An online fault monitoring and operation and maintenance early warning device for photovoltaic modules

Abstract

The present application relates to the field of photovoltaic technology, especially to a kind of photovoltaic module online fault monitoring and operation early warning device, including online fault monitoring equipment;Cooling mechanism is installed in the inside of online fault monitoring equipment, and the lower portion of cooling mechanism is provided with circulation heat exchange part communicated with online fault monitoring equipment, and the side of circulation heat exchange part is communicated with receiving mechanism, and the inside of online fault monitoring equipment is fixedly connected with heat dispersion part, and heat dispersion part is located above cooling mechanism;When completing heat dissipation operation in the inside of online fault monitoring equipment, fan equipment is started, and the airflow in the inside of inner tube is conveyed to heat dispersion part by fan equipment, and after uniform flow of airflow is discharged through heat dispersion part, it is released to the inside of online fault monitoring equipment cavity to complete heat replacement;Low-temperature airflow after completing heat exchange is backflowed to the inside of inner tube, and secondary heat exchange cooling is completed by relying on underground constant-temperature cold source, so as to realize closed-loop circulation heat exchange of airtight type.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic technology, specifically to an online fault monitoring and maintenance early warning device for photovoltaic modules. Background Technology

[0002] The photovoltaic module online fault monitoring device is an intelligent operation and maintenance monitoring equipment adapted to distributed and centralized photovoltaic power plants. Relying on IoT sensing, edge computing, and AI diagnostic algorithms, it achieves uninterrupted online monitoring of photovoltaic modules around the clock, solving the pain points of traditional manual inspections such as lag, missed fault detection, and low operation and maintenance efficiency. The device is equipped with high-precision voltage, current, and temperature sensors to collect the operating parameters of individual modules and strings in real time, and simultaneously match them with environmental irradiance data. It can accurately identify common faults such as hot spot microcracks, module aging, shading mismatch, line arcing, and damage to lightning protection devices.

[0003] Photovoltaic arrays are mostly installed in open areas with abundant sunlight and no buildings or vegetation to block it, such as deserts and Gobi. These sites have high solar radiation intensity, low surface specific heat capacity, and extremely high ambient temperatures in summer. The combined effect of surface heat radiation and solar heat results in a consistently high-temperature working environment. Conventional photovoltaic monitoring devices integrate precision electronic components such as sensor chips, data motherboards, and communication modules. These components are densely packed, generate significant power consumption and heat, and after long-term exposure to direct sunlight and their own operating heat, the internal cavity temperature can far exceed the ambient temperature. This can easily accelerate chip aging, circuit oxidation, and capacitor bulging, significantly reducing the overall lifespan of the equipment and increasing the failure rate and replacement costs.

[0004] Currently, most industry-standard monitoring equipment adopts an open-ventilation passive heat dissipation structure. When used in high-temperature desert environments, the external hot air directly convects and exchanges heat, resulting in extremely poor heat dissipation efficiency and an inability to quickly dissipate internal heat. At the same time, the open ventilation structure opens up air channels between the inside and outside of the equipment, allowing desert sand, dust, and salt particles to flow into the equipment cavity with the airflow. These particles adhere to the circuit boards and precision sensor surfaces, causing short circuits, signal drift, and component corrosion. This double damage to internal core components further reduces the operational stability and service life of the device. Therefore, to address the above problems, an online fault monitoring and maintenance early warning device for photovoltaic modules is proposed. Summary of the Invention

[0005] The purpose of this invention is to provide an online fault monitoring and maintenance early warning device for photovoltaic modules to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: As an optional solution of the photovoltaic module online fault monitoring and operation and maintenance early warning device described in this invention, the photovoltaic module online fault monitoring and operation and maintenance early warning device includes an online fault monitoring device, a receiving mechanism, and a cooling mechanism; The online fault monitoring equipment has a cooling mechanism installed inside. Below the cooling mechanism is a circulating heat exchanger that is connected to the online fault monitoring equipment. One side of the circulating heat exchanger is connected to a receiving mechanism, and the outer side of the receiving mechanism is fixedly connected to the online fault monitoring equipment. A rotating door is also installed on one side of the online fault monitoring equipment. A heat dissipation component is fixedly connected inside the online fault monitoring equipment, and the heat dissipation component is located above the cooling mechanism. The cooling mechanism includes a sliding frame that is slidably connected to the online fault monitoring equipment. A fan is installed inside the sliding frame, a cover plate is installed on the top of the sliding frame, and a circulating heat exchanger is connected to the bottom of the sliding frame. Both the sliding frame and the cover plate have mating holes on their surfaces.

[0007] As an optional solution of the photovoltaic module online fault monitoring and operation and maintenance early warning device described in this invention, the circulating heat exchanger includes an outer tube and an inner tube. Both ends of the outer tube are connected to the bottom of the online fault monitoring device, and the end of the inner tube is precisely connected to the bottom docking hole of the sliding frame. A uniformly distributed connecting plate is fixedly connected to the outer side of the inner tube, and the other end of the connecting plate is fixedly connected to the outer tube. A receiving mechanism is connected to the side of the outer tube.

[0008] As an optional solution of the photovoltaic module online fault monitoring and operation and maintenance early warning device described in this invention, the heat dissipation component includes a hollow tube and a guide tube. The bottom of the hollow tube is fixedly connected to the online fault monitoring device. Multiple evenly distributed guide tubes are also connected to the outside of the hollow tube. The bottom of the hollow tube is precisely connected to the docking hole opened above the cover plate.

[0009] Photovoltaic arrays are mostly installed in open areas with abundant sunlight and no buildings or vegetation, such as deserts and Gobi. These sites have high solar intensity, low surface heat capacity, and extremely high ambient temperatures in summer. The combined effect of surface heat radiation and solar heat results in a consistently high-temperature working environment. Conventional photovoltaic monitoring devices integrate sophisticated electronic components such as sensor chips, data motherboards, and communication modules. These components are densely packed, generate significant power consumption and heat, and after prolonged exposure to direct sunlight and their own operating heat, the internal cavity temperature can far exceed the ambient temperature. This can accelerate chip aging, circuit oxidation, and capacitor bulging, significantly reducing the overall lifespan of the equipment and increasing the failure rate and replacement costs. Currently, most industry-standard monitoring equipment uses an open-ventilation passive cooling structure. When used in high-temperature desert sites, external hot air directly convects and exchanges heat, resulting in extremely poor heat dissipation efficiency and an inability to quickly dissipate internal heat. At the same time, the open ventilation structure opens up air channels between the inside and outside of the equipment, allowing desert sand, dust, and salt particles to enter the equipment cavity with the airflow. Corrosion, caused by substances adhering to the circuit board and precision sensor surfaces, leads to short circuits, signal drift, and component corrosion, resulting in double losses of internal core components and further reducing the device's operational stability and service life. This solution equips the bottom of the online fault monitoring equipment with a circulating heat exchanger, which is then deeply buried underground. When the online fault monitoring equipment completes heat dissipation, a fan is activated, driving airflow from inside the inner tube to the heat dissipation component. After being evenly distributed by the heat dissipation component, the airflow is released into the cavity of the online fault monitoring equipment to complete heat exchange. The cooled airflow after heat exchange returns to the inner tube, where it undergoes secondary heat exchange and cooling using an underground constant-temperature cold source, thus achieving a closed-loop circulating heat exchange. Simultaneously, the entire online fault monitoring equipment adopts a fully sealed encapsulation design, completely isolating it from external dust, salt, and alkali impurities, comprehensively ensuring the stable operation of the internal precision components.

[0010] As an optional solution of the photovoltaic module online fault monitoring and operation and maintenance early warning device described in this invention, the receiving mechanism includes an installation frame that is fixedly connected to the online fault monitoring equipment. A motor is fixedly connected inside the installation frame. A threaded shaft is fixedly connected to the end of the motor's main shaft. A threaded sleeve is screwed to the outside of the threaded shaft. A movable frame is fixedly connected to the other end of the threaded sleeve. The outside of the movable frame is slidably connected to the installation frame. One side of the movable frame is connected to a connecting pipe, and the other end of the connecting pipe is connected to a circulating heat exchanger.

[0011] As an optional solution of the photovoltaic module online fault monitoring and operation and maintenance early warning device described in this invention, a telescopic tube that can be extended and retracted is installed in the center of the connecting pipe.

[0012] As an optional solution of the photovoltaic module online fault monitoring and operation and maintenance early warning device described in this invention, a filter screen for filtering impurities is installed above the moving frame.

[0013] As an optional solution of the photovoltaic module online fault monitoring and operation and maintenance early warning device of the present invention, a movable column is fixedly connected above the threaded sleeve, a sliding block is rotatably connected to the other end of the movable column, a guide plate is slidably connected to the other end face of the sliding block, and the guide plate is rotatably connected to the mounting frame.

[0014] The online fault monitoring equipment has a side-mounted support mechanism. During the rainy season, the motor drives the threaded shaft to rotate, and the threaded shaft moves horizontally in conjunction with the threaded sleeve. The threaded sleeve synchronously pulls the moving column to move in the same direction. The sliding block at the top of the moving column slides with the guide plate, driving the inclined guide plate to flip and adjust, and synchronously driving the moving frame to extend outward from inside the installation frame. The inclined guide plate completes the rainwater diversion, collecting the precipitation into the moving frame. The rainwater is transported through the connecting pipe to the cavity between the outer and inner pipes, assisting the underground cold source in heat exchange, further improving the heat exchange rate of the air flowing inside the inner pipe, and enhancing the overall heat dissipation and cooling effect.

[0015] Compared with the prior art, the beneficial effects of the present invention are: This solution involves assembling a circulating heat exchanger at the bottom of the online fault monitoring equipment and burying it deep underground. When the equipment is cooling down, a fan is activated, driving airflow from the inner tube to a heat dissipation component. The airflow is then evenly distributed through the heat dissipation component and released back into the equipment's cavity to complete heat exchange. The cooled airflow then returns to the inner tube, where it undergoes secondary heat exchange and cooling using an underground constant-temperature cold source, thus achieving a closed-loop circulating heat exchange. Simultaneously, the entire online fault monitoring equipment employs a fully sealed encapsulation design, completely isolating it from external dust, salt, and alkali impurities, ensuring the stable operation of the precision components inside the equipment.

[0016] The online fault monitoring equipment has a side-mounted support mechanism. During the rainy season, the motor drives the threaded shaft to rotate, and the threaded shaft moves horizontally in conjunction with the threaded sleeve. The threaded sleeve synchronously pulls the moving column to move in the same direction. The sliding block at the top of the moving column slides with the guide plate, driving the inclined guide plate to flip and adjust, and synchronously driving the moving frame to extend outward from inside the installation frame. The inclined guide plate completes the rainwater diversion, collecting the precipitation into the moving frame. The rainwater is transported through the connecting pipe to the cavity between the outer and inner pipes, assisting the underground cold source in heat exchange, further improving the heat exchange rate of the air flowing inside the inner pipe, and enhancing the overall heat dissipation and cooling effect. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of an online fault monitoring and maintenance early warning device for photovoltaic modules. Figure 2 A schematic diagram of the structure of a receiving mechanism for an online fault monitoring and maintenance early warning device for photovoltaic modules; Figure 3 This is a schematic diagram of the installation structure of a movable frame for an online fault monitoring and maintenance early warning device for photovoltaic modules. Figure 4 This is a front view of the moving frame of an online fault monitoring and maintenance early warning device for photovoltaic modules; Figure 5 This is a schematic diagram of the installation structure of a sliding block for an online fault monitoring and maintenance early warning device for photovoltaic modules. Figure 6 This is a schematic diagram of the installation structure of the cooling mechanism of an online fault monitoring and maintenance early warning device for photovoltaic modules; Figure 7 This is a schematic diagram of the installation structure of the circulating heat exchange component of an online fault monitoring and maintenance early warning device for photovoltaic modules.

[0018] In the diagram: 1-Online fault monitoring equipment, 2-Receiving mechanism, 201-Mounting frame, 202-Moving frame, 203-Motor, 204-Threaded shaft, 205-Threaded sleeve, 206-Connecting pipe, 207-Telescopic pipe, 208-Moving column, 209-Sliding block, 210-Guide plate, 3-Cooling mechanism, 301-Sliding frame, 302-Cover plate, 303-Fan equipment, 4-Circulating heat exchanger, 401-Outer pipe, 402-Inner pipe, 403-Connecting plate, 5-Rotating door, 6-Heat dispersing component, 601-Hollow tube, 602-Guide tube. Detailed Implementation

[0019] Example 1: Please refer to Figure 1 , Figure 6 and Figure 7 The present invention provides a technical solution: A photovoltaic module online fault monitoring and maintenance early warning device includes an online fault monitoring device 1, a receiving mechanism 2, and a cooling mechanism 3; The online fault monitoring device 1 is equipped with a cooling mechanism 3. A circulating heat exchanger 4 connected to the online fault monitoring device 1 is located below the cooling mechanism 3. A receiving mechanism 2 is connected to one side of the circulating heat exchanger 4. The outer side of the receiving mechanism 2 is fixedly connected to the online fault monitoring device 1. A rotating door 5 is also installed on one side of the online fault monitoring device 1. A heat dispersing component 6 is fixedly connected inside the online fault monitoring device 1, and the heat dispersing component 6 is located above the cooling mechanism 3. The cooling mechanism 3 includes a sliding frame 301 that is slidably connected to the online fault monitoring device 1. A fan device 303 is installed inside the sliding frame 301. A cover plate 302 is installed on the top of the sliding frame 301. A circulating heat exchanger 4 is connected to the bottom of the sliding frame 301. Both the sliding frame 301 and the cover plate 302 have mating holes on their surfaces.

[0020] The circulating heat exchanger 4 includes an outer tube 401 and an inner tube 402. Both ends of the outer tube 401 are connected to the bottom of the online fault monitoring device 1, and the end of the inner tube 402 is precisely connected to the bottom docking hole of the sliding frame 301. The outer side of the inner tube 402 is fixedly connected with evenly distributed connecting plates 403. The other end of the connecting plate 403 is fixedly connected to the outer tube 401. The side of the outer tube 401 is connected to the receiving mechanism 2.

[0021] The heat dispersing component 6 includes a hollow tube 601 and a guide tube 602. The bottom of the hollow tube 601 is fixedly connected to the online fault monitoring device 1. The outer side of the hollow tube 601 is also connected to multiple evenly distributed guide tubes 602. The bottom of the hollow tube 601 is precisely connected to the docking hole opened above the cover plate 302.

[0022] Photovoltaic arrays are mostly deployed in open areas with abundant sunlight and no buildings or vegetation, such as deserts and Gobi. These sites have high solar intensity, low surface heat capacity, and extremely high summer temperatures. The combined effect of surface heat radiation and solar thermal effect results in a consistently high-temperature working environment. Conventional photovoltaic monitoring devices integrate sophisticated electronic components such as sensor chips, data motherboards, and communication modules. These components are densely packed, generating significant power consumption and heat. After prolonged exposure to direct sunlight and their own operating heat, the internal cavity temperature can far exceed the ambient temperature, accelerating chip aging, circuit oxidation, and capacitor bulging. This significantly reduces the overall lifespan of the equipment, increasing the failure rate and replacement costs. Currently, most industry-standard monitoring equipment uses an open-ventilation passive cooling structure. When used in high-temperature desert sites, external hot air directly convects and exchanges heat, resulting in extremely poor heat dissipation efficiency and an inability to quickly dissipate internal heat. Furthermore, the open ventilation structure opens up air channels between the inside and outside of the equipment, allowing desert sand, dust, and salt particles to enter the equipment cavity and adhere to the circuit boards. The surface of precision sensors is susceptible to short circuits, signal drift, and corrosion, resulting in double losses of internal core components and further reducing the operational stability and service life of the device. This solution involves assembling a circulating heat exchanger 4 at the bottom of the online fault monitoring device 1 and burying it deep underground. When the online fault monitoring device 1 completes heat dissipation, a fan 303 is activated, driving airflow from the inner tube 402 to the heat dissipation component 6. After being evenly distributed through the heat dissipation component 6, the airflow is released into the cavity of the online fault monitoring device 1 to complete heat exchange. The low-temperature airflow after heat exchange returns to the inner tube 402, where it undergoes secondary heat exchange and cooling using an underground constant-temperature cold source, thus achieving a closed-loop circulating heat exchange. Simultaneously, the online fault monitoring device 1 adopts a fully sealed encapsulation design, completely isolating it from external dust, salt, and alkali impurities, ensuring the stable operation of the precision components inside the device 1. Also includes the following: The online fault monitoring device 1 is internally equipped with four major functional hardware modules: a multi-source sensor acquisition module, an edge computing FPGA control module, a passive power supply and fault isolation module, and a wireless self-organizing network communication module. The multi-source sensor acquisition module is electrically connected to each sensor component to collect parameters such as photovoltaic module voltage, branch current, backplane temperature, and internal temperature and humidity of the junction box, and performs signal filtering and noise reduction to obtain accurate module operation monitoring signals. The edge computing FPGA control module is a hardware logic control chip used to receive sensor signals, perform local hardware fault identification, issue early warning and circuit isolation control commands, and store module operating parameters. The passive power supply and fault isolation module is used to achieve passive self-powering of the device based on the photovoltaic modules, receive control commands to cut off the main circuit of the faulty module and conduct the bypass, and achieve fault hardware isolation and circuit protection. The wireless self-organizing network communication module adopts a LoRa radio frequency hardware module for local wireless networking between devices, transmitting module monitoring data and fault early warning point signals, realizing local wireless data transmission, and also has an early warning function. The circulating heat exchanger 4 is divided into an outer tube 401 and an inner tube 402, which are fixed in the center by a connecting plate 403, so that the middle interlayer can be filled with water to facilitate subsequent air heat exchange. The hollow tube 601 and guide tube 602 are used to deliver cold air to the corresponding location to achieve targeted cooling.

[0023] Example 2: This example is an improvement upon Example 1. Please refer to [link / reference]. Figure 2 , Figure 3 , Figure 4 and Figure 5 Specifically, the receiving mechanism 2 includes a mounting frame 201 that is fixedly connected to the online fault monitoring device 1. A motor 203 is fixedly connected inside the mounting frame 201. A threaded shaft 204 is fixedly connected to the end of the main shaft of the motor 203. A threaded sleeve 205 is screwed to the outside of the threaded shaft 204. A movable frame 202 is fixedly connected to the other end of the threaded sleeve 205. The outside of the movable frame 202 is slidably connected to the mounting frame 201. One side of the movable frame 202 is connected to a connecting pipe 206, and the other end of the connecting pipe 206 is connected to the circulating heat exchanger 4.

[0024] A telescopic tube 207 that can be extended is installed in the center of the connecting tube 206.

[0025] A filter screen for filtering impurities is installed above the movable frame 202.

[0026] A movable column 208 is fixedly connected to the top of the threaded sleeve 205. A sliding block 209 is rotatably connected to the other end of the movable column 208. A guide plate 210 is slidably connected to the other end face of the sliding block 209, and the guide plate 210 is rotatably connected to the mounting frame 201.

[0027] The online fault monitoring device 1 has a fixed mounting mechanism 2 on its side. During the rainy season, the motor 203 drives the threaded shaft 204 to rotate, and the threaded shaft 204 moves horizontally in conjunction with the threaded sleeve 205. The threaded sleeve 205 synchronously pulls the moving column 208 to move in the same direction. The sliding block 209 at the top of the moving column 208 slides and engages with the guide plate 210, driving the inclined guide plate 210 to flip and adjust, and synchronously driving the moving frame 202 to extend outward from inside the mounting frame 201. The inclined guide plate 210 completes the rainwater diversion, collecting the precipitation into the moving frame 202. The rainwater is transported through the connecting pipe 206 to the cavity between the outer pipe 401 and the inner pipe 402, assisting the underground cold source in heat exchange, further improving the heat exchange rate of the air flowing inside the inner pipe 402, and enhancing the overall heat dissipation and cooling effect. Also includes the following: A telescopic pipe 207 is provided in the center of the connecting pipe 206. When the moving frame 202 moves, the telescopic pipe 207 can be used to ensure the stable movement of the connecting pipe 206 and ensure that the water flows smoothly into the cavity between the outer pipe 401 and the inner pipe 402. The filter screen is designed to filter external impurities and prevent them from entering the cavity between the outer tube 401 and the inner tube 402, which would cause blockage and affect heat exchange efficiency.

[0028] This article uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only for the purpose of helping to understand the method and core ideas of the present invention. The above descriptions are only preferred embodiments of the present invention. It should be noted that due to the limitations of textual expression, while there are objectively infinite specific structures, those skilled in the art can make several improvements, modifications, or changes without departing from the principles of the present invention, and can also combine the above technical features in an appropriate manner. These improvements, modifications, changes, or combinations, or the direct application of the inventive concept and technical solution to other situations without modification, should all be considered within the scope of protection of the present invention.

Claims

1. A photovoltaic module online fault monitoring and maintenance early warning device, characterized in that: It includes an online fault monitoring device (1), a receiving mechanism (2), and a cooling mechanism (3); The online fault monitoring device (1) is equipped with a cooling mechanism (3). A circulating heat exchanger (4) connected to the online fault monitoring device (1) is provided below the cooling mechanism (3). A receiving mechanism (2) is connected to one side of the circulating heat exchanger (4). The outer side of the receiving mechanism (2) is fixedly connected to the online fault monitoring device (1). A rotating door (5) is also installed on one side of the online fault monitoring device (1). A heat dispersing component (6) is fixedly connected inside the online fault monitoring device (1), and the heat dispersing component (6) is located above the cooling mechanism (3). The cooling mechanism (3) includes a sliding frame (301) that is slidably connected to the online fault monitoring device (1). The sliding frame (301) has a fan device (303) installed inside. A cover plate (302) is installed on the top of the sliding frame (301). A circulating heat exchanger (4) is connected to the bottom of the sliding frame (301). Both the sliding frame (301) and the cover plate (302) have mating holes on their surfaces.

2. The photovoltaic module online fault monitoring and maintenance early warning device according to claim 1, characterized in that: The receiving mechanism (2) includes a mounting frame (201) that is fixedly connected to the online fault monitoring equipment (1). A motor (203) is fixedly connected inside the mounting frame (201). A threaded shaft (204) is fixedly connected to the end of the main shaft of the motor (203). A threaded sleeve (205) is screwed to the outside of the threaded shaft (204). A movable frame (202) is fixedly connected to the other end of the threaded sleeve (205). The outside of the movable frame (202) is slidably connected to the mounting frame (201). One side of the movable frame (202) is connected to a connecting pipe (206), and the other end of the connecting pipe (206) is connected to the circulating heat exchanger (4).

3. The photovoltaic module online fault monitoring and maintenance early warning device according to claim 2, characterized in that: A telescopic tube (207) that can be extended is installed in the center of the connecting tube (206).

4. The photovoltaic module online fault monitoring and maintenance early warning device according to claim 2, characterized in that: A filter screen for filtering impurities is installed above the movable frame (202).

5. The photovoltaic module online fault monitoring and maintenance early warning device according to claim 2, characterized in that: A movable column (208) is fixedly connected to the top of the threaded sleeve (205). A sliding block (209) is rotatably connected to the other end of the movable column (208). A guide plate (210) is slidably connected to the other end face of the sliding block (209), and the guide plate (210) is rotatably connected to the mounting frame (201).

6. The photovoltaic module online fault monitoring and maintenance early warning device according to claim 1, characterized in that: The circulating heat exchanger (4) includes an outer tube (401) and an inner tube (402). Both ends of the outer tube (401) are connected to the bottom of the online fault monitoring device (1), and the end of the inner tube (402) is precisely connected to the bottom docking hole of the sliding frame (301). The outer side of the inner tube (402) is fixedly connected with a uniformly distributed connecting plate (403). The other end of the connecting plate (403) is fixedly connected to the outer tube (401). The side of the outer tube (401) is connected to a receiving mechanism (2).

7. The photovoltaic module online fault monitoring and maintenance early warning device according to claim 6, characterized in that: The heat dispersing component (6) includes a hollow tube (601) and a guide tube (602). The bottom of the hollow tube (601) is fixedly connected to the online fault monitoring device (1). The outer side of the hollow tube (601) is also connected to multiple evenly distributed guide tubes (602). The bottom of the hollow tube (601) is precisely connected to the docking hole opened above the cover plate (302).

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