Photovoltaic module defect recognition apparatus and method

Abstract

A photovoltaic module defect recognition device and method, photovoltaic detection equipment device technical field, including: base assembly, control unit and scanning unit, the top surface of the base assembly is fixed with the control unit, the lower end of the base assembly is fixed with the scanning unit, through the setting of the base assembly, the control unit and the scanning unit, a variety of defects can be detected at one time, the detection efficiency is improved, the consistency of continuous detection is also guaranteed, and the erected photovoltaic equipment can be detected in outdoor inspection.

Description

Technical Field

[0001] This invention belongs to the technical field of photovoltaic testing equipment, and in particular to a photovoltaic module defect identification device and method. Background Technology

[0002] Defects in the production and operation and maintenance phases of photovoltaic modules can be categorized into three types:

[0003] Internal hidden defects: microcracks, broken grids, poor soldering, black cores, PID degradation, cell perforation, which cannot be identified by the naked eye and are only visible by EL imaging; Surface appearance defects: glass scratches, chipped edges, dirt, solder ribbon misalignment, encapsulation bubbles, foreign object obstruction; Operational thermal defects: hot spots, bypass diode failure, junction box overheating, local aging temperature rise.

[0004] Existing photovoltaic panel testing methods and equipment have significant shortcomings:

[0005] Single-mode inspection equipment can only detect one type of defect, requiring multiple devices to perform inspections in stages, resulting in low efficiency; traditional manual inspection has a high rate of missed detections and poor consistency, and it is difficult to identify micro-cracks (<0.5mm); outdoor photovoltaic equipment is installed at a high altitude, making inspection difficult. Summary of the Invention

[0006] The purpose of this invention is to solve the above-mentioned problems existing in the prior art and to provide a photovoltaic module defect identification device and method.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A photovoltaic module defect identification device and method includes: a base assembly, a control unit, and a scanning unit. The control unit is fixed to the top surface of the base assembly, and the scanning unit is fixed to the lower end of the base assembly. The base assembly includes: a base, Mecanum wheels, a negative suction groove, a roller brush, air holes, a control valve, and a mounting base. Multiple Mecanum wheels are provided at both the front and rear ends of the base, and each Mecanum wheel is controlled by a drive motor. A negative suction groove is provided on the bottom surface of the base, and a roller brush is rotatably connected to the negative suction groove via a bracket. The roller brush is connected to a drive motor. An air hole is provided on the top surface of the negative suction groove, and a control valve is connected to the top surface of the air hole. The valve has fixed seats on both sides of the base, and set screws are screwed onto the fixed seats. The negative suction groove, roller brush, air hole and control valve are symmetrically arranged in pairs. The control unit includes: a fixed frame, a vacuum pump, a filter assembly and a PLC controller. The fixed frame is fixed at the upper end of the base. The vacuum pump is fixed inside the fixed frame. The filter assembly and PLC controller are fixed inside the fixed frame. The control valve is fixedly connected to the filter assembly through an air pipe. The air inlet of the vacuum pump is fixedly connected to the filter assembly. The PLC controller is signal-connected to the vacuum pump and the control valve. Drive motor 1 and drive motor 2 are signal-connected to PLC controller 1.

[0009] The filter assembly includes: a filter barrel, a top cover, an air inlet, a sealing ring, and a screen barrel. The filter barrel is fixed inside the fixed frame. The filter barrel has an opening. The top cover is screwed and sealed to the top surface of the filter barrel. The bottom surface of the filter barrel has an air inlet. The air inlet end of the air pump is fixedly connected to the air inlet. The sealing ring is installed inside the filter barrel. The screen barrel is fixed to the upper end of the sealing ring. The sealing ring slides and seals against the inner wall of the filter barrel. The control valve is fixedly connected to the outer wall of the filter barrel through an air pipe.

[0010] The scanning unit includes a scanning component and a paint tank. The scanning component and the paint tank are fixed on the bottom surface of the base. Two scanning components are symmetrically arranged with the paint tank as the center, and the two paint tanks are connected to each other.

[0011] Both scanning components include: a multi-module acquisition scanning head, a spraying pipe, a control box, a feeding pump, and a second PLC controller. The multi-module acquisition scanning head is fixed to the bottom surface of the base. The spraying pipe is fixed to the rear end of the multi-module acquisition scanning head. The control box is fixed to the upper end of the spraying pipe. The feeding pump is fixed inside the control box. The feed pump inlet is fixedly connected to the paint tank, and the feed pump outlet is fixedly connected to the spraying pipe. The second PLC controller is fixed inside the control box. The second PLC controller is signal-connected to the multi-module acquisition scanning head and the feeding pump.

[0012] A method for using a photovoltaic module defect identification device:

[0013] Step 1: Place the device on the photovoltaic panel, and use the PLC controller to power on the air pump to create negative pressure at the bottom of the base, pressing the device onto the photovoltaic panel.

[0014] Step 2: Control the Mecanum wheels to move and inspect the photovoltaic panels using the PLC controller and drive motor.

[0015] Step 3: Control the rotation of the roller brush through PLC controller 1 and drive motor 2 to sweep up the dust on the photovoltaic panel;

[0016] Step 4: Scan the photovoltaic panel for defects using a multi-module acquisition scanning head;

[0017] Step 5: When a defect is detected, the feed pump is started by controlling the PLC controller to extract the paint from the paint tank and spray it onto the photovoltaic panel for marking.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] This invention provides a photovoltaic module defect identification device and method. By setting up a base assembly, a control unit and a scanning unit, multiple types of defects can be detected at once, which improves the detection efficiency, ensures the consistency of continuous detection, and allows for patrol inspection of installed photovoltaic equipment during outdoor inspections. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the internal structure of the present invention.

[0021] Figure 2 This is a schematic diagram of the filter component structure;

[0022] Figure 3 This is a schematic diagram showing the connection between the sealing ring and the screen barrel;

[0023] Figure 4 This is a schematic diagram of the scanning component structure;

[0024] Figure 5 This is a bottom view of the overall structure. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the invention, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0026] Please see Figure 1-5This invention provides a technical solution: a photovoltaic module defect identification device and method, comprising: a base assembly 1, a control unit 2, and a scanning unit 3. The control unit 2 is fixed on the top surface of the base assembly 1, and the scanning unit 3 is fixed on the lower end of the base assembly 1. The base assembly 1 includes: a base 11, Mecanum wheels 12, a negative suction groove 13, a roller brush 14, an air hole 15, a control valve 16, and a fixed seat 17. Multiple Mecanum wheels 12 are provided at both the front and rear ends of the base 11, and each Mecanum wheel 12 is controlled by a drive motor. The bottom surface of the base 11 is provided with a negative suction groove 13, and a roller brush 14 is rotatably connected to the negative suction groove 13 via a bracket. The roller brush 14 is connected to a drive motor. An air hole 15 is provided on the top surface of the negative suction groove 13, and a control valve 16 is connected to the top surface of the air hole 15. The control valve 16 is provided on both sides of the base 11, and a fixing seat 17 is provided on the fixing seat 17. A set screw is screwed on the fixing seat 17. The negative suction groove 13, the roller brush 14, the air hole 15 and the control valve 16 are symmetrically arranged in twos. The control unit 2 includes: a fixing frame 21, a vacuum pump 22, a filter assembly 23 and a PLC controller 24. The fixing frame 21 is fixed at the upper end of the base 11. The vacuum pump 22 is fixed inside the fixing frame 21. The filter assembly 23 and the PLC controller 24 are fixed inside the fixing frame 21. The control valve 16 is fixedly connected to the filter assembly 23 through an air pipe. The air inlet end of the vacuum pump 22 is fixedly connected to the filter assembly 23. The PLC controller 24 is signal connected to the vacuum pump 22 and the control valve 16. The drive motor 1 and the drive motor 2 are signal connected to the PLC controller 24.

[0027] The filter assembly 23 includes: a filter barrel 231, a top cover 232, an air inlet 233, a sealing ring 234, and a screen barrel 235. The filter barrel 231 is fixed inside the fixed frame 21. The filter barrel 231 has an opening. The top cover 232 is screwed and sealed to the top surface of the filter barrel 231. The bottom surface of the filter barrel 231 has an air inlet 233. The air inlet end of the air pump 22 is fixedly connected to the air inlet 233. The sealing ring 234 is provided inside the filter barrel 231. The screen barrel 235 is fixed to the upper end of the sealing ring 234. The sealing ring 234 slides and seals against the inner wall of the filter barrel 231. The control valve 16 is fixedly connected to the outer wall of the filter barrel 231 through an air pipe.

[0028] The scanning unit 3 includes a scanning component 31 and a paint tank 32. The scanning component 31 and the paint tank 32 are fixed on the bottom surface of the base 11. Two scanning components 31 are symmetrically arranged with the paint tank 32 as the center, and the two paint tanks 32 are connected to each other.

[0029] Both scanning components 31 include: a multi-module acquisition scanning head 311, a spraying pipe 312, a control box 313, a feeding pump 314, and a second PLC controller 315. The multi-module acquisition scanning head 311 is fixed to the bottom surface of the base 11. The spraying pipe 312 is fixed to the rear end of the multi-module acquisition scanning head 311. The control box 313 is fixed to the upper end of the spraying pipe 312. The feeding pump 314 is fixed inside the control box 313. The inlet end of the feeding pump 314 is fixedly connected to the paint tank 32, and the outlet end of the feeding pump 314 is fixedly connected to the spraying pipe 312. The second PLC controller 315 is fixed inside the control box 313. The second PLC controller 315 is signal-connected to the multi-module acquisition scanning head 311 and the feeding pump 314.

[0030] Furthermore, PLC controller 124 and PLC controller 2315 are existing technologies and are selected according to actual production conditions. The entire device is connected to an external power supply, and PLC controller 124 and PLC controller 2315 draw power from the machine body.

[0031] Furthermore, the multi-module acquisition scanning head 311 includes: a near-infrared EL camera: a 24-megapixel InGaAs high-sensitivity infrared array camera, equipped with an 850nm narrowband filter, to capture the electroluminescence signal of the solar cell and identify internal microcracks, broken grids, and poor soldering; a high-definition visible light camera: a 24-megapixel color industrial camera, equipped with a ring-shaped shadowless polarized light source to eliminate glass reflections and identify surface scratches, dirt, and packaging defects; an infrared thermal imaging camera: an uncooled thermal infrared detector, to acquire 4–14μm temperature field images and identify hot spots, diode overheating, and local attenuation; and accessories: a synchronous trigger controller, an optical calibration board, and a dustproof and light-shielding cover, with the three cameras sharing a common field of view and completing pixel-level spatial registration.

[0032] A method for using a photovoltaic module defect identification device:

[0033] Step 1: Place the device on the photovoltaic panel. Control the air pump 22 to generate negative pressure at the bottom of the base 11 through the PLC controller 24, and press the device onto the photovoltaic panel.

[0034] Step 2: Control the Mecanum wheel 12 to move and inspect the photovoltaic panel via PLC controller 24 and drive motor 1;

[0035] Step 3: Control the rotation of the roller brush 14 through PLC controller 24 and drive motor 2 to sweep up the dust on the photovoltaic panel;

[0036] Step 4: Scan the photovoltaic panel for defects using the multi-module acquisition scanning head 311;

[0037] Step 5: When a defect is detected, the feed pump 314 is started by controlling the PLC controller 315 to extract the paint from the paint tank 32 and spray it onto the photovoltaic panel for marking.

[0038] The working principle of this device is:

[0039] When inspecting outdoor photovoltaic equipment, the device is placed on the photovoltaic panel, with the Mecanum wheels 12 resting against it. The PLC controller 24 then powers on the air pump 22, generating suction to draw air through the negative suction groove 13, air hole 15, control valve 16, and air pipe into the filter canister 231. The air is then discharged from the filter canister 231 via the air pump 22. This creates a negative pressure at the bottom of the base 11, which, combined with atmospheric pressure, presses the device against the photovoltaic panel, achieving adhesion. The PLC controller 24 and drive motor 1 control the Mecanum wheels 12 to move the device across the photovoltaic panel for inspection. The Mecanum wheels 12 allow for omnidirectional movement of the device. The PLC controller 24 and drive motor 2 control the rotation of the roller brush 14, which rests against the photovoltaic panel. As the device moves, dust on the photovoltaic panel is swept up and sucked in by the air pump 22. The filter component 23 collects dust at the temporal part, which can further increase the accuracy of defect detection and avoid dust affecting detection and identification or causing identification errors. When the device is moving for inspection, the multi-module acquisition scanning head 311 scans for defects in the photovoltaic panel. When a defect is detected, the multi-module acquisition scanning head 311 sends a signal to the PLC controller 315. The PLC controller 315 controls the feed pump 314 to start, extracting the paint from the paint tank 32 and sending it into the spray pipe 312. The paint is then sprayed onto the photovoltaic panel for marking. When the multi-module acquisition scanning head 311 moves away from the defect location, it sends a signal to the PLC controller 315. The PLC controller 315 controls the feed pump 314 to stop, thereby stopping the spraying. In this way, the defect location can be marked, which facilitates the maintenance of the photovoltaic panel after the inspection. The device is symmetrically equipped with a negative suction groove 13, a roller brush 14, an air hole 15, a control valve 16, and a scanning component 31. This allows for testing from both sides of the device, reducing the need for turning around during inspections and increasing testing efficiency. When moving forward, the roller brush 14 located at the rear end is controlled to close via PLC controller 24, which prevents the roller brush 14 located at the rear end from sweeping away the paint. The surface of the roller brush 14 is made of long hairs. When starting, the hairs are swung up by centrifugal force for cleaning. When the roller brush 14 stops rotating, the hairs fall down naturally.

[0040] When inspecting the photovoltaic equipment on the production line, support rods are erected on both sides of the production line and inserted into the fixing base 17. After adjusting the distance between the multi-module acquisition scanning head 311 and the photovoltaic panel, the set screw is tightened to fix it. Then, the photovoltaic panel is inspected in the above manner.

[0041] After the cruise is completed, clean the filter assembly 23, unscrew the top cover 232, and then pull the screen barrel 235 to move the sealing ring 234 outward. The sealing ring 234 can scrape off the dust adhering to the inner wall of the filter barrel 231. Then clean the screen barrel 235, and then perform the above steps in the opposite direction to reset it. By setting the filter assembly 23, dust can be avoided during operation.

[0042] Furthermore, any content not described in detail in this specification is existing technology known to those skilled in the art.

[0043] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0044] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0045] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A photovoltaic module defect identification device, characterized in that: include: The base assembly (1), control unit (2), and scanning unit (3) are provided. The control unit (2) is fixed on the top surface of the base assembly (1), and the scanning unit (3) is fixed on the lower end of the base assembly (1). The base assembly (1) includes: a base (11), Mecanum wheels (12), negative suction grooves (13), roller brushes (14), air holes (15), control valves (16), and a fixed seat (17). Multiple Mecanum wheels (12) are provided at the front and rear ends of the base (11). Each Mecanum wheel (12) is controlled by a drive motor. A negative suction groove (13) is provided on the bottom surface of the base (11). A roller brush (14) is rotatably connected to the negative suction groove (13) through a bracket. A drive motor (2) is connected to the roller brush (14). An air hole (15) is provided on the top surface of the negative suction groove (13). A control valve (16) is connected to the top surface of the air hole (15). Both sides of the base (11) are provided with... A fixed base (17) is provided, and a set screw is screwed onto the fixed base (17). The negative suction groove (13), roller brush (14), air hole (15) and control valve (16) are symmetrically arranged in twos. The control unit (2) includes: a fixed frame (21), a vacuum pump (22), a filter assembly (23) and a PLC controller (24). The fixed frame (21) is fixed at the upper end of the base (11). The vacuum pump (22) is fixed inside the fixed frame (21). The filter assembly (23) and PLC controller (24) are fixed inside the fixed frame (21). The control valve (16) is fixedly connected to the filter assembly (23) through an air pipe. The air inlet end of the vacuum pump (22) is fixedly connected to the filter assembly (23). The PLC controller (24) is signal connected to the vacuum pump (22) and the control valve (16). The drive motor (1) and the drive motor (2) are signal connected to the PLC controller (24).

2. The photovoltaic module defect identification device according to claim 1, characterized in that: The filter assembly (23) includes: a filter barrel (231), a top cover (232), an air inlet (233), a sealing ring (234), and a screen barrel (235). The filter barrel (231) is fixed inside the fixed frame (21). The filter barrel (231) has an opening. The top cover (232) is screwed and sealed to the top surface of the filter barrel (231). The bottom surface of the filter barrel (231) has an air inlet (233). The air inlet end of the air pump (22) is fixedly connected to the air inlet (233). The filter barrel (231) has a sealing ring (234) inside. The upper end of the sealing ring (234) is fixedly connected to the screen barrel (235). The sealing ring (234) slides and seals against the inner wall of the filter barrel (231). The control valve (16) is fixedly connected to the outer wall of the filter barrel (231) through an air pipe.

3. The photovoltaic module defect identification device according to claim 1, characterized in that: The scanning unit (3) includes a scanning component (31) and a paint tank (32). The scanning component (31) and the paint tank (32) are fixed on the bottom surface of the base (11). The scanning component (31) is symmetrically arranged with the paint tank (32) as the center, and the two paint tanks (32) are connected to each other.

4. The photovoltaic module defect identification device according to claim 3, characterized in that: Both scanning components (31) include: a multi-module acquisition scanning head (311), a spray pipe (312), a control box (313), a feed pump (314), and a second PLC controller (315). The multi-module acquisition scanning head (311) is fixed on the bottom surface of the base (11). The spray pipe (312) is fixed at the rear end of the multi-module acquisition scanning head (311). The control box (313) is fixed at the upper end of the spray pipe (312). The feed pump (314) is fixed inside the control box (313). The feed pump (314) is fixedly connected to the paint tank (32) at the inlet end and to the spray pipe (312) at the outlet end. The second PLC controller (315) is fixed inside the control box (313). The second PLC controller (315) is signal connected to the multi-module acquisition scanning head (311) and the feed pump (314).

5. The method of using the photovoltaic module defect identification device according to claim 4, characterized in that: The method includes the following steps: Step 1: Place the device on the photovoltaic panel, and control the air pump (22) to be powered on by the PLC controller (24) to generate negative pressure at the bottom of the base (11) and press the device onto the photovoltaic panel; Step 2: Control the Mecanum wheel (12) to move and inspect the photovoltaic panel using PLC controller 1 (24) and drive motor 1; Step 3: Control the rotation of the roller brush (14) through PLC controller 1 (24) and drive motor 2 to sweep up the dust on the photovoltaic panel; Step 4: Scan the photovoltaic panel for defects using a multi-module acquisition scanning head (311); Step 5: When a defect is detected, the feed pump (314) is started by controlling the PLC controller (315) to extract the paint from the paint tank (32) and spray it onto the photovoltaic panel for marking.

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