MOBILE POWER SYSTEM
20180212087 ยท 2018-07-26
Inventors
Cpc classification
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
Y02E10/40
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
Y02E70/30
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
H02S30/00
ELECTRICITY
F24S40/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F24S40/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02S30/00
ELECTRICITY
H02S40/38
ELECTRICITY
Abstract
A mobile power plant comprising a retractable flexible solar array structure comprising a plurality of thin film photovoltaic modules mounted on a flexible substrate; a spool attached to a portion of the flexible solar array structure and around which the flexible solar array structure can be rolled; power cabling integrated into the flexible solar array structure for transmitting power from the plurality of photovoltaic modules to the spool-end of the flexible solar array structure; a transportable container in which the spool is mounted, the transportable container being capable of housing the flexible solar array structure when it is in a rolled configuration.
Claims
1. A mobile power plant comprising: a flexible solar panel structure comprising a plurality of thin film photovoltaic panels mounted on a flexible substrate, the flexible substrate comprising a layered structure; a spool attached to a portion of the flexible solar panel structure and around which the flexible solar panel structure can be rolled; insulated power cabling integrated into the layered structure of the flexible substrate extending along a length direction of the flexible solar panel structure, wherein at least some of the insulated power cabling transmits power from the plurality of thin film photovoltaic panels to a spool-end of the flexible solar panel structure using a parallel connection, a transportable container in which the spool is mounted, the transportable container being capable of housing the flexible solar panel structure when it is in a rolled configuration.
2. A mobile power plant according to claim 1, having a battery bank and charge controllers for storing energy generated by the flexible solar panel structure.
3. A mobile power plant according to claim 1, having an inverter for transferring power from the flexible solar panel structure or battery bank to output AC power.
4. A mobile power plant according to claim 1, wherein the layered structure of the flexible substrate a tension-bearing substrate layer onto which the thin film photovoltaic panels are mounted, the tension-bearing substrate layer being capable of bearing a tensile stress imposed on the flexible solar panel structure when it is unrolled.
5. A mobile power plant according to claim 1, wherein the transportable container is an ISO standard shipping container.
6. A mobile power plant according to claim 2, comprising a power connection configured to receive power from an external source to charge a battery bank of the mobile power plant to enable integration into a grid, the power connection being capable of being implemented as required by an existing smart-grid control system or smart grid industry standard.
7. A mobile power plant according to claim 1, comprising an electronics system configured to control and/or limit a charge state, power output, or other relevant properties of the mobile power plant to enable integration into a grid, the electronics system being capable of being implemented as required by an existing smart-grid control system or smart grid industry standard.
8. A mobile power plant according to claim 1, comprising a telecommunications system configured to enable control of relevant properties of the mobile power plant to be carried out remotely by a human operator or by a computer system, the telecommunications system being capable of being implemented as required by an existing smart-grid control system or smart grid industry standard.
9. A mobile power plant according to claim 1, including a secondary backup power source and/or secondary energy storage module.
10. A mobile power plant according to claim 9, wherein the secondary backup power source includes one or more of a diesel generator, a fuel cell, and a hydrogen generator.
11. A mobile power plant according to claim 1, having a series of support poles and guy ropes capable of raising one side edge of the flexible panel structure once deployed, in order to incline it towards the sun.
12. A mobile power plant according to claim 2, having retractable high power DC connectors between the spool and the charge controllers, so that in use the power cabling received at the rotating spool can be connected to fixed power cables that connect to the charge controllers and/or an inverter.
13. A mobile power plant according claim 1, wherein the flexible substrate comprises a layered structure, the power cabling being integrated into a single layer of the flexible substrate.
14. A mobile power plant according to claim 1, wherein the flexible substrate comprises a layered structure that includes a layer of protective backing material on the flexible solar panel structure.
15. A mobile power plant according to claim 1, wherein the flexible substrate comprises a layered structure that includes an environmental sealing coating for preventing environmental damage to the flexible solar panel structure.
16. A mobile power plant according to claim 1, having one or more feeder arms, the one or more feeder arms being capable of guiding the flexible panel structure into the transportable container.
17. A mobile power plant according to claim 1, with a retractable weather-protective screen to at least partially cover an openable side of the container from which the panel structure may extend in use.
18. A mobile power plant according to claim 17, wherein a lower part of the screen has a brush or sweeper edge which is capable of removing attached debris from the lower side of the flexible panel structure during retraction or deployment of the flexible panel structure.
19. A mobile power plant according to claim 1, wherein the spool is motorized.
20. A mobile power plant according to claim 1, comprising a grid-synchronous AC inverter to enable integration into a grid.
21. A mobile power plant according to claim 1, wherein protection is provided against Electromagnetic Pulse (EMP) attack or lightning strike, the protection comprising mesh screening to form a Faraday Cage around the transportable container, the mesh screening being attached to the walls of the transportable container.
22. A mobile power plant according to claim 1, wherein protection is provided against Electromagnetic Pulse (EMP) attack or lightning strike, the protection comprising surge protectors at the point of connection of the incoming power cabling from the panel structure to isolate any incoming surge that has been created in the panel structure and protect the components in the container.
23. A mobile power plant according to claim 22, wherein the mesh screening is attached to the walls of the transportable container and the weather-protective screen.
24. A mobile power plant according to claim 23, where the container is armored, the armor being capable of providing protection against small arms fire, RPGs, and/or IEDs.
Description
BRIEF DESCRIPTION OF THE FIGURES
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DETAILED DESCRIPTION
[0078] In the descriptions that follow, a 100 kW output 40 ft (12.2 m) container model is described as preferred. However, other lower outputs in smaller containers are also possible, and power outputs larger than 100 kW may also be possible within 40 ft (12.2 m) or even larger container sizes.
[0079] A key advantage of the mobile power plant 1 of the present invention is that the thin nature of the flexible array structure 3both the PV panels (not labelled for clarity) and the substrate to which they are mountedmeans that a very large length of PV panels can be stored rolled up 5 inside the container 7 (
[0080] This presents a very large area of panelup to 2000 m.sup.2 in the case of a 40 ft (12.2 m) container 7. When stowed as shown in
[0081] In the embodiment of
[0082] In the unrolled or deployed configuration (
[0083] The flexible array structure 3 can be rolled around a spool 30. In some examples, the spool 30 is hollow. In some examples, the spool 30 is not hollow. In some examples, the spool 30 is not motorised. In some examples, the spool 30 is motorised.
[0084] A battery bank 32 is laid across the floor of the container 7, in order to spread the weight inside the container 7 and leave the greatest width available for the spool 30 and therefore for storable PV panels.
[0085] In a preferred example, at least enough battery capacity should be provided in order to maintain 30% of output for 24 hours. Based on the preferred 100 kW output unit in a 40 ft (12.2 m) container 7, this equates to 720 kWh of useable battery capacity.
[0086] Any suitable battery chemistry may be chosen. Due to the large amount of storage provided, preference may be given to those battery chemistries which provide an adequate energy density, deep discharge capability and long cycle life whilst still maintaining strong cost competitiveness. Therefore, as an example, lead acid (up to 50 wh/kg and 50% depth of discharge (DoD)) may not be preferred because the weight of the batteries would approach 29 tonnes (29,000 kg), which is in excess of the 40 ft (12.2 m) ISO container maximum net load of 26.5 tonnes (26,500 kg). As another example, advanced lithium ion batteries (of the Lithium Cobalt or Lithium Manganese type) may not be preferred from a cost perspective ($500 or more per kWh). Lithium iron phosphate or lithium yttrium iron phosphate batteries may provide an appropriate balance as they are cost competitive with lead acid batteries when an 80% DoD capacity has been accounted for, and they have an energy density of up to 90 wh/kg resulting in total battery weight of around 10 tonnes (10,000 kg). In some examples, a Flow Battery (a type of reversible fuel cell appropriate for large scale energy storage) could be used.
[0087] Even with batteries capable of very high charge-discharge efficiencies of 95% or more, large amounts of heat may be expected to be generated within the battery bank 32perhaps around 5 to 7 kW of heating. The skilled person will therefore understand that cooling fans (not shown) may be preferred and in such cases the battery bank 32 should be structured in such a way as to leave air circulation gaps between cells, and have extraction fans and vents appropriately positioned so that the air flows evenly through all the cells within the battery bank. Similarly, cooling fans may be required to remove excess heat from the charge controllers and/or inverter.
[0088] Three possible options for the electrical layout and connections between the panels are shown in
[0089] The first option is illustrated in
[0090] The second option is shown in
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[0092] The number of parallel cable runs may be many more or less than that shown. Strings of 2 modules in series are shown with each string having dedicated cabling back to the junction boxes. Each of these strings can be considered as a subsection of the array. The example shows 3 longitudinal strings, although many more longitudinal strings may be present with cable-laying density higher than that illustrated. The example also illustrates how junction boxes (which may be located in the spool) may be used to parallel a number of strings together prior to connection to a dedicated inverter or charge controller to create a separately managed modular array supersection. For the purposes of clarity, longitudinal modular array supersections are shown, although in reality it may be advantageous to create lateral modular array supersections because this approach facilitates better performance under longitudinal shading variationsand additionally enables good performance if the array is only partially unrolled.
[0093] In this example the subsections are strings of modules connected in series. In other example modules may be connected in parallel to for a subsection.
[0094] In a typical example, a subsection may be about 100W-400W and a supersection might be about 2000W-8000W.
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[0096] A preferred arrangement for connecting power cabling from within a rotatable spool 30 to fixed power cabling that runs to the charge controllers 34 is described with reference to
[0097] A solution to integrating the DC power cabling within the array structure 3 is shown in the cross-section view
[0098] An alternative configuration of the array cross-section is shown in
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[0102] The performance figures noted in the above preferred example are based on currently commercially available and relatively inexpensive flexible PV panels with an efficiency of 12.6% producing around 106 W/m.sup.2. There is much greater potential for efficiency improvement in thin-film panels such as CIGS, GaAs, CdTe and organic dye-based cells, as these are still in the early stages of commercialisation and. optimisation continues to yield percentage gains. Alta Devices, for example, has already achieved 28.8% efficiency in their GaAs cells, potentially resulting in 240 W/m.sup.2 or more. Whilst these panels are currently very expensive, their use in the power plant of the present invention may provide a unit producing in excess of 300 kWp. With further optimisation with as thin and strong as possible a substrate this may approach 500 kWp. The trend of improved efficiencies and reducing costs of thin-film solar cell technology is likely to lead to further strengthening of the present invention in the future.
[0103] In addition to the above, a number of other features may be considered important in the potential markets available to this invention. A first example is integration into a wider area grid or a localized power grid (a micro-grid). Whilst the power plant of the invention is capable of performing as a stand-alone off-grid energy source, it may be preferred to operate it in conjunction with other sources of energy, preferably with other renewable sources of energy, such as wind-turbines, hydro power or the wider grid. There is presently an increased focus on enabling micro-grid technologies such as so-called smart grid control systems which collect data from grid-connected generators or loads and manage the balance of power generation and demand.
[0104] Accordingly, the power plant of the invention may be provided with a grid-synchronous AC-inverter so that it may be connected to a grid with which to share its power output. In addition to sharing its power output, it may be advantageous for a smart-grid to have control over energy storage facilities and to be able to feed excess power to them when necessary. Accordingly, the system of the invention may be provided with a power connection to receive power from an external source to charge the batteries included in the mobile power plant. This feature may be particularly helpful, for example, when an energy source such as a wind turbine elsewhere in the grid is generating at high output, but the mobile power plant is not due to high cloud cover or during the night. In this case, the mobile power plant could still receive a full battery charge and the excess power from the wind turbine would not be wasted. In order to enable this level of control by a smart-grid management system, electronics systems which control and/or limit the charge state and power output of the mobile power plant may be used, and/or telecommunications systems (which may be LAN, WiFi, cellular data or other form of data network connection) to enable the feedback of data and receipt of control commands. These methods may be implemented using products of existing smart-grid control systems or as per a published industry standard for such methods.
[0105] A second additional feature that may be considered of importance is the inclusion of a secondary backup power source such as a diesel generator or fuel cell with the mobile power plant of the invention. This may be particularly useful in locations of variable solar irradiance, so that backup power can be provided beyond the capacity of the included battery bank on the occasion of particularly bad weather for generation of solar energy. A diesel generator may be preferable from a cost perspective, and may be deployed in a hybrid model by being sized at the projected average power consumption and used to charge the batteries when instantaneous consumption is less than the generator power output (plus any remaining PV output). The battery backup then acts to meet any excess of demand above the generator output. This approach may result in overall greater efficiency than using a generator sized at the maximum power of the mobile power plant of the invention running at full power continuously.
[0106] A third additional feature is an apparatus for use in a method of inclining the solar array structure towards the sun for use in higher latitudes where the correct panel angle can result in significant percentage power output gains. One way to achieve this would be to deploy the array structure on an appropriate south-facing slope (or north facing in the southern hemisphere) of approximately the correct angle. However, there may be many occasions when the system must be deployed on flat land or where an appropriate slope is not available. Therefore, a system of support poles and guy ropes may be used to raise one side edge of the array structure once deployed. The poles may be of adjustable length in order to set the correct angle, and may fit into rings or other attachment points on at least one edge of the flexible array structure. Guy ropes and ground pegs may be used to secure the poles in position and to secure the opposite edge to the ground. The tension-bearing substrate within the array structure may be particularly useful in such a scenario.
[0107] A fourth additional feature is related to military requirements for protection against Electromagnetic Pulse (EMP) events. These EMP events may be caused by lightning strikes or by high-altitude nuclear detonations and they have the effect of causing instantaneous and damaging current and voltage surges in electrical equipment. Whilst the array structure was stowed, including appropriate mesh screening to form a Faraday Cage around the container may be suitable. This could also function to provide some protection to the electronic components inside the container even whilst the array structure is deployed, by extending the mesh into the weather-protective screen previously mentioned, this sealing closely up against the array structure. However in this scenario, strong voltage/current surges may still arrive through the DC power cabling of the array structure, so high performance surge protectors and/or fuses may be required to isolate any incoming surge that has been created in the array structure and protect the components in the container. One option for protecting the array structure while deployed may be to encase the entire array structure in a wire mesh. This may cause significant performance reduction of the solar panels.
[0108] A fifth additional feature, also related to military requirements, concerns protection against conventional attack. A necessary thickness of armour may be included in the container walls for protection of the mobile power plant whilst stowed against small arms fire, RPGs, IEDs or similar threats. This may also provide some level of protection for the components in the container even whilst it is deployed. The resilience question is important in this case in regards to the array structure. So, this may be another reason why multiple lines of DC power cabling may be preferable (see above discussion), so that an impact could be received on one side of the array structure (perhaps knocking out a single line of panels)but the rest can continue generating power.
[0109] The skilled person will appreciate that modifications to the above-described examples may be made that fall within the scope of the invention. The scope of the invention is defined by the claims.