Sampling inspection detection system for photovoltaic module
By designing a random inspection and testing system for photovoltaic modules, the problem of traditional online random inspection and testing requires suspension of production lines, and the quality random inspection of photovoltaic modules is realized without affecting the normal operation of the production line, improving detection efficiency and production efficiency.
Patent Information
- Application Number
- CN202421239191.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-31
- Publication Date
- 2025-03-18
- Estimated Expiration
- 2034-05-31
AI Technical Summary
Traditional online sampling inspections require the suspension of production lines, which affects the production rhythm and capacity efficiency of the production line.
A random inspection and detection system for photovoltaic modules is designed, which includes a constant temperature room, a buffer rack, multiple detection equipment and a transmission device, which can independently perform quality sampling of photovoltaic modules without affecting the normal operation of the production line.
By separating the sampling process from the production line, production activities and quality control are allowed to be carried out in parallel, production interruptions caused by inspection are avoided, inspection efficiency is improved, and customer needs are met.
Smart Images
Figure CN222638505U_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to the technical field of random inspection and testing of photovoltaic modules, and in particular to a random inspection and testing system for photovoltaic modules. Background Art
[0002] Photovoltaic modules, also commonly known as solar panels or solar modules, are devices that use the photovoltaic effect to convert sunlight directly into electrical energy. Strict quality control is required during the manufacturing process of photovoltaic modules. In order to ensure its performance and reliability, each factory will arrange internal random inspections and cooperate with customers for random inspections. The random inspections include but are not limited to module power testing, insulation grounding verification, electroluminescence (EL) defect detection, wet leakage evaluation, and appearance performance inspection.
[0003] At present, the quality inspection of photovoltaic modules adopts the traditional online inspection method, that is, online inspection is carried out after the production line is suspended.
[0004] However, this online sampling method has limitations. Each sampling inspection requires the production line to be stopped, which affects the production rhythm and production efficiency of the production line. Utility Model Content
[0005] A technical problem to be solved by the present disclosure is that traditional online random inspections require the production line to be suspended, affecting the production rhythm and production efficiency of the production line.
[0006] To solve the above technical problems, the embodiments of the present invention provide a random inspection system for photovoltaic modules, comprising: a constant temperature room; a buffer rack for placing photovoltaic modules to be inspected; multiple inspection equipment, including: a 360° flip inspection table for performing appearance inspection on the front and back of photovoltaic modules; a power test darkroom with a built-in power tester for performing power testing on photovoltaic modules; an insulation and voltage withstand tester for testing the insulation and voltage withstand performance of photovoltaic modules; an EL tester for detecting internal defects of photovoltaic modules; a wet leakage test pool with a built-in wet leakage tester for testing the moisture resistance and leakage performance of photovoltaic modules; and a conveying device connected to the buffer rack and various inspection equipment for conveying photovoltaic modules; wherein the buffer rack, the inspection equipment and the conveying device are located in the constant temperature room.
[0007] In some embodiments, the cache rack is connected to a heating component, a cooling component and a temperature sensor; wherein the heating component and the cooling component are used together to adjust the temperature of the photovoltaic component placed on the cache rack, and the temperature sensor is used to monitor the temperature of the photovoltaic component.
[0008] In some embodiments, the random inspection system further includes: a plurality of trays connected to each inspection device via a conveying device for placing unqualified photovoltaic modules.
[0009] In some embodiments, the random inspection system also includes: a control device, which is respectively connected to the cache rack, the conveying device and each inspection device, wherein the control device is used to, when receiving an OK signal output by the cache rack, control the conveying device to convey the photovoltaic components adjusted to a preset temperature from the cache rack to each inspection device in sequence; when receiving an OK signal output by the current inspection device, control the conveying device to convey the qualified photovoltaic components from the current inspection device to the next inspection device until the inspection is completed.
[0010] In some embodiments, the control device is further used to control the conveying device to convey unqualified photovoltaic components from the current testing device to the corresponding tray when receiving an NG signal output by any testing device.
[0011] In some embodiments, the sampling inspection system also includes: an air drying box, a cleaning box, and a packaging table, which are connected to the conveying device in sequence, wherein the air drying box is used to air dry qualified photovoltaic modules; the cleaning box is used to clean the qualified photovoltaic modules after air drying; and the packaging table is used to package the qualified photovoltaic modules after cleaning.
[0012] In some embodiments, the constant temperature room is equipped with a temperature control device and a light adjustment device; wherein the temperature control device is used to control the ambient temperature inside the constant temperature room to 23±2°C, and the light adjustment device is used to control the light intensity inside the constant temperature room to 1000Lux.
[0013] In some embodiments, the constant temperature chamber is also equipped with an air filtering device for maintaining a dust-free environment inside the constant temperature chamber.
[0014] In some embodiments, the conveying device includes at least one of the following conveying components: a conveyor belt, a robotic arm, and a sensor.
[0015] In some embodiments, the cache rack is a three-section cache rack, wherein each section of the cache rack has a storage capacity of 20-60 photovoltaic modules.
[0016] Through the above technical solution, the sampling inspection system provided by the present disclosure can independently perform quality sampling inspections on photovoltaic modules without affecting the normal operation of the production line. By separating the sampling inspection process from the production line, the system allows production activities and quality control to be carried out in parallel, thereby avoiding production interruptions caused by inspections, improving inspection efficiency, and meeting customer needs. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In order to more clearly illustrate the embodiments of the present disclosure or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present disclosure. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.
[0018] Figure 1 It is a structural schematic diagram of a random inspection and detection system for photovoltaic modules disclosed in an embodiment of the present disclosure.
[0019] Description of reference numerals:
[0020] 1. Constant temperature room; 2. Cache rack; 3. 360° flip test table; 4. Power test darkroom; 5. Insulation withstand voltage tester; 6. EL tester; 7. Wet leakage test pool; 8. Conveyor device; 9. Pallet. DETAILED DESCRIPTION
[0021] The following is a further detailed description of the embodiments of the present disclosure in conjunction with the accompanying drawings and examples. The detailed description of the following embodiments and the accompanying drawings are used to exemplarily illustrate the principles of the present disclosure, but cannot be used to limit the scope of the present disclosure. The present disclosure can be implemented in many different forms and is not limited to the specific embodiments disclosed herein, but includes all technical solutions that fall within the scope of the claims.
[0022] The present disclosure provides these embodiments to make the present disclosure thorough and complete, and to fully express the scope of the present disclosure to those skilled in the art. It should be noted that unless otherwise specifically stated, the relative arrangement of the parts and steps, the composition of the materials, the numerical expressions and the numerical values set forth in these embodiments should be interpreted as being merely exemplary, and not as limiting.
[0023] It should be noted that, in the description of the present disclosure, unless otherwise specified, the meaning of "multiple" is greater than or equal to two; the terms "upper", "lower", "left", "right", "inner", "outer", etc., indicating the orientation or positional relationship, are only for the convenience of describing the present disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present disclosure. When the absolute position of the object being described changes, the relative positional relationship may also change accordingly.
[0024] In addition, the words "first", "second" and similar words used in the present disclosure do not indicate any order, quantity or importance, but are only used to distinguish different parts. "Vertical" does not mean vertical in the strict sense, but is within the tolerance range. "Parallel" does not mean parallel in the strict sense, but is within the tolerance range. "Include" or "comprising" and similar words mean that the elements before the word include the elements listed after the word, and do not exclude the possibility of including other elements.
[0025] It should also be noted that in the description of the present disclosure, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected or indirectly connected through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present disclosure can be understood according to the specific circumstances. When a specific device is described as being located between a first device and a second device, there may or may not be an intermediate device between the specific device and the first device or the second device.
[0026] All terms used in the present disclosure have the same meanings as those understood by those of ordinary skill in the art to which the present disclosure belongs, unless otherwise specifically defined. It should also be understood that terms defined in general dictionaries, for example, should be interpreted as having meanings consistent with their meanings in the context of the relevant technology, and should not be interpreted in an idealized or extremely formal sense, unless explicitly defined as such herein.
[0027] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.
[0028] After a batch of PV modules is produced, customers may request random inspections of the PV modules that have been packaged in the warehouse to ensure the quality of the batch of PV modules. At this time, the PV modules specified by the customer need to be unpacked and undergo a series of strict standardized testing processes to ensure that they meet the expected quality standards in terms of performance, safety and durability to meet customer needs.
[0029] The traditional online sampling method is: the inspectors first unpack the PV modules to be inspected and move them to a 360° flip table to perform an appearance inspection on the PV modules under a solar simulator. Secondly, the PV modules are placed in the production line (the current production line needs to be stopped) for power testing, insulation withstand voltage testing, and EL testing. Finally, the PV modules are evaluated for wet leakage in the laboratory.
[0030] This online sampling method has the following disadvantages: 1. Production interruption: The production line needs to be stopped every time a sampling inspection is performed, which will cause production interruptions and affect production rhythm and continuity. 2. Inefficiency: Since photovoltaic modules need to be manually transported to different inspection locations, the inspection process is time-consuming and inefficient. 3. Increased costs: Production suspension will result in loss of production capacity, increase production costs, and require additional human resources to perform sampling tasks. 4. Insufficient environmental control: Inspections performed in the production line may not provide stable and consistent environmental conditions, such as temperature and light intensity, which may affect the accuracy of the test results.
[0031] Based on this, the present disclosure proposes a random inspection system for photovoltaic modules, which aims to improve the efficiency of photovoltaic module inspection through an integrated and automated random inspection system, while reducing the impact on the production process, and ultimately achieve the purpose of improving production efficiency and reducing costs.
[0032] Figure 1 Schematic diagram of the structure of the sampling inspection system for photovoltaic modules disclosed in the embodiment of the present disclosure. Figure 1 As shown, the sampling inspection system includes: a constant temperature room 1, a buffer rack 2, a 360° flip test table 3, a power test darkroom 4, an insulation withstand voltage tester 5, an EL tester 6, a wet leakage test pool 7 and a conveying device 8. Among them, the constant temperature room 1 is used to provide a stable inspection environment. The buffer rack 2 is used to place the photovoltaic modules to be inspected. The 360° flip test table 3 is used to perform an appearance inspection on the front and back of the photovoltaic modules. The power test darkroom 4 has a built-in power tester for power testing of photovoltaic modules. The insulation withstand voltage tester 5 is used to test the insulation performance of photovoltaic modules. The EL tester 6 is used to detect internal defects of photovoltaic modules. The wet leakage test pool 7 has a built-in wet leakage tester for testing the moisture resistance and leakage performance of photovoltaic modules. The conveying device 8 is connected to the buffer rack 2 and various detection equipment for conveying photovoltaic modules. The buffer rack 2, various detection equipment and the conveying device 8 are all arranged in the constant temperature room 1.
[0033] In some embodiments, the sampling inspection system further includes: a plurality of trays 9, which are connected to each inspection device through a conveyor 8 and are used to place unqualified photovoltaic modules. Unqualified photovoltaic modules can be automatically diverted from the conveyor to the trays 9, avoiding errors and delays that may be caused by manual separation. At the same time, unqualified photovoltaic modules are removed to the corresponding trays 9, which is equivalent to classifying the unqualified modules for further analysis.
[0034] In the embodiments of the present disclosure, the detection equipment can be flexibly increased or decreased or the detection sequence can be changed according to actual detection requirements to meet the detection requirements of photovoltaic modules of different types or specifications.
[0035] The system can independently perform quality inspections on photovoltaic modules without affecting the normal operation of the production line. By separating the inspection process from the production line, the system allows production activities and quality control to proceed in parallel, thus avoiding production interruptions caused by inspections.
[0036] In some embodiments, the constant temperature room 1 is equipped with a temperature control device and a light adjustment device, wherein the temperature control device is used to control the ambient temperature inside the constant temperature room 1 at 23±2°C, and the light adjustment device is used to control the light intensity inside the constant temperature room 1 at 1000 Lux.
[0037] It should be noted that the temperature range of 23±2℃ complies with the standard test conditions (STC) specified by the International Electrotechnical Commission (IEC), which can ensure the accuracy of the test results. The light intensity of 1000Lux is a commonly used light level in laboratory tests to simulate natural light conditions, which helps ensure that the photovoltaic performance evaluation of photovoltaic modules is carried out under standardized light.
[0038] By setting up a constant temperature room and constant temperature and lighting conditions, the impact of environmental variables on test results can be reduced, and photovoltaic modules can be protected from potential thermal damage or light attenuation due to excessively high ambient temperature or excessive light, thereby improving the performance and reliability of the entire detection system.
[0039] In some embodiments, the constant temperature chamber 1 is also equipped with an air filter device to maintain a dust-free environment inside the constant temperature chamber. On the one hand, a dust-free environment helps to improve the detection accuracy, while avoiding physical damage or scratches to the photovoltaic modules during the detection process, and keeping the modules in good condition. On the other hand, dust and pollutants may damage the detection equipment, and a dust-free environment helps to extend the maintenance cycle and service life of the equipment.
[0040] In some embodiments, the cache rack 2 is a three-section cache rack, wherein each section of the cache rack has a storage capacity of 20-60 photovoltaic modules, for example, each section of the cache rack can store 40 photovoltaic modules. The three-section design provides more storage space, allowing more photovoltaic modules to be cached at the same time, thereby improving the storage efficiency of the cache rack.
[0041] In some embodiments, the cache rack 2 may be connected to a heating assembly, a cooling assembly and a temperature sensor, wherein the heating assembly and the cooling assembly are used together to adjust the temperature of the photovoltaic assembly placed on the cache rack 2, and the temperature sensor is used to monitor the temperature of the photovoltaic assembly.
[0042] By setting heating components, cooling components and temperature sensors on the cache rack, the temperature of the photovoltaic components to be tested can be adjusted so that the photovoltaic components on the cache rack can quickly reach the standard test temperature and output an OK signal when the temperature of the photovoltaic components is at 23±2℃, thereby improving test accuracy, reducing waiting time and improving overall detection efficiency.
[0043] In some embodiments, the conveyor 8 may include at least one of the following conveyor components: a conveyor belt, a robotic arm, and a sensor. The size of the conveyor 8 meets the conventional format (2.5 meters * 1.3 meters), and can be used for separate segmented testing to meet the needs of different customers, and can also be used as a conventional laboratory test project.
[0044] The setting of the conveyor allows the PV modules to automatically move from one testing device to another during the testing process without manual intervention, thereby improving the level of automation of the testing. Through the connection of the conveyor, the various testing devices can work together seamlessly, ensuring that the PV modules can smoothly enter the next testing stage after completing one testing stage.
[0045] In some embodiments, the sampling inspection system further includes: a control device, which is respectively connected to the cache rack 2, the conveying device 8 and each inspection device. The control device is used to control the conveying device 8 to sequentially convey the photovoltaic components adjusted to the preset temperature from the cache rack 2 to each inspection device when receiving the OK signal output by the cache rack 2; and control the conveying device 8 to convey the qualified photovoltaic components from the current inspection device to the next inspection device when receiving the OK signal output by the current inspection device until the inspection is completed.
[0046] Specifically, when an OK signal is received from the cache rack, it indicates that the photovoltaic module has reached the preset temperature, and the photovoltaic module is then transferred to the 360° flip inspection station. When an OK signal is received from the 360° flip inspection station, it indicates that the appearance inspection of the photovoltaic module is qualified, and the qualified photovoltaic module is then transferred to the power test darkroom. When an OK signal is received from the power tester built into the power test darkroom, it indicates that the power output of the photovoltaic module is qualified, and the qualified photovoltaic module is then transferred to the insulation withstand voltage tester. When an OK signal is received from the insulation withstand voltage tester, it indicates that the insulation performance and withstand voltage performance of the photovoltaic module are qualified, and the qualified photovoltaic module is then transferred to the EL tester. When an OK signal is received from the EL tester, it indicates that there are no obvious internal defects in the photovoltaic module, and the qualified photovoltaic module is then transferred to the wet leakage test pool. When an OK signal is received from the wet leakage tester built into the wet leakage test pool, it indicates that the moisture resistance and leakage performance of the photovoltaic module are qualified. At this point, the inspection is completed and the qualified photovoltaic modules can be transported to the final packaging area for air drying, cleaning, packaging and storage.
[0047] In some embodiments, the control device is further used to control the conveying device 8 to convey unqualified photovoltaic components from the current testing device to the corresponding tray 9 when receiving an NG signal output by any testing device.
[0048] Specifically, when an NG signal is received from a 360° flip inspection table, a power test darkroom, an insulation withstand voltage tester, an EL tester, or a wet leakage test pool, indicating that the photovoltaic module is unqualified, the unqualified photovoltaic module will be diverted to the corresponding tray.
[0049] In some embodiments, the sampling inspection system further includes: an air drying box, a cleaning box, and a packaging station, which are sequentially connected to the conveying device 8, wherein the air drying box is used to air dry qualified photovoltaic modules; the cleaning box is used to clean qualified photovoltaic modules after air drying; and the packaging station is used to pack qualified photovoltaic modules after cleaning. The air drying and cleaning processes help ensure that the photovoltaic modules meet the required cleaning and drying standards before packaging, avoiding performance degradation due to contamination or moisture. The final packaging prepares for the sale and market distribution of photovoltaic modules, ensuring that the modules are delivered to customers in the best condition.
[0050] For ease of understanding, the overall sampling process of the above-mentioned sampling inspection system is specifically described below.
[0051] For example, the inspectors unpack the photovoltaic modules specified by the customer for random inspection and transfer them to the constant temperature room cache rack through the conveyor. Each cache rack can hold 40 photovoltaic modules for constant temperature adjustment. When the state adjustment of the sampled photovoltaic modules reaches 23±2℃, they are transferred to the 360° flip inspection table through the conveyor for front and back inspection and size inspection. Those that pass the inspection are transferred to the power test darkroom, and those that fail are diverted to the pallet. Photovoltaic modules that pass the appearance inspection are tested for power in the power test darkroom, and those that pass are transferred to the insulation withstand voltage tester, and those that fail are diverted to the pallet. Photovoltaic modules that pass the power test are tested for insulation performance by the insulation withstand voltage tester, and those that pass are transferred to the EL tester, and those that fail are diverted to the pallet. Photovoltaic modules that pass the insulation withstand voltage test are tested for electrical performance by the EL tester, and those that pass are transferred to the wet leakage tester, and those that fail are diverted to the pallet. The photovoltaic modules that have passed the wet leakage performance test are transferred to the air drying box to dry the water stains, and then transferred to the cleaning box for cleaning, and then transferred to the packaging station for packaging, and finally put into storage. At this point, the random inspection is completed.
[0052] The sampling inspection system of the embodiment of the present disclosure has the following beneficial effects:
[0053] 1. Automation: Through automated conveying devices and testing equipment, human intervention can be reduced and the speed and efficiency of testing can be improved.
[0054] 2. Environmental control: Carry out testing in a constant temperature room to ensure stable environmental conditions and improve the consistency and accuracy of test results.
[0055] 3. Production continuity: Offline sampling does not affect the normal operation of the production line, avoids production interruptions, and ensures production capacity efficiency.
[0056] 4. Comprehensive testing: Integrates multiple testing equipment to conduct comprehensive quality testing on photovoltaic modules, including appearance, power, insulation, internal defects and moisture resistance.
[0057] 5. Data management: The automated system facilitates the recording and analysis of test data, which helps with quality control and subsequent improvements.
[0058] So far, various embodiments of the present disclosure have been described in detail. In order to avoid obscuring the concept of the present disclosure, some details known in the art are not described. Based on the above description, those skilled in the art can fully understand how to implement the technical solution disclosed here.
[0059] Although some specific embodiments of the present disclosure have been described in detail by way of examples, it should be understood by those skilled in the art that the above examples are for illustration only and are not intended to limit the scope of the present disclosure. It should be understood by those skilled in the art that the above embodiments may be modified or some technical features may be replaced by equivalents without departing from the scope and spirit of the present disclosure. In particular, the various technical features mentioned in the various embodiments may be combined in any manner as long as there is no structural conflict.
Claims
1. A sampling inspection system for photovoltaic modules, characterized in that: include: Constant temperature room (1); A buffer rack (2) for placing photovoltaic modules to be inspected; Multiple testing equipment, including: A 360° flip inspection table (3) for inspecting the appearance of the photovoltaic module on both sides; A power test darkroom (4), with a built-in power tester for performing power testing on the photovoltaic module; An insulation and withstand voltage tester (5), used to test the insulation performance and withstand voltage performance of the photovoltaic module; An EL tester (6) for detecting internal defects of the photovoltaic module; A wet leakage test pool (7) having a built-in wet leakage tester for testing the moisture resistance and leakage performance of the photovoltaic module; and A conveying device (8), connected to the cache rack (2) and each detection device, and used for conveying the photovoltaic module; Wherein, the cache rack (2), the detection equipment and the conveying device (8) are located in the constant temperature room (1).
2. The sampling inspection system according to claim 1, characterized in that: The cache rack (2) is connected to a heating component, a cooling component and a temperature sensor; wherein the heating component and the cooling component are used together to adjust the temperature of the photovoltaic component placed on the cache rack (2), and the temperature sensor is used to monitor the temperature of the photovoltaic component.
3. The sampling inspection system according to claim 2, characterized in that: The sampling inspection system further comprises: a plurality of trays (9) connected to various inspection devices via the conveying device (8) and used for placing unqualified photovoltaic modules.
4. The sampling inspection system according to claim 3, characterized in that: The sampling inspection system further comprises: a control device, which is respectively connected to the buffer rack (2), the conveying device (8) and each inspection device, wherein the control device is used to: Upon receiving an OK signal output by the cache rack (2), controlling the conveying device (8) to sequentially convey the photovoltaic components adjusted to a preset temperature from the cache rack (2) to various detection devices; When an OK signal output by the current testing device is received, the conveying device (8) is controlled to convey the qualified photovoltaic components from the current testing device to the next testing device until the testing is completed.
5. The sampling inspection system according to claim 4, characterized in that: The control device is also used to control the conveying device (8) to convey unqualified photovoltaic components from the current testing device to the corresponding tray (9) when receiving an NG signal output by any testing device.
6. The sampling inspection system according to claim 4, characterized in that: The sampling inspection system further comprises: an air drying box, a cleaning box, and a packaging table, which are sequentially connected to the conveying device (8), wherein: The air drying box is used to air dry qualified photovoltaic modules; The cleaning box is used to clean the qualified photovoltaic modules after air drying; The packaging station is used to package the cleaned qualified photovoltaic modules.
7. The sampling inspection system according to claim 1, characterized in that: The constant temperature room (1) is equipped with a temperature control device and a light adjustment device; wherein the temperature control device is used to control the ambient temperature inside the constant temperature room (1) to 23±2°C, and the light adjustment device is used to control the light intensity inside the constant temperature room (1) to 1000Lux.
8. The sampling inspection system according to claim 7, characterized in that: The constant temperature chamber (1) is also equipped with an air filtering device for maintaining a dust-free environment inside the constant temperature chamber (1).
9. The sampling inspection system according to claim 1, characterized in that: The conveying device (8) comprises at least one of the following conveying components: a conveyor belt, a robotic arm, and a sensor.
10. The sampling inspection system according to claim 1, characterized in that: The cache rack (2) is a three-section cache rack, wherein each section of the cache rack has a storage capacity of 20-60 photovoltaic modules.