A photovoltaic module array load testing device based on a real installation environment
Patent Information
- Application Number
- CN202522254791.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-24
- Publication Date
- 2026-09-29
- Estimated Expiration
- 2035-10-24
AI Technical Summary
目前，光伏组件在出厂前需要在实验室内进行静态和动态载荷测试，通过吸盘吸附在组件正表面玻璃，进行上下位移模拟组件在户外受到大风的环境，但是现实环境中在实验室检测合格后的光伏组件在实地安装使用后，仍会出现在大风、台风等恶劣环境下被吹倒、损坏等情况
在实地安装光伏组件后再进行整体载荷测试，将桩基、支架组件、实地土地情况均纳入测试范围内，从而模拟光伏系统实地安装后的完整结构，让测试结果更贴合实际使用工况，避免测试与应用脱节。
Smart Images
Figure CN224816097U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of photovoltaic module technology, and in particular to a photovoltaic module array load testing device based on an on-site installation environment. Background Technology
[0002] Wind pressure and wind suction tests are crucial for evaluating the wind resistance of photovoltaic modules. The wind pressure test simulates the pressure exerted on the windward side of the module (usually the front of the module) by extreme wind speeds, testing the structural integrity and power degradation of the module under sustained pressure. The wind suction test simulates the performance of the module under negative pressure (suction) on the leeward side (usually the back of the module), and is usually used in combination with the wind pressure test.
[0003] Laboratory simulation primarily involves static and dynamic load testing methods. Currently, photovoltaic (PV) modules undergo static and dynamic load testing in the laboratory before leaving the factory. This involves using suction cups to attach the modules to the glass surface and simulating vertical displacement to mimic the effects of strong winds outdoors. However, in real-world environments, even PV modules that pass laboratory testing can still be blown over or damaged in harsh conditions such as strong winds and typhoons after installation. The root cause is that current laboratory methods for mechanical load testing of PV modules are incomplete, often testing only individual modules and focusing solely on the module itself, without considering the complex and diverse geographical environment and the interactions between modules. Because PV modules are first installed on fixed supports, which are then secured to the ground via pile foundations, the reliability of the pile foundations, the stability of the fixed supports, and the adherence to construction standards all affect the wind resistance of the entire PV system. Utility Model Content
[0004] To address the aforementioned issues, this invention provides a photovoltaic module array load testing device based on the actual installation environment. It can comprehensively consider the pile foundation, fixed support, and actual land conditions to conduct an overall effective mechanical load test on the photovoltaic module array, simulating the stress state of the outdoor module array under special scenarios such as strong winds, and providing technical support for power station design evaluation and installation methods.
[0005] Therefore, the technical solution of this utility model is: a photovoltaic module array load testing device based on the actual installation environment, including a photovoltaic module, a support assembly, a testing assembly and a simulated load assembly. The support assembly includes a column, a diagonal brace, a mounting beam and a pile foundation. The column is fixed on the pile foundation, the mounting beam is fixed above the column, and the diagonal brace is fixed between the column and the mounting beam. The photovoltaic module is fixed on the mounting beam. The simulated load component is divided into a wind pressure simulation unit and a wind suction simulation unit that work separately. The wind pressure simulation unit includes several loads of equal weight, which are placed on the photovoltaic module. The wind suction simulation unit includes several jacks, which are evenly distributed under the mounting beam, with the tops of the jacks abutting against the mounting beam. The detection component includes a pressure sensor and an infrared sensor. The pressure sensor is located between the jack and the mounting beam and is used to detect the load applied by the jack. The infrared sensor is used to measure the deformation of the diagonal brace and the mounting beam.
[0006] Based on the above scheme and as a preferred embodiment of the above scheme: the detection component further includes a level, which is used to mark the initial position of each pile foundation.
[0007] Based on the above scheme and as a preferred embodiment of the above scheme: the detection component further includes an angle meter, which is used to measure the verticality of each pile foundation.
[0008] Based on the above scheme and as a preferred embodiment of the above scheme: the detection component further includes a length measuring tool, which is used to measure the displacement change of each pile foundation.
[0009] Based on the above scheme and as a preferred embodiment of the above scheme: the wind suction simulation unit further includes a mounting base, which is placed on the ground and the jack is placed on the mounting base.
[0010] Based on the above scheme and as a preferred embodiment of the above scheme: the load is a sandbag of equal weight, a lightweight tray is placed on the photovoltaic module, and the sandbags are stacked on the lightweight tray.
[0011] This invention enables the testing of wind pressure and air suction of photovoltaic module arrays in actual installation environments. During wind pressure testing: Sandbags are stacked on the components at the wind pressure test site. According to the load design standard of the support system, the corresponding number of sandbags is used to simulate the stress on the windward side of the entire support system under strong wind conditions and the condition of the support after being stressed.
[0012] During the wind suction test: jacks were used to remove the mounting beams on the back of the components. According to the load design standards of the support system, multiple jacks were used to remove multiple components to simulate the stress on the leeward side of the entire support system under strong wind conditions and the condition of the support after being stressed.
[0013] The verticality of each pile foundation was measured before and after the test using an angle meter, and the angular change of each pile foundation was recorded. The initial position of each pile foundation was marked at the bottom of the array using a level. After the test, the displacement change of the level on the pile foundation was observed and measured with a ruler, and the displacement change of the pile foundation was recorded. Infrared sensors were used to measure the installation beams and diagonal braces, and the displacement changes of the installation beams and diagonal braces relative to the ground were recorded. These changes were then compared with the standard range values specified in the code. If they met the standard requirements, the installation was considered qualified; otherwise, adjustments were required.
[0014] Compared with the prior art, the beneficial effects of this utility model are: After the photovoltaic modules are installed on-site, an overall load test is conducted, including the pile foundation, support components, and the actual land conditions. This simulates the complete structure of the photovoltaic system after on-site installation, making the test results more consistent with actual operating conditions and avoiding a disconnect between testing and application.
[0015] Wind pressure tests are conducted by using sandbags of equal weight to accurately simulate the load. A controllable negative pressure is applied using jacks and pressure sensors to simulate the pressure load on the windward side and the negative pressure load on the leeward side of the component, thus meeting the different wind resistance performance evaluation requirements.
[0016] 3. By utilizing detection components such as pressure sensors, infrared sensors, angle gauges, levels, and length measuring tools, key data such as load magnitude, support deformation, pile verticality, and pile displacement can be collected simultaneously. All detection data can be quantified and recorded, and can be compared with the standard range values to avoid subjective judgment errors and provide an objective and accurate basis for determining the installation qualification.
[0017] 4. After testing, data such as changes in pile foundation angle, displacement, and support deformation can be used to directly determine whether the current installation is qualified. If it is not qualified, the pile foundation or support can be adjusted accordingly, reducing rework costs later. By exposing potential problems in the installation structure in advance, the overall stability of the photovoltaic system can be improved from the source, extending the service life of photovoltaic modules and the entire system. Attached Figure Description
[0018] Figure 1 This is a schematic diagram of the wind pressure test state of this utility model; Figure 2 This is a diagram showing the position distribution of the infrared sensors during the wind pressure test of this utility model. Figure 3 This is a schematic diagram of the wind suction test state of this utility model; Figure 4 This is a diagram showing the position distribution of the infrared sensors during the wind suction test of this utility model. Figure 5 This is a diagram showing the position distribution of the jacks during the wind suction test of this utility model.
[0019] The components in the diagram are labeled as follows: 1. Photovoltaic module; 2. Column; 3. Diagonal brace; 4. Installation beam; 5. Pile foundation; 6. Sandbag; 7. Lightweight pallet; 8. Jack; 9. Installation base; 10. Ground; 11. Pressure sensor. Detailed Implementation
[0020] In the description of this utility model, it should be noted that the directional terms such as "center", "horizontal (X)", "longitudinal (Y)", "vertical (Z)", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation and positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. They should not be construed as limiting the specific protection scope of this utility model.
[0021] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features. Thus, the use of "first" and "second" to define a feature may explicitly or implicitly include one or more of that feature. In the description of this utility model, "several" or "a number" means two or more, unless otherwise explicitly specified.
[0022] See the attached figures. The photovoltaic module array load testing device based on a real-world installation environment described in this embodiment includes a photovoltaic module 1, a support assembly, a testing assembly, and a simulated load assembly. The support assembly includes a column 2, diagonal braces 3, a mounting beam 4, and a pile foundation 5. The column 2 is fixed to the pile foundation 5, the mounting beam 4 is fixed above the column 2, and the diagonal braces 3 are fixed between the column 2 and the mounting beam 4. The photovoltaic module 1 is fixed to the mounting beam 4. The pile foundation, column, and mounting beam are constructed according to the actual terrain to form a stable support system for the photovoltaic module.
[0023] The simulated load assembly is divided into a separately operating wind pressure simulation unit and a wind suction simulation unit. The wind pressure simulation unit includes several loads of equal weight, which can be evenly placed on the photovoltaic modules. The loads can be sandbags 6 of equal weight. A lightweight tray 7 is placed on the photovoltaic modules, and the sandbags 6 are stacked on the lightweight tray 7. The lightweight tray can be a foam tray with negligible weight, thereby avoiding scratches and wear on the surface of the photovoltaic modules caused by the sandbags. During the wind pressure test, according to the load design standard of the support system, the corresponding number of sandbags is used to simulate the stress on the windward side of the entire support system under high wind conditions and the condition of the support after being stressed.
[0024] The wind suction simulation unit includes several jacks 8 and mounting bases 9. The mounting bases 9 are placed on the ground 10, and the jacks 8 are placed on the mounting bases 9 to prevent the jacks from sinking during the measurement process and causing test data distortion. The jacks 8 are evenly distributed below the mounting beam 4, and the top of the jacks 8 is perpendicular to the mounting beam 4 and does not contact the mounting beam 4. During the wind suction test, the jacks 8 are used to lift the mounting beam on the back of the components. According to the load design standard of the support system, multiple jacks are used to lift multiple components to simulate the stress on the leeward side of the entire support system under a strong wind environment and the condition of the support after being stressed.
[0025] The detection components include a level, an angle gauge, a ruler (length measuring tool), a pressure sensor, and an infrared sensor. The pressure sensor 11 is located between the jack 8 and the mounting beam 4 and is used to detect the load applied by the jack. The angle gauge is used to measure the verticality of each pile foundation before and after the test, and the angle change of each pile foundation is recorded. The level is used to mark the initial position of each pile foundation at the bottom of the array. After the test, the displacement change of the level on the pile foundation is observed, measured with a ruler, and the displacement change of the pile foundation is recorded. The infrared sensor is used to measure the displacement change of the mounting beam and the diagonal brace relative to the ground.
[0026] This embodiment allows for wind pressure and wind suction tests of photovoltaic module arrays in a real-world installation environment. During wind pressure testing: Sandbags are stacked on the components at the wind pressure test site. According to the load design standard of the support system, the corresponding number of sandbags is used to simulate the stress on the windward side of the entire support system under strong wind conditions and the condition of the support after being stressed.
[0027] For example: the on-site modules are installed in 2P configurations, with each module supported by 3 purlins (mounting beams) and installed using 3 bolts and 3 clamping blocks. The design load values for the support system corresponding to the two sets of photovoltaic modules are q1 and q2. Based on the on-site conditions and project requirements, the value of q1 is determined to be 2.979 kN / m. 2 The q² value is 0.745 kN / m 2 The area of the on-site component is 2.58m². 2 The partial factor for local wind load is 0.6. Calculations show that the lower component experiences a force of 4.61 kN during the wind pressure test. Since the weight of a single sandbag is 20 kg, 24 sandbags are placed at the lower end. Similarly, the upper component experiences a force of 1.15 kN, and 6 sandbags are placed at the upper end.
[0028] During the wind pressure test, a large number of sandbags were prepared on site. The weight of each sandbag was weighed on site and controlled to be within 20kg. A test platform was set up on site, which was separate from the test support system, but the sandbags could be placed evenly on the components by hand. The number of sandbags was increased simultaneously on the upper and lower nine components to control the uniformity of load application.
[0029] A total of 28 modules in 14 rows were randomly selected on-site. This test used 9 rows, comprising 18 modules, as a single unit for testing. The selected modules were... Figure 2 The area within the red box is defined as follows: M1-M8 are pile foundation numbers, S1-S7 are infrared sensor numbers, S2 / S3 / S5 / S6 are diagonal brace data acquisition points, and S1 / S4 / S7 are purlin data acquisition points. The purlin data acquisition point is located at the center point between the piles. The positions of the diagonal brace data acquisition points are as follows: Figure 1 As shown.
[0030] The specific measurement process is as follows: ① Before the test, the verticality of each pile foundation was measured with an angle meter; ② Use a level to mark the initial position of each pile foundation at the bottom of the array; ③ Use infrared sensors to measure the purlins and diagonal braces, and record the displacement changes of the purlins and diagonal braces relative to the ground; the deformation of the diagonal braces is summarized in the table below: The deformation of the purlins is summarized in the table below: ④ Apply sandbags and observe the infrared displacement changes during the loading process. After the applied load for each stage is reached, keep it stationary for the corresponding time. ⑤ After the test, observe the displacement change of the level on the pile foundation, measure it with a ruler, and record the displacement change of the pile foundation; ⑥ After the test, use an angle meter to measure the verticality of each pile foundation and record the angle change of each pile foundation; the pile foundation angle and displacement changes are shown in the table below: Where “-” represents downward displacement of the pile foundation and “+” represents upward displacement of the pile foundation; the pile foundation is erected on the ground, with the left side angle ranging from 0° to +90° and the right side angle ranging from -90° to 0°.
[0031] During the wind suction test: Jacks were used to remove the mounting beams on the back of the components. Following the load design standards of the support system, multiple jacks were used to remove multiple components to simulate the stress on the leeward side of the entire support system under high wind conditions and the condition of the support after being stressed. The location of the wind suction sensors is shown in the diagram. Figure 4As shown, the selected components are shown in the red box area. M1-M8 are pile foundation numbers, S1-S7 are infrared sensor numbers, S2 / S3 / S5 / S6 are diagonal brace data acquisition points, and S1 / S4 / S7 are purlin data acquisition points. The purlin data acquisition points are located at the center point between the piles. The positions of the diagonal brace data acquisition points are as follows: Figure 3 As shown. The locations of the jacks are as follows. Figure 5 As shown, D1~D18 are the jack numbers.
[0032] The specific measurement process is as follows: ① Before the test, the verticality of each pile foundation was measured with an angle meter; ② Use a level to mark the initial position of each pile foundation at the bottom of the array; ③ Use infrared sensors to measure the installation beam and diagonal brace, and record the displacement changes of the installation beam and diagonal brace relative to the ground; the deformation of the diagonal brace is summarized in the table below: The deformation of the purlins is summarized in the table below: ④ Use pressure sensors to collect the force value applied to the component by each jack, adjust the load applied to the component by adjusting the jack, observe the infrared displacement change during the loading process, and hold the load at each stage for the corresponding time. ⑤ After the test, observe the displacement change of the level on the pile foundation, measure it with a ruler, and record the displacement change of the pile foundation; ⑥ After the test, use an angle meter to measure the verticality of each pile foundation and record the angle change of each pile foundation; the pile foundation angle and displacement changes are shown in the table below: In summary, after the wind suction and wind pressure tests, the components showed no obvious damage, the support system showed no obvious deformation, and the pile foundation showed no obvious tilting or settlement. The deformation of the purlins and diagonal braces met the L / 240 requirement stipulated in the relevant regulations (different countries and regions have different structural specifications; this example uses the requirements of the test site). In this test array, the purlin span was 2800mm, and L / 240 was 11.6mm; the diagonal brace span was 3200mm, and L / 240 was 13.3mm. The deformation of both the purlins and diagonal braces in this test was less than L / 240, meeting the standard requirements.
[0033] The above description is merely a preferred embodiment of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions falling within the scope of this utility model's concept are protected. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of this utility model should also be considered within the protection scope of this utility model.
Claims
1. A photovoltaic module array load testing device based on an on-site installation environment, characterized in that: The system includes photovoltaic modules, support components, testing components, and simulated load components. The support components include columns, diagonal braces, mounting beams, and pile foundations. The columns are fixed to the pile foundations, the mounting beams are fixed above the columns, and the diagonal braces are fixed between the columns and the mounting beams. The photovoltaic modules are fixed to the mounting beams. The simulated load component is divided into a wind pressure simulation unit and a wind suction simulation unit that work separately. The wind pressure simulation unit includes several loads of equal weight, which are placed on the photovoltaic module. The wind suction simulation unit includes several jacks, which are evenly distributed under the mounting beam, with the tops of the jacks abutting against the mounting beam. The detection component includes a pressure sensor and an infrared sensor. The pressure sensor is located between the jack and the mounting beam and is used to detect the load applied by the jack. The infrared sensor is used to measure the deformation of the diagonal brace and the mounting beam.
2. The photovoltaic module array load testing device based on a field installation environment as described in claim 1, characterized in that: The detection assembly also includes a level, which is used to mark the initial position of each pile foundation.
3. The photovoltaic module array load testing device based on a field installation environment as described in claim 1, characterized in that: The detection assembly also includes an angle meter, which is used to measure the verticality of each pile foundation.
4. The photovoltaic module array load testing device based on a field installation environment as described in claim 1, characterized in that: The detection component also includes a length measuring tool, which is used to measure the displacement change of each pile foundation.
5. The photovoltaic module array load testing device based on a field installation environment as described in claim 1, characterized in that: The wind suction simulation unit also includes a mounting base, which is placed on the ground, and the jack is placed on the mounting base.
6. The photovoltaic module array load testing device based on a field installation environment as described in claim 1, characterized in that: The load is sandbags of equal weight, and a lightweight tray is placed on the photovoltaic module, with the sandbags stacked on the lightweight tray.