Chain of Power Devices
20240097440 ยท 2024-03-21
Inventors
Cpc classification
H02J1/00
ELECTRICITY
H02J1/12
ELECTRICITY
H02J3/46
ELECTRICITY
Y02E10/56
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
H01R4/00
ELECTRICITY
H02J2300/26
ELECTRICITY
H02S40/34
ELECTRICITY
H02J3/388
ELECTRICITY
H02S50/00
ELECTRICITY
H02S40/32
ELECTRICITY
H02J3/38
ELECTRICITY
H01R25/00
ELECTRICITY
H02S50/10
ELECTRICITY
International classification
H02J1/12
ELECTRICITY
H01R4/00
ELECTRICITY
H01R25/00
ELECTRICITY
H02J3/38
ELECTRICITY
H02S50/10
ELECTRICITY
H02J3/46
ELECTRICITY
H02S40/32
ELECTRICITY
H02S40/34
ELECTRICITY
H02S40/36
ELECTRICITY
Abstract
Various implementations described herein are directed to methods for connecting power devices prior to deployment in a photovoltaic installation, for cost savings and easy deployment. Some embodiments disclosed herein include manufacturing a chain of power devices already coupled by conductors, and providing a mechanical assembly for convenient storage and deployment.
Claims
1. An apparatus comprising: a chain of power devices, each power device of the chain of power devices comprising: two inputs configured to couple to a respective power source, a first output coupled to a first conductor, and a second output coupled to a second conductor, wherein outputs of adjacent power devices, of the chain of power devices, are connected to each other via direct connections to respective conductors therebetween, and wherein, for each power device of the chain of power devices: at least one of the first conductor or the second conductor is coupled to an adjacent power device in the chain of power device, and lengths of the first conductor and the second conductor are determined during manufacturing of the apparatus to allow coupling of each power device, of the chain of power devices, to a respective power source.
2. The apparatus of claim 1, wherein, for each power device of the chain of power devices, the first conductor and the second conductor are internally connected to circuitry inside a respective power device.
3. The apparatus of claim 1, wherein, for each power device of the chain of power devices, the first conductor and the second conductor are connected between adjacent power devices, of the chain of power devices, during manufacturing of the apparatus without use of external connectors.
4. The apparatus of claim 1, wherein each power device of the chain of power devices has a total of two connection points.
5. The apparatus of claim 1, wherein, for each power device of the chain of power devices, at least one of the first conductor and the second conductor is soldered or connected via a screw to a respective power device.
6. The apparatus of claim 1, wherein each power device of the chain of power devices comprises at least one of a direct current to direct current (DC/DC) converter or a direct current to alternating current (DC/AC) converter.
7. The apparatus of claim 1, wherein one or more power devices of the chain of power devices are configured to output a time-varying direct current (DC) signal that emulates a rectified sine wave.
8. The apparatus of claim 1, wherein one or more power devices of the chain of power devices are configured to regulate an output of one or more power generators coupled to the one or more power devices.
9. The apparatus of claim 1, wherein one or more power devices of the chain of power devices further comprise at least one of: a communication device, a residual current device, a fuse, a measuring device, or a monitoring device.
10. The apparatus of claim 1, further comprising: a packaging assembly configured to store the chain of power devices.
11. A method comprising: connecting, during manufacturing of a plurality of power devices, the plurality of power devices to each other by directly connecting conductors therebetween to form a chain of power devices; connecting outputs of adjacent power devices, of the plurality of power devices, to each other by directly connecting conductors therebetween to form a chain of power devices; and connecting two inputs, of each power device of the plurality of power devices, to a respective power source, wherein each power device of the plurality of power devices comprises: a first output coupled to a first conductor, and a second output coupled to a second conductor, wherein, for each power device of the plurality of power devices: at least one of the first conductor or the second conductor is coupled to an adjacent power device in the chain of power devices, and lengths of the first conductor and the second conductor are determined during manufacturing of the plurality of power devices to allow coupling of each power device, of the plurality of power devices, to a respective power source.
12. The method of claim 11, wherein, for each power device of the plurality of power devices, the first conductor and the second conductor are directly connected by soldering or screwing the conductors into place within a power device enclosure.
13. The method of claim 11, wherein the connecting the two inputs comprises: connecting the two inputs, of each power device of the plurality of power devices, to the outputs of the respective power source.
14. The method of claim 11, wherein, for each power device of the plurality of power devices: the first conductor and the second conductor are internally connected to circuitry inside the respective power device, the first conductor and the second conductor are connected between adjacent power devices, of the chain of power devices during manufacturing of the apparatus without use of external connectors, and each power device of the plurality of power devices has a total of two connection points.
15. The method of claim 11, wherein each power device of the plurality of power devices comprises at least one of a direct current to direct current (DC/DC) converter or a direct current to alternating current (DC/AC) converter.
16. The method of claim 11, wherein one or more power devices of the plurality of power devices are configured to output a time-varying direct current (DC) signal that emulates a rectified sine wave.
17. The method of claim 11, wherein one or more power devices of the plurality of power devices are configured to regulate an output of one or more power generators coupled to the one or more power devices.
18. The method of claim 11, wherein one or more power devices of the plurality of power devices further comprise at least one of: a communication device, a residual current device, a fuse, a measuring device, or a monitoring device.
19. The method of claim 11, further comprising: storing the chain of power devices using a packaging assembly.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other features, aspects, and advantages of the present disclosure will become better understood with regard to the following description, claims, and drawings. The present disclosure is illustrated by way of example, and not limited by, the accompanying figures. A more complete understanding of the present disclosure and the advantages thereof may be acquired by referring to the following description in consideration of the accompanying drawings, in which like reference numbers indicate like features, and wherein:
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
DETAILED DESCRIPTION
[0018] In the following description of various illustrative embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown, by way of illustration, various embodiments in which aspects of the disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made, without departing from the scope of the present disclosure.
[0019] Since power devices may often be used in bulk (e.g., one power device per photovoltaic generator may be used in a solar installation including multiple photovoltaic strings, each string including ten, twenty or more photovoltaic generators), costs may be reduced and deployment may be easier by packaging power devices in a form which enables multiple devices to be strung out and deployed at one time, along a photovoltaic string. Furthermore, use of a storage device such as a spool to wind multiple cable-connected devices around can make storage and deployment easier and cheaper.
[0020] Referring to
[0021] In some embodiments, one or more PV power device 102a-y may comprise a power conversion circuit such as a direct currentdirect current (DC/DC) converter such as a buck, boost, buck-boost, flyback and/or forward converter. In some embodiments, one or more PV power device 102a-y may comprise a direct currentalternating current (DC/AC) converter, also known as an inverter or a microinverter. In some embodiments, one or more PV power device 102a-y may include a Maximum Power Point Tracking (MPPT) and/or Impedance Matching circuit with a controller, configured to extract regulated (e.g. increased) power from the PV generator the power device is coupled to. One or more PV power device 102a-y may further comprise a control device such as a microprocessor, Digital Signal Processor (DSP) and/or a field-programmable gate array (FPGA). In some embodiments, one or more PV power device 102a-y may comprise circuitry and/or sensors configured to measure parameters on or near the photovoltaic generator, such as the voltage and/or current output by the generator, the power output by the generator, the irradiance received by the generator and/or the temperature on or near the generator.
[0022] In the illustrative embodiment depicted in
[0023] Since PV power devices of known systems may be generally manufactured, packaged and sold separately, PV installations which include a plurality of PV generators, e.g., installation 100a may require unpacking a large number of devices, individually coupling each device to its corresponding photovoltaic generator, and then coupling the power devices to one another using cables which may be sold separately as well. In some embodiments introduced herein, a power device chain is provided. The power device chain may include a plurality of power devices each coupled to at least one other power device using conductors of appropriate length at the time of manufacturing. Accordingly, power device chains as described herein may be packaged and sold as a single unit, and deployed as a single unit when installing installation 100a. For example, power devices 102a-m may comprise a string of power devices or part of a string of power devices, and may be coupled to one another during manufacturing. During installation, the string may simply be strung out alongside photovoltaic modules 101a-m and each device may be coupled to its corresponding module quickly and easily, forming photovoltaic string 316a.
[0024] As shown in
[0025] Referring now to
[0026] characteristics as illustrative installation 100a of
[0027] In the illustrative embodiment show in
[0028] Reference is now made to
[0029] Referring to
[0030] installation 100d, comprising a plurality of photovoltaic generators 101a-m each coupled to a power device 122a-m. Each power device may have two outputs, one coupled to a mutual power bus, and one coupled to a mutual ground bus, coupling all the power devices in parallel. In some embodiments, one or more power device 122a-m may comprise a DC/DC converter, with each converter's positive output coupled to the power bus, and the negative terminal coupled to the ground bus. In some embodiments, one or more power device 122a-m may comprise a DC/AC converter, with the AC outputs synchronized to allow parallel coupling. In some embodiments including an AC output by the power devices, the AC output may be a single phase coupled to the power and ground buses, and in some embodiments three or more phases may be output to more than two buses. The system may further include the power bus and ground bus being input to grid-coupling device 120. In embodiments including a DC output by the power devices, grid coupling device 120 may include a DC/AC inverter. In embodiments including an AC output by the power devices, grid coupling device 120 may include a transformer. Grid coupling device 120 may be similar to or the same as system power device 110 of
[0031] Referring to
[0032] photovoltaic power device. System 100e includes two photovoltaic modules (e.g. photovoltaic panels or a different type of photovoltaic generator) 111a, 111b coupled to each other in series, with a photovoltaic power device 112a coupled in parallel to the serially coupled modules 111a, 111b. Similar to other embodiments disclosed herein, a plurality of power devices 112a-x may be coupled in series to form a photovoltaic string 321a, with multiple strings 321a-n coupled in parallel between the ground and power buses. In some embodiments, inverter 123 may receive a DC input from the ground and power buses and output AC power to the grid or home. In similar embodiments, the power devices may be precoupled to one another at the time of manufacturing, with the conductors coupling the power devices being sized to allow the desired number of photovoltaic generators to be coupled to each power device. For example, if each two PV generators are to be coupled to one another and to a single power device, the length of each conductor between power devices being around double the width or length of each photovoltaic module.
[0033] Referring to
[0034] various ways. In one illustrative embodiment, photovoltaic power device 102 may comprise a casing 231 containing circuitry 230, input terminals 210c and 210d, and output conductors 220c and 220d. In other embodiments, casing 231 may be replaced by a surface on which circuitry 230 is mounted, the surface being snapped to a different part of a photovoltaic apparatus such as a junction box. In some embodiments, there may be more than two input terminals. For example, some embodiments may include four input terminals for coupling the power device to two photovoltaic modules, the power device processing power input from both modules.
[0035] In some embodiments, circuitry 230 may include a power conversion circuit such as a direct currentdirect current (DC/DC) converter such as a buck, boost, buck-boost, Cuk, charge pump, flyback and/or forward converter. In some embodiments, circuitry 230 may include a direct currentalternating current (DC/AC) converter, also known as an inverter or a microinverter. In some embodiments, circuitry 230 may include a Maximum Power Point Tracking (MPPT) circuit with a controller, configured to extract increased power from the PV generator the power device is coupled to. Circuitry 230 may further comprise a control device such as a microprocessor, Digital Signal Processor (DSP) and/or an FPGA. In some embodiments, circuitry 230 may include circuitry and/or sensors configured to measure parameters on or near the photovoltaic generator, such as the voltage and/or current output by the generator, the power output by the generator, the irradiance received by the generator and/or the temperature on or near the generator. Input terminals 210c and 210d may be coupled to outputs of one or more photovoltaic modules, and may also be coupled to circuitry 230 for processing and/or measuring the power output by the corresponding photovoltaic module. Output conductors 220c and 220d may couple the photovoltaic power device to adjacent devices, to form a serial or parallel photovoltaic string. The input and output terminals may be physically connected to different parts of casing 231. The input terminals 210c and 210d may be physically located next to one another along one side of casing 231, with output conductors 220c and 220d occupying opposite sides of casing 231, on either side of input terminals 210c and 210d. In other embodiments, the input terminals and output conductors may be configured differently, as will be shown herein. The location of the input terminals and output conductors may be chosen considering the layout and wiring design of the system at hand. Mechanical considerations, such as enabling optimal storing of the entire chain of power devices, may also factor into designing the location of the input terminals and output conductors. The photovoltaic power device 102 shown in
[0036] Referring now to
[0037] configured such that input terminal 210a is adjacent to output conductor 220a, both connected to a side of casing 231, and on the opposite side of casing 231 input terminal 210b is adjacent to output conductor 220b. This illustrative embodiment may be particularly suited for coupling photovoltaic power device 103a to two photovoltaic generators (in systems such as those shown in
[0038] Referring now to
[0039] configured such that input terminals 210e and 210f are located on opposing sides of casing 231, while output conductors 220e and 220f are located on the other pair of opposite sides of casing. Thus, four sides of the casing contain either an input terminal or an output conductor. This illustrative embodiment may, in some configurations, enable optimal packaging of the chain of power devices and enable it to be stored in a compact convenient way. The chain according this embodiment can be deployed in a way that couples each power device to either one or two photovoltaic modules.
[0040] Referring now to
[0041] embodiments, circuitry 230 may include power converter 240. Power converter 240 may include a direct current-direct current (DC/DC) converter such as a buck, boost, buck-boost, flyback and/or forward converter. In some embodiments, power converter 240 may include a direct currentalternating current (DC/AC) converter, also known as an inverter or a microinverter. In some embodiments, circuitry 230 may include Maximum Power Point Tracking (MPPT) circuit 295, configured to extract increased power from the PV generator the power device is coupled to. In some embodiments, power converter 240 may include MPPT functionality, and MPPT circuit 295 may not be included. Circuitry 230 may further comprise control device 270 such as a microprocessor, Digital Signal Processor (DSP) and/or an FPGA. Control device 270 may control and/or communicate with other elements of circuitry 230 over common bus 290. In some embodiments, circuitry 230 may include circuitry and/or sensors 280 configured to measure parameters on or near the photovoltaic generator, such as the voltage and/or current output by the generator, the power output by the generator, the irradiance received by the generator and/or the temperature on or near the generator. In some embodiments, circuitry 230 may include communication device 250, configured to transmit and/or receive data and/or commands from other devices. Communication device 250 may communicate using Power Line Communication (PLC) technology, or wireless technologies such as ZigBee, Wi-Fi, cellular communication or other wireless methods. In some embodiments, PLC signals may be transmitted and/or received over output conductors 220a and/or 220b. In some embodiments, a communications link (e.g. an optical fiber) may be integrated with output conductors 220a and/or 220b and may be communicatively coupled to communication device 250. In some embodiments, a thermal sensor device (e.g. a thermocouple device or a Linear Heat Detector) may be integrated with output conductors 220a and 220b and may provide temperature measurements (e.g. measurements obtained at various locations along output conductors 220a and 220b) to control device 270. Input terminals 210a and 210b may be coupled to outputs of one or more photovoltaic modules, and may also be coupled to circuitry 230 for processing and/or measuring the power output by the corresponding photovoltaic module. In some embodiments, circuitry 230 may include safety devices 260 (e.g. fuses, circuit breakers and Residual Current Detectors). The various components of circuitry 230 may communicate and/or share data over common bus 290.
[0042]
[0043] Conductors 412a-412d may be (e.g. during manufacturing or chain 410) internally connected to circuitry (e.g. circuitry 230 of
[0044] Referring now to
[0045] comprise output conductors which double as ground and power buses of a parallel-connected photovoltaic installation, similar to the system shown in
[0046] Referring now to
[0047] Reference is now made to
[0048] Reference is now made to
[0049] Referring to
[0050] Referring now to
[0051] used to store a chain of power devices in a way that enables convenient storing and fast and easy deployment of the chain of power devices. A chain of photovoltaic power devices may comprise PV power devices 102 coupled to one another by output conductors 220. The chain may be stored by being wound around storage device 400. In the illustrative embodiment depicted in
[0052] In some embodiments, an apparatus includes a plurality of power devices and a plurality of photovoltaic generators connected to the power devices. The power devices may include an input terminal, a common terminal and first and second output terminals. An input terminal of a first power device may be connected to a first power source terminal of one of the plurality of photovoltaic generators, a first output terminal of a second power device may be connected to a second power source terminal of one of the plurality of photovoltaic generators, and a second output terminal of the second power device may be connected to a common terminal of the first power device. The first and second output terminals may output a common output voltage, with a total output current flowing through the power device (e.g. a photovoltaic string current where the power device is part of a photovoltaic string) being divided between a first output current flowing through the first output terminal and a second output current flowing through the second output terminal. The first output current may further flow through a connected photovoltaic generator, and in some embodiments, the power device may be operated to provide a first output current corresponding to a Maximum Power Point current of the photovoltaic generator. The power device may be operated to provide a second output current corresponding to a differential current between the total output current and the first output current.
[0053] In some embodiments, the first output terminal may comprise a connector designed to be connected to a photovoltaic generator terminal, for example, using an MC4? connector. In some embodiment, the second output terminal and the common terminal may comprise conductors preconnected to the power device and other power devices (e.g. conductors 220c and 220d of
[0054] At least one of the power devices may include a combiner box configured to couple to a plurality of photovoltaic strings and to combine power from the plurality of photovoltaic strings. One or more power devices may include one or more sensors or sensor interfaces configured to measure or to receive measurements of one or more parameters associated with the plurality of photovoltaic generators. One or more power devices may include one or more safety switches configured to disconnect and/or short circuit the photovoltaic generators upon detection of a predefined potentially unsafe condition or in response to a manual trigger. The manual trigger may include activation of a rapid-shutdown switch or button.
[0055] In some embodiments, the power device may include output conductors configured to transmit and/or receive PLC signals. A communications link (e.g. may be integrated with output conductors and may be communicatively coupled to a communication device. A thermal sensor device may be integrated with output conductors and may provide temperature measurements to a control device associated with the apparatus. The thermal sensor device may include a thermocouple device and/or a linear heat detector. Temperature measurements by the thermal sensor device may be obtained at one or more locations along the output conductors.
[0056] In some embodiments, an apparatus includes a plurality of power devices and a plurality of conductors connecting, each connecting one power device to at least one other power device. A first conductor may be connected between an input of a first power device and a first output of a first power generator. A second conductor may be connected between an output of the first power device and a second output of first power generator. A third conductor may be connected between an output of a second power device and the common terminal of the first power device. The conductors may be internally connected to circuitry inside a respective power device. At least one of the plurality of conductors may, at a first end, be soldered or connected via a screw to the power device. A second end of the conductor may be soldered or connected via a screw to another power device. Specifically, the first end and second end may each be connected to a power converter or monitoring device in a respective power device.
[0057] Other embodiments may consider alternative storage techniques, such as packing power device chains into boxes, winding the chain around multiple poles, and the like.
[0058] Although selected embodiments of the present invention have been shown and described, it is to be understood the present invention is not limited to the described embodiments. Instead, it is to be appreciated that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and the equivalents thereof. Further, elements of one embodiment may be combined with elements from other embodiments in appropriate combinations or subcombinations. For example, conductors 234a-b of
[0059] In illustrative embodiments disclosed herein, photovoltaic generators are used as examples of power sources which may make use of the novel features disclosed. Each PV generator may comprise one or more solar cells, one or more solar cell strings, one or more solar panels, one or more solar shingles, or combinations thereof. In some embodiments, the power sources may include batteries, flywheels, wind or hydroelectric turbines, fuel cells or other energy sources in addition to or instead of photovoltaic panels. Systems, apparatuses and methods disclosed herein which use PV generators may be equally applicable to alternative systems using additional power sources, and these alternative systems are included in embodiments disclosed herein.