Cabinet or frame-mounted photovoltaic array for suboptimal solar energy conversion and method and apparatus for maximizing collection efficiency

Abstract

The present invention describes a photovoltaic (PV) generator ideally suited for off-grid and remote areas, having a substantially upright structure and comprising a cabinet adapted for grounding on which a plurality of vertically disposed PV panels are mounted. The cabinet accommodates a control circuit for collecting, storing and delivering electrical energy generated by the PV panel. And redundant energy is accumulated in the battery pack and is conveyed as required when the PV panel is insufficient in power supply. The generator is optimized to rated power, ideally for off-grid life (average daily output of 200 Wh / day) and for maintaining home use during seasonal minimum values of solar radiation, and is provided with sufficient PV energy harvesting area to deliver average daily rated power.

Description

Technical Field

[0001] This invention relates to the design and installation of photovoltaic cells or modules in an array to form a generator, particularly suitable for remote areas and latitudes where solar energy is unreliable or highly variable (especially with seasonal variations).

[0002] In a first aspect, the invention relates to an off-grid solar generator that provides a constant rated power in all seasons in regions with large seasonal variations in solar energy (e.g., all latitudes in the United Kingdom (UK)) without the need for supplemental power sources; in a second aspect, the invention relates to a hybrid grid generator that can be connected to other generators of the invention, supplemental power sources, and / or the main power source of regional or national grid infrastructure. The British mainland lies between 50° and 59° North latitude, and the average angle of solar radiation varies considerably between summer and winter. Many other countries are also located in similar northern latitudes (including most of Canada, the Nordic countries, and much of the Russian Federation); however, only the southern ends of Chile and Argentina have significant population centers in their respective southern latitudes.

[0003] On the other hand, the present invention relates to an enclosure or integral structure that is weatherproof, robust, easy to maintain, and deployable or transportable to remote and off-grid areas to provide useful daily power output under suboptimal conditions, particularly during months with the lowest average harvestable solar radiation.

[0004] As used herein, the terms "generator unit" and "integrated structure" primarily refer to a cabinet or enclosed enclosure that houses the control circuitry and protects it from weather and interference from curious individuals. The term also extends to structures suitable for supporting solar / photovoltaic panels and for connection to auxiliary energy sources such as batteries, electric generators, wind turbines, and, of course, the main power grid. However, the scope of this invention is not limited thereto and should be understood to include any reinforced enclosure suitable for deployment in remote areas and for hoisting or otherwise lifting during its positioning in or recovery from the site. This is particularly important when the deployment or recovery weight may be significantly greater than the weight of the unit when unloaded, and equally applies to enclosures housing battery packs.

[0005] The terms “cabinet” and “rack” used in this document are intended to refer to a unit or structure formed as an integral generator and adapted to be connected to an auxiliary energy source and other units (which may form groups or arrays).

[0006] Although the term "useful amount" is used to refer to the expected daily power output from the generator unit during the seasonal minimum of solar radiation (November, December, and January in northern latitudes), it should not limit the overall rated power of the unit, which can be connected to other generator units or external power sources (including the main power supply) and have its power output enhanced by these. Furthermore, the term "useful amount" has specific meanings in different contexts, which will be described below with reference to the various applications to which the generator unit can be applied. Background Technology

[0007] There are many methods and technologies for extracting energy from the sun, each with its own advantages and disadvantages, depending on the application scenario and factors ranging from environmental impact to capital and maintenance costs.

[0008] One of the areas with the most technological advancements is in the collection, storage, and distribution of solar energy, which is collected through photovoltaic (PV) cells. Most PV cells are typically arranged in interconnected arrays to form modules, and multiple modules together form a “solar panel.”

[0009] Each PV cell can generate approximately 0.6V when exposed to nominal sunlight, and when combined in a panel of 72 cells, they can produce 300W. Therefore, modular panels can transmit a useful amount of electrical energy even under direct sunlight. This has become a de facto implementation for residential rooftop installations as well as commercial and large-scale "solar power plants," including ground-mounted panel arrays, for generating electricity for businesses ranging from farms to data centers and for connecting to national or regional power grids.

[0010] The factors concerning solar photovoltaic power generation collection, which will be discussed in more detail below, differ between commercial and large-scale applications and residential and remote (or “off-grid”) applications, and this invention is particularly concerned with the latter.

[0011] In recent years, with the industrialization of printed PV cell technology and the proliferation of modules with integrated DC-DC converters and microinverters, the capital cost of PV modules and panels has decreased significantly. As the cost of solar collection decreases and the demand for near-constant energy supply in off-grid and residential applications (even at low or nominal levels), especially where the cost of supplied energy may be prohibitively high, the focus must now be placed on storing the generated energy.

[0012] Sunlight refers to the amount of radiation or exposure in a particular region; however, many factors come into play when it comes to solar energy collection. Most importantly, there is the seasonal variation in specific latitudes where the intensity of solar radiation, even at its peak during the season, is insufficient to provide usable levels of electricity, necessitating the use of additional sources.

[0013] For any given latitude, an average or optimal slab angle can be calculated; however, for any chosen angle oriented vertically, several factors must be considered, such as structural strength to withstand incident wind forces. Similarly, when the slab angle is horizontal, snow load is critical, and structural strength must also be taken into account. Clearly, snow accumulation significantly impacts solar radiation collection. Under less severe conditions, dust or debris deposits on the slab mean that regular cleaning is necessary to maintain optimal collection.

[0014] Aligning solar panels with azimuths corresponding to specific latitudes or selecting different azimuths among the panels in a solar array to adapt to seasonal changes is an effective practice.

[0015] Existing technologies are rife with structures and arrangements for tracking the sun's path to optimize the incidence of solar radiation on the receiving surface of PV cells. However, whether employing single-axis tracking (e.g., daytime tracking) or dual-axis tracking that varies with the day and seasons, significant additional costs and inherent complexity are required. For remotely transportable or at least mobile PV generators, robustness and service life are critical.

[0016] It is evident from the patent literature that many different methods have been employed to address certain technical deficiencies. Specific concerns exist in each area; however, many aspects are common and will be explained below.

[0017] As is well known, in the prior art, there are buildings and equipment on which PVs are vertically fixed. The main reason for doing so is that there are convenient vertical surfaces available, and their placement is rarely considered beyond convenience, which is considered a major compromise for positioning on a vertical surface.

[0018] International patent application publication number WO2023 / 019362 of SOLIDEL CANADA INC. discloses a vertical structure including a lamp post with multiple photovoltaic panels mounted on it, suitable for storing solar energy collected during the day to power streetlights at night via coupled batteries. This invention differs from previous solar-powered lamp posts in that it provides PV panels along the length of the structure rather than providing panels or arrays tilted according to latitude. By arranging the solar panels to be configured around the vertical riser of the post, the known deficiency of insufficient energy accumulation in street lighting is solved.

[0019] Chinese Patent Publication No. CN107882364, published by Xiaochang County Ruike Intelligent Technology Co., Ltd., describes a small outdoor seating structure with a sunshade device in the form of an awning. Between a pair of bench seats, a table has a central pillar for supporting an electric cooling fan, which is powered by a battery stored in the bottom of the seats. At the top of the corner support pillars, horizontal solar panels form a top structure. Additional vertically arranged PV panels are connected to the top panel and fixed between the two upright support pillars. This invention relates only to the power supply of the cooling fan.

[0020] US Patent Publication No. US2017 / 0141721 by SCHMIDT, ROBERT F describes a modular, portable photovoltaic solar power generation, storage, and supply device and lighthouse. The device consists of an elongated cubic or cuboid prism-shaped support structure with a flat bottom, flat sides, and a flat decorative top. When the various components of the device (e.g., solar panel arrays, telescopic masts, lighting assemblies, or load-bearing extensions) are retracted to a position where their boundaries can be defined by the perimeter of the cubic or prism, they form a protective, crate-like module. This modular design allows for the rapid and efficient storage, loading, or transport of modules in large quantities in flatbed trucks, containers, warehouses, and other locations and configurations. In these locations and configurations, modules can be stacked end-to-end and side-by-side without leaving any idle space, and up to three modules can be stacked for significantly higher storage density. Multiple modules can be interconnected to progressively build larger power generation, storage, and distribution systems, providing an easily adaptable solution for larger temporary power demands.

[0021] Chinese Patent Publication No. CN107733067, published by Xiaogan Qile Creative Design Co., Ltd., describes a solar charging shed, comprising a structure (which can be used as a vehicle parking garage / shed) with supporting columns for roof-mounted solar panels and side-wall solar panels. The panels are connected to a battery pack, which includes a current stabilizing device on which charging interfaces are arranged. The shed facilitates the storage of solar energy in the battery pack for charging vehicles.

[0022] International patent publication number WO2003 / 012806 of SOLAR FENCE GROUP LTD discloses a building component comprising prefabricated elements on which multiple solar cells are mounted on a solar cell carrier (essentially a PV panel). The surface of the PV panel includes prisms or facets to collect solar energy from multiple angles. The solar cell carrier comprises a lightweight, transparent or translucent material, making the panel suitable for use in greenhouses. Structures comprising vertically arranged PV panels or structures to which PV panels are vertically fixed are also disclosed for physical structural benefits and for providing solar energy.

[0023] SOLIVUS LIMITED's international patent application publication number WO2023 / 170416 discloses an improvement on the solar generator described in SOLIVUS LIMITED's international patent application publication number WO2020 / 039181, utilizing TFPV cells to avoid reliance on flat silicon wafers and similar technologies. Essentially as described above, the invention relates to a solar generator including an outer wall defining a cavity therein. The outer wall comprises a frame formed by a plurality of extruders, each extruder having a channel, the extruders being arranged such that the channels on adjacent extruders face each other. The aim is to provide back-to-back flexible solar panels between pairs of supporting extruders.

[0024] The purpose of this invention is to overcome the shortcomings of existing technology and to provide a robust and durable solar power generation device for remote and off-grid areas.

[0025] Another object of the present invention is to provide a solar power generation device with additional features that, when combined, provide excellent practicality and functionality in the field.

[0026] The invention also relates to achieving a balance of physical, environmental, financial and electrical constraints, representing the best overall compromise to provide a “useful amount” of electricity every day of the year, regardless of season, weather conditions and cloud cover, optionally independently of external energy sources and far from fixed energy sources (such as main grid power).

[0027] Ideally, the power generation device of the present invention achieves its goal through a single energy source, namely solar radiation, with a battery pack storing energy to provide power at night. The device can also be used with a wind turbine to enhance energy generation and storage.

[0028] Preferably, the device can be connected to the standard transmission trunk infrastructure of existing buildings to provide alternative, emergency, or backup power in residential or off-grid environments. The device can also be used as an alternative power source or to enhance power supply in areas where it may be interrupted by the national or regional mains power supply. Summary of the Invention

[0029] A first aspect of the invention provides a photovoltaic (PV) generator on which photovoltaic panels are operatively formed with at least two principal surfaces to optimize solar radiation collection under suboptimal conditions with respect to diurnal and seasonal variations in direct and indirect solar radiation incidence. The generator comprises: The cabinet enclosure has structural frame elements and grounding elements attached thereto; and A control circuit for regulating the electrical energy generated by the PV panel and an energy accumulator connected to the control circuit are sealed inside the housing. At least two PV panels are positioned on the main vertical plane, with at least one facing the arc opposite the sun (due south in northern latitudes) and at least one positioned substantially perpendicular to it. Thus, PV energy harvesting is physically optimized across all seasonal and diurnal variations, resulting in reduced mechanical and financial costs.

[0030] In a preferred configuration, PV panels are disposed on each of the main vertical faces. In most embodiments described below, the cabinet is substantially cuboid in shape, but with a sloping top portion. While the area of ​​each main face may be equal, it is preferred that the face facing and away from the sun's arc be equal and twice the area of ​​the other main faces (which are substantially perpendicular to it in the cuboid configuration). It is understood that the cabinet may also be trapezoidal prism in shape, with the faces facing and away from the sun not being equal.

[0031] Optionally, the PV panel installed on the top portion extends on the main surface facing away from the sun's arc.

[0032] Advantageously, the PV panels installed on the top section are tilted at the optimal tilt angle (TW) at the winter solstice (EW).

[0033] In the preferred configuration, the structural frame elements are integrally formed with the PV panel.

[0034] Advantageously, the energy storage device includes a first group of batteries with deep cycling characteristics and a second group of batteries with high power transfer characteristics, wherein battery technology is combined with a charging controller and voltage monitoring circuitry to optimize charging and power transfer under suboptimal conditions.

[0035] In a preferred arrangement, the first battery pack comprises a working group of batteries that are frequently and deeply cycled and have an excellent weight-to-kWh ratio, and the second battery pack comprises a spare group that provides additional charging capacity and a lower charging temperature capability than the working group batteries. Each group has a charge balancer to compensate for differences in state of charge during charge and discharge cycles.

[0036] Advantageously, the first battery pack includes lithium-ion or lithium iron phosphate batteries, and the second battery pack includes adsorbed glass fiber mat (AGM) batteries, each disposed in a configuration associated with the desired system voltage.

[0037] In a first preferred alternative construction, the housing has a box-like form, wherein structural frame components provide their peripheral corners and PV panels are fixed therebetween to form the outer surface of the protective cabinet.

[0038] Ideally, the total surface area of ​​the PV panels is optimized to generate at least 200Wh of electricity per day.

[0039] In one exemplary configuration of the invention, the generator assembly is reinforced for easy transport and on-site maintenance, and includes features that make the assembly highly resistant to harsh weather conditions.

[0040] Optionally, the grounding element includes a lockable steering wheel, thereby enabling the device to be accurately positioned before fixing.

[0041] Alternatively, grounding elements include a mounting plate through which anchor bolts or anchor screws are fixed.

[0042] Advantageously, each PV panel is attached to the cabinet via a detachable frame adapted to enclose the PV panel and provide wiring for the cables associated with each panel.

[0043] In a preferred configuration, the PV panels are installed within a frame suitable for connection to each other, forming at least two sides of the cabinet.

[0044] Ideally, the structural frame elements include extruded profiles with slots and channels to accommodate and retain the PV panels and associated cables.

[0045] Advantageously, the frame releasably holds the PV panel and includes hinge elements at its perimeter for easy access to the cabinet interior.

[0046] Each of its PV panels has a dedicated and appropriately rated charge controller associated with it to manage the solar energy collected from each panel within the face, thereby maximizing the generated charging output efficiency.

[0047] The energy storage device transmits direct current (DC) power to the device or local power connector, or provides alternating current (AC) power output via an inverter.

[0048] The present invention also provides a component kit for the solar generator device or cabinet as defined above, the component kit comprising: Select the number of PV panels and install them within the frame in the selected configuration; The charging controller is rated for the maximum voltage and current produced for each side of the framed board to match the controller's power conversion algorithm; and Manual disconnect switches, automatic circuit breakers, fuses, and busbars provide selective and fault-triggered isolation and direct charge from the charge controller to the battery cell terminals.

[0049] Advantageously, PV panels include toughening layers on all surfaces to maximize the indirect output of solar radiation.

[0050] Plate frames may include extruded stainless steel profiles for rigidity and strength, or extruded aluminum profiles for a combination of strength and lightweight properties.

[0051] Ideally, pairs of PV panels are mounted in a single frame and electrically connected in series to maximize the generated voltage.

[0052] For high-demand applications and situations requiring AC power, the component kit also provides: Discrete DC charging controller; and Inverter with manual disconnect switch.

[0053] Optionally, a first working battery pack including lithium-ion or lithium iron phosphate batteries and a backup battery pack including adsorbed glass fiber mat (AGM) batteries are also provided, each in a configuration associated with the required system voltage.

[0054] For applications involving the continuous year-round use of AC or DC powered equipment: The deep discharge working group is sized to 250% of the maximum daily watt-hour load to ensure that the working cell is discharged to a preference of 40% below capacity, thereby maximizing its lifespan.

[0055] For applications serving multiple low-load devices (rather than a few high-load devices), each device is equipped with a combined solar charge controller and inverter, one for each PV panel, with a standby mode function to minimize background load. Attached Figure Description

[0056] The invention will now be described in more detail with reference to the accompanying drawings, which illustrate, by way of example only, embodiments of a solar cabinet and a frame-mounted solar generator, including multiple solar photovoltaic panels fixed thereto, and illustrating supplementary components thereof. In the drawings: Figure 1 This is a schematic diagram of an exemplary prior art arrangement for power supply to a small farm, utilizing an array of photovoltaic (PV) panels connected in a daisy-chain configuration to a controller cabinet or cabinet, and having an optional or backup power source, such as a wind turbine. Figure 2a This is a diagram showing the sun's path and the optimal angles for the placement of solar panels during the British winter and summer solstices; Figure 2b It is a bar graph showing the average level of direct and indirect solar radiation available to solar panels each month of the year at the latitude corresponding to London, UK (51.5° North). Figure 3 This is a perspective view of a first embodiment of a solar cabinet according to the present invention, with PV panels located on each exterior of the cabinet; Figure 4 It is a schematic diagram of the control circuit components housed in a cabinet or enclosure; Figure 5a and 5bThese are oblique and perspective views of the enhanced structure of the first embodiment of the solar cabinet, with PV panels located on each exterior of the cabinet; Figure 5c Is with Figure 5b A similar exposed perspective view, with the battery and control circuitry configured in an alternative way; Figure 5d and 5e This is a perspective view of another construction of the first embodiment of the solar cabinet, with substantially equal PV panel areas present on each exterior of the cabinet (each face is provided with an MPPT). Figures 6a to 6c These are perspective views of various structures of frame-type PV panels; Figure 7 This is a perspective view of the remote monitoring station; Figure 8 This is a perspective view of the generator assembly and heat pump combination of the present invention; Figure 9 This is a perspective view of a variant of a first embodiment of a PV generator unit, featuring multiple anchorable receiving compartments for receiving and charging removable EV batteries. Figure 10a and 10b Is with Figure 5d and 5e Detailed side and perspective views of a similar generator assembly are shown, featuring a pivotable top section to present a combined landing and charging platform for autonomous power tools (drones). Figure 11 It is a perspective view of a generator unit with enhanced safety features; Figure 12 It is a perspective view of a generator unit, having a communication module attached to a secondary surface, the communication module optionally including a cellular base station or a signal repeater. Detailed Implementation

[0057] Refer to the attached diagram and first refer to... Figure 1 As an example of existing technology, Figure 1 A generator assembly for powering a small farm or detached house is shown, comprising an array of solar panels (a) arranged in three groups connected in a daisy-chain configuration via cable connectors (b). The panels are fixed at an angle corresponding to the site's latitude and facing south for a northern hemisphere site. To increase input from the solar panels (and provide additional power at night), a wind turbine (c) is installed. For large power plants, turbines operating at medium to high voltage offer a lower cost per kilowatt, while small wind turbines (SWTs) typically cost two to four times more per kilowatt due to the relatively immature SWT market. Many “microwind” installations, i.e., rotor swept area less than 40 cm², are used. 2Those have rated power ranging from 1kW to 7kW. A 6kW turbine can generate up to 9000kWh of electricity per year.

[0058] A typical household uses about 11,000 kWh of electricity per year, which is equivalent to about 30 kWh per day.

[0059] The DC outputs of the PV panel (a) and wind turbine (b) can be fed to the battery pack housed within a cabinet (e) via a fixed power output junction box (d). Within the cabinet, voltage regulators, monitoring, and control electronics are also housed in a weatherproof enclosure. A power inverter can also be found within the cabinet (e) or optionally within the junction box (d), where a power feeder (f) couples the power generation components to demand. A supplementary PV panel (g) is mounted on the poles attached to the cabinet for the control electronics.

[0060] As mentioned earlier, this arrangement has many drawbacks, especially for remote areas and offline living situations where stability and maintainability are essential requirements.

[0061] The existing technology configuration is not suitable for small home or off-grid applications, nor is it suitable for power hubs used to charge electric vehicles.

[0062] As mentioned above, the angle of incidence of direct solar radiation on a surface exhibits significant diurnal and seasonal variations. The primary diurnal effect is the arc formed by the sun (relative to the incident surface, i.e., the static PV panel) during the day between sunrise and sunset. Other diurnal variations include cloud cover and shadows from nearby vegetation or structures (e.g., buildings, but possibly other PV panels in the array). Using an automatic tracking mechanism to track the sun's arc to keep the PV panel's plane perpendicular to the sun overcomes most, but not all, diurnal variations, but significantly increases the cost of power collection. For static PV panels, to maximize the collection of incident radiation, they should face directly south in northern latitudes and directly north in southern latitudes, i.e., lie in an east-west plane.

[0063] To account for seasonal variations, the tilt angle of the PV panels depends on the latitude of the site. Figure 2a In the diagram, cabinet 1 is centrally located within a circle, marked with four basic directions: N, S, E, and W. The first line, ES, represents an elevation view of the sun's daily path at the summer solstice and signifies the optimal slope or tilt angle TS of the PV panel to collect the maximum available solar radiation at that time of year. Similarly, the second line, EW, represents an elevation view of the sun's path at a significantly lower point during the winter solstice, but still represents the optimal tilt angle TW of the PV panel to collect solar radiation at that time of year. For static PV panels, the optimal tilt angle can be represented by the median of the two extreme values ​​(represented by lines ES and EW and their corresponding tilt angles TE and TW), with the median value closely aligning with the spring and autumn equinoxes.

[0064] When calculating the usable energy that can be harvested from solar radiation, it is important to distinguish between "direct radiation" (light collected by the plate from the sun) and "diffuse radiation" (light energy collected by the plate primarily from clouds or reflected / ambient light). Figure 2b The bar chart shows the monthly average direct and diffuse radiation for the region at 51°N (London, UK) throughout the year, measured in average daily kilowatt-hours of energy incident per square meter (kWh / day.m²). From this example, during November, December, and January, the available average daily direct sunlight allows approximately 0.5kWh to 0.75kWh of energy to be generated per square meter of exposed PB panels. Furthermore, during any period between October and February, the average ambient or diffuse radiation does not exceed 1kWh per square meter of available PV panels.

[0065] A combination of daily average direct and indirect (ambient, diffuse, or reflected) irradiation can be used to calculate the minimum area of ​​PV panels required to achieve the nominal ratings of the PV panel array or assembly. Now refer to... Figure 3 The first embodiment of the solar generator unit 10 is shown, which includes a cabinet 12, the cabinet defining a cabinet body and having four planes 13 and a top portion 14.

[0066] In its most basic iteration, the device includes a cabinet to which vertically mounted PV panels 15 are fixed to the front, back, and sides. The front is the south-facing side in the northern latitude region and has the total area of ​​the receiving PV panels to provide rated output. For low output requirements, the average daily output in winter may be as low as 200Wh, which may be sufficient to charge many electronic devices or, in a very specific application of the invention, to maintain operating current for recording, storing, and transmitting collected data at a remote monitoring station. The collected energy can be enhanced by placing reflectors that deflect directly incident light at an angle toward the receiving panels. In a preferred configuration, the top 14 includes PV panels whose slope can be adjusted to optimize solar radiation collection and / or prevent snow and leaves from accumulating on it.

[0067] In the improved orientation of the cabinet with a rectangular cross-section, the front faces east towards the rising sun, while the back is set towards the setting sun, in order to maximize the incident area during winter and allow the south-facing sides and top panel to collect usable light during the strongest part of the day.

[0068] The cabinet forms a unit used to store energy via battery banks and energy management or control circuitry. Figure 3 In the basic embodiment shown, seven PV panels 15 are arranged on five surfaces (two sides, front, back and top).

[0069] PV panels are designed and rated to withstand harsh environmental conditions. In the case of cabinets formed from extruded or shaped aluminum frame components, the final cabinet will have good corrosion resistance and be able to withstand high temperatures and extreme UV conditions. Anodized stainless steel is the preferred material for producing the cabinet, with the panels attached to the existing surface via frame fasteners.

[0070] It integrates a variety of environmental management features to allow the cabinet to exist in potentially extreme outdoor environments.

[0071] Discrete vents, internally protected by a fine mesh (to prevent insect ingress), are constructed within the top frame or beneath the top panel to allow hot air and any gases generated during battery charging to escape. Equivalent vents can also be located in the bottom or supporting base plate to allow cool air to enter and circulate. This feature can be coupled with automatic and temperature-triggered waterproof cooling fans to improve airflow from bottom to top. A series of fans can be triggered when a predetermined threshold is reached, provided the operating temperature may exceed the thermal limits of the internal components. An additional optional feature directs airflow across the PV panels to reduce surface temperature, thereby minimizing the negative temperature coefficient, in which case the power generated by the PV panels may be less than the power utilized by the cooling fans.

[0072] A grounding rod (not shown) can be placed and connected to the frame components before the cabinet is installed to allow grounding of the cabinet and internal equipment, providing a connection from the cabinet and the internal frame. When grounding screws are used to secure the cabinet, these screws can also be used to ground the power generation unit.

[0073] In rack deployments in more extreme low-temperature environments, grooved corrugated plastic panels, used alone or in combination with commercially available insulation materials, can reduce extreme temperatures within the rack, thereby allowing equipment and batteries to operate over a wider range within their design parameters. Air gaps can also be incorporated between the external panels and frame components to prevent thermal bridging.

[0074] like Figure 4As shown, seven 100W PV panels (five shown only) are connected to a charge controller 16 for each panel to regulate the charging current supplied to the battery cells. In the exemplary configuration, one of the charge controllers 16a (associated with one PV panel (hereinafter referred to as the “top panel”) is connected to the spare group RB of the deep-cycle battery of the type described herein and is capable of charging at 5°C. The remaining four charge controllers 16 transfer harvested electrical energy from the remaining panels to charge a group of batteries (referred to as the “workgroup” WB), ideally comprising lithium-ion or lithium iron phosphate (LiFePO4) batteries, both with excellent power characteristics. Power is converted from DC to AC via a 2kW inverter INV to provide the main voltage via the circuit breaker RCD or directly to the household consumer unit. In the illustrated embodiment, the output voltage is used to power the Grundfos CMBE AC booster pump P to maintain the water pressure in the supply.

[0075] The backup battery RB is powered by the isolated DC-DC charger 17 to maintain the operating voltage of each battery in the work group WB. The DC-DC charger 17 is a 30A unit designed to charge the work group WB if the voltage of each battery drops below 12.5V when the backup battery voltage exceeds 11V.

[0076] Associated with the inverter is a startup sensor 18, which enables a low-power standby mode. A remote monitoring unit 19 measures the voltages of the working and backup batteries, as well as the inverter load, and may include a communication module for issuing alarms to users or maintenance contractors. Advantageously, a pressure sensor is configured to automatically start and stop the booster pump P, thereby optimizing available power.

[0077] It is worth noting that powering multiple charge controllers 16 via solar panels 15, with each PV panel operating differently on each face depending on day and season, provides an opportunity to combine multiple battery technologies to fully utilize their respective advantages and compensate for their respective weaknesses. By incorporating battery technologies into the generator circuit described in this invention, the lifespan of both battery technologies can be increased, which is particularly relevant to frequent cycling or frequent loads, especially in summer applications.

[0078] Advantageously, the working group (WB) comprises lithium-ion or lithium iron phosphate batteries connected in series to generate the required circuit voltage (e.g., two 12V batteries present a 24V circuit). Additional batteries can be connected in parallel if needed to provide extra capacity to the working group. A charge balancer can be used to ensure that differences in the state of charge between the batteries are compensated during the charging process.

[0079] In the preferred configuration detailed below, each face of the charging station is optimized to power the 48V battery pack within the battery module, thereby enabling the PV panel to generate an open-circuit voltage of 60V under maximum solar irradiance and a voltage of approximately 51V under load, which is the charging voltage of the corresponding battery pack.

[0080] Commercially available lithium-ion and lithium iron phosphate batteries typically feature built-in protection circuits, cycle deeper and more frequently than alternative technologies, and have a more favorable weight-to-kilowatt-hour ratio compared to alternative technologies.

[0081] However, it should be noted that these batteries will degrade over time between 80% and 100% charge, are more expensive per watt-hour compared to other battery technologies, and have poor charging characteristics below 5°C.

[0082] The absorbent glass mat (AGM) batteries that make up the spare group RB are connected in series to generate a circuit up to 48V. AGM batteries can also be connected in parallel to generate additional capacity as needed, but each group is limited to three batteries in parallel. A charge balancer is always used to ensure that differences in the state of charge between the batteries are compensated for during charging. Overcurrent protection devices are installed on the circuit to compensate for the lack of built-in protection features.

[0083] It's worth noting that AGM batteries are less prone to degradation from prolonged periods at 100% charge (compared to lithium-based batteries), are relatively inexpensive per kilowatt-hour of capacity compared to other technologies, can be charged below 0°C, and exhibit deep discharge characteristics, capable of discharging up to 40% of their capacity per day and exceeding 1000 cycles before they begin to degrade. However, in contrast, battery cells degrade much faster if frequently cycled at discharge rates exceeding 40% for more than 2 hours.

[0084] The lowest temperatures may also occur during the winter minimum, so it is essential to charge batteries with the lowest operating temperature range.

[0085] Those skilled in the art will understand that the above example diagrams may change as battery technology improves and operating and charging characteristics achieve better performance.

[0086] like Figure 4 As shown, the lithium-based battery working group WB is directly charged by the charge controller 16, except for the charge controller 16a associated with the top plate, which is connected to the spare group RB. The plates selected to charge the working group WB are those that receive the maximum solar radiation during the winter minimum, thus favoring keeping them at a full charge state as much as possible.

[0087] In cases of frequent daily cycling of the AGM standby group RB, it is advantageous to add a lithium-based or alternative frequently cycled or sacrificial battery for charging by the top-plate charge controller 16a, directing most of the cycles to this battery, thereby reducing the depth of discharge experienced by the AGM battery and reducing the time the lithium battery is at full charge. An isolated DC-DC converter (or charger) 17 is used to transfer energy from the lithium battery of the working group WB to the AGM battery of the standby group RB, and must be sized to charge at a rate as close as possible to the AGM battery discharge rate. When a load is connected via the inverter INV, the voltage drop experienced by the working group WB triggers the charging process of the standby group RB, which continues until the working group battery is fully charged or the standby group is depleted.

[0088] This approach reduces the cycle depth of the working group's batteries, thereby increasing their lifespan, while also reducing the time the standby group spends at 100% charge, further increasing its lifespan. This arrangement also directs stronger summer solar output from the top panels to the standby group batteries, allowing them to cycle more frequently and recover faster when solar energy is more abundant, thus again reducing the working group's cycle depth. Advantageously, the solar panels that generate maximum output in winter to charge the group actually powering the load do not need to consume energy to keep the working group's battery temperature within operating range during periods of minimum solar energy. Therefore, the energy overhead of heating the lithium batteries to absorb charge or converting energy via DC-DC charging processes is avoided when energy is least abundant.

[0089] Utilizing dual-cell technology to optimize solar energy collection at minimum levels provides additional capacity to a given system, economically reducing the total cost of the system without incurring any of the concessions that single-cell technology would offer.

[0090] Figure 5a and 5b It shows the relationship with Figure 3 A similar cabinet 10, but with greater capacity and an internal structural frame 11. As before, each wall 13 has a solar panel 15 attached thereto, ideally via a panel frame (such as...). Figures 6a to 6c As shown, the structural frame element 11 of the cabinet 12 is fixed to the plate frame. The top portion 14 is set at an angle relative to the front or back to optimize solar energy collection, thereby ensuring optimal conditions during the summer months.

[0091] The cabinet is sized and shaped to accommodate standard batteries to form spare groups (RB) and working groups (WB). Lithium-based batteries (such as lithium-ion or lithium iron phosphate batteries) are used as working batteries and supplied in sufficient quantities to ensure a depth of discharge of less than 40% per day during the second-best solar collection periods (especially in winter), thereby maximizing battery life (25 to 40 years per battery, anywhere).

[0092] The stacked working group WB's batteries are connected in a 4S3P configuration (i.e., four batteries in series and three batteries in parallel) and transmitted through the wall-mounted inverter INV to a maximum storage capacity of 33kWh and a maximum power output of 15kW (240V, 60A from 48V, 312A).

[0093] The embodiments described have multiple uses and can be used as hybrid grid charging cabinets with integrated solar power generation.

[0094] Figure 5c The illustration shows a subtle but important improvement in the arrangement of an embodiment of the solar generator cabinet, where the workpieces are arranged in a linear stack. In a preferred configuration, a standard 19-inch bracket structure can be used, and selected components (such as lithium battery packs, inverters, and charge controller circuitry) can be encapsulated for simple, detachable connections within the bracket.

[0095] Figure 5d and 5e Another construction of the first embodiment of the solar generator cabinet is shown, wherein the internal frame 11 provides support for standard industrial bracket-mounted components (such as the bracket-mounted lithium battery pack described above). As production scales up, the availability of reliable, inexpensive, and potentially "plug-and-play" component modules becomes standardized, including power connections grounded to the frame elements, which facilitates rapid capacity expansion of the cabinet's capacity. As described below, the invention can be provided as a "component kit," allowing purchasers to select a minimal number of operating components and increase capacity, add spare battery banks, or connect to an external energy source as needed.

[0096] In the illustrated embodiment, the charging controller 16 and the inverter INV are mounted to the backplate (with a 10cm gap around the inverter); however, these components can be provided as a bracket-mounted alternative.

[0097] The cabinet may comprise an aluminum or steel sheet, to which the PV panel is fixed. This facilitates direct attachment of the PV panel to the cabinet. Alternatively, the PV panel is mounted within a frame, which is then secured to the cabinet panel. In the most preferred configuration, the PV panel mounted within a rigid frame forms the front, back, and sides of the cabinet (and ideally, the top portion as well).

[0098] Figures 6a to 6c A panel frame component F for holding a pair of PV panels is shown. The first construction of the panel frame includes a lip region L for mounting the panels to an existing panel of the cabinet; and mounting holes H through which tamper-proof bolts can be secured. The PV panel cover portion C includes a folded box structure B to provide cable routing from the PV panels to the charging controller 16 within the cabinet.

[0099] In a preferred embodiment of the invention, frame element 11 comprises extruded aluminum or steel profiles joined together at 90-degree angle joints to form an outer frame. As described above, an internal support can be used, forming part of the structural integrity of the cabinet. The solar panel is located within the surrounding frame components and attached to the frame by rest pins that position the panel within grooves in the extrusion. This assembly method allows the panel to be vertically mounted into the pre-assembled frame.

[0100] Bottom components, for example Figures 5a to 5e As shown, it can be made of thermoplastic polyurethane (TPU) with pores formed inside to allow the internal frame to be secured to it, thus forming the core of the internal frame shape. Additionally, there are ground mounting holes to allow the bottom to be secured to the ground or concrete slab using appropriately rated bolts. As mentioned above, ground screws can be used to secure the station cabinet. Ventilation holes in the bottom component allow air to enter the cabinet from the bottom and are protected by a mesh cover to prevent insects from entering. Drainage holes with mesh covers can also be provided for water entering the cabinet or condensation that forms within it.

[0101] The top portion 14 or optional top PV panel 15 is connected to the internal frame in the form of TPU, which can be separately covered with the external colored composite aluminum panel to achieve the desired aesthetic effect.

[0102] The inverter INV can be installed in the upper left or upper right corner of the cabinet, with a clearance of 10cm or more around it in all directions. The batteries are stacked vertically in the internal area opposite the inverter to ensure that any escaping gases from the batteries do not affect the inverter.

[0103] To extract maximum energy from the respective PV panels 15, a maximum power point tracking (MPPT) controller is provided for each PV panel coverage area of ​​the cabinet. Controller 16 is located above the batteries on the fireproof back panel. Circuitry for balancing battery charging rates, such as monitoring unit 19, may also be located on the back panel.

[0104] A brushless motor-driven DC fan is mounted within a TPU-form component at the top of the cabinet. The fan, combined with vents at the bottom and top of the cabinet, ensures rapid airflow from the bottom to the top and atmosphere when needed, thus keeping the internal equipment cool. The fan is triggered by a temperature sensor with preset threshold values.

[0105] The central LED light strip can be used to visually indicate the current status, capacity level, and charging or discharging level of the batteries in the cabinet, as well as to provide visual alerts to users for any issues that may need to be investigated.

[0106] The panels are optionally joined together by 3D-printed joints, which are fixed inside the corner of each aluminum frame on each solar panel surface and have a central pivot for bolting them together to form a robust network of connections on the surface. These joints can optionally be hinged so that the panels on each surface open in an accordion-like manner, allowing full access to the internal equipment.

[0107] Insulation material can be installed inside the panel openings to provide improved temperature stability within the structure.

[0108] The openings between the sloping top panel and the side and front panels can be illuminated by LED light strips to indicate charging status and solar output by changing colors and patterns.

[0109] The generator device of this invention can be configured as a remote monitoring station to provide power to air or water sampling devices and their associated transmissions via a communication module. Figure 7 In this configuration, the remote monitoring station 70 is constructed to house the testing facility and includes a door D for authorized personnel access. PV panels 73 are mounted on all main surfaces (including the door) and ideally also on the top section. The monitoring station is mounted on a bottom plate 75, and anchor screws 76 at each corner of the bottom plate 75 secure the station 70 in place.

[0110] As can be understood from the above, various ground fixing methods can be used, while larger power generation units may require a load-bearing base or concrete pad.

[0111] In many homes, gas-fired central heating is being replaced by ground-source or air-source heat pumps, and legislation in many jurisdictions prohibits the supply of town gas to newly constructed homes. A often underestimated fact is that heat pumps consume significant amounts of electricity and can have a substantial economic impact on users. The improved generator 80 of this invention can, as... Figure 8 As shown, it is integrated with the heat pump HP to reduce operating costs. PV panels 83 are located on all available main surfaces, including the top portion 84. For optimal configuration for collecting solar radiation, the heat pump vents are positioned on the surface facing away from the sun's curve.

[0112] Figure 9A variation of the power generation device including a charging station 90 is shown, wherein the surface facing away from the sun is replaced by a surface with multiple battery receiving sections R therein. Each receiving section is adapted to receive a removable EV battery, such as those from an electric motorcycle, bicycle, or scooter. If the charging station 90 is commissioned by the same manufacturer, the receiving section may include a charging connector that can be directly connected to the EV battery. This arrangement facilitates battery replacement schemes; after confirming that a valid and rechargeable battery has been stored and completing payment verification, a fully charged battery can be removed from the receiving section when it is opened. In other cases, a terminal connection can be provided for a series of batteries; however, charging will only begin after the receiving section is closed and payment verification (if any) is completed. For card payment convenience, a communication module for payment verification can be installed within the cabinet. In a preferred arrangement, newly stored batteries accelerate battery charging, and fully charged batteries become part of either the working group WB or the standby group RB according to a predetermined charging standard.

[0113] Figure 10a and 10b A generator assembly 100 is shown, comprising a landing and charging platform for an autonomous aircraft, such as a drone (AD). A top portion 114 of the cabinet is adapted to pivot open about a motor drive shaft 117. The drone is magnetically locked to the inside of the top portion, and can be dispatched from the top portion when a release force is applied to disable the magnetic lock. The drone battery is wirelessly charged via inductive coupling. During drone dispatch, the top portion is closed to avoid obstructing the PV panel 113 and to allow further charging through the PV panel (if present) in the top portion.

[0114] Figure 11 A generator unit 120 with enhanced security features is shown, including a camera SC mounted on a secondary surface of the cabinet and a reinforced security lock GL. In one configuration shown, a camera platform PL is mounted on a pole that is ideally telescopically extended from inside the cabinet, optionally via a similar... Figure 10a and 10b The top section can be pivoted and unfolded from inside the cabinet as shown.

[0115] Finally, regarding Figure 12 The generator assembly 130 may include any configuration described or shown in the figures, having a communication module mounted on at least one secondary face of the cabinet housing. In the illustrated configuration, a cellular base station module M is disposed on each secondary corner face. Additional circuitry associated with this module or each module is also housed within the cabinet.

[0116] The present invention also provides a component kit for a generator unit assembly system, the component kit comprising: Select the number of PV panels and install them within the frame in the selected configuration; A charging controller, rated for the maximum voltage and current produced on each side of the framed plate, to match the controller's power conversion algorithm; and Manual disconnect switches, automatic circuit breakers, fuses, and busbars provide selective and fault-triggered isolation and direct charge from the charge controller to the battery cell terminals.

[0117] Advantageously, PV panels include toughening layers on all surfaces to maximize the indirect output of solar radiation.

[0118] The frame can be made of stainless steel for rigidity and strength, or shaped aluminum for a combination of strength and lightweight properties.

[0119] Ideally, pairs of PV panels are mounted in a single frame and electrically connected in series to maximize the generated voltage.

[0120] For high-demand applications and situations requiring AC power, this component kit also offers: Discrete DC charging controller; and Inverter with manual disconnect switch.

[0121] Optionally, a first working battery pack and a backup battery pack are also provided.

[0122] In a preferred arrangement, the backup battery pack includes AGM batteries and is configured in a way that is associated with the required system voltage, such as 4S3P for a 12V system. The working battery pack includes lithium-based batteries, such as those based on lithium-ion or lithium iron phosphate battery technology, and is configured in a way that is associated with the system voltage, such as 4S1P, if appropriate.

[0123] When transferring energy from the AGM battery pack to the lithium battery pack, the isolated DC charging controller is rated to charge at twice the maximum load.

[0124] Inverters are rated up to 15kW to convert energy from the workgroup into AC power for distribution via IP-rated output interfaces. Automatic load protection and standby power mode are supported to reduce background energy consumption.

[0125] For applications involving the continuous year-round use of AC or DC powered equipment: The deep discharge working group (lithium battery) is sized to 250% of the maximum daily power (Wh) load to ensure that the working battery is discharged to below 40% of its capacity, thereby maximizing its lifespan.

[0126] For applications serving multiple low-load devices (rather than a few high-load devices), a combined device with a solar charge controller and inverter is set up for each device output (in fact, one for each PV panel), with a standby mode function to minimize background load.

[0127] Of course, it should be understood that the present invention is not limited to the specific details set forth herein, which are given by way of example only, and various modifications and variations may be made within the scope of the appended claims.

Claims

1. A photovoltaic (PV) generator apparatus on which photovoltaic panels are operatively formed with at least two principal vertical planes to optimize solar radiation collection under suboptimal conditions with respect to diurnal and seasonal variations in direct and indirect solar radiation incidence, the generator comprising: A cabinet housing defining the main vertical plane and its top portion, the cabinet housing having structural frame elements and grounding elements attached thereto; A control circuit for regulating the electrical energy generated by the PV panel and an energy storage device connected to the control circuit are housed in a sealed enclosure. At least two PV panels are positioned on the main vertical plane, with at least one facing the arc opposite the sun (due south in northern latitudes) and at least one positioned substantially perpendicular to it. Thus, the collection of PV energy is physically optimized across all seasons and diurnal variations, resulting in reduced mechanical and financial costs.

2. The photovoltaic (PV) generator device according to claim 1, wherein the PV panel is disposed on each of the main vertical planes.

3. The photovoltaic (PV) generator apparatus according to claim 1 or 2, wherein the PV panel mounted on the top portion extends on the main surface of the arc facing away from the sun.

4. The photovoltaic (PV) generator apparatus according to any one of claims 1 to 3, wherein the PV panel mounted on the top portion is tilted toward the optimal tilt angle (TW) at the winter solstice (EW).

5. The photovoltaic (PV) generator device according to any one of the preceding claims, wherein the structural frame element is integrally formed with the PV panel.

6. The photovoltaic (PV) generator device according to any one of the preceding claims, wherein the energy storage unit comprises a group of batteries having deep cycle characteristics and a group of batteries having high power transmission characteristics, and wherein battery technology is combined with a charging controller and voltage monitoring circuitry to optimize charging and power transmission under suboptimal conditions.

7. The photovoltaic (PV) generator device according to any one of the preceding claims, wherein the housing has a box-like form, wherein structural frame members provide its peripheral corners and PV panels are fixed therebetween.

8. The photovoltaic (PV) generator device according to any one of the preceding claims, wherein the total surface area of ​​the PV panels is optimized to generate at least 200 Wh of daily power generation.

9. The photovoltaic (PV) generator device according to any one of the preceding claims, wherein the generator device includes a communication module.

10. The photovoltaic (PV) generator apparatus according to any one of the preceding claims, wherein the generator apparatus includes a payment verification tool.

11. The photovoltaic (PV) generator apparatus according to any one of the preceding claims, wherein each PV panel is attached to the housing by a removable frame adapted to enclose the PV panel and provide wiring for cables associated with each panel.

12. The photovoltaic (PV) generator apparatus according to any one of the preceding claims, wherein the structural frame element includes an extruded profile having slots and channels to receive and retain PV panels and associated cables.

13. The photovoltaic (PV) generator device according to any one of the preceding claims, wherein the structural frame elements releasably hold the PV panels and include hinge elements at their periphery for easy access to the interior of the cabinet.

14. A photovoltaic (PV) generator apparatus according to any one of the preceding claims, wherein each face having PV panels has a dedicated and appropriately rated charge controller associated therewith to manage the solar energy collected from each panel within the face, thereby maximizing the generated charge output efficiency.

15. The photovoltaic (PV) generator device according to any one of the preceding claims, wherein the energy storage device transmits direct current (DC) electricity to the device or a local power connector, or provides alternating current (AC) output through an inverter.

16. A component kit for a solar generator device of the type of claim 1, the component kit comprising: Select the number of PV panels and install them within the frame in the selected configuration; The charging controller is rated for the maximum voltage and current produced on each side of the frame plate to match the controller's power conversion algorithm. as well as Manual disconnect switches, automatic circuit breakers, fuses, and busbars provide selective and fault-triggered isolation and direct charge from the charge controller to the battery cell terminals.

17. The component kit of claim 16, wherein the PV panel includes a toughening layer on all surfaces to maximize the indirect yield of solar radiation, and the panel frame comprises an extruded profile of stainless steel for rigidity and strength, or an extruded profile of aluminum for a combination of strength and lightweight properties.

18. The component kit of claim 16 or 17, wherein pairs of PV panels are mounted in a single frame and electrically connected in series to maximize the generated voltage.

19. The component kit according to any one of claims 16 to 18, wherein, For high-demand applications and situations requiring AC power, the component kit also provides: Discrete DC charging controller; and Inverter with manual disconnect switch.

20. The component kit according to any one of claims 16 to 19, further comprising a first working battery pack including lithium-ion or lithium iron phosphate batteries and a backup battery pack including adsorbed glass fiber mat (AGM) batteries, respectively disposed in a configuration associated with the desired system voltage.

21. The component kit according to any one of claims 16 to 20, wherein, For applications involving the continuous year-round use of AC or DC powered equipment: The deep discharge working group is sized to 250% of the maximum daily power (Wh) load to ensure that the working cell is discharged to a preference of less than 40% of its capacity, thereby maximizing its lifespan.

22. The component kit according to any one of claims 16 to 21, wherein, For applications serving multiple low-load devices (rather than a few high-load devices), each device is equipped with a combined solar charge controller and inverter, i.e., one for each photovoltaic panel, with a standby mode function to minimize background load.

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