Bionic adaptive photovoltaic module load test head and test method

Abstract

The application belongs to the technical field of photovoltaic module performance test, and discloses a bionic adaptive photovoltaic module load test head and a test method, wherein the bionic adaptive photovoltaic module load test head comprises a rigid substrate and a flexible stylus array, each stylus unit comprises a stylus rod, a guide sleeve, an elastic element, a universal connecting piece, a flexible contact, a pressure sensor, a data acquisition system and a control system, the guide sleeve is fixed on the rigid substrate, the stylus rod is located in the guide sleeve, the elastic element is sleeved on the stylus rod, the universal connecting piece is connected to the end of the stylus rod, the flexible contact is connected to the universal connecting piece, the pressure sensor is integrated on the stylus unit, the data acquisition system is electrically connected with the pressure sensor of the stylus unit, and the control system is electrically connected with the loading mechanism and the data acquisition system respectively; the application can adaptively adjust the angle, and can also collect pressure signals of all the styluses.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module performance testing technology, specifically to a biomimetic adaptive photovoltaic module load test head and testing method. Background Technology

[0002] Photovoltaic module load testing is an important means of evaluating the structural reliability of modules under natural environments such as wind pressure and snow load. It quantitatively tests the bending strength, deformation characteristics and durability of modules by simulating external pressure.

[0003] Currently, the pressure application methods in photovoltaic module load testing are mainly divided into two categories: rigid pressure block loading and flexible airbag loading. Rigid pressure block loading uses a rigid pressure plate driven by a hydraulic or electric cylinder to directly contact the module surface to apply pressure; flexible airbag loading, on the other hand, inflates an airbag and uses a flexible membrane to adhere to the module surface to apply pressure. However, existing technologies have the following problems: First, there is the problem of force direction deviation. When the module bends and deforms under load, the rigid pressure block cannot tilt with the module surface, causing the force direction to deviate from the normal direction, resulting in shear force interfering with the test results. Although airbag loading can adhere to the module surface, the pressure direction changes locally with the normal of the airbag membrane, also generating shear components. Second, it is impossible to obtain local pressure distribution. Existing technologies can only measure the total load or the pressure at a few points, making it difficult to obtain detailed pressure distribution data on the module surface, and thus unable to provide accurate boundary conditions for finite element analysis.

[0004] Therefore, existing technologies suffer from problems such as deviation in the direction of force application and inability to obtain local pressure distribution, which urgently need to be addressed. Summary of the Invention

[0005] The purpose of this invention is to provide a biomimetic adaptive photovoltaic module load test head and test method to overcome the problems existing in the prior art. This invention can adaptively adjust the angle through universal connectors to always be perpendicular to the local tangent plane of the module surface. At the same time, each stylus unit integrates a pressure sensor, which can synchronously collect the pressure signals of all styluses through a data acquisition system.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: In a first aspect, the present invention provides a biomimetic adaptive photovoltaic module load test head, comprising: Rigid substrate, used to connect to external loading mechanisms; The flexible stylus array consists of several independent stylus units densely arranged on the rigid substrate; Each of the stylus units includes: Stylus rod; A guide sleeve is fixed on the rigid base plate, and the stylus rod is located inside the guide sleeve to constrain the movement direction of the stylus rod; An elastic element is sleeved on the stylus rod to provide elastic cushioning for the stylus rod; A universal connector is attached to the end of the stylus rod to enable adaptive angle adjustment; A flexible contact, connected to the universal connector, is used to contact the surface of the photovoltaic module under test; A pressure sensor, integrated on the stylus unit, is used to measure the pressure on the stylus unit in real time; The data acquisition system is electrically connected to the pressure sensors of all stylus units to synchronously acquire the pressure signals of each pressure sensor. The control system is electrically connected to both the loading mechanism and the data acquisition system, and is used to control the action of the loading mechanism based on the pressure signal fed back by the data acquisition system.

[0007] In some embodiments, the universal connector is a universal ball joint or a flexible hinge.

[0008] In some embodiments, the elastic element is a compression spring, or the elastic element is a miniature linear motor or piezoelectric actuator using an active control method, used to independently control the loading force of each stylus unit.

[0009] In some embodiments, the stylus unit further includes a top connector, wherein the pressure sensor is integrated inside the top connector.

[0010] In some embodiments, the data acquisition system includes a plurality of acquisition cards, wherein the sampling frequency of the acquisition cards is ≥100Hz.

[0011] In some embodiments, the spacing between two adjacent stylus units is 50-80 mm.

[0012] Secondly, the present invention also provides a testing method for the biomimetic adaptive photovoltaic module load test head using the above-described embodiments, comprising the following steps: The control system controls the loading mechanism to drive the rigid substrate to rise to the initial position; The control system controls the rigid substrate to move from its initial position toward the surface of the photovoltaic module under test. At the same time, the data acquisition system monitors the pressure sensors of each stylus unit to determine the contact state between all stylus units and the surface of the photovoltaic module under test. The control system records the overall downward displacement of the rigid substrate and the initial compression of each stylus unit at this time. Based on the contact state, the overall downward displacement, and the initial compression, a height distribution map of the initial surface of the photovoltaic module under test is established. According to the preset test mode and height distribution map, the control system controls the loading mechanism to drive the rigid substrate to continue moving. During the movement, each stylus unit is adaptively compressed through the elastic element, and the flexible contact is always perpendicular to the local cutting plane of the photovoltaic module under test through the universal connector, so as to apply test load to the photovoltaic module under test. After the target load or target displacement is reached, the pressure values ​​of all stylus units are synchronously collected by the data acquisition system, and the total load and pressure distribution are calculated by the control system.

[0013] In some embodiments, the step of monitoring the pressure sensors of each stylus unit through the data acquisition system to determine the contact state between all stylus units and the surface of the photovoltaic module under test specifically includes: When any pressure sensor signal first reaches the set threshold, it is determined that the stylus unit has contacted the component surface.

[0014] In some embodiments, the preset test mode includes a displacement control mode or a load control mode; the displacement control mode includes: The target displacement is set directly through the control system. The load control mode includes: setting a target total load through the control system; during the load application process, accumulating the real-time pressure of each stylus unit through the data acquisition system; obtaining the current total load through the real-time pressure; comparing the current total load with the target total load; and adjusting the final displacement of the rigid substrate in a closed-loop control manner based on the comparison result until the current total load reaches the target total load.

[0015] In some embodiments, after calculating the total load and pressure distribution, the method further includes: The control system uses the total load and pressure distribution as amplitude references and controls the loading mechanism to drive the rigid substrate to reciprocate according to the preset dynamic load-time curve or dynamic displacement-time curve. During the reciprocating motion, the data acquisition system monitors the dynamic changes in pressure of each stylus unit in real time to obtain the real-time dynamic pressure distribution. The control system compares the real-time dynamic pressure distribution with the pressure distribution and calculates the pressure distribution deviation, which is used to analyze the response characteristics and performance degradation of the photovoltaic module under test under dynamic load.

[0016] The above technical solution has the following advantages or beneficial effects: Firstly, this invention provides a biomimetic adaptive photovoltaic module load test head. By employing a flexible stylus array composed of densely arranged independent stylus units, each stylus unit integrates a universal connector and an elastic element. When the photovoltaic module undergoes bending deformation, the flexible contacts of each stylus unit can adaptively adjust their angle via the universal connector, always remaining perpendicular to the local tangential plane of the module surface, fundamentally eliminating the interference of shear force on the test results. Simultaneously, each stylus unit integrates a pressure sensor, and the pressure signals of all styluses are synchronously collected by a data acquisition system. The control system precisely controls the action of the loading mechanism based on the feedback signals, enabling the acquisition of a high-resolution pressure distribution cloud map of the module surface. This provides accurate boundary conditions for finite element analysis, solving the problems of force direction deviation and the inability to obtain local pressure distribution in existing technologies, significantly improving the accuracy and data richness of load testing.

[0017] In some embodiments, by using a universal ball joint or a flexible hinge as a universal connector, the contact can achieve a large-angle adaptive tilt of more than ±20°, ensuring that when the photovoltaic module undergoes large bending deformation, the flexible contact can still be closely attached to the module surface and keep the force direction perpendicular to the local tangential plane, further eliminating shear force interference and improving the accuracy and reliability of test data.

[0018] In some embodiments, by setting a data acquisition system with a sampling frequency ≥100Hz, the dynamic pressure changes of all stylus units during the loading process can be captured in real time and synchronously, meeting the high-speed data acquisition requirements of static testing and dynamic fatigue testing; the high sampling rate ensures the time resolution of the pressure distribution cloud map, providing reliable data support for analyzing the response characteristics of the components under transient loads.

[0019] In some embodiments, by setting the spacing between adjacent stylus units to 50-80mm, it is possible to ensure that 4-9 stylus units are distributed above each photovoltaic cell, which not only guarantees the spatial resolution of pressure distribution measurement, but also avoids the increased cost and structural interference caused by excessively dense stylus units. This spacing range matches the typical cell size of photovoltaic modules, achieving an optimized balance between measurement accuracy and economy.

[0020] Secondly, this invention provides a testing method using the aforementioned biomimetic adaptive photovoltaic module load test head. First, a height distribution map of the module's initial surface is established through contact detection, providing a precise morphological reference for subsequent loading. During load application, each stylus unit adaptively compresses the elastic element according to the height distribution map, and a universal connector ensures the flexible contact remains perpendicular to the module's local tangential plane, fundamentally eliminating shear force interference and ensuring the measured load purely reflects the module's bending resistance. The control system works in conjunction with a preset mode and real-time feedback, enabling both constant displacement loading and constant load loading. After reaching the target, all stylus pressure values ​​are simultaneously collected, and the total load and fine pressure distribution are calculated, providing precise boundary conditions for finite element analysis. This method solves the problems of force direction deviation and inability to obtain local pressure distribution in existing technologies, significantly improving the accuracy and data richness of load testing, and is applicable to various scenarios such as static testing and dynamic fatigue testing.

[0021] In some embodiments, by using the first time the pressure sensor signal reaches a set threshold as the basis for determining the contact state, the precise identification of the contact moment between each stylus unit and the component surface is achieved. This method eliminates the influence caused by stylus length differences, installation errors, or uneven component surfaces, providing a reliable data foundation for subsequently establishing an accurate height distribution map and ensuring the repeatability and consistency of the test.

[0022] In some embodiments, by setting two modes, displacement control and load control, this test method can flexibly switch loading strategies according to different test standards. The load control mode adopts closed-loop control, accumulates the pressure of each stylus in real time and compares it with the target value, and dynamically adjusts the substrate displacement until the set total load is reached to ensure loading accuracy. The displacement control mode is suitable for test scenarios with constant deformation. The two modes work together to meet diverse test requirements.

[0023] In some embodiments, by performing dynamic testing steps after static testing, and using the total load and pressure distribution obtained from static testing as the amplitude benchmark and comparison benchmark for dynamic loading, the correlation analysis of the component's response characteristics under static and dynamic loads is realized; real-time monitoring of dynamic pressure distribution and calculation of the deviation from the static distribution can effectively evaluate the performance degradation law of the component under cyclic loading, providing a quantitative basis for component fatigue durability research. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of a biomimetic adaptive photovoltaic module load test head structure according to an embodiment of the present invention; In all the accompanying drawings, the same reference numerals denote the same technical features, specifically: 1. Loading mechanism; 2. Flexible stylus array; 3. Rigid substrate; 4. Connecting seat; 5. Pressure sensor; 6. Guide sleeve; 7. Compression spring; 8. Displacement sensor; 9. Stylus rod; 10. Internal circuitry; 11. Universal ball joint; 12. Flexible contact; 13. Data acquisition system; 14. Control system. Detailed Implementation

[0025] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0026] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention 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. Therefore, they should not be construed as limitations on this invention.

[0027] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0028] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0029] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Currently, in photovoltaic module load testing, pressure application methods are mainly divided into two categories: rigid pressure block loading and flexible airbag loading. Rigid pressure blocks apply pressure by directly contacting the module surface with a flat plate or block, while flexible airbags apply pressure by causing a flexible film to adhere to the module surface through gas expansion. Typical solutions in existing technologies include: Option 1: Use a rigid pressure plate and apply a uniform load to the component by driving it with a hydraulic cylinder or electric cylinder.

[0032] Option 2: Use an integral airbag, which expands by inflation to apply pressure to the surface of the component.

[0033] The aforementioned prior art has the following drawbacks: Issues with force direction deviation: When photovoltaic modules bend under load, the rigid pressure block cannot tilt with the module surface, and the force direction remains vertically downward. This causes the actual force acting on the module surface to decompose into normal pressure (effective load) and tangential shear force (interference force). The shear force interferes with the module's true bending response, causing the test data to deviate from reality. Changes in airbag force direction with deformation: Although the airbag can conform to the module surface, the pressure it applies is always perpendicular to the airbag membrane surface. When the module bends, the local normal of the airbag membrane also changes, causing the pressure direction to no longer be perpendicular to the module's initial plane, also generating a shear component. Edge stress concentration: The rigid pressure block easily generates stress concentration at the module edges and frame, leading to local overload. The pressure decays quickly at the edges when loaded with airbags, making it difficult to simulate the constraint state under actual installation conditions. Inability to obtain local pressure distribution: Existing technologies can only measure the total load or the pressure at a few points, making it impossible to obtain detailed pressure distribution data on the module surface, and thus difficult to verify the accuracy of finite element analysis.

[0034] This invention provides a biomimetic adaptive photovoltaic module load test head, inspired by the grasping mechanism of octopus tentacles or human fingers. Through a large number of densely distributed flexible styluses, each styluse can independently and adaptively adjust the direction and magnitude of the applied force, so that it always maintains the direction of the applied force perpendicular to the surface of the module when the module is bent and deformed. It includes: a rigid substrate 3 and a flexible stylus array 2, wherein each stylus unit includes: a stylus rod 9, a guide sleeve 6, an elastic element, a universal connector, a flexible contact 12, a pressure sensor 5, a data acquisition system 12 and a control system 14; The rigid substrate 3 is used to connect to the external loading mechanism 1; the flexible stylus array 2 consists of several independent stylus units densely arranged on the rigid substrate 3; the guide sleeve 6 is fixed on the rigid substrate 3, and the stylus rod 9 is located inside the guide sleeve 6 to constrain the movement direction of the stylus rod 9; the elastic element is sleeved on the stylus rod 9 to provide elastic buffering for the stylus rod 9; the universal connector is connected to the end of the stylus rod 9 to achieve adaptive angle adjustment; the flexible contact 12 is connected to the universal connector to contact the surface of the photovoltaic module under test; the pressure sensor 5 is integrated on the stylus unit to measure the pressure on the stylus unit in real time; the data acquisition system 13 is electrically connected to the pressure sensors 5 of all stylus units to synchronously acquire the pressure signals of each pressure sensor 5; the control system 14 is electrically connected to the loading mechanism 1 and the data acquisition system 13 respectively to control the action of the loading mechanism 1 according to the pressure signal fed back by the data acquisition system 13.

[0035] This invention utilizes a biomimetic octopus-tentacle gripping mechanism, employing a flexible stylus array 2 composed of densely arranged independent stylus units. Its working principle is as follows: when the photovoltaic module bends under load, the universal connector at the end of each stylus unit drives the flexible contact 12 to adaptively deflect, always perpendicular to the local tangential plane of the module surface. This fundamentally eliminates shear force interference, ensuring that the load measured by the pressure sensor 5 purely reflects the module's bending resistance. Simultaneously, the buffering effect of the elastic element avoids rigid impact, the data acquisition system 13 synchronously collects the pressure signals from all styluses, and the control system 14 precisely drives the loading mechanism 1 based on feedback. Therefore, this invention can both adapt to changes in the module's surface morphology to maintain perpendicular force application and obtain a high-resolution global pressure distribution cloud map, effectively solving the problems of force direction deviation and the inability to obtain local pressure distribution in existing technologies, significantly improving the accuracy and data richness of load testing.

[0036] Example: This embodiment provides a biomimetic adaptive photovoltaic module load test head, including: a rigid substrate 3 and a flexible stylus array 2, wherein each stylus unit includes: a stylus rod 9, a guide sleeve 6, an elastic element, a universal connector, a flexible contact 12, a pressure sensor 5, a data acquisition system 12 and a control system 14; The rigid substrate 3 is used to connect to the external loading mechanism 1; the flexible stylus array 2 consists of several independent stylus units densely arranged on the rigid substrate 3; the guide sleeve 6 is fixed on the rigid substrate 3, and the stylus rod 9 is located inside the guide sleeve 6 to constrain the movement direction of the stylus rod 9; the elastic element is sleeved on the stylus rod 9 to provide elastic buffering for the stylus rod 9; the universal connector is connected to the end of the stylus rod 9 to achieve adaptive angle adjustment; the flexible contact 12 is connected to the universal connector to contact the surface of the photovoltaic module under test; the pressure sensor 5 is integrated on the stylus unit to measure the pressure on the stylus unit in real time; the data acquisition system 13 is electrically connected to the pressure sensors 5 of all stylus units to synchronously acquire the pressure signals of each pressure sensor 5; the control system 14 is electrically connected to the loading mechanism 1 and the data acquisition system 13 respectively to control the action of the loading mechanism 1 according to the pressure signal fed back by the data acquisition system 13.

[0037] In some embodiments, the rigid substrate 3 serves as the back plate of the pressure head and is made of a high-strength, lightweight material (such as aluminum alloy or carbon fiber composite material), and is connected to the loading mechanism 1 (such as a servo electric cylinder, hydraulic cylinder, or ball screw). The rigid substrate 3 has densely packed mounting holes for fixing the stylus unit.

[0038] In some embodiments, the flexible pin array 2 consists of hundreds to thousands of independent pin units arranged in a dense matrix, covering the entire component testing area. The pin spacing can be adjusted as needed, with a typical spacing of 50-80 mm between two adjacent pin units, ensuring that 4-9 pins are distributed above each cell.

[0039] In some embodiments, in addition to a regular matrix arrangement, a non-uniform distribution can be adopted according to the layout of the module cells, with denser contact pins in key areas such as the center of the cell and the solder strip position, and appropriately sparser in the border area.

[0040] In some embodiments, the universal connector is a universal ball joint 11 or a flexible hinge, used to achieve a tilt angle of ±20° between the flexible contact 12 and the axis of the stylus rod 9.

[0041] In some embodiments, the flexible hinge includes an elastic diaphragm and a cross spring sheet, which is frictionless, maintenance-free, and suitable for high-frequency dynamic testing.

[0042] In some embodiments, the elastic element is a compression spring 7, or the elastic element is a miniature linear motor or piezoelectric actuator using an active control method, used to independently control the loading force of each stylus unit.

[0043] In some embodiments, the compression spring 7 can provide elastic cushioning, allowing each stylus to adapt to height differences on the component surface, and the stiffness of the compression spring 7 can be selected according to the test pressure range.

[0044] In some embodiments, the stylus rod 9 has a hollow structure with internal wiring and is connected to a universal ball joint 11 at the bottom.

[0045] In some embodiments, the universal ball joint 11 can achieve a tilt angle of ±20°, ensuring that the contact can fit against the component surface at any bending angle.

[0046] In some embodiments, the flexible contact 12 is made of silicone or polyurethane material, with a diameter of 8-15mm, and the contact surface is designed with fine texture to increase friction and prevent slippage.

[0047] In some embodiments, the flexible contact 12, in addition to silicone contacts, may use a micro-adhesive material (such as micro-adhesive) to increase adhesion to the component surface and prevent slippage; or use a ball contact to reduce friction, suitable for dynamic testing.

[0048] In some embodiments, the stylus unit further includes a top connector 4, wherein the pressure sensor 5 is integrated inside the top connector 4.

[0049] In some embodiments, the pressure sensor 5 has a range of 0-500 N and an accuracy of 0.5% FS.

[0050] In some embodiments, the guide sleeve 6 is a precision-machined sleeve with a smooth inner wall, which constrains the movement direction of the stylus and prevents it from swaying.

[0051] In some embodiments, the data acquisition system 13 includes several acquisition cards, the sampling frequency of which is ≥100Hz, for acquiring pressure signals of all styluses; optional displacement sensors are provided to monitor the compression of each stylus.

[0052] In some embodiments, the control system 14 drives the loading mechanism according to the test mode (displacement control or load control) and monitors the pressure of each stylus in real time to ensure the accuracy and uniformity of load application.

[0053] In some embodiments, in addition to estimating the height by the compression of the stylus rod 9, a laser displacement sensor 8 or a structured light three-dimensional scanning system can be integrated on the rigid substrate 3 to directly measure the surface morphology of the component.

[0054] This invention utilizes a biomimetic multi-contact adaptive pressure head structure: composed of densely arranged independent stylus units, each with spring buffering, pressure sensing, and omnidirectional adaptive adjustment capabilities. The omnidirectional adaptive mechanism of the stylus unit uses a universal ball joint 11 or a flexible hinge to allow the flexible contact 12 to automatically adjust its angle, ensuring that the applied force direction remains perpendicular to the surface under any component bending condition. A high-resolution pressure distribution measurement method based on the flexible stylus array 2 is employed: by synchronously acquiring the pressure of all styluses, a pressure distribution cloud map of the component surface is reconstructed to obtain precise mechanical boundary conditions. A coordinated strategy for displacement control and load control is implemented: the control mode is automatically switched according to test requirements to achieve constant displacement loading, constant load loading, or complex load spectrum loading.

[0055] This embodiment also provides a testing method using the above-mentioned biomimetic adaptive photovoltaic module load test head, including the following steps: Step 1: The loading mechanism 1 is controlled by the control system 14 to drive the rigid substrate 3 to rise to the initial position.

[0056] In some embodiments, step 1 specifically includes: The loading mechanism 1, controlled by the control system 14, drives the rigid substrate 3 to rise to its initial position, at which point all the stylus units are retracted. The photovoltaic module under test is then placed on the test platform, and its frame is secured.

[0057] Step 2: The rigid substrate 3 is controlled by the control system 14 to move from its initial position toward the surface of the photovoltaic module under test. At the same time, the pressure sensor 5 of each stylus unit is monitored by the data acquisition system 13 to determine the contact state between all stylus units and the surface of the photovoltaic module under test. The control system 14 records the overall downward displacement of the rigid substrate 3 and the initial compression of each stylus unit. Based on the contact state, the overall downward displacement and the initial compression, the height distribution map of the initial surface of the photovoltaic module under test is inverted and established.

[0058] In some embodiments, the step of monitoring the pressure sensor 5 of each stylus unit through the data acquisition system 13 to determine the contact state between all stylus units and the surface of the photovoltaic module under test specifically includes: When the signal from any pressure sensor 5 first reaches the set threshold 2N, it is determined that the stylus unit has contacted the component surface.

[0059] Step 3: The control system 14 controls the loading mechanism 1 to drive the rigid substrate 3 to continue moving according to the preset test mode and height distribution map. During the movement, each stylus unit is adaptively compressed by the elastic element to match the height fluctuation of the component surface. At the same time, the flexible contact 12 is always perpendicular to the local cutting plane of the photovoltaic module under test by the universal connector, so as to apply a standard and pure normal test load to the photovoltaic module under test.

[0060] In some embodiments, the preset test mode includes a displacement control mode or a load control mode; The displacement control mode includes: directly setting the target displacement through the control system 14; The load control mode includes: setting a target total load through the control system 14; during the load application process, accumulating the real-time pressure of each stylus unit through the data acquisition system 13; obtaining the current total load through the real-time pressure; comparing the current total load with the target total load; and adjusting the final displacement of the rigid substrate 3 in a closed-loop control manner based on the comparison result until the current total load reaches the target total load.

[0061] In some embodiments, the displacement control mode directly sets a target displacement (i.e., the distance the substrate continues to descend from the contact point) through the control system 14, and the control system descends at a low and uniform speed to the target displacement and then stops.

[0062] In some embodiments, a target pressure distribution can also be set and achieved by iteratively adjusting the preload of the compression spring 7 of each stylus or by using active pressure control (such as an electro-controlled magnetorheological fluid damper).

[0063] In some embodiments, each stylus unit is equipped with a miniature linear motor or piezoelectric actuator to enable independent active pressure application at each point, simulating more complex pressure distribution patterns.

[0064] Step 4: After the target load or target displacement is reached, the pressure values ​​of all stylus units are collected synchronously by the data acquisition system 14, and the total load and pressure distribution are calculated by the control system 14.

[0065] Step 5: Using the total load and pressure distribution as amplitude references, the control system 14 controls the loading mechanism 1 to drive the rigid substrate 3 to reciprocate according to the preset dynamic load-time curve or dynamic displacement-time curve. During the reciprocating motion, the data acquisition system 13 monitors the dynamic changes of pressure in each stylus unit in real time to obtain the real-time dynamic pressure distribution. The control system 14 compares the real-time dynamic pressure distribution with the pressure distribution and calculates the pressure distribution deviation, which is used to analyze the response characteristics and performance degradation of the photovoltaic module under test under dynamic load.

[0066] In some embodiments, steps 4 and 5 specifically include: After reaching the target load or displacement, the pressure values ​​of all stylus units are synchronously acquired by the data acquisition system 14, and the total load and pressure distribution are calculated by the control system 14. For example, an intuitive pressure distribution cloud map can be generated for analyzing local stress conditions. Combined with displacement sensor data, the relationship between the local bending curvature of the component and the pressure can also be calculated. By repeating the loading-unloading cycle, the hysteresis characteristics and residual deformation of the component can be studied. Furthermore, this test head also supports a dynamic testing mode. After completing static loading and calculating the total load and pressure distribution, this can be used as an amplitude benchmark for dynamic testing. Specifically, the control system 14 controls the loading mechanism 1 to drive the rigid substrate 3 to reciprocate according to the preset dynamic load-time curve or dynamic displacement-time curve. During the reciprocating motion, the data acquisition system 13 monitors the dynamic changes of the pressure of each stylus unit in real time to obtain the real-time dynamic pressure distribution. Subsequently, the control system 14 compares the real-time dynamic pressure distribution with the previous static pressure distribution to calculate the pressure distribution deviation, thereby accurately analyzing the response characteristics and performance degradation of the photovoltaic module under test under dynamic load.

[0067] This invention eliminates shear stress interference: through the adaptive adjustment of the universal ball joint 11, it ensures that the direction of force application is always perpendicular to the local tangential plane of the component surface, making the test results more purely reflect the bending performance of the component and significantly improving data accuracy. It adapts to large deformation testing: even if the component undergoes large bending deformation (e.g., deflection exceeding 50 mm), the pressure head can still work effectively and can be used to study the ultimate bearing capacity and failure mode of the component. It obtains high-resolution pressure distribution: pressure data from hundreds to thousands of measuring points can be obtained, providing accurate boundary conditions for finite element analysis, and verifying and correcting simulation models. It avoids edge stress concentration: the flexible buffering characteristics of the stylus ensure uniform load distribution, eliminating stress concentration at the edge caused by the rigid pressure block. It has wide applicability: it is applicable to components of different sizes and structures, including double-glass components, flexible components, and curved surface components, without the need to change tooling.

[0068] The structure and working principle of the present invention will be further explained below: This specification describes a biomimetic adaptive photovoltaic module load test head. In the initial state, the control system 14 drives the loading mechanism 1 to raise the rigid substrate 3 to its initial position. During testing, the rigid substrate 3 descends at a constant speed, and the data acquisition system 13 monitors the pressure sensors 5 of each probe unit in real time. When the signal from any pressure sensor 5 first reaches a set threshold, it is determined that the probe unit has contacted the module surface. The control system 14 records the overall descent displacement of the rigid substrate 3 and the initial compression of each probe unit, thereby reconstructing the initial height distribution map of the module surface.

[0069] Upon entering the loading phase, the control system 14 drives the rigid substrate 3 to continue moving according to the preset test mode and height distribution map. During this process, the compression springs 7 of each stylus unit adaptively compress according to the local height differences of the component, achieving flexible and uniform loading. Simultaneously, the universal ball joint 11 or flexible hinge drives the flexible contact 12 to automatically deflect, ensuring it remains perpendicular to the local tangential plane of the component surface, fundamentally eliminating shear force interference. The pressure sensor 5 measures the pressure on each stylus in real time, the data acquisition system 13 synchronously acquires all pressure signals, and the control system 14 calculates the total load and reconstructs a high-resolution pressure distribution cloud map, providing accurate boundary conditions for the mechanical performance analysis of the component.

[0070] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the above embodiments should be considered exemplary rather than restrictive in all respects; the scope of protection of the present invention is defined by the appended claims, not by the foregoing description, and thus all changes falling within the meaning and scope of the equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0071] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity; those skilled in the art should consider the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art. The above content is merely illustrative of the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made to the technical solutions based on the technical concept proposed in this invention fall within the scope of protection of the claims of this invention.

Claims

1. A biomimetic adaptive photovoltaic module load test head, characterized in that, include: Rigid substrate (3) for connecting to an external loading mechanism (1); The flexible stylus array (2) consists of several independent stylus units densely arranged on the rigid substrate (3); Each of the stylus units includes: Stylus rod (9); The guide sleeve (6) is fixed on the rigid base plate (3), and the stylus rod (9) is located inside the guide sleeve (6) to constrain the movement direction of the stylus rod (9); An elastic element is sleeved on the stylus rod (9) to provide elastic cushioning for the stylus rod (9); A universal connector is attached to the end of the stylus rod (9) to enable adaptive angle adjustment; A flexible contact (12) is connected to the universal connector and is used to contact the surface of the photovoltaic module to be tested. A pressure sensor (5) is integrated on the stylus unit for real-time measurement of the pressure on the stylus unit; The data acquisition system (13) is electrically connected to the pressure sensors (5) of all the stylus units and is used to synchronously acquire the pressure signals of each pressure sensor (5); The control system (14) is electrically connected to the loading mechanism (1) and the data acquisition system (13) respectively, and is used to control the action of the loading mechanism (1) according to the pressure signal fed back by the data acquisition system (13).

2. The biomimetic adaptive photovoltaic module load test head according to claim 1, characterized in that, The universal connector is a universal ball joint (11) or a flexible hinge.

3. A biomimetic adaptive photovoltaic module load test head according to claim 1, characterized in that, The elastic element is a compression spring (7), or the elastic element is a miniature linear motor or piezoelectric actuator with active control, used to independently control the loading force of each stylus unit.

4. A biomimetic adaptive photovoltaic module load test head according to claim 1, characterized in that, The stylus unit also includes: The pressure sensor (5) is integrated inside the top connector (4).

5. A biomimetic adaptive photovoltaic module load test head according to claim 1, characterized in that, The data acquisition system (13) includes several acquisition cards, and the sampling frequency of the acquisition cards is ≥100Hz.

6. A biomimetic adaptive photovoltaic module load test head according to claim 1, characterized in that, The spacing between two adjacent stylus units is 50-80 mm.

7. A test method using the biomimetic adaptive photovoltaic module load test head according to any one of claims 1 to 6, characterized in that, Includes the following steps: The loading mechanism (1) is controlled by the control system (14) to drive the rigid substrate (3) to rise to the initial position; The rigid substrate (3) is controlled by the control system (14) to move from its initial position toward the surface of the photovoltaic module to be tested. At the same time, the pressure sensor (5) of each stylus unit is monitored by the data acquisition system (13) to determine the contact state between all stylus units and the surface of the photovoltaic module to be tested. The overall downward displacement of the rigid substrate (3) and the initial compression of each stylus unit are recorded by the control system (14). Based on the contact state, the overall downward displacement and the initial compression, a height distribution map of the initial surface of the photovoltaic module to be tested is established. According to the preset test mode and height distribution map, the control system (14) controls the loading mechanism (1) to drive the rigid substrate (3) to continue moving. During the movement, each stylus unit is adaptively compressed through the elastic element, and the flexible contact (12) is always perpendicular to the local cutting plane of the photovoltaic module under test through the universal connector, so as to apply test load to the photovoltaic module under test. After the target load or target displacement is reached, the pressure values ​​of all stylus units are synchronously collected by the data acquisition system (14), and the total load and pressure distribution are calculated by the control system (14).

8. A biomimetic adaptive photovoltaic module load test head according to claim 7, characterized in that, The step of monitoring the pressure sensors (5) of each stylus unit through the data acquisition system (13) to determine the contact state between all stylus units and the surface of the photovoltaic module under test specifically includes: When the signal of any pressure sensor (5) reaches the set threshold for the first time, it is determined that the stylus unit has contacted the component surface.

9. A biomimetic adaptive photovoltaic module load test head according to claim 7, characterized in that, The preset test modes include displacement control mode or load control mode; The displacement control mode includes: directly setting the target displacement through the control system (14); The load control mode includes: setting a target total load through the control system (14), accumulating the real-time pressure of each stylus unit through the data acquisition system (13) during the load application process, obtaining the current total load through the real-time pressure, comparing the current total load with the target total load, and adjusting the final displacement of the rigid substrate (3) in a closed-loop control manner based on the comparison result until the current total load reaches the target total load.

10. A biomimetic adaptive photovoltaic module load test head according to claim 7, characterized in that, After calculating the total load and pressure distribution, the following is also included: The control system (14) uses the total load and pressure distribution as the amplitude reference and controls the loading mechanism (1) to drive the rigid substrate (3) to reciprocate according to the preset dynamic load-time curve or dynamic displacement-time curve. During the reciprocating motion, the dynamic changes of pressure in each stylus unit are monitored in real time through the data acquisition system (13) to obtain the real-time dynamic pressure distribution; The control system (14) compares the real-time dynamic pressure distribution with the pressure distribution and calculates the pressure distribution deviation, which is used to analyze the response characteristics and performance degradation of the photovoltaic module under test under dynamic load.

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