid steel structure with a maximum radius of curvature of eight meters and a minimum radius of curvature of 2.5 meters. Photovoltaic modules were installed using the construction method described in this invention. A total of 320 flexible adaptive support units were deployed, with a spacing of 550 mm in high-curvature areas (radius of curvature less than four meters) and 1100 mm in low-curvature areas. The module type was monocrystalline silicon PERC, with dimensions of 2278 mm × 1134 mm and a rated power of 550 W. During installation, the laser tracking system sampling frequency was 10 Hz, and the positioning accuracy of the six-degree-of-freedom fine-tuning platform reached ±0.2 mm. After electrical matching, the maximum deviation of Voc within the string was 1.6%, and the maximum deviation of Isc was 1.2%. After the sealant cured, a pull-out test showed a bond strength of 2.8 MPa. After six months of system operation, no sealing failure, hot spots, or structural cracks were found.

[0036] As a comparison, another area of ​​the same building was installed using a traditional rigid support system. The supports were standardized aluminum alloy profiles, bolted to the building purlins via angle brackets. Due to their inability to adapt to curved surfaces, there was a maximum assembly gap of 12 mm between the components and the roof. To force a fit, some supports were cut and bent on-site, resulting in localized stress concentration. The electrical series was composed of randomly selected components, with a Voc deviation of 3.5% and an Isc deviation of 2.8% within the string. After three months of operation, infrared thermal imaging revealed seven hot spots, with a maximum temperature rise of 22 degrees Celsius; simultaneously, fatigue cracks appeared at three support connection points.

[0037] The table below summarizes the key performance indicators of the embodiments and comparative examples:

[0038] Performance indicators Example (of the present invention) Comparative example (traditional method) Component edge alignment error (mm) ≤0.4 1.8–3.5 Maximum gap between curved surfaces (mm) ≤0.6 5.2–12.0 String Voc Deviation (%) 1.6 3.5 String Isc deviation (%) 1.2 2.8 Sealant bond strength (MPa) 2.8 1.9 Hot spot incidence (after 6 months of operation) 0 / 1200 pieces 7 / 800 pieces Cracks in the support structure (after 6 months of operation) 0 3 places Annual power generation loss rate (estimated) 1.8% 6.3%

[0039] The above data show that the construction method described in this invention is significantly superior to the traditional rigid installation system in terms of geometric adaptability, electrical consistency, structural reliability, and long-term power generation performance.

[0040] Furthermore, the method described in this invention is also applicable to other complex architectural forms. For example, in a spiral glass curtain wall project, the curtain wall surface is continuously twisted along its height, with a twist angle of 15 degrees per meter. Using the method of this invention, flexible adaptive support units are non-uniformly arranged along the curtain wall keel, and combined with a six-degree-of-freedom fine-tuning platform to compensate for the attitude deviation caused by the twist in real time, successfully achieving seamless integration of photovoltaic modules and the curved surface of the curtain wall. In another folded-plate concrete facade project, the facade is composed of multiple inclined planes spliced ​​together, with obvious ridges at the corners. This invention effectively avoids the problem of component frame cracking caused by rigid connections in traditional methods by densifying the support units on both sides of the corners and using an elastic buffer layer to absorb the small misalignments at the plane intersections.

[0041] In a preferred embodiment of the present invention, the central collaborative controller can be extended to access a drone inspection system. The drone, equipped with a high-resolution camera and an infrared thermal imager, periodically conducts aerial inspections of the installed photovoltaic arrays, identifying potential obstructions, stains, or areas of thermal anomaly, and mapping the image coordinates back to the BIM model to trigger cleaning or maintenance work orders. This function further enhances the system's intelligent operation and maintenance capabilities.

[0042] In summary, this invention achieves local geometric adaptation through flexible adaptive support units, ensures global assembly accuracy through a dynamic pose correction mechanism, and guarantees the digitalization, traceability, and repeatability of the construction process through a BIM-driven closed-loop control system. This method not only solves the technical bottleneck of photovoltaic module installation on complex building structures but also provides a complete technical path and engineering implementation paradigm for the large-scale promotion of building-integrated photovoltaics in high-difficulty, high-value scenarios.

[0043] The technical solutions of the present invention are not limited to the specific embodiments described above. Any technical modifications made in accordance with the technical solutions of the present invention fall within the protection scope of the present invention.

Claims

1. A method for constructing photovoltaic modules suitable for complex building structures, characterized in that, Includes the following steps: Several flexible adaptive support units are arranged on the surface of the main building structure. Each flexible adaptive support unit consists of a base anchor, a three-dimensional adjustable hinge mechanism, and an elastic buffer layer. The base anchor is connected to the building structure and has a spherical groove at its top. The three-dimensional adjustable hinge mechanism includes a ball-head connecting rod, a radial locking ring, and an axial limiting sleeve. The bottom of the ball-head connecting rod is embedded in the spherical groove, and the top is connected to the photovoltaic module frame. The elastic buffer layer is disposed between the ball-head connecting rod and the photovoltaic module backsheet. A dynamic pose correction mechanism is used to adjust the installation posture of photovoltaic modules. The dynamic pose correction mechanism includes a laser tracking and positioning system that collects the actual spatial posture of the installed photovoltaic modules in real time, a six-degree-of-freedom fine-tuning platform integrated on the end effector of the hoisting equipment, and a central collaborative controller. The central collaborative controller generates motion commands for the six-degree-of-freedom fine-tuning platform based on the measured deviation data collected by the laser tracking and positioning system and the preset building information model, so as to adjust the posture of the photovoltaic modules in a closed-loop feedback manner. During the installation of photovoltaic modules, the central coordinating controller executes an electrical series-parallel consistency guarantee process. The process includes matching photovoltaic modules with similar output characteristics to the same electrical series based on the electrical parameters of each photovoltaic module pre-entered into the building information model database and the expected output characteristics calculated according to the actual installation tilt angle, orientation and surrounding shading of the modules.

2. The photovoltaic module construction method applicable to complex building structures according to claim 1, characterized in that, The flexible adaptive support units are arranged at a non-uniform density along the building skin, and their spatial coordinates are determined by the curvature gradient field in the building information model. In areas with drastic curvature changes, the spacing between the flexible adaptive support units is no more than 600 mm; in areas with gentle curvature, the spacing between the flexible adaptive support units is no more than 1,200 mm. The position data of all the flexible adaptive support units are pre-imported into the on-site construction control system and registered and aligned with the total station measurement point cloud.

3. The photovoltaic module construction method applicable to complex building structures according to claim 1, characterized in that, The base anchor is connected to the building structure by chemical anchoring or pre-embedded bolts; the ball head connecting rod has a ball head at the bottom, which forms a universal joint with the spherical groove; the ball head connecting rod has an external thread at the top, which connects to the internal thread hole on the photovoltaic module frame by threaded connection; the radial locking ring is fitted around the ball head connecting rod and located at the top opening of the base anchor, and applies radial pressure by rotation to lock the rotational freedom of the ball head connecting rod; the axial limiting sleeve is coaxially fitted on the ball head connecting rod, with its lower end abutting against the top surface of the base anchor and its upper end contacting the elastic buffer layer.

4. The photovoltaic module construction method applicable to complex building structures according to claim 1, characterized in that, The elastic buffer layer is made of silicone rubber composite material with a thickness of three to five millimeters. A strain sensing network is embedded inside the elastic buffer layer. The strain sensing network consists of distributed fiber Bragg grating sensors arranged along three orthogonal directions (X, Y, and Z) to monitor the shear force and compressive stress on the backsheet of the photovoltaic module in real time. When any of the fiber Bragg grating sensors detects that the local stress exceeds a preset threshold, the central coordinating controller triggers an early warning signal and records the spatial coordinates of the corresponding location.

5. The photovoltaic module construction method applicable to complex building structures according to claim 1, characterized in that, In the dynamic pose correction mechanism, the six-degree-of-freedom fine-tuning platform includes three translational degrees of freedom and three rotational degrees of freedom. During the photovoltaic module placement process, the six-degree-of-freedom fine-tuning platform adjusts the module posture according to the closed-loop feedback signal of the central coordinating controller until the alignment error between the edge of the photovoltaic module and the adjacent installed photovoltaic module does not exceed 0.5 mm, and the overall installation surface satisfies the C1 continuity condition.

6. The photovoltaic module construction method applicable to complex building structures according to claim 1, characterized in that, The central collaborative controller has a built-in micro-deformation prediction module for the building skin. Based on historical meteorological data and a material thermal expansion coefficient library, the micro-deformation prediction module calculates the expected deformation of the building structure due to temperature changes in the next 24 hours using a thermo-mechanical coupled finite element model, and adjusts the initial preload of each flexible adaptive support unit accordingly. The preload is applied to the radial locking ring by an electric torque wrench, and its value is dynamically set according to the local radius of curvature and wind load level, ranging from 15 Nm to 25 Nm.

7. The photovoltaic module construction method applicable to complex building structures according to claim 1, characterized in that, In the electrical series-parallel consistency guarantee process, the electrical parameters include the open-circuit voltage and short-circuit current of the photovoltaic modules; the matching logic follows the principle that the open-circuit voltage deviation of any two photovoltaic modules in the same electrical series shall not exceed 2%, and the short-circuit current deviation shall not exceed 1.5%.

8. The photovoltaic module construction method applicable to complex building structures according to claim 1, characterized in that, It also includes an integrated sealing and waterproofing process; the integrated sealing and waterproofing process includes: filling the joint between the photovoltaic module frame and the building skin with a two-component polyurethane sealant, the injection path of which is automatically completed by a robot end effector according to a preset trajectory; before the sealant cures, the joint area is locally heated to 45 degrees Celsius using an infrared heating device; and a water guide channel structure is set around each of the flexible adaptive support units, the water guide channel being fixed to the outer edge of the base anchor by a snap-fit ​​method, for guiding rainwater to flow out along a predetermined direction.

9. The photovoltaic module construction method applicable to complex building structures according to claim 3, characterized in that, The outer wall of the axial limiting sleeve is provided with an axial displacement scale mark, the minimum resolution of which is 0.1 mm. After the photovoltaic module is installed, the axial displacement scale mark is visually read to assess the axial compression of the elastic buffer layer at each support point.

10. The photovoltaic module construction method applicable to complex building structures according to claim 1, characterized in that, The construction method forms an integrated control loop of "perception-decision-execution-feedback"; the building information model integrates geometric information, structural mechanical properties, electrical topology relationships, and climate response characteristics; during on-site construction, a multi-source perception layer is formed by a total station, a laser tracking and positioning system, and a strain sensor network; the central collaborative controller runs a deterministic scheduling algorithm to coordinate the action sequences of hoisting equipment, a six-degree-of-freedom fine-tuning platform, and electric torque tools; all construction operation results are fed back to the building information model for version updates to maintain synchronization between the digital model and the physical project.

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