Photovoltaic module connection and mounting structure

Abstract

The application provides a photovoltaic module connecting and mounting structure, which comprises at least two adjacent photovoltaic modules, each of which comprises photovoltaic module glass, a corrugated back plate and a frame, the photovoltaic module glass and the corrugated back plate are bonded by structural adhesive to form a bearing unit, a prefabricated silicone strip is clamped into the bearing unit in the direction of the long side of two sides, a preset hole is arranged on the frame, a rivet is installed through the preset hole and an angle code, a structural weld is formed by laser welding a stainless steel welding wire at the joint of the frame and the corrugated back plate, a sealant is filled in the gap between the folded edge of the corrugated back plate and the photovoltaic module glass, a penetrating self-drilling screw hook fixing piece is arranged between the frame bending grooves of two adjacent photovoltaic modules, and the penetrating self-drilling screw hook fixing piece is clamped and limited to a lower support piece through a self-tapping screw.

Description

Technical Field

[0001] This invention belongs to the field of solar energy technology, specifically relating to a photovoltaic module connection and installation structure. Background Technology

[0002] In the solar energy industry, the connection and installation structure of photovoltaic modules directly affects the system's stability, waterproof performance, and service life. Traditional photovoltaic module connection methods typically employ single mechanical fastening (such as bolt connections) or adhesive bonding. Existing connection structures often rely on single-point mechanical connections or partial adhesive bonding between the frame and the backsheet. Under wind and snow loads or long-term vibration, stress concentration can easily occur, leading to connection failure. Summary of the Invention

[0003] This application provides a photovoltaic module connection and installation structure, aiming to solve the technical problem that existing technologies, in order to address the above-mentioned problems, mostly focus on a single aspect (such as only optimizing the sealing material or only strengthening the mechanical connection), and have not yet formed a systematic solution that combines multiple technical features such as "pre-connection positioning - structural welding - sealing and seepage prevention - joint limiting".

[0004] Firstly, this application provides a photovoltaic module connection and installation structure for the solar energy industry, comprising at least two adjacent photovoltaic modules. Each photovoltaic module includes photovoltaic module glass, a corrugated backsheet, and a frame. The photovoltaic module glass and the corrugated backsheet are bonded together with structural adhesive to form a support unit. Pre-made silicone strips are inserted into the long sides of the support unit. The frame has preset holes, through which rivets and corner brackets are installed to complete the pre-connection and positioning of the frame and the corrugated backsheet. The joint between the frame and the corrugated backsheet is formed by laser welding stainless steel welding wire to ensure overall structural integrity. The gap between the folded edge of the corrugated backsheet and the photovoltaic module glass is filled with sealant to form a seepage barrier. A through-drilling screw hook fastener is provided between the bent grooves of the frames of two adjacent photovoltaic modules. The through-drilling screw hook fastener clamps and limits the lower support member with self-tapping screws to ensure stable positioning and anti-misalignment control of the photovoltaic module joint.

[0005] This application establishes initial mechanical support through pre-connection positioning of rivets and corner brackets, and forms a continuous structural weld by laser welding of stainless steel welding wire, making the frame and corrugated back panel a rigid whole. Mechanical tests show that the shear strength of the connection part is increased by 40% compared with the traditional structure, effectively dispersing dynamic loads such as wind load and snow load. The first physical barrier is formed by the prefabricated silicone strips on both sides of the load-bearing unit through the interference fit of the slots, and the second chemical barrier is formed by the sealant filling the gap between the corrugated back panel fold and the glass. The two anti-seepage structures work together, and the water seepage rate is reduced compared with the traditional single sealing structure as verified by rain test. The through-hole self-drilling screw hook fastener is rigidly connected to the lower support component via self-tapping screws. The U-shaped body and the bent groove design of the frame can achieve ±0.5 mm splice error control, which significantly improves the flatness and alignment accuracy of the component installation and avoids the hot spot effect caused by misalignment. The standardized slot design of the prefabricated silicone strip, the adaptation of the laser welding visual positioning system, and the mechanized installation of the hook fastener all support automated production line production. Compared with traditional manual installation, the efficiency is improved, and the connection parameters (such as weld width and sealant thickness) can be precisely controlled by the equipment to ensure product consistency.

[0006] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0007] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0008] Figure 1 This is a schematic diagram of the photovoltaic module connection and installation structure provided in one embodiment of this application.

[0009] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Detailed Implementation

[0010] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0011] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the order described. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0012] It should be understood that, in order to clearly describe the technical solutions of the embodiments of the present invention, the terms "first" and "second" are used in the embodiments of the present invention to distinguish identical or similar items with essentially the same function and effect. Those skilled in the art will understand that the terms "first" and "second" do not limit the quantity or execution order, and the terms "first" and "second" are not necessarily different.

[0013] It should be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0014] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0015] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0016] In solar photovoltaic (PV) systems, the connection and installation structure of PV modules directly affects the system's stability, waterproofing, and lifespan. Traditional PV module connection methods typically employ simple mechanical fastening (such as bolt connections) or adhesive bonding, which presents the following technical problems: 1. Insufficient overall load-bearing capacity: Existing connection structures mostly rely on single-point mechanical connections or local adhesive bonding between the frame and the back plate. Under wind and snow loads or long-term vibration, stress concentration is prone to occur, leading to connection failure. 2. Weak water resistance: The gap between the back panel and the glass is often sealed with a single sealing material and lacks structural limiting design. Rainwater can easily seep into the component from the joint, causing short circuits or material corrosion. 3. Unstable seam positioning: The seam fixing of adjacent components relies on external clamps or simple screw connections, lacking a dynamic limiting mechanism. Misalignment is prone to occur during installation, affecting the overall structural accuracy and aesthetics. 4. Poor process compatibility: Traditional connection processes (such as arc welding and manual glue application) are difficult to control parameters precisely, resulting in unstable connection strength and sealing effect, and are not conducive to automated production.

[0017] In existing technologies, most improvements to address the aforementioned issues focus on single aspects (such as optimizing sealing materials or strengthening mechanical connections), and a systematic solution combining multi-dimensional technical features such as pre-connection positioning, structural welding, sealing and seepage prevention, and joint limiting has not yet been developed. Therefore, there is an urgent need to propose a photovoltaic module connection and installation structure that combines load-bearing reliability, seepage prevention performance, and installation accuracy.

[0018] To resolve the above issues, please refer to [link / reference]. Figure 1 This application provides a photovoltaic module connection and installation structure, including at least two adjacent photovoltaic modules 11. Each photovoltaic module 11 includes a photovoltaic module glass 12, a corrugated back plate 13, and a frame 14. The photovoltaic module glass and the corrugated back plate are bonded together with structural adhesive to form a support unit. Pre-made silicone strips are inserted into the long sides of the support unit. The frame has preset holes, through which rivets and corner brackets are installed to complete the pre-connection and positioning of the frame and the corrugated back plate. The joint between the frame and the corrugated back plate is formed by laser welding stainless steel welding wire to ensure the overall integrity of the load. The gap between the folded edge of the corrugated back plate and the photovoltaic module glass is filled with sealant to form a seepage barrier. A through-type self-drilling screw hook fastener is provided between the bent grooves of the frames of two adjacent photovoltaic modules. The through-type self-drilling screw hook fastener clamps and limits the lower support member with self-tapping screws to ensure the stable positioning and anti-misalignment control of the photovoltaic module joint.

[0019] Specifically, this solution integrates four core technology modules—pre-connection positioning, structural welding, sealing and seepage prevention, and joint limiting—to construct a multi-dimensional collaborative photovoltaic module connection and installation system. This solves the problems of insufficient force, weak seepage prevention, unstable positioning, and poor process compatibility in traditional connection methods. Key innovations include: a composite connection between the corrugated backsheet and the frame: combining rivet pre-positioning with laser welding to form a rigid-flexible mechanical transmission path; a multi-layered sealing and seepage prevention structure: constructing a multi-layered waterproof barrier through a combination of prefabricated silicone strips, structural adhesive, and sealant; dynamically limiting joint fasteners: using penetrating self-drilling screw hook fasteners to achieve precise positioning and vibration-resistant displacement of adjacent modules; and automated compatible processes: adapting laser welding and prefabrication assembly processes to automated production, improving connection accuracy and stability.

[0020] The fabrication of the photovoltaic module's basic structure includes: Construction of the load-bearing unit: The photovoltaic module glass (front) and the corrugated backsheet (back) are bonded together with structural adhesive to form a rigid load-bearing unit. Corrugated backsheet design: A wavy edge structure is adopted (e.g., Figure 1As shown), it enhances longitudinal bending strength and disperses external loads; bonding process: structural adhesive is evenly applied along the plane contact area between the glass edge and the corrugated back plate, and after curing, it forms a high-strength bonding layer, replacing the stress concentration problem of traditional single-point mechanical connection.

[0021] The prefabricated silicone strips are installed by inserting them into the gaps between the glass and the corrugated backsheet on both long sides of the load-bearing unit (i.e., the left and right sides of the photovoltaic module). The silicone strips have a trapezoidal or dovetail cross-section, which precisely matches the glass edge and the grooves of the corrugated backsheet to form an initial seal and provide positioning guidance for subsequent frame installation.

[0022] The frame connection and pre-positioning include: Frame structure design: The frame is made of aluminum alloy or stainless steel, with a bending groove on the inner side to match the corrugated back panel edge, and pre-set holes (such as countersunk holes and through holes) on the outer side for installing rivets and corner brackets. The frame length is equal to the side of the photovoltaic module, and there are installation notches at both ends to facilitate the fixing of corner brackets (right-angle connectors).

[0023] Pre-connection positioning involves inserting the frame along the long sides of the load-bearing unit, embedding the folded edge of the corrugated back panel into the bending groove on the inner side of the frame, and after initial alignment, driving rivets through the pre-drilled holes in the frame to temporarily fix the frame to the corrugated back panel. The rivet spacing is determined according to load calculations (e.g., 200-300mm interval) to ensure uniform stress during pre-connection and avoid local deformation.

[0024] Structural welding enhances overall load-bearing capacity. Laser welding is employed to fuse stainless steel welding wire at the junction of the frame and corrugated back panel (the interface between the bent groove and the corrugated edge), forming continuous or segmented structural welds. Laser welding parameters (power, speed, focal length) are precisely controlled by automated equipment, allowing the weld depth to penetrate into the frame and back panel materials, forming a metallurgical bond. This replaces the single-point load-bearing mode of traditional bolted connections, achieving surface contact load transfer and improving overall wind and seismic resistance. The weld location avoids the silicone strip and sealant areas to prevent high temperatures from affecting the performance of the sealing materials.

[0025] The sealing and seepage prevention treatment includes: Primary sealing (pre-fabricated silicone strip): The pre-fabricated silicone strip is inserted before frame installation, filling the initial gap between the glass and the corrugated backsheet, blocking direct rainwater infiltration. Secondary sealing (sealant filling): Silicone-based sealant is injected into the gap between the corrugated backsheet edge and the photovoltaic module glass (i.e., the area not covered by the silicone strip at the edge of the supporting unit), using automated sealing equipment to form a continuous seepage barrier. The sealant covers the junction lines between the frame and glass, and between the frame and the corrugated backsheet, with a thickness of not less than 2mm. After curing, it works synergistically with the silicone strip to prevent rainwater from seeping into the module from the seams or frame joints.

[0026] The positioning and fixing of adjacent component seams includes: hook fastener design: the through-type self-drilling screw hook fastener is an "L" or "U" shaped metal part, with a self-drilling screw hole at one end and a hook structure at the other end, which is adapted to the bending groove on the outside of the frame.

[0027] The installation steps include: inserting the hook end of the clamping fastener into the bending groove of the frame of two adjacent photovoltaic modules, ensuring a tight fit between the hook and the inner wall of the groove; driving self-tapping screws through the self-drilling screw holes, penetrating the clamping fastener and the lower support (such as the photovoltaic bracket beam), and tightening to clamp the support. The spacing of the self-tapping screws is designed according to the module size and load (e.g., 2-3 screws per meter). The hook structure restricts the lateral displacement of the module, while the self-tapping screws provide longitudinal tension, forming a two-way limit to avoid misalignment during installation and seam displacement caused by long-term vibration.

[0028] The overall assembly process includes: preparing the bonding support unit for the photovoltaic module glass and the corrugated backsheet, and inserting the pre-made silicone strip; installing the frame and pre-positioning it with rivets and corner brackets to ensure positional accuracy; laser welding the joint between the frame and the corrugated backsheet to form a structural weld; filling with sealant to complete the edge sealing and seepage prevention treatment; connecting adjacent modules to the support through clip fasteners and self-tapping screws, adjusting the splice spacing and fixing them to achieve overall positioning.

[0029] The solutions to traditional technical problems and the corresponding methods of this structure are shown in the table below: Through the aforementioned structure and process, this solution achieves a systematic improvement in the mechanical reliability, anti-seepage performance, and installation accuracy of photovoltaic module connections, making it suitable for efficient installation and long-term stable operation in scenarios such as distributed photovoltaics and large-scale power plants.

[0030] In some embodiments, the prefabricated silicone strip has a T-shaped cross-section, and the long edges of the two sides of the support unit are provided with slots that match the T-shaped structure. The prefabricated silicone strip is connected to the support unit through the limiting protrusions of the slots in an interference fit. The prefabricated silicone strip is made of silicone rubber material with a Shore hardness of 50-60A, and both ends of the prefabricated silicone strip extend 5-10 mm inside the edge contour lines of the photovoltaic module glass and the corrugated back sheet in the length direction.

[0031] The initial sealing and positioning functions are achieved by the interference fit between the prefabricated silicone strip with the T-section and the bearing unit slot. The material hardness and length parameters ensure the seepage prevention effect and structural compatibility.

[0032] The structural design includes: T-shaped slots are machined on the long edges of both sides of the photovoltaic module glass and the corrugated backsheet, and the inner wall of the slot is provided with limiting protrusions (0.5-1mm in height) to match the upper flange of the T-shaped cross-section of the silicone strip; the prefabricated silicone strip is made of silicone rubber with a Shore hardness of 50-60A, and the cross-section is T-shaped (bottom width 8-10mm, top flange width 5-6mm, total height 6-8mm), and both ends of the length direction are 5-10mm shorter than the edge outline of the photovoltaic module (to avoid exposure and aging).

[0033] The installation process involves applying a small amount of silicone-based lubricant to the slot in the support unit (after the glass and back panel are bonded), then pushing the silicone strip into the slot. The locking and fixing is achieved through the interference fit between the limiting protrusion and the slot (fitting tolerance ±0.2mm). After the silicone strip is inserted, its bottom fills the gap between the glass and the back panel, and the top flange is embedded in the slot to form a mechanical limit, preventing the silicone strip from falling off and blocking the direct infiltration path of rainwater.

[0034] In some embodiments, the preset holes are distributed in an array at equal intervals along the length of the frame, with a spacing of 80-120 mm between adjacent holes. The corner bracket is an L-shaped metal part with positioning through holes on both sides coaxial with the preset holes. The rivet is fixed to the frame by a hydraulic riveting machine with a pressure of 6-8 kN. The surface of the corner bracket that contacts the corrugated back plate is provided with anti-slip teeth, with a tooth height of 0.3-0.5 mm and a tooth pitch of 1-2 mm.

[0035] By using pre-set holes at equal intervals, hydraulic riveting corner brackets, and anti-slip serrated design, the pre-connection accuracy and friction between the frame and the corrugated back panel are improved.

[0036] The hole and corner bracket structure includes: preset holes (counterhead holes with a diameter of 4-5mm) are opened at intervals of 80-120mm along the length of the frame, with the center of the hole 10-15mm from the edge of the frame to ensure uniform force after riveting; the corner bracket is an L-shaped metal part (thickness 3-4mm, side length matching the cross-section of the frame), with positioning through holes (diameter 4.2-5.2mm) on both sides coaxial with the preset holes, forming a ±0.2mm tolerance fit with the holes of the frame; the surface of the corner bracket that contacts the corrugated back plate is processed with anti-slip serrations (tooth height 0.3-0.5mm, tooth pitch 1-2mm, in a diamond or rectangular array) to increase the friction of the contact surface.

[0037] The installation process involves aligning the corner brackets with the pre-drilled holes on the frame, and then using a hydraulic riveting machine to drive in rivets (3-4mm in diameter, made of aluminum alloy or stainless steel) with a pressure of 6-8 kN. The rivet heads are then fully fitted with the countersunk holes on the frame. After the corner brackets are installed, their anti-slip serrations are embedded in the surface of the corrugated back panel (when the back panel material is metal or composite material), or they are reinforced with structural adhesive to prevent relative slippage during pre-connection.

[0038] In some embodiments, the laser welding employs a pulsed fiber laser with a welding power of 800-1200 watts and a pulse frequency of 50-100 Hz. The diameter of the stainless steel welding wire is 0.8-1.2 mm. The structural weld is continuously welded along the overlapping edge of the frame and the corrugated back plate, with a weld width of 1.5-2.5 mm. During the laser welding process, the weld trajectory is calibrated in real time by a visual positioning system, and the image acquisition frequency of the visual positioning system is not less than 200 frames / second.

[0039] By setting process parameters for pulsed fiber laser welding and using a visual positioning system, the continuity and precision of structural welds are ensured.

[0040] The welding equipment and parameters include: a pulsed fiber laser (wavelength 1064nm), welding power 800-1200W, pulse frequency 50-100Hz, and spot diameter 0.3-0.5mm; the filler material is 304 stainless steel welding wire with a diameter of 0.8-1.2mm, the wire feeding speed is synchronized with the welding speed (welding speed 5-8mm / s), forming a continuous weld with a width of 1.5-2.5mm.

[0041] Process control includes: before welding, the overlapping edge contour of the frame and the corrugated back plate is collected by a vision positioning system (industrial camera + image processing algorithm), and the laser head trajectory is calibrated in real time (accuracy ±0.1mm). The image acquisition frequency is ≥200 frames / second. The weld is continuously welded along the contact interface between the inner bending groove of the frame and the folded edge of the corrugated back plate to avoid breakpoints. After welding, the integrity of the weld is detected by AOI to ensure that there are no defects such as false welds and porosity.

[0042] In some embodiments, the sealant is a two-component silicone sealant, which includes component A and component B, with a mixing ratio of 10:1. The sealant is injected into the gap using an automatic dispensing machine at a pressure of 0.3-0.5 MPa, with a filling thickness of 2-3 mm. The filling trajectory of the sealant is continuously distributed in a serpentine pattern along the contour line of the gap. After filling, the sealant is surface-cured using an ultraviolet curing device for 5-10 minutes.

[0043] By employing a two-component silicone sealant and an automated dispensing process, combined with a serpentine filling trajectory and UV curing, sealing reliability is improved.

[0044] The sealant is a two-component silicone sealant (component A: base adhesive + component B: curing agent, mixing ratio 10:1), with a tensile strength ≥1.5MPa and elongation at break ≥300% after curing. An automatic sealant applicator (equipped with a precision screw pump) is used to inject the sealant into the gap between the corrugated back panel edge and the glass at a pressure of 0.3-0.5MPa, filling a thickness of 2-3mm. The sealant application path follows the gap contour in a continuous serpentine pattern (wave crest spacing 5-8mm) to ensure a uniform, bubble-free sealant layer. Immediately after application, the sealant is placed in a UV curing device (wavelength 365nm, illuminance ≥1000mW / cm²), with a surface curing time of 5-10 minutes and complete curing requiring 24 hours (room temperature 25℃, humidity 50%). After curing, the sealant layer bonds tightly to the glass, back panel, and silicone strip, forming a secondary waterproof barrier.

[0045] In some embodiments, the clamping fastener includes a U-shaped body and a self-drilling screw guide hole. The opening width of the U-shaped body matches the depth of the bending groove of the frame. The self-tapping screw has a diameter of 4-6 mm and a length of 30-50 mm. The self-tapping screw is screwed into the lower support member with a preset torque using an electric screwdriver. The inner surface of the clamping fastener is provided with an elastic buffer pad. The thickness of the elastic buffer pad is 1-2 mm and the Shore hardness is 40-50A.

[0046] The U-shaped hook structure, self-drilling screw specifications, and elastic buffer pad design enable flexible positioning of the joints and prevent vibration-induced loosening.

[0047] The fastener structure includes: a U-shaped main body with an opening width matching the depth of the bent groove in the frame (tolerance ±0.5mm), and a guide hole (4.5-6.5mm in diameter to prevent screw misalignment) on the inner side for installing self-drilling screws; the self-tapping screws are M4-M6 in size and 30-50mm in length (selected according to the thickness of the support component), with a thread depth covering the thickness of the support component + 10mm to ensure fastening force; an elastic buffer pad (1-2mm thick, EVA or silicone material with a Shore hardness of 40-50A) is pasted on the inner side of the clip, and the surface of the buffer pad has a grid pattern to increase the friction with the groove in the frame.

[0048] The installation process involves inserting the clip fastener into the groove of the adjacent component's frame, with the buffer pad fitting against the inner wall of the groove. A self-tapping screw is then screwed in with an electric screwdriver at a preset torque (8-12 N·m). The screw penetrates the fastener and the support (such as an aluminum alloy bracket) to achieve clamping. The buffer pad absorbs the thermal expansion and contraction displacement of the component due to temperature changes (compensation amount ±1 mm), avoiding stress concentration caused by rigid connections.

[0049] In some embodiments, the system further includes an intelligent layout optimization module. This module acquires the dimensional parameters, material mechanical property parameters, and preset load condition data of the photovoltaic module; simulates the stress distribution in the connection area between the frame and the corrugated backplate based on a finite element analysis model to generate an initial hole layout scheme; iteratively optimizes the initial hole layout scheme using a genetic algorithm, with the objective function being the minimization of weld stress uniformity and material usage, and outputs the optimal hole coordinates and quantity; and transmits the optimal hole coordinates and quantity to a CNC machine tool to control the processing and forming of the preset holes.

[0050] Based on finite element analysis and genetic algorithm, the layout of the preset holes in the frame is optimized to balance the uniformity of stress and material cost.

[0051] Data input and simulation include: input parameters: photovoltaic module dimensions (length × width × thickness), mechanical properties of corrugated backsheet material (elastic modulus, yield strength), preset load conditions (wind and snow load, vibration frequency); establish a finite element analysis model (ABAQUS or ANSYS), perform stress simulation on the connection area between the frame and the backsheet, identify high stress areas, and generate an initial hole layout (number of holes ≥ 4, edge hole distance from the endpoint 50-100mm).

[0052] Genetic algorithm is used for iterative optimization. The objective function is "weld stress uniformity (weight 0.7) + material consumption (weight 0.3)". The constraints are hole spacing ≥ 80 mm and distance from the edge ≥ 10 mm. The optimized hole coordinates and quantity are transmitted to a CNC machine tool. The preset holes are processed by drilling or stamping processes with a hole accuracy of ± 0.5 mm.

[0053] In some embodiments, the system further includes a seam positioning control system. This system uses a laser rangefinder installed in the bending groove of the frame to collect real-time seam gap data of adjacent photovoltaic modules. The seam gap data is input to a PID control algorithm module to calculate and generate the displacement adjustment amount of the through-type self-drilling screw hook fastener. A servo motor drives the hook fastener to move along a preset guide rail until the error corresponding to the seam gap data is controlled within a preset error. The proportional coefficient of the PID control algorithm module ranges from 0.8 to 1.2, the integral coefficient ranges from 0.1 to 0.3, and the derivative coefficient ranges from 0.2 to 0.5.

[0054] By using a laser rangefinder and a PID control algorithm, the position of the clamping fastener is adjusted in real time to ensure the accuracy of the seam gap.

[0055] A laser rangefinder (accuracy ±0.1mm) is installed inside the bend groove of the frame, and the corresponding sensor of the adjacent component is aligned to collect the gap data of the splice in real time (sampling frequency 10Hz); the bottom of the clamp fixing part is equipped with a servo motor driven guide rail slider (stroke ±5mm, resolution 0.01mm), and the guide rail is arranged along the component arrangement direction (lateral).

[0056] The control process includes: preset the standard value of the seam gap (e.g., 2-3mm); when the sensor detects that the gap error exceeds ±0.5mm, the data is input into the PID control algorithm module; the algorithm calculates the displacement adjustment (proportional coefficient 0.8-1.2, integral coefficient 0.1-0.3, derivative coefficient 0.2-0.5), drives the servo motor to move the clamping hook fixing part until the gap error is ≤ ±0.2mm; after the adjustment is completed, the self-tapping screws are automatically locked, forming a closed-loop control.

[0057] In some embodiments, a welding parameter adaptive module is further included. The welding parameter adaptive module detects the material thickness of the corrugated back plate and the surface coating thickness of the frame in real time using a spectrometer. The detection data is input to a fuzzy control algorithm model, and the matching laser power, welding speed, and wire feed speed parameters are output. The input variables of the fuzzy control algorithm model are the material thickness and coating thickness, and the output variables are the welding parameters. Its fuzzy rule base contains multiple preset control rules. The laser welding equipment is controlled to perform welding operations through the output welding parameters, and the weld temperature is monitored by an infrared thermal imager. When the temperature fluctuation exceeds ±5℃, a parameter compensation mechanism is triggered.

[0058] Material parameters are detected by a spectrometer, and laser welding parameters are dynamically adjusted by combining fuzzy control algorithms to adapt to different working conditions.

[0059] The detection and input process includes: before welding, the thickness of the corrugated backing material (range 1-3mm) and the thickness of the coating on the frame surface (such as anodized layer, thickness 5-20μm) are detected by a spectrometer (accuracy ±1%); the detection data are input into the fuzzy control algorithm model, the input variables are divided into three levels: "thin", "medium" and "thick" (defined by membership function), and the output variables are laser power, welding speed and welding wire feed speed.

[0060] Control rules and execution include: preset rules in the fuzzy rule base (such as "material thickness + coating thickness → high power + slow speed"), which generate matching parameters through Mamdani inference; during the welding process, an infrared thermal imager (accuracy ±2℃) monitors the weld temperature, and when the temperature fluctuation exceeds ±5℃, a parameter compensation mechanism is triggered (such as power fine-tuning ±5%) to ensure the consistency of weld quality.

[0061] In some embodiments, a structural health monitoring system is also included. This system uses stress-strain sensors and acceleration sensors arranged on the frame, corrugated backplate, and clamp fasteners to collect vibration signals and stress data in real time at a frequency of 1000-2000 Hz. The vibration signals and stress data are input into a convolutional neural network model for feature extraction to identify abnormal states such as loosening of the connection structure and weld cracks. The convolutional neural network model contains at least three convolutional layers and two fully connected layers, and is trained using supervised learning with historical fault data samples. When an abnormal state is detected, a warning message is sent to the monitoring terminal via a wireless communication module. The warning message includes the coordinates of the abnormal location and a fault type code.

[0062] By using multi-sensor data acquisition and convolutional neural networks (CNN), loosening and crack defects in the connection structure can be identified in real time.

[0063] The sensor deployment involves attaching stress and strain sensors (accuracy ±0.1%FS) and accelerometers (range ±10g, resolution 0.01g) to key stress points on the frame, near the weld seams of the corrugated back plate, and at the connection points of the clip fasteners, with a sampling frequency of 1000-2000Hz. The sensor signals are transmitted to the edge computing unit via wired / wireless means for noise reduction preprocessing (bandpass filter to remove 50Hz power frequency interference).

[0064] Fault identification and early warning include: preprocessing data input into a convolutional neural network model (containing 3 convolutional layers + 2 fully connected layers, with training samples containing 1000+ sets of normal / loose / crack data), extracting feature vectors from vibration signals and stress data; when the model identifies an abnormal state (confidence ≥ 95%), it sends early warning information to the monitoring terminal via a LoRa / NB-IoT module. The information includes the coordinates of the abnormal location (based on component number encoding) and the fault type encoding (e.g., "01" represents weld crack, "02" represents hook loosening), supporting remote operation and maintenance.

[0065] In some embodiments, by constructing a digital twin model of the photovoltaic module connection structure, the assembly process is simulated in virtual space. Combined with the particle swarm optimization algorithm (PSO), parameters such as prefabricated silicone strips and frame hole positions are dynamically adjusted to achieve accurate mapping between the physical structure and the virtual model, and to predict installation defects in advance.

[0066] The construction of the digital twin model includes: acquiring the actual geometric data of the photovoltaic module glass, corrugated backsheet, and frame using 3D scanning equipment (accuracy ±0.05mm), and importing it into Unity or ANSYS Twin Builder to create a 1:1 digital twin; the model integrates material properties (elastic modulus of structural adhesive, Shore hardness of silicone strip), load conditions (wind speed level 12, snow load 1.5kPa), and assembly process constraints (rivet spacing tolerance ±2mm). The intelligent optimization process involves: inputting initial design parameters (such as silicone strip length and number of frame holes), iteratively optimizing using the PSO algorithm, with the objective function being "assembly stress concentration factor <1.2 + sealant filling time reduced by 20%"; virtually simulating processes such as rivet pre-positioning and laser welding, displaying the weld stress distribution cloud map in real time, automatically identifying high-stress areas and adjusting the hole layout (e.g., adding 1-2 auxiliary holes in stress concentration areas); and synchronizing the optimized parameters to the physical production line to guide the cutting of prefabricated silicone strips (accuracy ±0.1mm) and the processing of frame holes, achieving a closed loop of "design-simulation-manufacturing".

[0067] In some embodiments, by developing an installation robot with autonomous decision-making capabilities, equipped with a visual recognition module and an edge computing unit, the positional deviation of photovoltaic modules can be identified in real time. The clamping force and positioning accuracy of the clamping hook fasteners can be dynamically adjusted through a fuzzy neural network to solve the installation misalignment problem in complex terrain.

[0068] The hardware system deployment includes: the robot end effector integrates a binocular vision camera (1920×1080 resolution, ranging accuracy ±1mm), a six-axis force sensor (range 0-50N, resolution 0.1N), and a gripper fixing mechanism (displacement accuracy ±0.05mm); the edge computing unit is equipped with NVIDIA Jetson AGX Orin, running a lightweight fuzzy neural network model (number of parameters <1 million), with a response time <50ms.

[0069] Intelligent positioning control includes: a camera acquiring real-time images of the seams between adjacent components, detecting the position of the bend groove in the frame using the YOLOv8 algorithm, and calculating the lateral offset (Δx) and angular deviation (θ); a force sensor sensing the contact force between the clamping fastener and the frame, triggering a fuzzy neural network adjustment strategy when the contact force is >8N or <3N: if Δx > 2mm and θ > 1°, outputting the command "servo motor moves left by 0.5mm + clamping hook rotates -0.5°"; and combining historical installation data (stored 1000+ successful cases), continuously optimizing control rules through online learning to adapt to different installation angles (0°-60° tilt).

[0070] In some embodiments, by utilizing transfer learning technology, the welding defect detection model trained under standard operating conditions can be transferred to different production lines. Combined with online few-shot learning, it can quickly adapt to new materials (such as carbon fiber backing plates) or new processes (variable thickness borders), achieving high-precision real-time detection of laser welds.

[0071] Model construction and transfer include: The base model uses ResNet-50 and is pre-trained on a large-scale standard weld dataset (containing 100,000+ images of normal / cracked / porosity welds) to extract deep features such as weld texture and weld width. When the production line switches to a new type of corrugated backplate (e.g., thickness changes from 2mm to 3mm), only 50-100 new working condition images need to be collected. The last 3 fully connected layers are fine-tuned through transfer learning, with a training time of <30 minutes. Online detection process: During welding, a line scan camera (scanning speed 1000 lines / second) acquires weld images in real time and transmits them to an edge server for preprocessing (grayscale conversion, noise reduction). The transferred model performs real-time inference to identify weld defects (accuracy ≥98%). When a crack is detected (confidence >95%), the welding equipment is immediately stopped, and the defective component number is marked through the MES system. This links and traces the entire process data, such as rivet hole positions and silicone strip installation parameters, to form a quality closed loop.

[0072] In some embodiments, by embedding a shape memory alloy (SMA) drive unit at the connection between the photovoltaic module frame and the corrugated backsheet, the deformation of the drive unit is adjusted in real time through a reinforcement learning algorithm (PPO) to actively balance the stress concentration caused by wind and snow loads and improve the structural life.

[0073] The intelligent drive structure design involves attaching SMA sheets (0.2mm thick, 20mm long) near the preset holes on the frame, with both ends fixed to the frame and the corrugated back plate respectively. After being heated by electricity, it can produce a linear deformation of 1-2mm (response time <10s). It integrates a miniature temperature sensor (accuracy ±0.5℃) and a stress-strain sensor (resolution 1με) to monitor the SMA drive status and stress in the connection area in real time. Reinforcement learning control strategy: State space: current stress distribution (data from 10 sensors), ambient wind speed (acquired by an ultrasonic anemometer), SMA temperature; Action space: SMA driving current (0-1A, step size 0.1A), adjusting deformation direction (stretching / contraction); Reward function: stress concentration factor reduction (weight 0.6) + energy consumption cost (weight 0.4). The PPO algorithm was trained 2 million times in an offline simulation environment (simulating a 10-year life cycle load); When running online, the algorithm outputs a driving command every 50ms. When an instantaneous wind speed > 25m / s is detected, the SMA contraction action is triggered first to offset 30%-50% of the peak stress.

[0074] In some embodiments, by constructing a knowledge graph of the photovoltaic module connection structure, material parameters, installation processes, environmental data, and historical fault records are integrated, and the root cause of problems such as sealing failure and weld cracking is quickly located through a graph neural network (GNN) to guide preventive maintenance.

[0075] The knowledge graph construction includes: entity types: materials (silicone strip hardness, sealant mixing ratio), process parameters (laser power, rivet pressure), environmental factors (average annual rainfall, temperature difference), and fault types (water seepage location, crack length); relationship modeling: "insufficient sealant curing → water seepage probability ↑30%", "hole spacing > 120mm → weld stress concentration risk ↑25%", etc., accumulating more than 1000 causal relationship chains. Fault diagnosis application: When the structural health monitoring system (Example 9) detects sealant failure in a component, it inputs data such as fault location, water seepage time, and recent rainfall into the GNN model; the model traverses the knowledge graph, infers possible root causes (such as "sealant application pressure 0.2MPa < standard value 0.3MPa" or "insufficient silicone strip length leading to edge sealing blind spots"), and outputs the top 3 root causes and their confidence levels (≥90%); based on the root cause analysis results, maintenance personnel optimize the corresponding process parameters (such as adjusting the sealant application machine pressure to 0.4MPa) and update the fault case library through the knowledge graph, forming a self-evolving system.

[0076] In some embodiments, by establishing a digital thread for the photovoltaic module connection structure, blockchain technology is used to connect data from the entire process of design, manufacturing, installation, and operation and maintenance. Combined with natural language processing (NLP), cross-stage data semantic interoperability is achieved, ensuring that quality issues are traceable and process improvements are quantifiable.

[0077] The data chain construction includes: Design phase: storing hole coordinates and finite element analysis reports generated by the intelligent layout optimization module; Manufacturing phase: recording laser welding parameters and sealant application trajectory, and binding individual components with RFID tags (encoding rules: factory code + batch + serial number); Installation phase: uploading clamp fastener torque data and joint gap calibration records; Operation and maintenance phase: storing real-time data from stress and strain sensors and fault repair logs, with data stored on the blockchain (blockchain nodes include manufacturers, installers, and owners).

[0078] The intelligent traceability application includes: when a batch of weld cracks occur in a power plant, the component code is input into the traceability system, and the NLP model automatically analyzes the related data: it locates the laser welding power fluctuation of the same batch of components (±100W exceeding the standard ±50W), and the corresponding period's visual positioning system calibration frequency is insufficient (150 frames / second < standard 200 frames / second); it generates process improvement suggestions: "Improve the welding power control accuracy to ±30W, and force the visual system refresh rate to ≥200 frames / second", and pushes them to all power plants using this batch of components to achieve preventive maintenance.

[0079] This application establishes initial mechanical support through pre-connection positioning of rivets and corner brackets, and forms a continuous structural weld by laser welding of stainless steel welding wire, making the frame and corrugated back panel a rigid whole. Mechanical tests show that the shear strength of the connection part is increased by 40% compared with the traditional structure, effectively dispersing dynamic loads such as wind load and snow load. The first physical barrier is formed by the prefabricated silicone strips on both sides of the load-bearing unit through the interference fit of the slots, and the second chemical barrier is formed by the sealant filling the gap between the corrugated back panel fold and the glass. The two anti-seepage structures work together, and the water seepage rate is reduced compared with the traditional single sealing structure as verified by rain test. The through-hole self-drilling screw hook fastener is rigidly connected to the lower support component via self-tapping screws. The U-shaped body and the bent groove design of the frame can achieve ±0.5 mm splice error control, which significantly improves the flatness and alignment accuracy of the component installation and avoids the hot spot effect caused by misalignment. The standardized slot design of the prefabricated silicone strip, the adaptation of the laser welding visual positioning system, and the mechanized installation of the hook fastener all support automated production line production. Compared with traditional manual installation, the efficiency is improved, and the connection parameters (such as weld width and sealant thickness) can be precisely controlled by the equipment to ensure product consistency.

[0080] It should be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. It should be understood that when an element or layer is referred to as “on,” “adjacent to,” “connected to,” or “coupled to” other elements or layers, it may be directly on, adjacent to, connected to, or coupled to other elements or layers, or there may be intervening elements or layers. Conversely, when an element is referred to as “directly on,” “directly adjacent to,” “directly connected to,” or “directly coupled to” other elements or layers, there are no intervening elements or layers. It should be understood that although the terms first, second, third, etc., may be used to describe various elements, components, areas, layers, and / or portions, these elements, components, areas, layers, and / or portions should not be limited by these terms. These terms are merely used to distinguish one element, component, area, layer, or portion from another element, component, area, layer, or portion. Therefore, without departing from the teachings of this application, the first element, component, area, layer, or portion discussed below may be referred to as a second element, component, area, layer, or portion.

[0081] Spatial relation terms such as “below,” “under,” “below,” “under,” “above,” “above,” etc., are used herein for convenience of description to describe the relationship between one element or feature shown in the figure and other elements or features. It should be understood that, in addition to the orientation shown in the figure, spatial relation terms are intended to also include different orientations of the device in use and operation. For example, if the device in the figure is flipped, then the element or feature described as “below,” “under,” or “below” other elements or features will be oriented “above” other elements or features. Therefore, the exemplary terms “below” and “under” can include both above and below orientations. The device may be otherwise oriented (rotated 90 degrees or otherwise) and the spatial descriptive terms used herein will be interpreted accordingly.

[0082] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. When used herein, the singular forms “a,” “an,” and “the” are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “comprising” and / or “including,” when used in this specification, identify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups. When used herein, the term “and / or” includes any and all combinations of the associated listed items.

[0083] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0084] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A photovoltaic module connection and mounting structure, applied to solar energy industry, characterized in that, The system includes at least two adjacent photovoltaic (PV) modules. Each PV module comprises PV module glass, a corrugated backsheet, and a frame. The PV module glass and the corrugated backsheet are bonded together with structural adhesive to form a support unit. Pre-fabricated silicone strips are inserted into the long sides of the support unit. The frame has preset holes through which rivets and corner brackets are installed to complete the pre-connection and positioning of the frame and the corrugated backsheet. The joint between the frame and the corrugated backsheet is formed by laser welding stainless steel welding wire to ensure overall structural integrity. The gap between the folded edge of the corrugated backsheet and the PV module glass is filled with sealant to form a seepage barrier. A through-drilling self-drilling screw hook fastener is provided between the bent grooves of the frames of two adjacent PV modules. The through-drilling self-drilling screw hook fastener clamps and limits the lower support component with self-tapping screws to ensure stable positioning and anti-misalignment control of the PV module joints.

2. The photovoltaic module connection and mounting structure of claim 1, wherein, It also includes a structural health monitoring system, which collects vibration signals and stress data in real time through stress and strain sensors and acceleration sensors arranged on the frame, corrugated back plate and clamp fasteners; inputs the vibration signals and stress data into a convolutional neural network model for feature extraction to identify abnormal states such as loosening of the connection structure and weld cracks; when an abnormal state is identified, it sends a warning message to the monitoring terminal through a wireless communication module, the warning message including the coordinates of the abnormal location and the fault type code.

3. The photovoltaic module connection and mounting structure of claim 1, wherein, The prefabricated silicone strip has a T-shaped cross-section, and the long edges on both sides of the bearing unit are provided with slots that match the T-shaped structure. The prefabricated silicone strip is connected to the bearing unit through the limiting protrusions of the slots in an interference fit.

4. The photovoltaic module connection and mounting structure of claim 1, wherein, The preset holes are arranged in an array at equal intervals along the length of the frame. The corner bracket is an L-shaped metal part with positioning through holes on both sides that are coaxial with the preset holes. The rivets are fixed to the frame by a hydraulic riveting machine, and the surface of the corner bracket that contacts the corrugated back plate is provided with anti-slip serrations.

5. The photovoltaic module connection and mounting structure of claim 1, wherein, The laser welding uses a pulsed fiber laser. The structural weld is continuously welded along the overlapping edge of the frame and the corrugated back plate. During the laser welding process, the weld trajectory is calibrated in real time by a visual positioning system.

6. The photovoltaic module connection and mounting structure of claim 1, wherein, The sealant is a two-component silicone sealant, which includes component A and component B. The mixing ratio of component A to component B is 10:

1. The sealant is injected into the gap using an automatic dispensing machine. The filling trajectory of the sealant is continuously distributed in a serpentine pattern along the contour line of the gap. After filling, the sealant is surface cured using an ultraviolet curing device.

7. The photovoltaic module connection and mounting structure of claim 1, wherein, The clamping fastener includes a U-shaped body and a self-drilling screw guide hole. The opening width of the U-shaped body matches the depth of the bending groove of the frame. The self-tapping screw is screwed into the lower support member with a preset torque using an electric screwdriver. The inner surface of the clamping fastener is provided with an elastic buffer pad.

8. The photovoltaic module connection and mounting structure of claim 1, wherein It also includes an intelligent layout optimization module, which acquires the size parameters, material mechanical property parameters and preset load condition data of the photovoltaic module; The stress distribution of the connection area between the frame and the corrugated back plate is simulated based on the finite element analysis model to generate an initial hole layout scheme. The initial hole layout scheme is iteratively optimized using a genetic algorithm with the objective function of minimizing the uniformity of weld stress and the amount of material used, and the optimal hole coordinates and quantity are output. The optimal hole coordinates and quantity are transmitted to a CNC machine tool to control the processing and forming of the preset holes.

9. The photovoltaic module connection and mounting structure of claim 1, wherein, Furthermore, a laser rangefinder installed in the bending groove of the frame collects the splice gap data of adjacent photovoltaic modules in real time; the splice gap data is input into the PID control algorithm module to calculate and generate the displacement adjustment amount of the through-type self-drilling screw hook fastener; the hook fastener is driven by a servo motor to move along a preset guide rail until the error corresponding to the splice gap data is controlled within the preset error.

10. The photovoltaic module connection and mounting structure of claim 1, wherein, The material thickness of the corrugated back plate and the surface coating thickness of the frame are detected in real time using a spectrometer. The detection data is input into a fuzzy control algorithm model, which outputs matching laser power, welding speed, and wire feed speed parameters. The input variables of the fuzzy control algorithm model are material thickness and coating thickness, and the output variables are welding parameters. The corresponding fuzzy rule base contains multiple preset control rules. The laser welding equipment is controlled to perform welding operations through the output welding parameters, and the weld temperature is monitored by an infrared thermal imager. When the temperature fluctuation exceeds ±5℃, a parameter compensation mechanism is triggered.

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