Photovoltaic module output power test-oriented control system and photovoltaic module system
By controlling the on/off state of the power output terminal and the external output terminal of the photovoltaic module, the problem of balancing output power and safety during the testing process of the photovoltaic module is solved, realizing normal output during the testing process and safe open circuit during transportation and installation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-01
- Publication Date
- 2026-03-10
AI Technical Summary
Existing photovoltaic modules need to output normal power during factory testing, but they also need to be kept in a safe open-circuit state during transportation and installation, which existing devices cannot achieve simultaneously.
Design a control system, including a rapid shutdown device and a control unit, to control the on/off state of the photovoltaic module's power output terminal and external output terminal by reserving test points and bypass fixtures or electronic switches, so as to achieve normal output of the photovoltaic module during the test and open circuit safety during non-test periods.
The photovoltaic modules were able to output power normally during factory testing, ensuring the smooth progress of the tests. At the same time, they maintained a safe open circuit during transportation and installation to ensure the safety of the modules.
Smart Images
Figure CN223987077U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of photovoltaic technology, and in particular to a control system and a photovoltaic module system for testing the output power of photovoltaic modules. Background Technology
[0002] In integrated photovoltaic (PV) modules, the power output terminal is typically connected to an RSD (Rapid-Shut-Down) device to ensure the safety of the PV module during transportation and installation. The RSD device is usually kept disconnected, keeping the PV module in an open-circuit state and preventing it from outputting electrical energy.
[0003] However, photovoltaic modules need to undergo various tests during factory production and processing, mainly including power output tests, EL (Electroluminescence) tests, and insulation tests. At this time, the photovoltaic modules need to be able to output power normally within a specific time.
[0004] Therefore, in order to address the need for integrated photovoltaic modules to output normal power during testing, there is an urgent need to propose a device that can both enable photovoltaic modules to output normal power after being powered on during factory testing and maintain an open-circuit safety state during transportation and installation. Utility Model Content
[0005] In view of this, the present application provides a control system and a photovoltaic module system for testing the output power of photovoltaic modules in order to solve at least one problem existing in the background art.
[0006] In a first aspect, embodiments of this application provide a control system for testing the output power of photovoltaic modules, the control system comprising:
[0007] A fast shutdown device is connected between the power output terminal and the external output terminal of the photovoltaic module; wherein the power output terminal of the photovoltaic module is connected to the photovoltaic module, and the external output terminal is connected to the power-consuming terminal equipment; and
[0008] A control device is used to control the connection between the power output terminal and the external output terminal of the photovoltaic module, so as to control the conduction of the connection between the power output terminal and the external output terminal of the photovoltaic module during photovoltaic module testing.
[0009] In conjunction with the first aspect, in an alternative implementation,
[0010] A first reserved test point is provided on the connecting wire between the power output terminal of the photovoltaic module and the fast shutdown device; a second reserved test point is provided on the connecting wire between the external output terminal and the fast shutdown device.
[0011] The control device includes a bypass fixture for bridging the first reserved test point and the second reserved test point during photovoltaic module testing, so that the photovoltaic module can open its external output through the first reserved test point and the second reserved test point.
[0012] In conjunction with the first aspect, in an optional embodiment, the bypass fixture includes an anti-backflow device connected to a second reserved test point.
[0013] In conjunction with the first aspect, in an alternative embodiment, the anti-backflow device includes at least one of the following: a transistor, a relay, and a fuse.
[0014] In conjunction with the first aspect, in an alternative implementation,
[0015] The fast shutdown device includes an RSD main controller and an electronic switch; the RSD main controller and the electronic switch are connected in series between the power output terminal of the photovoltaic module and the external output terminal; the electronic switch is used to switch on and off under the control of the RSD main controller.
[0016] The control device includes a jumper device for attaching to both ends of the electronic switch during photovoltaic module testing, so that the photovoltaic module can be turned on to output external power through the jumper device.
[0017] In conjunction with the first aspect, in an optional embodiment, the jumper device includes at least one of the following: straight type, elbow type, plug type, hinge type, and sleeve type.
[0018] In conjunction with the first aspect, in an alternative embodiment, the electronic switch includes at least one of the following: a relay, a DC contactor, and a high-voltage MOSFET.
[0019] In conjunction with the first aspect, in an alternative implementation,
[0020] The fast shutdown device includes an RSD main controller and an electronic switch; the RSD main controller and the electronic switch are connected in series between the power output terminal of the photovoltaic module and the external output terminal; the electronic switch is used to switch on and off under the control of the RSD main controller.
[0021] The control device is the RSD master controller in the fast shutdown device, used to control the electronic switch to be in the on state by default during photovoltaic module testing, so that the photovoltaic module can open its external output through the fast shutdown device; and to control the electronic switch to be in the off state by default during non-testing of the photovoltaic module, so that the photovoltaic module can close its external output.
[0022] Secondly, embodiments of this application provide a photovoltaic module system, characterized in that the photovoltaic module system includes a photovoltaic module and a control system for testing the output power of the photovoltaic module as described in the first aspect, connected to the photovoltaic module.
[0023] The beneficial effects of the technical solution provided in this application include: the control device can control the connection between the power output terminal and the external output terminal of the photovoltaic module, so that the photovoltaic module can output power normally after being powered on during factory testing, and can be in an open circuit safety state during transportation and installation. This ensures that the various tests of the photovoltaic module in the factory are carried out smoothly, and at the same time ensures the safety of the module during transportation and installation.
[0024] Additional aspects and advantages of the embodiments of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the embodiments of this application. Attached Figure Description
[0025] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, are provided. The drawings are not necessarily drawn to scale, and local features may be enlarged or reduced to more clearly show details of those features. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings:
[0026] Figure 1 A schematic block diagram of a control system for testing the output power of photovoltaic modules, consistent with at least one embodiment of this application;
[0027] Figure 2 This is a schematic block diagram of Example 1 of the control system for testing the output power of photovoltaic modules in this application.
[0028] Figure 3 This is a schematic block diagram of Example 2 of the control system for testing the output power of photovoltaic modules in this application.
[0029] Figure 4 This is a schematic block diagram of Example 3 of the control system for testing the output power of photovoltaic modules in this application. Detailed Implementation
[0030] To make the technical solution and beneficial effects of this application more apparent and understandable, a detailed description is provided below by listing specific embodiments. The accompanying drawings are not necessarily drawn to scale, and local features may be enlarged or reduced to more clearly show the details of the local features; unless otherwise defined, the technical and scientific terms used herein have the same meanings as those in the technical field to which this application pertains.
[0031] The embodiments described in this application are not exhaustive, but merely illustrative of some embodiments, and are not intended to limit the scope of protection of this application. Unless otherwise specified, each step in a particular embodiment can be implemented as an independent embodiment, and the steps can be arbitrarily combined. For example, a solution after removing some steps in a particular embodiment can also be implemented as an independent embodiment, and the order of the steps in a particular embodiment can be arbitrarily interchanged. Furthermore, the optional implementation methods in a particular embodiment can be arbitrarily combined; moreover, the embodiments can be arbitrarily combined with each other. For example, some or all steps of different embodiments can be arbitrarily combined, and a particular embodiment can be arbitrarily combined with the optional implementation methods of other embodiments.
[0032] In each embodiment of this application, unless otherwise specified or in case of logical conflict, the terminology and / or descriptions of the embodiments are consistent and can be referenced by each other. Technical features in different embodiments can be combined to form new embodiments based on their inherent logical relationships.
[0033] The terminology used in the embodiments of this application is for the purpose of describing specific embodiments only and is not intended to limit the scope of this application.
[0034] In some embodiments, unless otherwise stated, elements expressed in the singular form, such as “a,” “an,” “the,” “the,” “the,” “the,” “the,” “the,” “this,” etc., can mean “one and only one,” or “one or more,” “at least one,” etc. For example, when using articles such as “a,” “an,” “the,” etc. in translation, the noun following the article can be understood as either a singular or a plural expression.
[0035] In some embodiments, the terms “at least one of,” “one or more,” “a plurality of,” and “multiple” may be used interchangeably. “Multiple” means at least two, such as two or three; “several” means at least one, such as one, two, or three, unless otherwise explicitly specified.
[0036] In some embodiments, prefixes such as "first," "second," etc., are merely used to distinguish different descriptive objects and do not impose restrictions on the position, order, priority, value, or content of the descriptive objects. The description of the descriptive objects should be based on the context of the embodiments, and the use of prefixes should not create unnecessary restrictions. For example, the numerical value of a descriptive object is not limited by ordinal numbers and can be one or more. For instance, in "first device," the numerical value of "device" can be one or more. Furthermore, objects modified by different prefixes can be the same or different. For example, if the descriptive object is "device," then "first device" and "second device" can be the same device or different devices, and their types can be the same or different.
[0037] In some embodiments, unless otherwise expressly defined, the terms "installation," "connection," "linking," "fixing," "setting," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can also refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.
[0038] This application provides a control system for testing the output power of photovoltaic modules. Figure 1 A schematic block diagram of a control system for testing the output power of photovoltaic modules, consistent with at least one embodiment of this application, is shown. As shown, the control system includes:
[0039] A fast shutdown device (or RSD device) 1 is connected between the photovoltaic module's power output terminal 2 and its external output terminal 3; wherein, the photovoltaic module's power output terminal 2 is connected to the photovoltaic module, and the external output terminal 3 is connected to the power-consuming terminal equipment; and
[0040] The control device 4 is used to control the connection between the power output terminal 2 of the photovoltaic module and the external output terminal 3, so as to control the conduction of the connection between the power output terminal 2 of the photovoltaic module and the external output terminal 3 during the photovoltaic module test.
[0041] In this embodiment, the RSD device is kept disconnected by default, so that the photovoltaic module is in an open circuit state and does not output electrical energy, thereby ensuring the safety of the photovoltaic module during transportation and installation.
[0042] In some examples, under the action of control device 4, on the one hand, during photovoltaic module testing, such as during various tests including power output testing, EL testing, and insulation testing in the factory production process, the connection between the photovoltaic module power output terminal 2 and the external output terminal 3 is made conductive, and the photovoltaic module can output power normally by default; on the other hand, during non-testing periods of the photovoltaic module, such as during the transportation and installation of the photovoltaic module, the connection between the photovoltaic module power output terminal 2 and the external output terminal 3 is disconnected, thereby enabling the output of the photovoltaic module to be in a closed circuit state.
[0043] Thus, the embodiments of this application, through the control device, can control the connection between the power output terminal and the external output terminal of the photovoltaic module, thereby ensuring that the photovoltaic module can output power normally after being powered on during factory testing, and can also be in an open-circuit safe state during transportation and installation. This ensures that the various tests of the photovoltaic module are carried out smoothly in the factory, while also ensuring the safety of the module during transportation and installation.
[0044] In some examples, the specific method by which the control device 4 controls the connection between the photovoltaic module power output terminal 2 and the external output terminal 3 may include at least one of the following: using a controllable switch to open or close the connection; using a wire directly connected between the photovoltaic module power output terminal 2 and the external output terminal 3, or disconnecting the wire, to open or close the circuit, etc.
[0045] Figure 2 The figure shows a schematic block diagram of an example 1 of the control system for testing the output power of photovoltaic modules in this application. As shown in the figure, in an optional embodiment, a first reserved test point 21 is provided on the connecting wire between the photovoltaic module power output terminal 2 and the fast shutdown device 1; a second reserved test point 31 is provided on the connecting wire between the external output terminal 3 and the fast shutdown device 1.
[0046] The control device 4 includes a bypass fixture 5, which is used to bridge the first reserved test point 21 and the second reserved test point 31 during photovoltaic module testing, so that the photovoltaic module can open its external output through the first reserved test point 21 and the second reserved test point 31.
[0047] Thus, by reserving specific test points (i.e., the first reserved test point 21 and the second reserved test point 31) at both ends of the RSD device 1, and in conjunction with the external bypass fixture 5, the photovoltaic module can be turned on to output power normally through the test points during the factory testing process, so that the test can be carried out smoothly.
[0048] In this embodiment of the application, the bypass fixture 5 can make the first reserved test point 21 and the second reserved test point 31 electrically connected, so that power can be output to the outside in sequence through the first reserved test point 21, the bypass fixture 5 and the second reserved test point 31.
[0049] In an optional embodiment, the bypass fixture 5 includes an anti-backflow device connected to the second reserved test point 31.
[0050] In some examples, the anti-reverse current device includes at least one of the following: a transistor, a relay, or a fuse, to ensure the safety of the testing process. The transistor may include an anti-reverse current diode, etc.
[0051] In some examples, when photovoltaic modules leave the factory, the test points can be covered by the casing and potting compound, so that the RSD equipment can output normally, ensuring that the modules are in an open circuit state during transportation and installation.
[0052] In this embodiment, when the photovoltaic module is undergoing power supply testing at the factory, the test point can be connected through the bypass fixture 5, and the bypass quick-shutdown device 1 can be used to ensure that the photovoltaic module can output power normally in various tests. Before the photovoltaic module leaves the factory, the test point can be covered by structural components such as the casing, or by applying glue to the test point. The photovoltaic module is controlled by the RSD device and is in a default off or open circuit state, which can ensure the power safety and reliability of the photovoltaic module during transportation and installation.
[0053] Therefore, the reserved test point scheme adopted in this embodiment only requires adding power test points and external bypass fixtures to the PCB board, and the structure can be adjusted accordingly, which is simple and convenient to implement.
[0054] Figure 3 The figure shows a schematic block diagram of Example 2 of the control system for photovoltaic module output power testing in this application. As shown in the figure, in an optional embodiment, the fast shutdown device 1 includes an RSD master controller 11 and an electronic switch 12; the RSD master controller 11 and the electronic switch 12 are connected in series between the photovoltaic module power output terminal 2 and the external output terminal 3; the electronic switch 12 is used to switch on and off under the control of the RSD master controller 11.
[0055] The control device 4 includes a jumper device 6, which is installed at both ends of the electronic switch 12 during photovoltaic module testing, so that the photovoltaic module can be turned on to output externally through the jumper device 6.
[0056] In this embodiment, the jumper device 6 can be a wire used to connect two or more nodes in a circuit, typically made of copper or aluminum wire.
[0057] During factory testing, the jumpers of photovoltaic modules are kept connected to ensure that the modules can output power normally during various tests and that the tests can proceed smoothly. Before leaving the factory, the jumpers are removed by default, and the modules are in a closed-circuit state, so they do not output power to the outside world, ensuring safety during transportation and installation.
[0058] Thus, by adding hardware bypass jumper devices 6 to both ends of the electronic switch 12 of RSD device 1, jumpers can be installed during factory testing to bypass the electronic switch function module of RSD device 1. The photovoltaic module will output power normally upon power-up, allowing the test to proceed smoothly. Furthermore, by using physical hardware jumpers, no additional control circuitry is required, making control reliable and simple.
[0059] In some examples, the jumper device 6 includes at least one of the following: straight type, elbow type, plug type, hinge type, and sleeve type.
[0060] Among them, plug-type patch cords can use plug connectors, offering good detachability. Hinged-type patch cords can use a hinged structure, suitable for connections at different angles. Sleeve-type patch cords can use insulating sleeves to protect the wires, improving safety.
[0061] In some examples, the electronic switch 12 includes at least one of the following: a relay, a DC contactor, or a high-voltage MOSFET (metal-oxide-semiconductor field-effect transistor).
[0062] The electronic switch 12 can be selected according to actual needs. In addition to the types mentioned above, the electronic switch 12 may also include other electronic switches with similar functions.
[0063] In this embodiment, the RSD main controller 11 can be a circuit with signal processing capabilities. In one implementation, the processor can be a circuit with instruction reading and execution capabilities, such as a Central Processing Unit (CPU), a microprocessor, a graphics processing unit (GPU) (which can be understood as a type of microprocessor), or a digital signal processor (DSP). In another implementation, the processor can implement certain functions through the logical relationships of hardware circuits. The logical relationships of the aforementioned hardware circuits are fixed or reconfigurable. For example, the processor is a hardware circuit implemented using an application-specific integrated circuit (ASIC) or a programmable logic device (PLD), such as an FPGA. In a reconfigurable hardware circuit, the process of the processor loading a configuration document and configuring the hardware circuit can be understood as the process of the processor loading instructions to achieve the above functions. In addition, a processor can also be a hardware circuit designed for artificial intelligence, which can be understood as a type of ASIC, such as a Neural Network Processing Unit (NPU), a Tensor Processing Unit (TPU), a Deep Learning Processing Unit (DPU), etc.
[0064] Figure 4 The figure shows a schematic block diagram of Example 3 of the control system for photovoltaic module output power testing in this application. As shown in the figure, in an optional embodiment, the fast shutdown device 1 includes an RSD master controller 11 and an electronic switch 12; the RSD master controller 11 and the electronic switch 12 are connected in series between the photovoltaic module power output terminal 2 and the external output terminal 3; the electronic switch 12 is used to switch on and off under the control of the RSD master controller 11.
[0065] The control device 4 is the RSD master controller 11 in the fast shutdown device 1, which is used to control the electronic switch 12 to be in the on state by default during photovoltaic module testing, so that the photovoltaic module can open the external output through the fast shutdown device 1; and to control the electronic switch 12 to be in the off state by default during photovoltaic module non-testing, so that the photovoltaic module can close the external output.
[0066] In this embodiment, the powered devices are controlled by the local firmware to be in a specific state. For example, during factory testing, the RSD master controller 11 controls the local electronic switch 12 to be in the on state by default when powered on, and the photovoltaic module outputs power normally to the outside. After the test is completed, the firmware parameters can be set to the default off state to ensure that the photovoltaic module does not output power to the outside before leaving the factory. The RSD master controller 11 controls the on / off state of the electronic switch 12 by sending control commands to the electronic switch 12.
[0067] Thus, by controlling the opening and closing of the internal electronic switch 12 through local firmware (such as the RSD main controller 11), during the photovoltaic module factory testing process, based on the triggering of test events (such as manually triggered test events), the firmware controls the internal electronic switch 12 to close, ensuring that the photovoltaic module can output power normally in various tests and that the tests proceed smoothly. Furthermore, after the tests are completed, the internal firmware controls the electronic switch 12 to close, ensuring that the photovoltaic module remains in an open-circuit state even when exposed to sunlight during transportation and installation, guaranteeing the overall safety of the photovoltaic module. Moreover, by using local firmware control, no other components are needed; the entire process can be completed automatically simply by manually triggering the software control.
[0068] This application provides a photovoltaic module system, referencing... Figure 2 , Figure 3 and Figure 4 The photovoltaic module system includes photovoltaic modules and a control system for testing the output power of photovoltaic modules as described in the above embodiments, which is connected to the photovoltaic modules.
[0069] In this embodiment, the photovoltaic module is the object to be tested and controlled. The output state of the photovoltaic module during factory testing and transportation and installation is mainly controlled by the jumper device 6 (hardware jumper, physical jumper), RSD main controller 11 (software control) and bypass fixture 5 (fixture jumper, hardware test point). This ensures that the photovoltaic module outputs normal power in various tests in the factory, and at the same time ensures that the photovoltaic module is always in the off-circuit state during transportation and installation, thus ensuring its safety.
[0070] In this way, whether it's hardware jumper control, fixture test point control, or local RSD firmware control, the normal output power of the photovoltaic modules can be guaranteed during various tests in the factory, ensuring smooth testing. Simultaneously, it ensures that the photovoltaic modules remain in an off-circuit state throughout transportation and installation, preventing any external power output and ensuring safety throughout the entire process. The hardware jumper and fixture test point methods utilize physical control, eliminating the need for control circuitry; the local RSD firmware control is entirely automated via software, requiring only manual triggering of test events, making control simple, reliable, and easy to implement.
[0071] It should be understood that the above embodiments are exemplary and not intended to encompass all possible implementations. Various modifications and changes can be made to the above embodiments without departing from the scope of this disclosure. Similarly, the various technical features of the above embodiments can be arbitrarily combined to form other embodiments of this application that may not be explicitly described. Therefore, the above embodiments only illustrate several implementations of this application and do not limit the scope of protection of this patent application.
Claims
1. A control system for testing the output power of photovoltaic modules, characterized in that, The control system comprises: a quick-off device connected between a photovoltaic module power output and an external output; wherein the photovoltaic module power output is connected to a photovoltaic module, and the external output is connected to a terminal device; a control device for controlling the connection between the photovoltaic module power output and the external output to control the connection between the photovoltaic module power output and the external output to be in a conducting state during photovoltaic module testing.
2. The control system for photovoltaic module output power testing according to claim 1, wherein: a first reserved test point is arranged on a connecting wire between the photovoltaic module power output and the quick-off device; and a second reserved test point is arranged on a connecting wire between the external output and the quick-off device; the control device comprises a bypass tool for being connected between the first reserved test point and the second reserved test point during photovoltaic module testing, so that the photovoltaic module opens the external output through the first reserved test point and the second reserved test point.
3. The control system for photovoltaic module output power test according to claim 2, wherein, The bypass tool comprises an anti-backflow device connected to the second reserved test point.
4. The control system for photovoltaic module output power test according to claim 3, wherein, The anti-backflow device comprises at least one of a transistor, a relay, and a fuse.
5. The control system for photovoltaic module output power testing according to claim 1, wherein: the quick-off device comprises an RSD master control and an electronic switch; the RSD master control and the electronic switch are connected in series between the photovoltaic module power output and the external output; and the electronic switch is used for being controlled by the RSD master control to be in a conducting state or a non-conducting state; the control device comprises a jumper device for being installed at two ends of the electronic switch during photovoltaic module testing, so that the photovoltaic module opens the external output through the jumper device.
6. The control system for photovoltaic module output power test according to claim 5, wherein, The jumper device comprises at least one of a straight type, an elbow type, a plug type, a hinge type, and a sleeve type.
7. The control system for photovoltaic module output power test according to claim 5, wherein, The electronic switch comprises at least one of a relay, a direct-current contactor, and a high-voltage MOS tube.
8. The control system for photovoltaic module output power testing according to claim 1, wherein: the quick-off device comprises an RSD master control and an electronic switch; the RSD master control and the electronic switch are connected in series between the photovoltaic module power output and the external output; and the electronic switch is used for being controlled by the RSD master control to be in a conducting state or a non-conducting state; the control device is the RSD master control in the quick-off device, and is used for controlling the electronic switch to be in a conducting state by default during photovoltaic module testing, so that the photovoltaic module opens the external output through the quick-off device; and controlling the electronic switch to be in a non-conducting state by default during non-photovoltaic module testing, so that the photovoltaic module closes the external output.
9. A photovoltaic module system, characterized by, The photovoltaic module system comprises a photovoltaic module, and a control system for photovoltaic module output power testing according to any one of claims 1-8 connected to the photovoltaic module.