Integrated curved photovoltaic power generation dome for vehicle and manufacturing method thereof

Abstract

The application provides a vehicle integrated curved-surface photovoltaic power generation dome and a manufacturing method thereof, and belongs to the technical field of photovoltaics. The dome comprises a hyperboloidal glass, a PV assembly, a control unit, an energy storage battery and a battery pack frame. The hyperboloidal glass, the PV assembly and the battery pack frame have the same shape and are all curved-surface structures, and the three are sequentially and layerwisely connected. The output end of the PV assembly is electrically connected to the input end of the control unit, and the output end of the control unit is electrically connected to the energy storage battery and a vehicle load. The control unit and the energy storage battery are both embeddedly installed in the interior of the battery pack frame. The application enables the power generation dome to be closely combined with a hyperboloidal or spherical vehicle roof through the layerwise design of three layers of the same curved-surface structure, and integrates the functions of power generation, maximum power point tracking control, energy storage and monitoring into one, so that the structure is compact and the adaptability is strong, and the application is suitable for photovoltaic power generation of a curved-surface roof of a new energy vehicle.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic technology, and in particular relates to an integrated curved photovoltaic power generation dome for vehicles and its manufacturing method. Background Technology

[0002] Currently, new energy photovoltaic power generation technology mainly uses planar photovoltaic modules based on crystalline silicon cells. However, with the continuous improvement of modern building technology, structures such as building domes and vehicle roofs are increasingly designed with curved or spherical shapes, making it difficult for traditional planar photovoltaic modules to be directly applied to such curved structures. The emergence of thin-film photovoltaic cells has expanded the application scenarios of photovoltaic power generation, making them suitable for various occasions such as vehicle-mounted curved photovoltaic domes, building curved photovoltaic glass, and photovoltaic flexible backpacks.

[0003] The maximum output power achievable by the load depends on two factors: the photovoltaic cells' own power generation capacity and the conversion efficiency of the maximum power point tracking (MPPT) controller. These two factors jointly determine the system's final output power. To ensure that the photovoltaic modules always operate at their maximum power point, common MPPT algorithms include fixed voltage tracking, incremental conductance, and perturbation-observation. In recent years, with the development of artificial intelligence technology, intelligent algorithms based on fuzzy control, neural networks, genetic algorithms, and particle swarm optimization have also been applied to quickly find the maximum power point.

[0004] Regarding photovoltaic controller topology, grid-connected photovoltaic power generation controllers require isolation transformers due to safety regulations. Compared to isolated MPPT converters, non-isolated topologies, by eliminating the need for high-frequency isolation transformers, are easier to design with small size and high efficiency.

[0005] High-power photovoltaic-storage systems used in residential or commercial energy storage applications typically separate the power generation, control, and storage units. Photovoltaic modules require independent mounting brackets, and the connecting wires between units result in additional power losses. The overall system size is also large, making installation and maintenance inconvenient. Furthermore, due to limitations in real-time matching between power generation and consumption, power management for both generation and storage is crucial.

[0006] In terms of energy storage safety, lithium batteries pose an explosion risk under extreme conditions such as being punctured, burned, or impacted.

[0007] In terms of material properties, the indirect bandgap characteristics of monocrystalline silicon require a thicker semiconductor layer for its absorption spectrum, resulting in heavier modules and a larger MPPT controller. Therefore, flat photovoltaic panels are difficult to meet the requirements of curved and lightweight applications.

[0008] In the prior art, CN202410063064.X discloses a maximum power point tracking method that uses a gradient algorithm to calculate the perturbation step size in real time. Although this method avoids the mismatch problem caused by empirically setting the step size, it still has shortcomings such as large computational load, high requirements for processor clock speed, and the possibility of getting trapped in local optima. CN121285057A proposes a curved photovoltaic tile based on back-contact batteries. In this structure, the battery cell size is uniform and the curvature of each battery cell is consistent, which is suitable for one-dimensional curved building roofs. However, it is still difficult to achieve effective bonding and application for more complex curved surface structures such as hyperboloids or spheres. CN202510278555.0 discloses a photovoltaic and energy storage integrated machine that installs photovoltaic modules on the surface of a mobile power supply. It solves the problem of inconvenience in carrying and using photovoltaic panels and energy storage power supplies to a certain extent. However, its energy storage box is large in size and does not have an MPPT controller, resulting in low power generation efficiency. CN118826105A proposes an energy storage control system and method that dynamically allocates electricity by analyzing the power generation and consumption in each region. This system is suitable for large-scale regional energy storage systems and independent power consumption systems, but it is difficult to apply directly to single power generation, storage and consumption systems.

[0009] In summary, there is a lack of existing technologies for vehicle-mounted or building-mounted photovoltaic power generation systems that can simultaneously meet the requirements of surface adaptation, high-efficiency power generation, integrated design, and intelligent power management. Summary of the Invention

[0010] The purpose of this invention is to provide an integrated curved photovoltaic power generation dome, which aims to solve the above-mentioned technical problems through integrated structure, curved surface adaptation design and intelligent monitoring and management, and achieve the unity of high efficiency, miniaturization, curved surface adaptation and intelligent management.

[0011] To achieve the above objectives, the present invention adopts the following technical solution: An integrated curved photovoltaic power generation dome for vehicles, characterized in that it includes: hyperboloid glass, PV modules, control unit, energy storage battery, and battery pack frame; The hyperboloid glass, PV module and curved battery pack have the same shape and are all curved structures, and are stacked and connected in sequence; The output of the PV module is electrically connected to the input of the control unit, and the output of the control unit is electrically connected to the energy storage battery and the vehicle load. Both the control unit and the energy storage battery are embedded inside the battery pack rack.

[0012] Furthermore, the control unit includes: a monitoring and communication unit, a DC-DC converter, a digital logic processor, and a three-port converter; the digital logic processor is electrically connected to the monitoring and communication unit, the DC-DC converter, and the three-port converter, respectively.

[0013] Furthermore, the control unit is composed of a first circuit board and a second circuit board; the first circuit board is a power conversion circuit with a three-port converter and a DC-DC converter mounted on the three-port converter; the second circuit board is a control circuit with a digital logic processor and a monitoring and communication unit; the first circuit board and the second circuit board are assembled vertically.

[0014] Furthermore, the first port of the three-port converter is connected to the output port of the PV module, the second port is connected to the energy storage battery, and the third port is connected to the vehicle load.

[0015] Furthermore, the curved battery pack rack is equipped with several equally spaced storage boxes, and multiple energy storage batteries and control units are installed in the storage boxes.

[0016] A method for fabricating an integrated curved photovoltaic power generation dome for vehicles includes the following steps: S1. A concave mold is made according to the curvature of the glass shape for the application. The glass is placed on the concave mold and bent into shape in a hot bending furnace at 500-900 degrees Celsius to obtain hyperboloid glass. S2. According to the size and curvature of the hyperboloid glass, the PV cells are cut into different sizes. The cut cells are connected in series and parallel to form a PV cell pack. The PV cell pack is installed on the PV cell pack frame. The PV cell pack and the PV cell pack frame together form a PV module. S3. The battery pack frame is customized according to the size and curvature of the PV module. The battery pack frame is equipped with a battery slot for installing the control unit and the energy storage battery. The energy storage battery is customized according to the curvature of the PV module. S4. Overlap and connect the hyperboloid glass, PV modules and battery packs in space to form a curved photovoltaic power generation dome.

[0017] Furthermore, in step S2, the thickness of the PV cell is 0.16 to 0.2 mm, and the maximum distance between the hyperboloid glass and the PV cell is controlled within 2 mm.

[0018] Furthermore, in step S3, the battery pack frame is made of lightweight aluminum alloy, and its outer frame curvature is consistent with the curvature of the hyperboloid glass and PV module.

[0019] Furthermore, the battery pack frame is 15mm thick, and its interior is hollowed out to form a battery slot with a depth of 10mm.

[0020] The beneficial effects of this invention are as follows: 1. Improved power density and adaptability to complex curved surfaces: The integrated flexible photovoltaic dome structure integrates power generation, control and energy storage, avoiding line losses in separate power generation and storage systems; at the same time, the size of the battery cells is customized according to the curvature of the flexible glass and connected in series and parallel to form power generation modules, which can be closely fitted to hyperboloid or spherical structures, solving the problem that planar photovoltaic modules are difficult to apply to complex curved surfaces.

[0021] 2. Compact structure, saving space and cost: Based on the flexible glass curvature, the battery pack frame is customized to match the outline of the photovoltaic module. It is used to embed the energy storage battery and miniaturized control unit (using third-generation semiconductor devices and planar inductors). It overcomes the defects of traditional photovoltaic and energy storage systems, such as separation, excessively long leads, and large size. It also eliminates the need for additional installation brackets, reducing the footprint and installation cost.

[0022] 3. Intelligent monitoring and power management: Based on wireless communication technology, it monitors charging and discharging power, temperature, humidity and power in real time, solving the problem of data opacity; it records the charging and discharging amount and the number of charging and discharging, monitors the real-time voltage of the energy storage battery and the minimum discharge voltage of the energy storage battery pack, which helps users judge the remaining power and make reasonable plans for vehicle load use, alleviate users' power anxiety and improve battery life and energy utilization. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the integrated curved photovoltaic power generation dome of the present invention; Figure 2 This is an exploded view of the integrated curved photovoltaic power generation dome of the present invention; Figure 3 This is a block diagram of the control structure of the present invention; Figure 4 This is a schematic diagram of the control unit structure of the present invention; Figure 5 This is a flowchart of the method of the present invention.

[0024] Reference numerals: 1-Hyperbolic glass, 2-PV module, 3-Control unit, 4-Energy storage battery, 5-Battery pack rack, 6-Monitoring and communication unit, 7-DC-DC converter, 8-Digital logic processor, 9-Three-port converter. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0026] The application principle of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0027] Please see Figures 1-4An integrated curved photovoltaic power generation dome for vehicles includes a hyperboloid glass 1, a PV module 2, a control unit 3, an energy storage battery 4, and a battery pack frame 5.

[0028] The hyperboloid glass 1 is connected to the PV module 2, and the PV module 2 is connected to the battery pack frame 5. The hyperboloid glass 1, PV module 2, and battery pack frame 5 are all the same in shape and size, and all adopt a curved shape.

[0029] The battery pack rack 5 is provided with several storage boxes arranged at equal intervals. The storage boxes of the battery pack rack 5 are equipped with energy storage batteries 4 and control units 3.

[0030] Control unit 3 is connected to the input terminal of energy storage battery 4 via its second port. Control unit 3 is connected to PV component 2 via its third port. If the radius of curvature of the roof dome is large, the energy storage battery 4 cells are larger; if the radius of curvature is small, the energy storage battery 4 cells are smaller. The energy storage battery pack consists of battery pack frame 5 and several energy storage batteries 4 installed in the battery pack frame 5. The energy storage battery pack has a voltage of 48V and a capacity of 5~10kWh.

[0031] Hyperboloid Glass 1 is a curved glass customized using molds and bending technology according to the application scenario; the shape of this glass is adapted to the application occasion. The design of hyperboloid glass is more suitable for the current mainstream car roof shape, reducing the car's wind resistance.

[0032] The control unit 3 includes a monitoring and communication unit 6, a DC-DC converter 7, a digital logic processor 8, and a three-port converter 9.

[0033] The control unit 3 is composed of two circuit boards. The first circuit board is the power conversion circuit, and the second circuit board is the control circuit. The two circuit boards are vertically assembled to form the control unit 3, which is installed in the middle of the energy storage battery pack frame 5.

[0034] The first circuit board is a three-port converter 9. The first port of the three-port converter 9 is connected to the photovoltaic input port, the second port is connected to the energy storage battery 4, and the third port is connected to the PV module 2. A DC-DC converter 7 is installed on the three-port converter 9.

[0035] The second circuit board houses the monitoring and communication unit 6 and the digital logic processor 8. The monitoring and communication unit 6 is electrically connected to the digital logic processor 8, which in turn is electrically connected to the three-port converter 9 and the DC-DC converter 7. The digital logic processor 8 is used for power flow management, MPPT control, and monitoring and communication with the vehicle's infotainment system. Communication with the vehicle's infotainment system is achieved through WiFi protocol in the monitoring and communication unit 6. The monitoring and communication unit 6 monitors power output by sampling the voltage and current at each port of the three-port converter 9 using the digital logic processor 8.

[0036] Please refer to Figure 5 A method for fabricating an integrated curved photovoltaic power generation dome for vehicles includes the following steps: S1. A steel concave mold is first made according to the glass's shape and curvature for the application. The glass is then placed on the concave mold and bent into shape in a hot bending furnace at 500-900 degrees Celsius to obtain hyperboloid glass 1. The customized curved glass using molds and bending technology allows for precise control of the glass's forming curvature, ensuring a high degree of fit between the hyperboloid glass and the roof shape of different vehicle models. This not only enhances the overall aesthetics and integration of the vehicle but also effectively reduces wind resistance and energy loss during driving.

[0037] S2. Based on the dimensions and curvature of the hyperboloid glass 1, the PV cells are cut into different sizes. A larger radius of curvature results in a larger PV cell, and a smaller radius of curvature results in a smaller PV cell. The cut cells are connected in series and parallel to form a PV cell pack. The PV cell pack is then mounted on a PV cell pack frame. The PV cell pack and the PV cell pack frame together constitute the PV module 2. The thickness of the PV cells is between 0.16 and 0.2 mm. The PV cells are flat, and the maximum distance between the hyperboloid glass 1 and the PV cells is controlled within 2 mm.

[0038] In this application, solar cells of different sizes are cut according to the curvature of the surface, which can maximize the use of the curved space and improve the area utilization rate of the PV solar cells. The ultra-thin PV solar cells (0.16~0.2mm) have good flexibility and bending adaptability, and can be closely attached to the curved glass. By controlling the distance between the double-curved glass 1 and the PV solar cells to within 2mm, the effective transmission of light energy is ensured, and the damage to the solar cells caused by rigid contact is avoided, thereby improving the photoelectric conversion efficiency and structural reliability.

[0039] S3. Based on the dimensions and curvature of the PV module 2, a battery pack frame 5 with a certain rigidity is customized. Space is provided within the battery pack frame 5 for the control unit 3 and the energy storage battery 4. The battery pack frame 5 is made of lightweight aluminum alloy, and its outer frame matches the curvature and dimensions of the glass. The thickness of the curved battery pack frame 5 is 15mm. A 10mm deep battery slot is hollowed out inside the battery pack frame 5.

[0040] The energy storage battery 4 is customized according to the curvature of the curved PV module 2. If the radius of curvature is large, the energy storage battery 4 is larger, and if the radius of curvature is small, the energy storage battery cell 4 is smaller. The energy storage batteries 4 are connected in series and parallel to form an energy storage battery pack.

[0041] This application uses a curved battery pack frame 5 made of lightweight aluminum alloy, which not only ensures the rigidity and dimensional stability of the overall structure, but also reduces the load on the vehicle roof; the hollow battery slot design facilitates the installation, replacement and heat dissipation of the energy storage battery 4; the energy storage battery 4 is customized according to the curvature, which maximizes the spatial matching between the energy storage system and the curved structure; the good thermal conductivity of aluminum alloy helps to dissipate the heat of the battery operation, ensuring the thermal safety of the system in the limited space of the vehicle roof.

[0042] S4. The hyperboloid glass 1, PV module 2, and curved battery pack frame 5 are spatially overlapped and connected to form a curved photovoltaic dome. The three-layer structure is completely overlapped in space and has the same curvature, achieving a high degree of integrated photovoltaic power generation dome. The hyperboloid glass, as the outer protective layer, has good light transmission and impact resistance, effectively protecting the internal PV modules. The aluminum alloy battery pack frame, as the bottom support, provides a stable structural foundation. After the overall assembly is completed, it can be directly installed on the roof of the vehicle without additional brackets or modifications, simplifying the installation process and improving the reliability and aesthetics of the system.

[0043] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An integrated curved photovoltaic power generation dome for vehicles, characterized in that, include: Hyperbolic glass (1), PV module (2), control unit (3), energy storage battery (4), battery pack rack (5); The hyperboloid glass (1), PV module (2) and curved battery pack frame (5) have the same shape and are all curved structures, and are stacked and connected in sequence; The output of the PV component (2) is electrically connected to the input of the control unit (3), and the output of the control unit (3) is electrically connected to the energy storage battery (4) and the vehicle load. The control unit (3) and the energy storage battery (4) are both embedded inside the battery pack frame (5).

2. The integrated curved photovoltaic power generation dome for vehicles according to claim 1, characterized in that, The control unit (3) includes: a monitoring and communication unit (6), a DC-DC converter (7), a digital logic processor (8), and a three-port converter (9); the digital logic processor (8) is electrically connected to the monitoring and communication unit (6), the DC-DC converter (7), and the three-port converter (9), respectively.

3. The integrated curved photovoltaic power generation dome for vehicles according to claim 2, characterized in that, The control unit (3) is composed of a first circuit board and a second circuit board. The first circuit board is a power conversion circuit with a three-port converter (9) and a DC-DC converter (7) installed on the three-port converter (9). The second circuit board is a control circuit with a digital logic processor (8) and a monitoring and communication unit (6). The first circuit board and the second circuit board are assembled vertically.

4. The integrated curved photovoltaic power generation dome for vehicles according to claim 3, characterized in that, The first port of the three-port converter (9) is connected to the output port of the PV module (2), the second port is connected to the energy storage battery pack, and the third port is connected to the vehicle load.

5. The integrated curved photovoltaic power generation dome for vehicles according to claim 1, characterized in that, The curved battery pack rack (5) is provided with several storage boxes arranged at equal intervals, and multiple energy storage batteries (4) and control unit (3) are installed in the storage boxes.

6. A method for fabricating an integrated curved photovoltaic power generation dome for vehicles, characterized in that, Includes the following steps: S1. A concave mold is made according to the curvature of the glass shape in the application. The glass is placed on the concave mold and bent into shape in a hot bending furnace at 500-900 degrees Celsius to obtain hyperboloid glass (1). S2. According to the size and curvature of the hyperboloid glass (1), the PV cell is cut into different sizes, and the cut cells are connected in series and parallel to form a PV cell pack. The PV cell pack is installed on the PV cell pack frame, and the PV cell pack and the PV cell pack frame together form a PV module (2). S3. A battery pack frame (5) is customized according to the size and curvature of the PV module (2). A battery slot for installing the control unit (3) and the energy storage battery (4) is provided in the battery pack frame (5), and the energy storage battery (4) is customized according to the curvature of the PV module (2). S4. The hyperboloid glass (1), PV module (2) and battery pack frame (5) are overlapped and connected in space to form a curved photovoltaic power generation dome.

7. The method for fabricating an integrated curved photovoltaic power generation dome for vehicles according to claim 6, characterized in that, In step S2, the thickness of the PV cell is 0.16 to 0.2 mm, and the maximum distance between the hyperboloid glass (1) and the PV cell is controlled within 2 mm.

8. The method for fabricating an integrated curved photovoltaic power generation dome for vehicles according to claim 6, characterized in that, In step S3, the battery pack frame (5) is made of lightweight aluminum alloy, and its outer frame curvature is consistent with the curvature of the hyperboloid glass (1) and the PV module (2).

9. The method for preparing an integrated curved photovoltaic power generation dome for vehicles according to claim 8, characterized in that, The battery pack holder (5) is 15mm thick and has a 10mm deep hollowed-out battery slot inside.

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