Solar array recombiner box with wireless monitoring capability
10347775 ยท 2019-07-09
Assignee
Inventors
Cpc classification
H01L2924/0002
ELECTRICITY
Y04S20/30
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
Y02E10/50
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
H01L2924/0002
ELECTRICITY
G01D2204/35
PHYSICS
Y02B90/20
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
H02S50/10
ELECTRICITY
H01L2924/00
ELECTRICITY
Y02B70/34
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
International classification
Abstract
A system for monitoring and wirelessly transmitting solar array parameters such as current, voltage and temperature in real time is primarily housed within a recombiner box. The system lends itself to retrofitting within some commercially available recombiner boxes. Signals emitted from the RF controller component of the system are received by a central processor, which includes a dashboard interface. Multiple systems in proximity can be linked to form a mesh network with one central processor.
Claims
1. A solar monitoring system comprising: A) A plurality of solar panels; B) One (re)combiner box for aggregating DC power, said (re)combiner box electrically coupled to said plurality of solar panels and including a fuse bar having a plurality of fuses; C) One sensor control module configured to be plugged into said fuse bar as a solitary unit, said sensor control module including a base with a plurality of locking mechanisms and a lid with corresponding locking mechanisms, said lid defining a plurality of apertures, said sensor control module located within said (re)combiner box and including a plurality of outwardly extending string monitor terminals positioned in a line with each of said string monitor terminals in a fixed position relative to each other while plugged into said fuse bar and while unplugged from said fuse bar, each of said string monitor terminals plugged into a corresponding fuse in said fuse bar, whereby said sensor control module is in communication with said plurality of solar panels, and wherein said sensor control module includes bobbins, the quantity of said bobbins equal to the quantity of said fuses, and said bobbins each including a core comprised of at least two separate portions; D) An RF controller in communication with said sensor control module, said RF controller including an antenna for wirelessly transmitting a signal; and E) A receiver for said signal.
2. The system of claim 1 wherein said sensor control module includes at least one current sensor.
3. The system of claim 2 wherein the number of said current sensors is equal to the number of said arrays.
4. The system of claim 1 wherein said sensor control module includes a voltage sensor.
5. The system of claim 1 wherein said RF controller includes a temperature circuit.
6. The system of claim 1 wherein said receiver is in communication with a processor, said processor configured to interpret said signal, and display said interpretation within an interface.
7. A monitoring system for an array of solar panels, said system comprising: A) A (re)combiner box for aggregating DC power electrically coupled to an array of solar panels, said (re)combiner box including at least one fuse bar with a plurality of fuses; B) An L-shaped sensor control module configured to be plugged into said fuse bar as a solitary unit, said sensor control module including an L-shaped base with a plurality of locking mechanisms and an L-shaped lid with a plurality of corresponding locking mechanisms, said L-shaped lid defining a plurality of apertures, the leg of the sensor control module including a plurality of outwardly extending string monitor terminals positioned in a line parallel to-said fuse bar with each of said string monitor terminals in a fixed position relative to each other while plugged into said fuse bar and while unplugged from said fuse bar, wherein each of said string monitor terminals is plugged into a corresponding fuse, and wherein said leg of the sensor control module includes bobbins, the quantity of said bobbins equal to the quantity of said fuses, and said bobbins each including a core comprised of at least two separate portions; and C) A bus bar engaged with the foot of the L, said bus bar parallel to, and engaged with, said fuse bar.
8. The monitoring system of claim 7 further comprising an RF controller in communication with said sensor control module, said RF controller including an antenna.
9. The monitoring system of claim 7 wherein said sensor module leg includes current sensors, the quantity of said current sensors equal to the quantity of said fuses.
10. The monitoring system of claim 9 wherein said current sensors are Hall effect sensors.
11. The monitoring system of claim 7 wherein said sensor module leg includes bobbins, the quantity of said bobbins equal to the quantity of said fuses, and said bobbins each including a screw assembly with a movable plate.
12. A system of collecting solar energy, said system including: A) A plurality of solar panels, each solar panel in communication with a single (re)combiner box for aggregating DC power having a plurality of fixed fuses; B) A single sensor control module configured to be plugged into said fixed fuses as a solitary unit, said sensor control module having a plurality of protruding rigid string monitor terminals positioned in a line with each of said string monitors in a fixed position relative to each other while plugged into said fixed fuses and while unplugged from said fixed fuses, each one of said string monitor terminals plugged into exactly one fixed fuse, said sensor control module in communication with said plurality of solar panels, and said sensor control module having a housing formed of a base with a plurality of locking mechanisms and a lid with corresponding locking mechanisms, said lid defining a plurality of apertures, said sensor control module located within and integrated with said (re)combiner box, and wherein said sensor control module includes bobbins, the quantity of said bobbins equal to the quantity of said fuses, and said bobbins each including a core comprised of at least two separate portions; C) An RF antenna in communication with said sensor control module; and D) At least one receiver in communication with said RF antenna.
13. The system of claim 12 wherein said at least one receiver is in communication with at least one processor.
14. The system of claim 12 further comprising at least one additional plurality of solar panels, said plurality and said additional plurality in communication one with another.
Description
BRIEF DESCRIPTION OF THE DRAWING
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
(19) In the following description, like reference characters designate like or corresponding parts throughout the several views. It should be understood that the following descriptions and illustrations describe preferred embodiments of the inventions, but are not intended to limit the inventions thereto.
(20) The following structure numbers shall apply to the following structures among the various FIGS.: 10Monitoring system; 12Temperature circuit; 13Solar array; 15Solar panel; 16Temperature sensor; 17Temperature sensor data output; 18Monitoring input branch; 19First HV return; 20Terminal block; 21Second HV return; 22Third HV return; 23Fourth HV return; 24Set of arrays; 25Recombiner box 26Fuses; 27Fuse bars; 28Leg; 29Foot; 30Sensor control module; 31Leg base; 32Leg lid; 33Leg end cap; 34End cap spring clip; 35Aperture; 36Locking mechanism; 37Sensor control module current inputs; 38Bus bar; 39First HV supply; 40Bobbin; 41Screw assembly; 42Bobbin input terminal; 43Windings; 44Bobbin output terminal; 45Core; 46Flexible circuit board; 47Pad stack; 48Hall-effect sensor; 49Notches; 50RF controller; 51Antennae; 52RF signal; 53Power supply; 54Control module multi-conductor cable; 55Battery; 56Charger; 58RF controller low voltage and ground; 60Power brick; 61Second HV supply; 63Brain; 64Boot base; 65Printed circuit board; 66Foot lid; 70Processor; 72RF dongle; 74Dashboard; 80Inverter; 82Movable plate; 83Screw lock box; 84Screw lock clamp; 85Clamp screw; 86Three-point terminal; 87Tab; 88String monitor terminal; 90Gap; 91Flex circuit holders; 92Flex board cut outs; 95Mesh network; 110User interface; 112Overview bar; 114Navigation bar; 116Preview graph; 118Lifetime graph; 120Site level sample graph; 122Site level preview graph; 124Site map; 126Combiner bar; 128Site level alert; 130Combiner lifetime graph; 132Combiner lifetime preview graph; 134Navigation tabs; 136Combiner navigation; 138Drill-down filter; 140Combiner sample graph; 142Combiner sample preview graph; 144Combiner alert; 146Combiner string level graph; 148String selection; 150Selection bar; and 152Badge.
(21) As used herein, recombiner box and combiner box are interchangeable terms, and the inventions can be used with either configuration.
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(23) The major components of system 10 include temperature circuit 12, terminal block 20, sensor control module 30, RF controller 50, power brick 60, and processor 70. Power leaving system 10 goes to inverter 80, in accordance with known solar power generation architecture.
(24) Temperature circuit 12 is connected to temperature sensor 16 by temperature sensor data output 17. Array 13 preferably includes only a single, properly positioned temperature sensor 16, as the temperature reported from one panel 15 can be representative of all panels, and more than one properly positioned temperature sensor would likely be unnecessarily redundant. Temperature circuit 12 is integrated with RF controller 50, with the latter transmitting temperature data RF signals 52 to processor 70.
(25) System 10 also includes terminal block 20, with first, second, third and fourth high voltage returns 19, 21, 22 and 23, respectively, which are on a common node, as shown in
(26) Power brick 60 powers system 10 by diverting high voltage from other components in the system, and stepping down the voltage to lower voltage, preferably 14V. As used herein, high voltage is at least 600V, and preferably 600V, 1000V or 1500V. Third high voltage return 22 and second high voltage supply 61 deliver high voltage from terminal block 20() and bus bar 38(+), respectively, to power brick 60. First high voltage supply 39 delivers high voltage from bus bar 38 to inverter 80, and therefore, like second high voltage supply 61, has the same potential as bus bar 38. Power brick 60 supplies 14V power and ground to RF controller 50, and to the components associated with sensor control module 30 via RF controller 50.
(27) RF controller 50 is in communication with, and receives current and voltage data from brain 63 of sensor control module via control module multi-conductor cable 54. RF controller 50 also receives temperature data from temperature sensor 16 via temperature sensor data output 17. These data are transmitted by antennae 51 as RF signals 52 to processor 70. RF controller 50 preferably includes RF engine (not shown) which is a product of Synapse Wireless Incorporated in Huntsville, Ala., and commercially available as RF100PC6 from Future Electronics in Huntsville, Ala.
(28) RF controller 50 also includes power supply/voltage regulator 53, charger 56 and battery pack 55. Power supply/voltage regulator 53 is fed by RF controller low voltage and ground 58. Those in the art will understand that RF controller low voltage and ground 58 is a multiconductor cable, but conducts voltage and ground only. Charger 56 is powered by power supply/voltage regulator 53. Battery pack 55 includes a circuit board for dealing with over-temperature, and for shutting down and monitoring capability. Battery pack 55 is necessary because solar power collected on-the-fly is not always adequate to power the system. For example, current available to power the system varies according to time of day, weather, and whether or not the system is functioning properly. Battery pack 55 ensures system 10 continues operating regardless of power generated. Preferably battery pack 55 is 3.6 V. Preferred battery pack 55 can be purchased as part number XSS-ICR18650-22-PC from House of Batteries, in Fountain Valley, Calif.
(29) Processor 70 includes RF dongle 72, which receives RF signals 52 emitted by antennae 51 of RF controller 50. Processor 70 can be a standard desktop, laptop computer, or industrial PC, which has access to, or has been loaded with, appropriate dashboard software, and preferably includes Synapse Wireless Incorporated of Huntsville, Ala.'s gateway adaptor, which is commercially available as RF100PC6 from Future Electronics in Huntsville, Ala. The minimum performance specifics of processor 70 vary according to the number of solar arrays 13, and therefore amount of data to be processed. RF dongle 72 is a product of Synapse Wireless Incorporated in Huntsville, Ala., and is commercially available as SN-132HO-NR from Future of Electronics of Huntsville, Ala.
(30) Screen shots from a representative dashboard program are set forth in
(31) Referring now to
(32) Preview graph 116 shows a miniature representation of the system over its lifetime. A user can click and drag to select a range, or select a quick zoom in selection bar 150, such as week, month or year. The selected range is displayed in lifetime graph 118.
(33) Referring now to
(34) The dashboard technology is capable of importing the combiner layout (ie graphic representation of where specific combiner boxes are physically located relative to each other) from an external site plan, and displaying that layout as site map 124, shown in
(35) It is further preferable that mousing over any section of site map 124 results in a tool tip pop up (not shown) that displays the real-time power, current and voltage, and the combiner ID for that section, in addition to highlighting it in the combiner bar 126.
(36) Site level alert 128, as shown in
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(38) Referring now to
(39) Processor 70 preferably also includes functionality to remotely alert users when certain threshold data, or combinations of data, are received. By way of example, a sudden and significant decrease in current for a given array 13 may indicate a problem with an individual solar panel 15. Suitable alerts could be communicated via telephone, text messaging, emails, beepers, sirens or the like.
(40) Sensor control module 30 is the nerve center of system 10. As shown in
(41) Referring to
(42) The guts of leg 28 include the screw assembly 41, which sits above bobbin 40, and flexible circuit board 46 including Hall effect sensors 48 (seen best in
(43) Referring to
(44) Referring now to
(45) As shown in
(46) Turning back to
(47) In order to facilitate flexibility of the system, length of leg 28 can be varied to accommodate different quantities of fuses. For example, lid 32 preferably defines 16 apertures 35, but leg 28 can be shortened by clipping, sawing, cutting or the like to accommodate as few as 1 fuse 26. Likewise, monitoring system 10 is capable of handling many fuses 26, depending upon recombiner box. System 10 preferably monitors up to 32 strings without excessive redundancy. Leg end cap 33 (
(48) As shown in
(49) An example of the system is a 5.5 MW installation including 12,000 panels 15 from First Solar, Inc. of Tempe, Ariz., model number FS-270. These panels are wired in series in the field using 10-string wire harnesses (aka monitoring input branch 18) from Shoals Technologies Group in Portland, Tenn. Accordingly, each array 13 includes ten panels 15. These wire harnesses go into combiner boxes 25, with each combiner box 25 accommodating 15 wires (input branches 18), which correspond with 15 arrays. The combiner boxes are available from Shoals Technologies Group as combiner box STG-CBC-1525. Sensor control module current inputs 37 connect inside the combiner box to the sensor control module 30. Data from sensor control module 30 is relayed by RF controller 50 to the central processor (70) on the site. The current and power output of each array 13 in the field is monitored over the internet with the correct password.
(50) Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, it is possible to add features to the system such as an indicator when a fuse is blown. Also, the system includes extra expansion slots, an expansion pack of sorts, for a variety of functionality such as interfacing with glass temperature gauges or other devices as desired by an end user. Moreover, the dashboard software can be modified to alert a user, or users, to a variety of conditions, for example when the energy output of one panel is significantly lower than others nearby, or when there is a significant decrease in energy output without a corresponding decrease in ambient temperature. These anomalies may indicate that panels in the field require attention because they are, for example, shaded, dirty, or broken. Also, the system could be configured to be a separate per string monitor that would permit every string to have its own module, versus integration into a large L system. It is also possible to integrate the current sensing into the fuse holder. In addition, it is possible to configure the system to monitor more than 32 strings at a time without excessive redundancy. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.