Precision welding detection equipment for photovoltaic module junction box

Abstract

The utility model discloses a pseudo soldering detection device for photovoltaic module junction box welding. The device comprises a casing which extends along the length direction of the photovoltaic module junction box welding pseudo soldering detection device; the three resistance measuring circuits are arranged in the shell; the six cylindrical protective shells are arranged in pairs, the three pairs of protective shells are arranged at the two ends of the machine shell in the length direction and in the middle of the machine shell respectively, the protective shells in the same pair are oppositely arranged in the width direction of the machine shell, the protective shells extend in the vertical direction, the upper portions of the protective shells are communicated with the machine shell, and the three pairs of protective shells are arranged in one-to-one correspondence with the three resistance measuring circuits; and the six probes are arranged in one-to-one correspondence with the six cylindrical protective shells, one part of each probe is arranged in the corresponding protective shell, the lower end of each probe extends downwards out of the corresponding protective shell, and the same pair of probes are connected to the corresponding resistance measuring circuits to serve as a pair of measuring pins of the corresponding resistance measuring circuits. The detection process is efficient and accurate, manpower is reduced, and missing detection is avoided.

Description

Technical Field

[0001] This utility model relates to a device for detecting poor welds in photovoltaic module junction boxes. Background Technology

[0002] With the transformation of the global energy structure and the continuous growth in demand for renewable energy, the solar photovoltaic industry has ushered in unprecedented development opportunities. As the core component of a solar power generation system, the quality of photovoltaic modules directly affects the stability and power generation efficiency of the entire system. Junction boxes, as an important part of photovoltaic modules, are particularly critical in terms of welding quality. The presence of poor welding not only reduces the electrical performance of the modules but may also cause safety hazards, such as localized overheating or even fire. According to a report by the International Energy Agency (IEA), approximately 20% of photovoltaic module failures are related to welding problems in junction boxes. Therefore, researching and developing an automatic detection device for poor welding in photovoltaic module junction boxes is of significant practical importance for improving the production quality of photovoltaic modules, ensuring the safe operation of photovoltaic systems, and promoting the healthy development of the photovoltaic industry. The application of automated detection technology can significantly improve detection efficiency and accuracy, reduce manual inspection costs, and simultaneously reduce energy losses and environmental impacts caused by poor welding, aligning with the concept of sustainable development.

[0003] Disadvantages of existing technology:

[0004] 1. Current technology requires two people to operate in order to complete the task.

[0005] 2. The existing manual inspection method for poor welds is a tensile sampling test, which uses tweezers to pick at the weld joint to see if it is firmly connected to determine whether it is a poor weld. There is a possibility of missing some.

[0006] 3. Different degrees of poor welding can lead to power loss of photovoltaic modules as high as 10% to 20%. Utility Model Content

[0007] This invention provides a photovoltaic module junction box welding cold solder joint detection device to save labor costs, improve the cold solder joint detection rate, and increase production efficiency.

[0008] The present invention achieves the above objectives through the following solutions.

[0009] This utility model provides a photovoltaic module junction box welding cold solder joint detection device, including:

[0010] The housing extends along the length of the photovoltaic module junction box welding defect detection equipment;

[0011] Three resistance measurement circuits are built into the housing;

[0012] Six cylindrical protective shells are arranged in pairs. Three pairs of protective shells are respectively set at both ends of the length direction of the housing and in the middle of the housing. The same pair of protective shells are arranged opposite each other along the width direction of the housing. The protective shells extend vertically and are connected to the housing at the top. The three pairs of protective shells are arranged in a one-to-one correspondence with the three resistance measurement circuits.

[0013] Six probes are provided, each corresponding to one of the six cylindrical protective shells. A portion of each probe is placed inside the corresponding protective shell, and the lower end of each probe extends downward out of the corresponding protective shell. The same pair of probes is connected to the corresponding resistance measurement circuit to serve as a pair of measurement pins for the corresponding resistance measurement circuit.

[0014] This invention does not limit the circuit structure of the resistance measurement circuit; any existing and known resistance measurement circuit can be used.

[0015] For example, a resistance measurement circuit provides a fixed output voltage, which is applied across the two ends of the component being measured (specifically, at the soldering points of the junction box, which are soldered to the positive and negative terminals of the photovoltaic module). The output current is detected, and the resistance value is obtained by dividing the output voltage by the output current.

[0016] Under normal circumstances, there is a certain resistance between the positive and negative terminals of a photovoltaic module, so the output current should be within a reasonable range.

[0017] In the case of a poor solder joint, the resistance between the two solder points of the junction box is close to infinite or approximately high resistance, and the output current is close to 0.

[0018] In some embodiments, the photovoltaic module junction box welding cold solder joint detection equipment further includes six connectors that correspond one-to-one with the probes. The lower end of the connector is connected to the upper end of the corresponding probe, and the upper end of the connector is connected to the corresponding resistance measurement circuit.

[0019] In some embodiments, the lower end of the protective shell is provided with an annular limiting structure, the central opening of the limiting structure serving as the lower opening of the protective shell, and the diameter of the central opening of the limiting structure being larger than the diameter of the probe and smaller than the lower diameter of the connector.

[0020] In some embodiments, six cylindrical protective shells are fixedly disposed relative to the housing.

[0021] In some embodiments, the photovoltaic module junction box welding failure detection equipment further includes a sliding member, which is disposed in the middle region of the housing and can move bidirectionally relative to the housing along the length of the housing. A pair of protective shells located in the middle of the housing are fixedly disposed relative to the sliding member.

[0022] In some embodiments, a slide rail is provided on the outer surface of the housing, and the slider slides within the slide rail.

[0023] In some embodiments, the photovoltaic module junction box welding defect detection equipment further includes a fixing bolt, a plurality of fixing holes are provided on the housing along its length, a fixing hole is provided on the sliding member, and the fixing bolt passes through the fixing hole on the sliding member and the fixing hole on the housing, thereby fixing the sliding member.

[0024] In some embodiments, the three resistance measuring circuits are fixedly disposed relative to the housing;

[0025] The current path between a pair of probes located at the middle of the length of the housing and the corresponding resistance measurement circuit includes flexible wires.

[0026] In some embodiments, the photovoltaic module junction box welding cold solder joint detection equipment also includes an alarm indication circuit connected to the three resistance measurement circuits.

[0027] The alarm circuit can alert on-site personnel to a poor solder joint in the photovoltaic module junction box.

[0028] In some implementations, the alarm circuit includes a buzzer.

[0029] If any resistance value detected by any resistance measurement circuit exceeds the set value, the buzzer will sound an alarm. This promptly alerts on-site personnel that there is a poor solder joint between the photovoltaic module and the junction box.

[0030] In some implementations, the alarm circuit includes an indicator light.

[0031] For example, by setting up three indicator lights, each corresponding to one of the three resistance measurement circuits, on-site personnel can determine which of the three junction boxes has a poor solder joint based on whether the indicator lights are on or off.

[0032] The beneficial effects of this utility model are as follows:

[0033] Placing a photovoltaic module junction box welding defect detection device on the photovoltaic module allows for simultaneous detection of the welding quality of three junction boxes on the photovoltaic module, improving detection efficiency and accuracy, reducing labor costs, and avoiding missed detections. Attached Figure Description

[0034] Figure 1 This is a structural schematic diagram of the photovoltaic module junction box welding defect detection equipment of this utility model.

[0035] Figure 2 This is a partial cross-sectional view of the photovoltaic module junction box welding defect detection equipment of this utility model.

[0036] Figure 3 This is a schematic diagram showing the connection relationship between the junction box and the photovoltaic module.

[0037] Figure 4 This is a structural diagram of the photovoltaic module junction box welding defect detection equipment in use.

[0038] Figure 5 This is a schematic diagram of the circuit connection of the photovoltaic module junction box welding cold solder joint detection equipment of this utility model.

[0039] The attached figures are labeled as follows:

[0040] 1. Housing;

[0041] 2. Sliding components;

[0042] 3. Protective casing;

[0043] 4. Probe;

[0044] 5. Lead wire;

[0045] 6. Junction box;

[0046] 7. Photovoltaic modules;

[0047] 8. Welding points;

[0048] 31. Connector;

[0049] 32. Limiting structure;

[0050] 9. Resistance measurement circuit;

[0051] 10. Control circuit;

[0052] 11. Indicator lights. Detailed Implementation

[0053] The present invention will be further described below with reference to specific embodiments, but the scope of protection of the present invention is not limited thereto.

[0054] Example 1

[0055] Figure 1 This is a structural schematic diagram of the photovoltaic module junction box welding defect detection equipment of this utility model. Figure 2 This is a partial cross-sectional view of the photovoltaic module junction box welding defect detection equipment of this utility model. Figure 3 This is a schematic diagram showing the connection relationship between the junction box and the photovoltaic module.

[0056] refer to Figures 1 to 3 This utility model provides a device for detecting poor solder joints in photovoltaic module junction boxes.

[0057] This utility model provides a photovoltaic module junction box welding cold solder joint detection device, including: a housing 1, three resistance measuring circuits 9, six cylindrical protective shells 3 and six probes 4.

[0058] The housing 1 extends along the length of the photovoltaic module junction box welding defect detection equipment.

[0059] In this embodiment, the housing 1 is a cuboid shape, with its length dimension being greater than its width dimension, and its width dimension being greater than its height dimension.

[0060] Three resistance measurement circuits 9 are built into the housing 1.

[0061] In this embodiment, three multimeters are used as three resistance measurement circuits. The three multimeters are placed inside the casing 1.

[0062] Six cylindrical protective shells 3 are arranged in pairs. The three pairs of protective shells 3 are respectively set at both ends of the length direction of the housing 1 and in the middle of the housing 1. The same pair of protective shells 3 are arranged opposite each other along the width direction of the housing 1. The protective shells 3 extend vertically and are connected to the housing 1 at the top. The three pairs of protective shells 3 are set in correspondence with the three resistance measuring circuits 9.

[0063] Six probes 4 are set one-to-one with six cylindrical protective shells 3. A part of the probe 4 is set inside the corresponding protective shell 3, and the lower end of the probe 4 extends downward out of the corresponding protective shell 3. The same pair of probes 4 is connected to the corresponding resistance measurement circuit 9 to serve as a pair of measurement pins of the corresponding resistance measurement circuit 9.

[0064] The six probes 4 use three multimeter measuring probes.

[0065] The photovoltaic module junction box welding defect detection equipment also includes six connectors 31 that correspond one-to-one with the probes 4. The lower end of the connector 31 is connected to the upper end of the corresponding probe 4, and the upper end of the connector 31 is connected to the corresponding resistance measurement circuit 9.

[0066] Connector 31 has a rigid conductor structure.

[0067] The lower end of the protective shell 3 is provided with an annular limiting structure 32. The central opening of the limiting structure 32 serves as the lower opening of the protective shell 3. The diameter of the central opening of the limiting structure 32 is larger than the diameter of the probe 4 and smaller than the lower diameter of the connector 31.

[0068] In some embodiments, the vertical position of connector 31 is adjustable (e.g., connector 31 is threaded to its upper structure), thereby making the vertical position of probe 4 adjustable. The limiting structure 32 defines the lowest downward position of connector 31, thereby preventing probe 4 from damaging the junction box 6 being tested.

[0069] The photovoltaic module junction box welding defect detection equipment also includes a sliding member 2. The sliding member 2 is located in the middle area of ​​the housing 1 and can move bidirectionally relative to the housing 1 along the length of the housing 1. A pair of protective shells 3 located in the middle of the housing 1 are fixed relative to the sliding member 2.

[0070] A slide rail is provided on the outer surface of the housing 1, and the sliding member 2 slides within the slide rail.

[0071] The sliding component 2 slides, causing a pair of probes 4 to slide, thus adapting to photovoltaic modules of different specifications.

[0072] That is, the position of the pair of probes 4 in the middle position is adjustable.

[0073] The photovoltaic module junction box welding defect detection equipment also includes a fixing bolt (not shown), a plurality of fixing holes (not shown) are provided on the housing 1 along its length direction, and a fixing hole (not shown) is provided on the sliding member 2. The fixing bolt passes through the fixing hole on the sliding member 2 and the fixing hole on the housing 1, thereby fixing the sliding member 2.

[0074] Three resistance measuring circuits 9 are fixedly mounted relative to the housing 1;

[0075] The current path between a pair of probes 4 located at the middle of the length of the housing 1 and the corresponding resistance measuring circuit 9 includes flexible wires.

[0076] Specifically, the upper end of connector 31 is connected to the corresponding multimeter via a wire.

[0077] The resistance readings of the three multimeters are visible to the user, allowing the user to directly observe the resistance values ​​between the three pairs of solder points 8.

[0078] Example 2

[0079] The difference from Embodiment 1 is that the resistance measurement circuit 9 is an independent resistance measurement circuit and is not integrated into the multimeter. The photovoltaic module junction box welding cold solder joint detection equipment also includes an alarm indication circuit connected to the three resistance measurement circuits 9.

[0080] The alarm circuit includes indicator light 11.

[0081] The alarm circuit also includes a control circuit 10.

[0082] The control circuit 10 is specifically a programmable logic controller (PLC).

[0083] The control circuit 10 detects the output current value of each resistance measuring circuit 9. When the current value of any resistance measuring circuit 9 is less than the set value, the corresponding indicator light 11 is illuminated. This alerts on-site personnel to identify which junction box has a poor solder joint.

[0084] The beneficial effects of this utility model are as follows:

[0085] Placing the photovoltaic module junction box welding defect detection equipment on the photovoltaic module 7 allows for simultaneous detection of the welding effect of the three junction boxes 6 on the photovoltaic module 7, improving detection efficiency and accuracy, reducing labor costs, and avoiding missed detections.

[0086] This utility model is not limited to the above-described embodiments. Any modifications, improvements, or substitutions that can be conceived by those skilled in the art without departing from the essential content of this utility model fall within the scope of this utility model.

Claims

1. A photovoltaic module junction box welding defect detection device, characterized in that, include: The housing extends along the length of the photovoltaic module junction box welding defect detection equipment; Three resistance measurement circuits are built into the housing; Six cylindrical protective shells are arranged in pairs. Three pairs of protective shells are respectively set at both ends of the length direction of the housing and in the middle of the housing. The same pair of protective shells are arranged opposite each other along the width direction of the housing. The protective shells extend vertically and are connected to the housing at the top. The three pairs of protective shells are arranged in a one-to-one correspondence with the three resistance measurement circuits. Six probes are provided, each corresponding to one of the six cylindrical protective shells. A portion of each probe is placed inside the corresponding protective shell, and the lower end of each probe extends downward out of the corresponding protective shell. The same pair of probes is connected to the corresponding resistance measurement circuit to serve as a pair of measurement pins for the corresponding resistance measurement circuit.

2. The photovoltaic module junction box welding defect detection equipment according to claim 1, characterized in that, It also includes six connectors that correspond one-to-one with the probes. The lower end of the connector is connected to the upper end of the corresponding probe, and the upper end of the connector is connected to the corresponding resistance measurement circuit.

3. The photovoltaic module junction box welding defect detection equipment according to claim 2, characterized in that, The lower end of the protective shell is provided with an annular limiting structure, and the central opening of the limiting structure serves as the lower opening of the protective shell. The diameter of the central opening of the limiting structure is larger than the diameter of the probe and smaller than the lower diameter of the connector.

4. The photovoltaic module junction box welding defect detection equipment according to claim 1, characterized in that, It also includes a slider, which is disposed in the middle region of the housing and can move bidirectionally relative to the housing along the length of the housing. A pair of protective shells located in the middle of the housing are fixedly disposed relative to the slider.

5. The photovoltaic module junction box welding defect detection equipment according to claim 4, characterized in that, A slide rail is provided on the outer surface of the housing, and the sliding member slides within the slide rail.

6. The photovoltaic module junction box welding defect detection equipment according to claim 4, characterized in that, It also includes a fixing bolt, and the housing has multiple fixing holes along its length. The sliding member has fixing holes, and the fixing bolt passes through the fixing holes on the sliding member and the fixing holes on the housing, thereby fixing the sliding member.

7. The photovoltaic module junction box welding defect detection equipment according to claim 4, characterized in that, The three resistance measurement circuits are fixedly arranged relative to the housing; The current path between a pair of probes located at the middle of the length of the housing and the corresponding resistance measurement circuit includes flexible wires.

8. The photovoltaic module junction box welding defect detection equipment according to claim 1, characterized in that, It also includes an alarm indication circuit connected to the three resistance measurement circuits.

9. The photovoltaic module junction box welding defect detection equipment according to claim 8, characterized in that, The alarm circuit includes a buzzer.

10. The photovoltaic module junction box welding defect detection equipment according to claim 8, characterized in that, The alarm circuit includes indicator lights.

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