Indoor simulation illumination test system of solar cell array

Abstract

The invention discloses an indoor simulation illumination test system of a solar cell array. The test system comprises a user interaction module used for forming a human-computer interface and determining a test task according to user operation, and task parameters of the test task comprise a target illumination intensity set value, test duration, a sampling mode, a recording strategy and a safety threshold; the communication module is used for abstracting a physical device into an addressable device object and providing command issuing and data reading capabilities for the device object; the control module is used for calculating a control quantity according to the target illumination intensity set value and an actual measurement value of the illumination sensor, and converting the control quantity into a corresponding adjustment instruction to perform an illumination test; the data stream processing module is used for performing stream processing on measurement data and control data generated in the illumination test process; and the safety protection module is used for executing a protection action when the safety event is triggered.

Description

Technical Field

[0001] This application relates to the field of battery testing technology, and in particular to an indoor simulated light testing system for solar cell arrays. Background Technology

[0002] With the rapid development of aviation technology, the large-area application of thin-film solar cells on aircraft wings has become an important technical means to improve the energy self-sufficiency of aircraft. These solar cells not only serve as power generation devices to supply energy to airborne equipment, but also act as structural components to bear the aerodynamic loads on the upper wing surface.

[0003] Due to the aging of the solar cells themselves and the effects of aerodynamic loads, it is particularly important to periodically test the power generation efficiency of the solar cells on the fuselage upper surface. The power generation efficiency of the solar cell array is generally tested outdoors.

[0004] However, existing outdoor testing methods have many technical drawbacks, including but not limited to severe weather constraints (e.g., test results are affected by environmental factors such as light intensity, temperature, and humidity, resulting in poor data repeatability), long testing cycles (e.g., waiting for suitable weather conditions, which cannot meet the needs of batch testing), low testing accuracy (e.g., unstable natural light intensity, making it difficult to achieve accurate standardized testing), low automation, low efficiency, and susceptibility to human error due to manual operation, as well as high safety risks (e.g., outdoor high-altitude operations pose safety hazards, and there are significant risks under adverse weather conditions).

[0005] Therefore, there is an urgent need to provide suitable testing methods to help overcome the technical shortcomings of existing outdoor testing methods. Summary of the Invention

[0006] This application provides an indoor simulated illumination testing system for solar cell arrays, aiming to address at least one deficiency in existing outdoor testing methods.

[0007] In a first aspect, embodiments of this application provide an indoor simulated illumination testing system for a solar cell array. The system includes: a user interaction module for forming a human-machine interface and determining a test task based on user operations; the task parameters of the test task include: a target illumination intensity setpoint, test duration, sampling method, recording strategy, and safety threshold; a communication module for abstracting physical devices into addressable device objects and providing command issuance and data reading capabilities to the device objects; wherein the physical devices include: a controller for performing light source control, a light sensor for measuring illumination intensity, and a temperature sensor for measuring temperature; a control module for calculating a control quantity based on the target illumination intensity setpoint and the actual measured value of the light sensor, and converting the control quantity into a corresponding adjustment command for illumination testing; a data stream processing module for streaming the measurement data and control data generated during the illumination test; and a safety protection module for executing protective actions when a safety event is triggered.

[0008] In some embodiments, the communication module includes: a multi-protocol communication engine for communicating with the controller and performing variable reading / writing and batch data transmission; an infrared peripheral communication control unit for communicating with the infrared learning and emission module and issuing infrared control commands to control the operating status of the light source; a communication queue management unit for constructing an asynchronous communication queue using a producer-consumer pattern; and a fault recovery unit for detecting communication anomalies and performing automatic recovery.

[0009] In some embodiments, the control module includes a PID closed-loop control unit, configured to calculate a control output based on the deviation between the target light intensity setpoint and the actual light intensity collected by the light sensor, so that the actual light intensity converges to the target light intensity setpoint.

[0010] In some embodiments, the data stream processing module includes: a real-time acquisition unit, configured to acquire multiple sampled data at a configurable sampling frequency, and add a timestamp and source identifier to each sampled data; wherein the sampled data includes: the actual light intensity acquired by the light sensor, the temperature data acquired by the temperature sensor, and the electrical parameters of the solar cell array under test; a performance calculation unit, configured to calculate the performance indicators of the solar cell array under test; a storage unit, configured to compress the data from the real-time acquisition unit and the performance calculation unit using differential coding and compression algorithms, and store it in a cache area; and a retrieval unit, configured to move the data in the cache area to a database that supports query and retrieval functions.

[0011] In some embodiments, the safety events include: over-temperature, communication failure, sensor malfunction, or emergency shutdown input; the protection actions include: stopping the light source output, cutting off the enable, recording the event, and issuing an alarm.

[0012] At least one beneficial effect of the indoor simulated illumination testing system for solar cell arrays in this application embodiment is that the user interaction module structures the test requirements into test tasks that include target illumination intensity settings, test duration, sampling method, recording strategy, and safety thresholds. Furthermore, the communication module abstracts physical devices such as the light source controller, illumination sensor, and temperature sensor into addressable device objects, enabling unified command issuance and data retrieval. The device objectification and unified interaction mechanism of the communication module facilitate collaborative work among multiple devices and task orchestration, improving the overall system performance.

[0013] Based on this, the control module calculates the control quantity and outputs adjustment commands based on the deviation between the target light intensity and the actual light intensity, thereby forming a stable and repeatable light simulation environment indoors, eliminating the influence of external weather and natural light fluctuations, realizing precise closed-loop control of light intensity, and thus ensuring the standardization and consistency of test conditions.

[0014] In addition, setting up a data stream processing module to perform real-time streaming processing and analysis of measurement and control data during the testing process can reduce data processing latency and improve testing efficiency. Setting up a safety protection module can perform protective actions such as shutdown, power limiting, alarm and recording when over-temperature, communication abnormality or other safety events are triggered, thus building a complete safety interlock and risk control system, thereby improving the reliability and safety of the system. Attached Figure Description

[0015] Figure 1 This is a functional block diagram of an indoor simulated illumination test system for a solar cell array according to an embodiment of this application; Figure 2 This is a schematic diagram of the main flow of the test system according to an embodiment of this application; Figure 3 This is a schematic diagram of the data processing flow of the test system according to an embodiment of this application. Detailed Implementation

[0016] To facilitate understanding of this application, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. It should be noted that when an element is described as being "fixed to" another element, it can be directly on the other element, or one or more intermediate elements may exist between them. When an element is described as being "connected" to another element, it can be directly connected to the other element, or one or more intermediate elements may exist between them. The terms "upper," "lower," "inner," "outer," "bottom," etc., used in this specification indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0017] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. The term "and / or" as used in this specification includes any and all combinations of one or more of the associated listed items.

[0018] Furthermore, the technical features involved in the different embodiments of this application described below can be combined with each other as long as they do not conflict with each other.

[0019] Figure 1 This is a functional block diagram of an indoor simulated illumination testing system for a solar cell array provided in an embodiment of this application. It interacts with multiple physical devices at the hardware device layer to achieve complete illumination testing.

[0020] Please continue reading. Figure 1 The physical devices of this hardware device layer include: a dimming controller 210 for performing light source control, a light sensor 220 for measuring light intensity, a temperature sensor 230 for measuring temperature, a metal halide lamp array 240 for providing light source, a solid-state relay 250 for controlling power supply, and a PLC controller 260.

[0021] The testing system is designed with a modular, layered architecture. It includes: a user interaction module 110, a communication module 120, a control module 130, a data stream processing module 140, and a security protection module 150.

[0022] The user interaction module 110 is used to generate a human-machine interface and determine the test task based on user operations. The task parameters of the test task include: target light intensity setting value, test duration, sampling method, recording strategy, and safety threshold.

[0023] Specifically, the user interaction module 110 can be a function designed using the MVVM architecture to provide an intuitive and efficient human-computer interaction interface.

[0024] The human-machine interface supports real-time parameter adjustment, including dynamic configuration of key parameters such as light intensity setting (0-1500W / m²), test time (0-9999 hours), and test interval (1-3600 seconds). It can display key indicators such as light intensity curve, temperature change trend, and power output waveform in real time, realizing data visualization and multi-dimensional real-time monitoring. When corresponding anomalies are detected, it can generate various alarm types such as over-temperature alarm, equipment fault alarm, and communication anomaly alarm.

[0025] Furthermore, the user interaction module 110 is equipped with role-based access control (RBAC), which supports a three-level permission system for operators, engineers, and administrators, enabling permission management for data information and test control.

[0026] The communication module 120 is used to abstract physical devices into addressable device objects and provide command issuance and data reading capabilities to these device objects. It enables interaction between the hardware device layer where the physical device resides and the test system.

[0027] For details, please continue reading. Figure 1 The communication module 120 includes: a multi-protocol communication engine 121, an infrared peripheral communication control unit 122, a communication queue management unit 123, and a fault recovery unit 124.

[0028] The multi-protocol communication engine 121 is used to communicate with the aforementioned PLC controller 260 (e.g., S7-1200 / 1500 series) and can perform functions such as variable reading and writing, batch data transmission, and disconnection reconnection.

[0029] The infrared peripheral communication control unit 122 can be a Modbus RTU controller supporting the standard Modbus RTU protocol and extended infrared functionality. It communicates with the infrared learning transmitter module to issue infrared control commands to control the operating status of the light source. The communication queue management unit 123 uses a producer-consumer model to build an asynchronous communication queue, ensuring the sequential and real-time execution of commands. The fault recovery unit 124 detects communication anomalies and performs automatic recovery. This can be achieved through a built-in heartbeat detection mechanism or similar methods to support automatic detection and rapid recovery from communication faults.

[0030] The control module 130 is the core control unit. It is used to calculate the control quantity based on the target light intensity setpoint and the actual measurement value of the light sensor, and convert the control quantity into the corresponding adjustment command to perform indoor light intensity testing on the solar cell array, as well as other logical operations.

[0031] For details, please continue reading. Figure 1 The control module 130 includes a PID closed-loop control unit 131. This unit is a functional unit that implements the PID closed-loop control algorithm, used to calculate the control output based on the deviation between the target light intensity setpoint and the actual light intensity collected by the light sensor, so that the actual light intensity converges to the target light intensity setpoint.

[0032] In some embodiments, please continue reading Figure 1 The control module 130 also includes a mode switching unit 132, a scheduling unit 133, and an adaptive parameter adjustment unit 134.

[0033] The mode switching unit 132 is used to switch between manual control mode and automatic control mode. The scheduling unit 133 is used to implement a priority-based multi-task scheduling mechanism to ensure the real-time response of the test system to critical tasks. The adaptive parameter adjustment unit 134 is used to dynamically adjust the control parameters according to the operating status of the test system, thereby improving adaptability.

[0034] The data stream processing module 140 is a functional module that adopts a streaming computing architecture to achieve efficient data processing. It is used to stream the measurement data and control data generated during the illumination test.

[0035] For details, please continue reading. Figure 1 The data stream processing module 140 includes: a real-time acquisition unit 141, a performance calculation unit 142, a storage unit 143, and a retrieval unit 144.

[0036] The real-time acquisition unit 141 is a functional module that supports multi-channel parallel data acquisition. It is used to acquire multiple sampled data at a configurable sampling frequency and add a timestamp and source identifier to each sampled data. These sampled data include: the actual light intensity collected by the light sensor, the temperature data collected by the temperature sensor, and the electrical parameters of the solar cell array under test.

[0037] The performance calculation unit 142 is used to calculate the performance indicators of the solar cell array under test based on the sampled data. It can calculate key performance indicators such as power efficiency, fill factor, and conversion efficiency in real time.

[0038] Storage unit 143 is used to compress the data of the real-time acquisition unit and the performance calculation unit using differential coding and compression algorithms, and store it in the cache area, thereby reducing the storage space occupied.

[0039] The retrieval unit 144 is used to move data from the cache area to a database that supports query and retrieval functions. For example, the database may be a database that supports persistent data storage based on SQLite and provides efficient data query and retrieval functions.

[0040] The safety protection module 150 is used to execute protective actions when a safety event is triggered, thus constructing a multi-layered safety protection system for the test system. Specifically, the safety events include: over-temperature, communication failure, sensor malfunction, or emergency shutdown input. Correspondingly, the protective actions executed include: stopping the light source output, cutting off the enable signal, recording the event, and issuing alarms.

[0041] For example, it implements an over-temperature protection mechanism, monitors the equipment temperature in real time and automatically cuts off the power and alarms when the temperature exceeds the limit, provides emergency shutdown functions for both software and hardware emergency stops, uses cryptographic principles to authenticate users and prevent unauthorized operations through permission verification, and automatically detects the status of each hardware device when the test system starts up, thereby preventing potential failures.

[0042] In some embodiments, the PID closed-loop control unit 131 specifically executes the PID control algorithm described by the following formula: u(t) = Kp × e(t) + Ki × ∫e(t)dt + Kd × de(t) / dt Where u(t) represents the controller output signal, e(t) represents the deviation between the set value and the actual value, Kp represents the proportional coefficient (range 0.8-1.2), Ki represents the integral coefficient (range 0.1-0.3), and Kd represents the derivative coefficient (range 0.05-0.15).

[0043] Accordingly, the adaptive parameter adjustment unit 134 specifically achieves adaptive adjustment of the PID parameters in the following manner: Kp' = Kp × (1 + α × |e(t)| / R) Ki' = Ki × (1 + β × ∫|e(t)|dt / T) Kd' = Kd × (1 + γ × |de(t) / dt| / S) Where α, β, and γ are adaptive adjustment coefficients, and R, T, and S are normalization parameters.

[0044] In some embodiments, the scheduling unit 133 specifically ensures the coordinated operation of each device through a time-slice round-robin scheduling algorithm.

[0045] In this scheduling algorithm, the device priority queue is first initialized, then the time slice quota for each device is calculated, and device operations are executed in priority order. During the operation, the device response status is monitored, and the priority weights are dynamically adjusted accordingly.

[0046] The following combination Figure 2 Please describe in detail the procedures and steps involved in conducting indoor lighting tests using the testing system. For example... Figure 2 As shown, the complete workflow of the testing system includes: Step S301: Begin.

[0047] Upon receiving a user instruction or operation, the software program is launched and the system startup process begins.

[0048] Step S302: System initialization.

[0049] The initialization operation includes: initializing the log module, initializing the memory / cache structure, initializing global state variables, and loading default parameters.

[0050] Step S303: Load the configuration file.

[0051] The system reads the configuration file from the preset path and parses it to obtain the device connection parameters, sampling period, controller parameters (such as PID parameters and output limits), safety thresholds (such as over-temperature thresholds and communication timeout thresholds), and interface display parameters. If the configuration is missing or the format is abnormal, the default configuration is used and alarm information is recorded.

[0052] Step S304: Establish device connection.

[0053] Based on the address and port / serial parameters in the configuration file, it establishes connections with the light source control controller, infrared learning and transmitting module, and sensor acquisition channel, and completes handshake or connectivity verification.

[0054] Step S305: Start the communication service.

[0055] This includes starting a communication thread or asynchronous communication task, establishing a command queue and a receiving queue, and enabling heartbeat detection, timeout retransmission, and disconnection reconnection mechanisms to ensure the reliability of subsequent periodic data acquisition and control command issuance.

[0056] Step S306: Initialize the user interface.

[0057] This involves creating and loading the main interface controls, and initializing user permission information and operation entry points.

[0058] Step S307: Enter the main loop.

[0059] The test system enters a loop operation state, performing tasks such as security checks, data display, user input processing, and control logic according to a preset cycle or event triggering mechanism, until it receives an exit command or a forced shutdown event occurs.

[0060] Please continue reading. Figure 2 After entering the main loop, steps S308 to S311 are executed periodically: Step S308: Perform the security check process.

[0061] This is achieved through the safety protection module 150, which prioritizes interlocking or emergency shutdown when the conditions for triggering a safety event are met, in order to ensure the safety of equipment and personnel.

[0062] Step S309: Update the data display.

[0063] The system reads the latest measured values ​​and control parameters (such as light intensity, temperature, control output, device online status, and alarm status) from the data cache or database and refreshes them to the human-machine interface display area (such as curves, tables, and status lights) to support real-time monitoring by users.

[0064] Step S310: Process user input.

[0065] The system receives and parses user operation commands, including parameter modification (target illumination, PID parameters, sampling / recording strategy), mode switching (manual / automatic), starting / stopping test tasks, device reset, alarm confirmation, etc.; and performs permission verification and legality checks on user input, and writes it to the task queue for execution when necessary.

[0066] Step S311: Determine whether to exit the system. If the result is "no", return to step S307 to continue the main loop; if the result is "yes", proceed to step S312 and close the test system.

[0067] The judgment conditions include user actively clicking to exit, host computer receiving exit command, system detecting unrecoverable serious faults or forced exit due to emergency shutdown, etc.

[0068] Step S312: Shut down the test system.

[0069] The shutdown operation includes: stopping the main loop and releasing resources, stopping the communication service thread, disconnecting the device connection, saving the operation log and key data, writing the shutdown event record, closing the user interface, and completing a series of operations such as program exit.

[0070] Please continue reading. Figure 2Step S308 specifically includes the following steps: Step S3081: Check the safety status.

[0071] Step S3082: Check the temperature status.

[0072] This process involves acquiring temperature data from a temperature sensor or PLC, validating the temperature data (e.g., whether it is within the measurement range, whether it has timed out and not been updated, and whether there is an abnormal jump), and generating the current temperature status.

[0073] Step S3083: Compare the current temperature with the over-temperature threshold to determine if the temperature is over-temperature. If "yes", it means that the safety threshold has been exceeded or the emergency shutdown condition has been reached, and proceed to step S3083; if "no", it means that the temperature is within the allowable range, and proceed to step S3084 to continue checking other safety items.

[0074] Step S3083: Trigger an over-temperature alarm and execute an emergency shutdown.

[0075] Emergency shutdown includes setting the light source control output to a safe value (e.g., output to zero / disable enable), issuing a shutdown command to the controller, freezing the automatic control logic, and entering an interlock state until manual confirmation or the reset condition is met.

[0076] Step S3084: Check the communication status.

[0077] The detection includes checking whether communication with each physical device is normal, and the check items include whether the heartbeat timed out, whether the most recent read / write operation was successful, and whether the error count exceeded the threshold.

[0078] Step S3085: Determine if communication is normal. If yes, proceed to step S3086; otherwise, proceed to step S3087.

[0079] If any critical link communication is interrupted or continuous read / write failures occur, the communication is considered abnormal. Conversely, if no critical link communication occurs, the communication is considered normal.

[0080] Step S3086: Check the permission status.

[0081] The permission check includes verifying the role permissions and key operation authorization status of the currently logged-in user, such as parameter modification, unlocking, starting testing, and manual control. If the permissions are insufficient, the operation will be rejected and the reason will be displayed.

[0082] Step S3087: Trigger a communication alarm and initiate the reconnection and recovery mechanism.

[0083] In some embodiments, please continue reading Figure 2 The control logic executed in the main loop includes the following sub-flows: Step S321: Execute the selected control strategy.

[0084] When safety conditions are met and the system is in a permissible control state, the corresponding control strategy is selected based on whether automatic or manual mode is chosen. For example, in automatic mode, closed-loop regulation is implemented, while in manual mode, the output is either user-defined or based on safety limits.

[0085] Step S322: Read sensor data and perform PID closed-loop regulation.

[0086] The deviation between the target light intensity setpoint and the current actual light intensity is calculated, and the control output is calculated in combination with the PID parameters. At the same time, output limiting, anti-integral saturation and sampling period control are performed to avoid overshoot, oscillation or sudden changes in control quantity.

[0087] Step S323: Issue control commands.

[0088] The control output is mapped into instructions for the light source drive device (such as power percentage, gear, dimming control value), which are sent to the PLC or infrared learning transmitter module through the communication module, and the system waits for a response or execution result readback.

[0089] Step S324: Update device status.

[0090] In some embodiments, such as Figure 3 As shown, the process steps executed by the data stream processing module 140 include: Step S401: Start data collection.

[0091] It can initiate the data acquisition process in response to user input on the interface or in response to test task scheduling instructions.

[0092] Step S402: Select the acquisition channel.

[0093] Based on the object under test or the preset task configuration, the corresponding sensor acquisition channel is selected. These acquisition channels include, but are not limited to, light sensor channels, temperature sensor channels, or other extended channels.

[0094] Step S403: Configure sampling parameters.

[0095] This involves setting the sampling period / frequency, sampling duration, timestamp source, data format, filtering parameters, calibration parameters, and anomaly detection threshold, and then writing the sampling parameters into the running configuration of the acquisition thread.

[0096] Step S404: Start the acquisition thread.

[0097] This involves creating and starting threads or asynchronous tasks for periodic data collection, initializing the in-thread cache and queue structure, and establishing a data reading interface with the communication module.

[0098] Step S405: Read sensor data.

[0099] The system reads raw sensor data from the acquisition channel via a communication module and adds a timestamp, channel identifier, and sequence number to each data entry. When reading fails or times out, an error code is recorded and an exception flag is triggered.

[0100] Step S406: Data preprocessing.

[0101] The process involves performing a preprocessing procedure on the raw data being read. This preprocessing procedure includes at least one or more of the following: filtering, calibration conversion, and anomaly detection, in order to obtain standardized data that can be used for display, control, or storage.

[0102] Step S407: Filtering.

[0103] In this process, moving average, low-pass filtering, median filtering, or other denoising algorithms are applied to the original data to suppress the impact of instantaneous noise and glitch data on subsequent processing.

[0104] Step S408: Calibration and conversion.

[0105] Based on the sensor calibration coefficients, range parameters, or linear / nonlinear mapping relationships, the original sampled values ​​are converted into engineering quantity unit data (such as illuminance values ​​and temperature values), and zero-point compensation and temperature drift compensation can be performed.

[0106] Step S409: Anomaly detection.

[0107] The system determines data anomalies based on thresholds, rates of change, statistical features, or communication quality indicators. When an anomaly is determined, the data is marked with an anomaly flag and an anomaly event is generated for subsequent alarm or removal strategies.

[0108] Step S410: Execute the data storage strategy and perform data storage.

[0109] According to the preset data storage strategy, the preprocessed data is written into the memory queue.

[0110] Step S411: Determine if the memory queue is full. If "No", proceed to step S412; if "Yes", proceed to step S413. One way to determine if the memory queue is full is to check whether the current length of the memory queue has reached the capacity threshold or whether the cumulative amount of data to be written has reached the batch write threshold.

[0111] Step S412: Store in the memory queue.

[0112] Specifically, the data collected in this instance is appended to a memory queue for subsequent batch persistence and real-time interface refresh, thereby reducing the I / O overhead caused by frequent database writes.

[0113] Step S413: Write to the SQLite database.

[0114] Specifically, when the memory queue is full, the data in the queue is written to the SQLite database in batches.

[0115] Step S414: Clear the memory queue.

[0116] After completing the batch database writing, the memory queue pointer is cleared or reset to release cache space and prepare for the next round of data collection.

[0117] Step S415: Trigger the update event.

[0118] Among these, data update events are generated to drive the refresh of the human-computer interface and the update of the database status.

[0119] Step S416: Update the interface display and update the database.

[0120] The user interaction module refreshes the real-time curves, numerical displays, and alarm prompts on the human-machine interface based on update events.

[0121] Step S417: End data collection.

[0122] The data collection process will terminate when the collection period is reached, a user's stop command is triggered, or a security policy requires data collection to stop.

[0123] In summary, the testing system provided in this application significantly improves control performance. Its light intensity control accuracy can reach ±1%, and the response time is shortened to less than 100ms. It can achieve rapid adjustment while maintaining a steady-state error of less than 0.5%, better ensuring the consistency and repeatability of test conditions and improving the reliability of test results.

[0124] In terms of system reliability, through structural and software strategy optimization, the equipment failure rate is reduced by approximately 80%, and the annual downtime can be controlled to within 24 hours. Furthermore, a robust data caching and storage mechanism keeps the data loss rate below 0.01%, ensuring data integrity. Its overall availability reaches 99.9%, meeting the requirements for continuous operation and stable production.

[0125] In terms of testing efficiency and cost-effectiveness, the testing cycle can be shortened by approximately 60% (e.g., from 72 hours to 28 hours), data processing speed can be increased by approximately 300%, and while supporting real-time analysis, the operation process is simplified, helping to reduce personnel training and operating costs. Correspondingly, the cost per test can be reduced from approximately 5,000 yuan to approximately 1,500 yuan (a reduction of approximately 70%), equipment utilization rate can be increased from approximately 60% to approximately 95%, and comprehensive improvements can be achieved in key indicators such as data accuracy and testing time.

[0126] In terms of social benefits, it provides a more standardized and replicable technical solution for the field of solar cell testing, promoting the progress of industry testing methods and evaluation systems; it reduces safety risks by replacing some outdoor high-altitude operations; and it reduces energy consumption by about 40% by using high-efficiency LED light sources, thus having energy-saving and environmental protection value.

[0127] To fully illustrate the inventive concept and technical effects of this application, the following provides a specific implementation of the testing system and its corresponding test results.

[0128] 1) Hardware configuration Main controller: Siemens S7-1500 series PLC, CPU model 1511-1PN Communication module: CM 1241 RS422 / 485 module Light source equipment: Metal halide lamp array, 16 lamps, 1000W each. Sensors: Illuminance sensor (range 0-2000W / m²), Temperature sensor (PT100) Actuators: Dimming controller (0-10V), solid-state relay Host computer: Industrial control computer, i7 processor, 16GB memory 2) Software Configuration Operating System: Windows 10 IoT Enterprise Development environment: Visual Studio 2019, .NET Framework 4.7.2 Database: SQLite 3.0 Communication libraries: S7.Net Plus, NModbus4 3) Implementation code of PID control algorithm: public class PIDController { private double Kp, Ki, Kd; private double integral; private double lastError; private double sampleTime; public PIDController(double kp, double ki, double kd, double ts) { Kp = kp; Ki = ki; Kd = kd; sampleTime = ts; integral = 0; lastError = 0; } public double Calculate(double setpoint, double actual) { double error = setpoint - actual; integral += error * sampleTime; double derivative = (error - lastError) / sampleTime; double output = Kp * error + Ki * integral + Kd * derivative; lastError = error; return output; } } Implementation code for communication management: public class CommunicationManager { private Plc s7Plc; private ModbusInfraredController modbusController; private bool isConnected; public bool Initialize(string plcIp, string modbusPort) { try { / / Initialize S7 communication s7Plc = new Plc(CpuType.S71500, plcIp, 0, 1); s7Plc.Open(); / / Initialize Modbus communication modbusController = new ModbusInfraredController(modbusPort); modbusController.Connect(); isConnected = s7Plc.IsConnected&&modbusController.IsConnected; return isConnected; } catch (Exception ex) { LogError($"Communication initialization failed: {ex.Message}"); return false; } } public async Task <bool>SendCommand(DeviceType device, byte[]command) { / / Implement command sending logic return await Task.FromResult(true); } } 5) Testing Experiments: 5.1) The following functional and performance tests were performed on the test system: Illumination control test: 10 test points were set within the range of 100-1500W / m² to verify the control accuracy; Communication stability test: Continuous operation for 72 hours was conducted, and the number of communication failures was counted; Data integrity test: The accuracy of data acquisition, storage, and analysis was verified; Security protection test: Various fault conditions were simulated to verify the protection function; Response time test: The time from the change of the set value to the system stabilization was measured; Concurrency processing test: Multiple test tasks were processed simultaneously to verify the system performance; Long-term stability test: Continuous operation for 168 hours was conducted, and the system status was monitored.

[0129] 5.2) The test results are shown in the table below:

[0130] It should be noted that, in the embodiments of this application, functionally named modules are used as examples to describe in detail the method steps to be implemented by the device provided in the embodiments of this application. Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the devices and modules described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here. Those skilled in the art will realize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described in terms of function in the above description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this invention.

[0131] Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this application. The computer software can be stored in a computer-readable storage medium, and when executed, the program can include the processes of the embodiments of the methods described above. The storage medium can be a magnetic disk, optical disk, read-only memory, or random access memory, etc.

[0132] The above description is merely an embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.< / bool>

Claims

1. An indoor simulated illumination testing system for a solar cell array, characterized in that, include: The user interaction module is used to form a human-computer interface and determine the test task based on the user's operation. The task parameters of the test task include: target light intensity setting value, test duration, sampling method, recording strategy and safety threshold. The communication module is used to abstract physical devices into addressable device objects and provide command issuance and data reading capabilities to the device objects; The physical device includes: a controller for performing light source control, a light sensor for measuring light intensity, and a temperature sensor for measuring temperature; The control module is used to calculate the control quantity based on the target light intensity set value and the actual measurement value of the light sensor, and convert the control quantity into a corresponding adjustment command to perform light test; The data stream processing module is used to perform streaming processing on the measurement data and control data generated during the illumination test. The security protection module is used to perform protective actions when a security event is triggered.

2. The indoor simulated lighting testing system according to claim 1, characterized in that, The communication module includes: A multi-protocol communication engine is used to communicate with the controller and complete variable reading / writing and batch data transmission. The infrared peripheral communication control unit is used to communicate with the infrared learning and transmitting module and issue infrared control commands to control the operating status of the light source. The communication queue management unit is used to build asynchronous communication queues using the producer-consumer pattern. The fault recovery unit is used to detect communication anomalies and perform automatic recovery.

3. The indoor simulated lighting testing system according to claim 1, characterized in that, The control module includes: The PID closed-loop control unit is used to: calculate the control output based on the deviation between the target light intensity setpoint and the actual light intensity collected by the light sensor, so that the actual light intensity converges to the target light intensity setpoint.

4. The indoor simulated lighting testing system according to claim 1, characterized in that, The data stream processing module includes: A real-time acquisition unit is used to acquire multiple sampled data at a configurable sampling frequency, and add a timestamp and source identifier to each sampled data. The sampling data includes: the actual light intensity collected by the light sensor, the temperature data collected by the temperature sensor, and the electrical parameters of the solar cell array under test; The performance calculation unit is used to calculate the performance indicators of the solar cell array under test. The storage unit is used to compress the data from the real-time acquisition unit and the performance calculation unit using differential coding and compression algorithms, and store it in the cache area; The retrieval unit is used to move data from the cache area to a database that supports query and retrieval functions.

5. The indoor simulated lighting testing system according to claim 1, characterized in that, The safety events include: overheating, communication failure, sensor malfunction, or emergency shutdown input; the protection actions include: stopping the light source output, cutting off the enable, recording the event, and issuing an alarm.

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