CN108988777B - Back-to-back assembly for photovoltaic power station and manufacturing method - Google Patents
Back-to-back assembly for photovoltaic power station and manufacturing method Download PDFInfo
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- CN108988777B CN108988777B CN201810970530.7A CN201810970530A CN108988777B CN 108988777 B CN108988777 B CN 108988777B CN 201810970530 A CN201810970530 A CN 201810970530A CN 108988777 B CN108988777 B CN 108988777B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 9
- 239000004020 conductor Substances 0.000 claims abstract description 109
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 93
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical group [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 58
- 238000003466 welding Methods 0.000 claims abstract description 19
- 238000001746 injection moulding Methods 0.000 claims abstract description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 7
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims description 12
- 239000003063 flame retardant Substances 0.000 claims description 12
- 229920000098 polyolefin Polymers 0.000 claims description 12
- 229910052802 copper Inorganic materials 0.000 claims description 11
- 239000010949 copper Substances 0.000 claims description 11
- 238000010438 heat treatment Methods 0.000 claims description 10
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 claims description 9
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 claims description 8
- 238000000034 method Methods 0.000 claims description 7
- 239000011780 sodium chloride Substances 0.000 claims description 6
- KOMNUTZXSVSERR-UHFFFAOYSA-N 1,3,5-tris(prop-2-enyl)-1,3,5-triazinane-2,4,6-trione Chemical compound C=CCN1C(=O)N(CC=C)C(=O)N(CC=C)C1=O KOMNUTZXSVSERR-UHFFFAOYSA-N 0.000 claims description 4
- 239000003963 antioxidant agent Substances 0.000 claims description 4
- 230000003078 antioxidant effect Effects 0.000 claims description 4
- 239000006229 carbon black Substances 0.000 claims description 4
- WHHGLZMJPXIBIX-UHFFFAOYSA-N decabromodiphenyl ether Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1OC1=C(Br)C(Br)=C(Br)C(Br)=C1Br WHHGLZMJPXIBIX-UHFFFAOYSA-N 0.000 claims description 4
- 239000003112 inhibitor Substances 0.000 claims description 4
- 239000000049 pigment Substances 0.000 claims description 4
- 239000002994 raw material Substances 0.000 claims description 4
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 claims description 4
- 238000009413 insulation Methods 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 2
- 230000008018 melting Effects 0.000 claims description 2
- 230000004927 fusion Effects 0.000 abstract 1
- 150000003839 salts Chemical class 0.000 abstract 1
- 239000000463 material Substances 0.000 description 9
- 210000001503 joint Anatomy 0.000 description 8
- 230000005540 biological transmission Effects 0.000 description 4
- 238000003825 pressing Methods 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 230000032683 aging Effects 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000010292 electrical insulation Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 238000010248 power generation Methods 0.000 description 2
- 230000004224 protection Effects 0.000 description 2
- 230000006750 UV protection Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/32—Electrical components comprising DC/AC inverter means associated with the PV module itself, e.g. AC modules
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/36—Electrical components characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Landscapes
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
The invention relates to a back-to-back assembly for a photovoltaic power station and a manufacturing method thereof, wherein a jig is respectively arranged below three or four sections of exposed aluminum alloy conductors, each section of exposed aluminum alloy conductor is respectively arranged in a semicircular groove II of the jig, two stranded tinned copper wire core conductors are respectively arranged in two semicircular grooves I of each jig, the two stranded tinned copper wire core conductors and the aluminum alloy conductors are welded together through a spot welder, a jig is buckled on each jig, and the two jigs are heated through a fusion welding machine, so that the two stranded tinned copper wire core conductors and the aluminum alloy conductors are fused into a whole; respectively injection molding a confluence joint at the joint of each aluminum alloy conductor and two stranded tinned copper wire core conductors which are fused into a whole, and putting the confluence joint into salt water for water tightness test; and the other ends of the two photovoltaic cables on each confluence connector are respectively connected with a solar connector. The assembly replaces the bus box, and meets the use requirements of customers.
Description
Technical Field
The invention relates to a back-to-back assembly for a photovoltaic power station and a manufacturing method thereof, which are particularly suitable for collecting direct current of a solar backboard for the photovoltaic power station, gradually collecting small current into large current, and finally collecting the large current into a junction box.
Background
The existing solar backboard direct current collection device for the photovoltaic power station generally adopts a collection box, small current is gradually collected into large current by the collection box, and finally the large current is collected to an inverter, and the direct current is converted into alternating current.
The disadvantage of the header box is: large volume, complex installation, high cost and large contact resistance. The collection flow box adopts metal sheath packing mostly, and the leakproofness is not good, causes short circuit easily under rainy season or humid environment, exposes the sheath for a long time and corrosion easily, and in addition, collection flow box occupies certain space and need examine concrete which photovoltaic line junction part when the inspection trouble, is difficult to examine when the trouble, takes time, takes a lot of work, and the operation installation is complicated.
In view of the shortcomings of the junction box, users provide a back-to-back assembly which is small in size, low in cost, convenient to install, convenient to maintain and capable of being used for replacing the junction box and has a collecting function, and the back-to-back assembly can be subjected to the influence of severe environments such as insolation, wind blowing, rain, lightning impact and the like for a long time in the collecting process, so that the back-to-back assembly is required to have the performances of strong drawing force, ultraviolet resistance, high temperature resistance and the like.
The back-to-back assembly is used in special environment areas such as a plateau and a basin, and has the characteristics of light aging resistance, lightning protection, water resistance, high electrical insulation performance and the like, and particularly in winter with severe cold at low temperature, the material still has high rebound resilience, and the cable harness can be freely bent without breaking.
Because photovoltaic power generation causes the cable to easily generate heat when transmitting current, the materials used for the back-to-back assembly are required to have the characteristics of high temperature resistance level, high flame retardance and the like, and the phenomena of heating, firing and the like of the transmission line are prevented.
Disclosure of Invention
In view of the state of the art and the requirements of users, the invention provides a back-to-back assembly for a photovoltaic power station and a manufacturing method thereof.
The connection mode of each joint adopts a hot welding process, the copper conductor and the aluminum conductor are melted together after heat treatment, no other materials are added in the welding process, the contact resistance is reduced, the area of the joint is reduced, and the drawing force of the joint is improved.
The formula of the confluence joint material has the characteristics of flame retardance and high elasticity, and can ensure the high-efficiency transmission function of the photovoltaic cable in low-temperature and humid environments.
The invention adopts the technical proposal for realizing the aim that: the back-to-back assembly for the photovoltaic power station comprises a solar connector, a photovoltaic cable and an aluminum alloy cable, wherein the photovoltaic cable is formed by sequentially arranging a halogen-free flame-retardant photovoltaic cable irradiation insulating layer and a halogen-free flame-retardant photovoltaic cable irradiation sheath outside a stranded tinned copper wire core conductor; the aluminum alloy cable is formed by sequentially arranging a cross-linked polyolefin insulating layer and a cross-linked polyolefin outer sheath outside an aluminum alloy conductor, and is characterized in that: the solar photovoltaic cable further comprises a pair of bus connectors, three or four bare aluminum alloy conductors are arranged on the aluminum alloy cable between two ends of one aluminum alloy cable at intervals, the three or four bare aluminum alloy conductors are respectively connected with two tin-plated copper wire core conductors arranged at intervals at one end of one pair of the photovoltaic cable, one bus connector is respectively injection-molded at the joint and the periphery of each aluminum alloy conductor and each twisted tin-plated copper wire core conductor, the number of the bus connectors is three or four, and the other end of each pair of the photovoltaic cable is respectively connected with one solar connector;
the specifications of the photovoltaic cables are all 8AWG photovoltaic cables with the specification of 10mm < 2 >, and the specifications of the aluminum alloy cables are aluminum alloy cables with the specification of 4/0 and 100mm < 2 >.
The manufacturing method of the back-to-back assembly for the photovoltaic power station is characterized by comprising the following steps of:
firstly, cable treatment, namely stripping a halogen-free flame-retardant photovoltaic cable irradiation insulating layer and a halogen-free flame-retardant photovoltaic cable irradiation sheath on one end of three or four pairs of photovoltaic cables, respectively leaving a section of stranded tinned copper wire core conductor, and stamping through a die to enable one surface of the stranded tinned copper wire core conductor to be a plane and the other surface to be a cambered surface;
stripping off the cross-linked polyolefin insulating layer and the cross-linked polyolefin outer sheath at three or four positions between two ends of an aluminum alloy cable, leaving three or four exposed aluminum alloy conductors, and stamping the three or four exposed aluminum alloy conductors through a die to enable one surface of each of the three or four exposed aluminum alloy conductors to be a plane and the other surface to be a cambered surface;
secondly, welding cables, namely respectively placing a jig below three or four sections of exposed aluminum alloy conductors on an aluminum alloy cable, respectively placing the exposed aluminum alloy conductors in a semicircular groove II horizontally arranged by the jig, respectively placing two stranded tinned copper wire core conductors at one end of a pair of cables in two semicircular grooves I vertically arranged by the three or four jigs, respectively lapping the two stranded tinned copper wire core conductors of each pair downwards and respectively on the exposed aluminum alloy conductor planes, performing heat treatment, welding the two stranded tinned copper wire core conductors and the aluminum alloy conductors which are lapped together by each pair by a spot welder, fastening a jig on each jig again and applying pressure, respectively pressing the two stranded tinned copper core conductors and the exposed aluminum alloy conductors which are welded together in one semicircular groove II and two semicircular grooves I corresponding to the two jigs after butt joint, and heating the two stranded tinned copper wire core conductors and the two aluminum alloy conductors by a welding machine to enable the two stranded tinned copper wire core conductors and the aluminum alloy conductors to be under the action of a high-pressure alloy conductor;
thirdly, injection molding, namely taking down three or four jigs, and respectively injection molding a confluence joint at the joint and the periphery of the aluminum alloy conductor and the two stranded tinned copper wire core conductors which are fused into a whole at three or four places to form an initial assembly;
fourthly, detecting, namely immersing each initial component in sodium chloride saline with the concentration of 25% for 2 hours to perform a water tightness test, and applying 1kV direct current voltage after immersing for 2 hours, wherein the insulation resistance is not less than 4G omega and is qualified;
installing solar connectors, and respectively connecting the other ends of the two photovoltaic cables on each initial assembly with one solar connector;
the confluence joint consists of the following raw materials in parts by weight: 100 parts of TPE, 20-30 parts of EVA, 1-3 parts of antioxidant, 2-4 parts of copper inhibitor, 10-15 parts of decabromodiphenyl ether, 5-10 parts of antimonous oxide, 1-2 parts of TAIC, 5-8 parts of high pigment carbon black and 0.5-1 part of zinc stearate.
The beneficial effects of the invention are as follows: the structure design of the invention replaces the use of the junction box, and is characterized in that three or four bare aluminum alloy conductors arranged on the aluminum alloy cable between two ends of one aluminum alloy cable are respectively connected with two tinned copper wire core conductors of a pair of photovoltaic cables, so that the structure design is convenient to install and simple to operate, the fault can be fixed-point checked, and only a fault device is replaced once the fault occurs, and the fault device does not need to be replaced in a large part, thus being particularly important for centralized generation large-scale power generation clusters.
An injection molding confluence joint is added at the joint of each conductor, so that the injection molding confluence joint has excellent insulating property and good sealing property, and short circuit fault is prevented.
The connection mode of the aluminum alloy conductor and the tinned copper wire core conductor adopts a hot welding mode. The combination of aluminum alloy cable and copper conductor in the market at present mainly adopts the form of couple, uses a metal couple to collude tin-plated copper conductor and aluminum alloy cable conductor of photovoltaic cable and compresses tightly, and this kind of mode contact resistance is big, and junction drawing force is little.
The heat welding method is adopted, the conductor is subjected to heat treatment in advance, then the treated aluminum alloy conductor and the tinned copper conductor are subjected to high temperature and pressure between the jigs, and the copper conductor and the aluminum conductor are melted together again through heat treatment, so that the drawing force of the welded conductor is greatly increased, no other materials are added in the welding process, the contact resistance is reduced, the area of the joint is reduced, and the drawing force of the joint is improved.
The material has the difficulty that the material has flame retardance and high elasticity, can ensure the high-efficiency transmission function of the photovoltaic cable under low temperature and humid environment, and cannot reduce the insulating property of the material.
The formula adopted by the bus joint material has the characteristics of flame retardance and high elasticity, has the characteristics of light aging resistance, lightning protection, water resistance, high electrical insulation performance and the like, and particularly has the characteristics of high rebound resilience in winter with severe cold at low temperature, capability of ensuring that a cable harness can be freely bent without breaking wires, and capability of ensuring the high-efficiency transmission function of a photovoltaic cable in low-temperature and humid environments.
The invention has small volume, the single joint has small bearing function, but has the function of the junction box completely, the manufacturing cost is low, the cost of the junction box in the prior art is generally 4-5 kiloyuan, the cost of the junction box in the prior art is generally 1-2 hundred yuan, the cost is saved by more than 20 times, and in a word, the use requirement of customers is met.
Drawings
FIG. 1 is a schematic view of a structure of the present invention incorporating four buss connectors;
FIG. 2 is an enlarged pictorial illustration of structure A of FIG. 1;
FIG. 3 is a schematic view of a structure of the present invention equipped with three bus bars;
fig. 4 is a schematic structural view of the photovoltaic cable of the present invention;
FIG. 5 is a schematic structural view of an aluminum alloy cable according to the present invention;
FIG. 6 is a schematic diagram of a fixture according to the present invention;
fig. 7 is a schematic diagram of a welding state of the photovoltaic cable and the aluminum alloy cable according to the present invention.
Detailed Description
As shown in fig. 1 to 7, a back-to-back assembly for a photovoltaic power station includes a solar connector 1, a photovoltaic cable 2, an aluminum alloy cable 3, and a busbar joint 4.
The photovoltaic cable 2 is formed by sequentially arranging a halogen-free flame-retardant photovoltaic cable irradiation insulating layer 2-2 and a halogen-free flame-retardant photovoltaic cable irradiation sheath 2-3 outside the stranded tinned copper wire core conductor 2-1. The aluminum alloy cable 3 is formed by sequentially arranging a cross-linked polyolefin insulating layer 3-2 and a cross-linked polyolefin outer sheath 3-3 outside an aluminum alloy conductor 3-1.
The two photovoltaic cables 2 are a pair, three or four exposed aluminum alloy conductors 3-1 are arranged on the aluminum alloy cable between two ends of one aluminum alloy cable 3 at intervals, the three or four exposed aluminum alloy conductors 3-1 are respectively connected with two tinned copper wire core conductors 2-1 arranged at intervals at one end of the pair of photovoltaic cables 2, a confluence joint 4 is respectively injection-molded at the connecting position and the periphery of each aluminum alloy conductor 3-1 and each two stranded tinned copper wire core conductors 2-1, the number of the confluence joints 4 formed by injection molding is three or four, and the other end of each pair of photovoltaic cables 2 is respectively connected with a solar connector 1.
The specifications of the photovoltaic cables 2 are all 8AWG photovoltaic cables with the specification of 10mm < 2 >, and the specifications of the aluminum alloy cables 3 are aluminum alloy cables with the specification of 4/0 and 100mm < 2 >.
The confluence joint 4 is rectangular, the front and the back of the confluence joint 4 are cambered surfaces 4-1, and the upper surface, the lower surface, the left side surface and the right side surface are planes.
The length of the aluminum alloy cable 3 is 178 meters, four confluence joints 4 are arranged on the aluminum alloy cable between two ends of the aluminum alloy cable 3, and the distance between the central axes of the four confluence joints 4 and the distance between two ends of the aluminum alloy cable 3 and the central axes of the adjacent confluence joints 4 are 35.6cm.
The length of the aluminum alloy cable 3 is 128 meters, three confluence joints 4 are arranged on the aluminum alloy cable between two ends of the aluminum alloy cable 3, and the distance between the central axes of the three confluence joints 4 and the distance between two ends of the aluminum alloy cable 3 and the central axes of the adjacent confluence joints 4 are 32cm.
The jig 5 is rectangular, a semicircular groove II 5-2 is horizontally arranged on the surface of the jig 5, two semicircular grooves I5-1 are vertically arranged on the surface of the jig 5, and the two semicircular grooves I5-1 are communicated with the semicircular groove II 5-2.
A manufacturing method of a back-to-back assembly for a photovoltaic power station comprises the following steps:
firstly, cable treatment, namely stripping a halogen-free flame-retardant photovoltaic cable irradiation insulating layer 2-2 and a halogen-free flame-retardant photovoltaic cable irradiation sheath 2-3 on one end of three or four pairs of photovoltaic cables 2, respectively leaving a section of stranded tinned copper wire core conductor 2-1, and stamping through a die to enable one surface of the stranded tinned copper wire core conductor 2-1 to be a plane and the other surface to be a cambered surface;
the three or four cross-linked polyolefin insulating layers 3-2 and the cross-linked polyolefin outer jackets 3-3 at the positions between two ends of one aluminum alloy cable 3 are stripped, three or four exposed aluminum alloy conductors 3-1 are reserved, one surface of each three or four exposed aluminum alloy conductor 3-1 is made to be a plane, and the other surface is made to be an arc surface through die stamping.
And secondly, welding cables, namely respectively placing a jig 5 below three or four sections of exposed aluminum alloy conductors 3-1 on an aluminum alloy cable 3, respectively placing the two sections of exposed aluminum alloy conductors 3-1 in semicircular grooves II 5-2 horizontally arranged in the jig 5, respectively placing two stranded tinned copper wire core conductors 2-1 at one end of a pair of photovoltaic cables 2 in two semicircular grooves I5-1 vertically arranged in each of the three or four jigs 5, respectively placing the two stranded tinned copper wire core conductors 2-1 of each pair of the two stranded tinned copper wire core conductors 2-1 downwards and respectively lapping the two stranded tinned copper wire core conductors 2-1 on the exposed aluminum alloy conductor 3-1, performing heat treatment, welding the two stranded tinned copper wire core conductors 2-1 and the aluminum alloy conductors 3-1 lapped together through a spot welder, respectively buckling one jig 5 on each jig 5, applying pressure, butting the two stranded tinned copper wire core conductors 2-1 and the two stranded copper wire core conductors 3-1 into a whole by the two welding machines, and heating the two stranded copper wire core conductors 2-1 and the two corresponding to the two semicircular grooves 1 through the two welding machines, and pressing the two stranded copper wire core conductors 3-1 into a whole by the two welding machines, and heating the two stranded copper wire core conductors 2-1 and the two welding machines.
And thirdly, injection molding, namely taking down three or four jigs 5, and respectively injection molding a confluence joint 4 at the joint and the periphery of the aluminum alloy conductor 3-1 and the two stranded tinned copper wire core conductors 2-1 which are fused into a whole at three or four places to form an initial assembly.
And fourthly, detecting, namely immersing each initial component in 25% sodium chloride saline for 2 hours to perform a water tightness test, and applying 1kV direct current voltage after immersing for 2 hours, wherein the insulation resistance is not less than 4G omega and is qualified.
And fifthly, installing solar connectors, and respectively connecting the other ends of the two photovoltaic cables 2 on each initial assembly with one solar connector 1.
The confluence joint 4 is composed of the following raw materials in parts by weight: 100 parts of TPE, 25 parts of EVA, 2 parts of antioxidant, 3 parts of copper inhibitor, 12 parts of decabromodiphenyl ether, 8 parts of antimonous oxide, 2 parts of TAIC, 6 parts of high pigment carbon black and 1 part of zinc stearate.
The jig 5 is made of tungsten carbide, so that the cable conductor and the jig can not be taken down because of being melted into a whole under the conditions of high temperature and pressure, and the metal adopted by the jig has a higher melting point relative to the copper conductor, so that the phenomenon that the jig and the cable copper conductor are welded together can not occur during welding.
Claims (2)
1. The back-to-back assembly for the photovoltaic power station comprises a solar connector (1), a photovoltaic cable (2) and an aluminum alloy cable (3), wherein the photovoltaic cable (2) is formed by sequentially arranging a halogen-free flame-retardant photovoltaic cable irradiation insulating layer (2-2) and a halogen-free flame-retardant photovoltaic cable irradiation sheath (2-3) outside a stranded tin-plated copper wire core conductor (2-1); the aluminum alloy cable (3) is formed by sequentially arranging a cross-linked polyolefin insulating layer (3-2) and a cross-linked polyolefin outer sheath (3-3) outside an aluminum alloy conductor (3-1), and is characterized in that: the solar photovoltaic cable also comprises a pair of bus connectors (4), wherein three or four exposed aluminum alloy conductors (3-1) are arranged on the aluminum alloy cable between two ends of one aluminum alloy cable (3) at intervals, the three or four exposed aluminum alloy conductors (3-1) are respectively connected with two tin-plated copper wire core conductors (2-1) which are arranged at intervals at one end of one pair of the photovoltaic cable (2), the connecting positions and the peripheries of the aluminum alloy conductors (3-1) at each position and the two stranded tin-plated copper wire core conductors (2-1) are respectively injection-molded with one bus connector (4), and the other end of each pair of the photovoltaic cable (2) is respectively connected with one solar connector (1);
the specification of the photovoltaic cable (2) is an 8AWG photovoltaic cable with the specification of 10mm < 2 >, and the specification of the aluminum alloy cable (3) is an aluminum alloy cable with the specification of 4/0 and 100mm < 2 >;
the bus connector (4) is rectangular, the front and rear surfaces of the bus connector (4) are cambered surfaces (4-1), and the upper surface, the lower surface, the left side surface and the right side surface are planes;
the length of the aluminum alloy cable (3) is 178 meters, four confluence joints (4) are arranged on the aluminum alloy cable between two ends of the aluminum alloy cable (3), and the distance between the central axes of the four confluence joints (4) and the distance between two ends of the aluminum alloy cable (3) and the central axes of the adjacent confluence joints (4) are 35.6cm;
the length of the aluminum alloy cable (3) is 128 meters, three confluence joints (4) are arranged on the aluminum alloy cable between two ends of the aluminum alloy cable (3), and the distance between the central axes of the three confluence joints (4) and the distance between two ends of the aluminum alloy cable (3) and the central axes of the adjacent confluence joints (4) are 32cm;
the method is characterized by comprising the following steps of:
firstly, cable treatment, namely stripping a halogen-free flame-retardant photovoltaic cable irradiation insulating layer (2-2) and a halogen-free flame-retardant photovoltaic cable irradiation sheath (2-3) on one end of three pairs or four pairs of photovoltaic cables (2), respectively leaving a section of stranded tinned copper wire core conductor (2-1), and stamping through a die to enable one surface of the stranded tinned copper wire core conductor (2-1) to be a plane and the other surface to be a cambered surface;
stripping off three or four cross-linked polyolefin insulating layers (3-2) and cross-linked polyolefin outer jackets (3-3) at positions between two ends of an aluminum alloy cable (3), leaving three or four exposed aluminum alloy conductors (3-1), and stamping one surface of the three or four exposed aluminum alloy conductors (3-1) through a die to form a plane, and forming the other surface of the three or four exposed aluminum alloy conductors as a cambered surface;
a second step of cable welding, a jig (5) is respectively placed below three or four sections of bare aluminum alloy conductors (3-1) on an aluminum alloy cable (3), the plane of each section of bare aluminum alloy conductor (3-1) faces upwards and is respectively placed in a semicircular groove II (5-2) horizontally arranged by the jig (5), two stranded tinned copper wire core conductors (2-1) at one end of a pair of photovoltaic cable (2) are respectively placed in two semicircular grooves I (5-1) vertically arranged by the three or four jigs (5), the plane of each pair of two stranded tinned copper wire core conductors (2-1) faces downwards and is respectively lapped on the plane of the bare aluminum alloy conductor (3-1) and is subjected to heat treatment, the two stranded copper wire core conductors (2-1) and the aluminum alloy conductor (3-1) which are lapped together are welded together through a spot welder, the jig (5) is buckled together on the upper surface of each jig (5) and is pressed, the two stranded copper wire core conductors (5) are pressed together by the jig (2-1) and the two stranded copper wire core conductors (2-1) are welded together by the spot welder, the two stranded copper wire core conductors (2-1) are pressed together by the butt welding machine, melting two stranded tinned copper wire core conductors (2-1) and an aluminum alloy conductor (3-1) into a whole under the action of high temperature and pressure;
thirdly, injection molding, namely taking down three or four jigs (5), and respectively injection molding a confluence joint (4) at the joint and the periphery of an aluminum alloy conductor (3-1) and two stranded tinned copper wire core conductors (2-1) which are fused into a whole at three or four places to form an initial assembly;
fourthly, detecting, namely immersing each initial component in sodium chloride saline with the concentration of 25% for 2 hours to perform a water tightness test, and applying 1kV direct current voltage after immersing for 2 hours, wherein the insulation resistance is not less than 4G omega and is qualified;
fifthly, installing solar connectors, and respectively connecting the other ends of the two photovoltaic cables (2) on each initial assembly with one solar connector (1);
the confluence joint (4) is composed of the following raw materials in parts by weight: 100 parts of TPE, 20-30 parts of EVA, 1-3 parts of antioxidant, 2-4 parts of copper inhibitor, 10-15 parts of decabromodiphenyl ether, 5-10 parts of antimonous oxide, 1-2 parts of TAIC, 5-8 parts of high pigment carbon black and 0.5-1 part of zinc stearate.
2. The method for manufacturing the back-to-back assembly for the photovoltaic power station according to claim 1, wherein the confluence joint (4) is composed of the following raw materials in parts by weight: 100 parts of TPE, 25 parts of EVA, 2 parts of antioxidant, 3 parts of copper inhibitor, 12 parts of decabromodiphenyl ether, 8 parts of antimonous oxide, 2 parts of TAIC, 6 parts of high pigment carbon black and 1 part of zinc stearate.
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