An electrical fault detection and shutdown circuit for a solar module junction box

Abstract

This invention provides an electrical fault detection and shutdown circuit for a solar module junction box. The circuit includes a positive input terminal, a negative input terminal, a positive output terminal, and a negative output terminal. It also includes a power supply module, a shutdown execution module, a PLC transceiver module, an MCU control module, a sensor module, and a shutdown control module. The sensor module enables effective real-time monitoring of module operating information. The MCU control module converts received information for subsequent modules to receive and identify it. Electrically connecting the PLC transceiver module to the shutdown control module transmits real-time module operating information to the shutdown control module. The shutdown control module detects and judges the received information, promptly marking abnormal modules. Sending a shutdown command from the shutdown control module disconnects the shutdown execution module, ensuring the safety of the solar module. The circuit is simple in structure and easy to use.

Description

Technical Field

[0001] This invention relates to the field of electrical fault detection technology, and in particular to an electrical fault detection and shutdown circuit for a solar module junction box. Background Technology

[0002] The electrical fault detection circuit of the solar junction box assembly is a supporting device for the internal electrical control and detection of the junction box. In case of emergency, such as fire or maintenance, the power supply needs to be disconnected in time. The junction box control circuit shuts down SW1, and the voltage of a single module drops below 1V. In case of emergency faults and maintenance, the battery string voltage drops below the safe voltage.

[0003] Existing traditional solar module junction boxes have certain drawbacks. First, they cannot effectively monitor the module's usage in real time, which can easily lead to safety hazards. Second, they are not conducive to the display and location of module faults. Third, their structure is relatively simple and cannot detect the module's operating status, which has a certain adverse effect on the solar power generation process. To address this, an electrical fault detection and shutdown circuit for solar module junction boxes is proposed. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing an electrical fault detection and shutdown circuit for a solar module junction box.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: an electrical fault detection and shutdown circuit for a solar module junction box, including a positive input terminal, a negative input terminal, a positive output terminal, and a negative output terminal. The circuit further includes a power supply module, a shutdown execution module, a PLC transceiver module, an MCU control module, a sensor module, and a shutdown control module. The power supply module supplies power to the solar module junction box and is located between the positive and negative input terminals. The shutdown execution module is located between the positive input terminal and the positive output terminal and is electrically connected to the power supply module. The PLC transceiver module is electrically connected to the power supply module. The MCU control module is electrically connected to the power supply module and is electrically connected to the PLC transceiver module. The PLC transceiver module is electrically connected to the PLC control module, and the MCU control module is electrically connected to the shutdown execution module. The sensor module is electrically connected to the MCU control module, and the shutdown control module is electrically connected to the PLC transceiver module. The MCU control module transmits the received work information from the sensor module to the PLC transceiver module, which in turn transmits the received work information to the shutdown control module. The shutdown control module detects and judges the received work information and marks abnormal components when an anomaly occurs. When the shutdown control module sends a shutdown command, the PLC transceiver module transmits the received shutdown command to the MCU control module, which then transmits the shutdown command to the shutdown execution module, which remains disconnected.

[0006] Preferably, the circuit also includes a buck output module, which is connected in parallel with the shutdown execution module. When the shutdown execution module is in the off state, the buck output module operates to keep the output voltage at a safe level.

[0007] Furthermore, the step-down output module includes a voltage regulator submodule and an isolation submodule. The input terminal of the voltage regulator submodule is electrically connected to the positive terminal of the input terminal, the output terminal of the voltage regulator submodule is electrically connected to the isolation submodule, and the isolation submodule is electrically connected to the positive terminal of the output terminal.

[0008] Furthermore, the voltage regulator submodule includes a series voltage regulator circuit, and the isolation submodule includes an isolation diode. The input terminal of the series voltage regulator circuit is electrically connected to the positive terminal of the input terminal, the output terminal of the series voltage regulator circuit is electrically connected to the anode terminal of the isolation diode, and the cathode terminal of the isolation diode is electrically connected to the positive terminal of the output terminal.

[0009] Preferably, the sensor module includes a voltage sensing submodule and a temperature sensing submodule, both of which are electrically connected to the input terminal of the MCU control module.

[0010] Preferably, the circuit also includes a bypass protection module located between the positive and negative terminals of the output.

[0011] Furthermore, the bypass protection module includes a bypass diode, with the anode of the bypass diode electrically connected to the negative terminal of the output terminal and the cathode of the bypass diode electrically connected to the positive terminal of the output terminal.

[0012] Preferably, the circuit also includes a display module, the input of which is electrically connected to the shutdown control module.

[0013] Preferably, the circuit also includes an alarm module, the input of which is electrically connected to the shutdown control module.

[0014] Preferably, the shutdown execution module includes a switch located between the positive input terminal and the positive output terminal.

[0015] Compared with existing technologies, the advantages of this invention are as follows: By setting a sensor module, the component's operating information can be effectively monitored in real time; by setting an MCU control module, the received information can be converted, facilitating information reception and identification by subsequent modules; by electrically connecting the PLC transceiver module to the shutdown control module, real-time component operating information can be transmitted to the shutdown control module, which then detects and judges the received component operating information, thereby promptly marking abnormal components when anomalies occur; the shutdown control module sends a shutdown command, which puts the shutdown execution module in a disconnected state, ensuring the safety of the solar module's use. The invention is simple in structure and easy to use. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the electrical fault detection and shutdown circuit of a solar module junction box according to an embodiment of the present invention. Figure 2 This is a schematic diagram of the electrical fault detection and shutdown circuit of a solar module junction box according to another embodiment of the present invention; Figure 3 This is a schematic diagram of the electrical fault detection and shutdown circuit of a solar module junction box according to another embodiment of the present invention, including a shutdown execution module, a step-down output module, and a bypass protection module. Detailed Implementation

[0017] To provide a further understanding of the purpose, structure, features, and functions of the present invention, detailed descriptions are provided below with reference to specific embodiments.

[0018] It should be noted that when a layer, region, or component is described as being electrically "connected" or "combined" to another layer, region, or component, the layer, region, or component may be "directly electrically connected or directly electrically combined" to the other layer, region, or component, or "indirectly electrically connected or indirectly electrically combined" to the other layer, region, or component such that an intermediate layer, region, or component is located therebetween.

[0019] Please see Figure 1 The present invention discloses an electrical fault detection and shutdown circuit for a solar module junction box, comprising an input positive terminal PVIn+, an input negative terminal PVIn-, an output positive terminal PVout+, and an output negative terminal PVout-. The input positive terminal PVIn+ and the input negative terminal PVIn- are used to electrically connect to the solar module according to their polarity, and the output positive terminal PVout+ and the output negative terminal PVout- are used to electrically connect to adjacent modules, inverters, and other devices according to their polarity.

[0020] The circuit also includes a power supply module 1, a shutdown execution module 2, a PLC transceiver module 3, an MCU control module 4, a sensor module 5, and a shutdown control module 6.

[0021] Power module 1 is used to power the solar module junction box. Power module 1 is located between the positive input terminal PVin+ and the negative input terminal PVin-. Shutdown execution module 2 is located between the positive input terminal PVin+ and the positive output terminal PVout+. It serves as the execution module for turning on or off the positive bus of the junction box. Shutdown execution module 2 is electrically connected to power module 1. PLC transceiver module 3 is electrically connected to power module 1. MCU control module 4 is electrically connected to power module 1, PLC transceiver module 3, and shutdown execution module 2. Sensor module 5 is electrically connected to MCU control module 4 to transmit the sensed working information to MCU control module 4. Shutdown control module 6 is electrically connected to PLC transceiver module 3 to receive the working information transmitted by PLC transceiver module 3 and to transmit shutdown commands to PLC transceiver module 3.

[0022] Specifically, the MCU control module 4 converts the received working information from the sensor module 5 and transmits it to the PLC transceiver module 3. The PLC transceiver module 3 then transmits the converted working information to the shutdown control module 6. The shutdown control module 6 detects and judges the received component working information and marks the abnormal component in a timely manner when an abnormality occurs. When the shutdown control module 6 sends a shutdown command, the PLC transceiver module 3 transmits the received shutdown command to the MCU control module 4 for conversion. The MCU control module 4 then transmits the converted shutdown command to the shutdown execution module 2, which is in a disconnected state.

[0023] The shutdown control module 6 locates the abnormal component by comparing the information of other normally functioning components in the entire string, and marks it.

[0024] When a component malfunction is caused by an emergency (such as a fire) or when maintenance is required and the voltage output needs to be actively disconnected, the user controls the shutdown control module 6 to send a shutdown command to the PLC transceiver module 3, causing the shutdown execution module 2 to be in the off state.

[0025] In practical use, the shutdown control module 6 operates independently of the solar module junction box. One shutdown control module 6 can control multiple junction boxes, facilitating user shutdown operations. The shutdown control module 6 simultaneously receives module operating information from the PLC transceiver modules 3 of multiple junction boxes. When a module malfunction is detected, the malfunctioning module is marked. The user then controls the shutdown control module 6 to send a shutdown command to the PLC transceiver module 3 of the junction box corresponding to the malfunctioning module, thus disconnecting the shutdown execution module 2 of that junction box.

[0026] This embodiment provides an electrical fault detection and shutdown circuit for a solar module junction box. By incorporating a sensor module 5, the circuit effectively monitors the module's operating information in real time. An MCU control module 4 converts the received information, facilitating subsequent information reception and identification by other modules. Electrically connecting a PLC transceiver module 3 to a shutdown control module 6 transmits real-time module operating information to the shutdown control module 6. The shutdown control module 6 detects and judges the received module operating information, promptly marking any abnormal modules. Sending a shutdown command from the shutdown control module 6 disconnects the shutdown execution module 2, ensuring the safety of the solar module's operation.

[0027] Preferably, the circuit further includes a bypass protection module 7, which is located between the positive output terminal PVout+ and the negative output terminal PVout- for bypass protection of the photovoltaic module.

[0028] Preferably, the sensor module 5 includes a voltage sensing submodule and a temperature sensing submodule. The output terminals of both the voltage sensing submodule and the temperature sensing submodule are electrically connected to the input terminals of the MCU control module 4 to transmit the voltage and temperature information of the component during operation to the MCU control module 4 for conversion.

[0029] Preferably, the circuit further includes a display module, the input of which is electrically connected to the output of the shutdown control module 6, so as to display the component's operating information in real time and display the abnormal solar component when an abnormality occurs.

[0030] Preferably, the circuit further includes an alarm module, the input of which is electrically connected to the output of the shutdown control module 6, so as to remind the user to take timely action when an abnormality occurs.

[0031] Please see Figure 2 , Figure 2 This is a schematic diagram of an electrical fault detection and shutdown circuit for a solar module junction box according to another embodiment of the present invention. Figure 1 Compared to the previous embodiment, in this embodiment, the circuit further includes a step-down output module 8, which is connected in parallel with the shutdown execution module 6. When the shutdown execution module 2 is in the off state, the step-down output module 8 operates to maintain the output voltage at a safe level, for example, around 1V. Simultaneously, it serves as a reference for the output voltage of each solar module after shutdown, facilitating backend voltage monitoring, ensuring the shutdown action is executed, and increasing reliability. For example, with a voltage reference of 1V, the overall voltage after 22 solar modules are connected in series is approximately 22V. If the backend determines the voltage is greater than 30V, it can be considered that the shutdown is not complete, and an audible and visual warning will be issued to prevent electric shock.

[0032] Please see Figure 3The step-down output module 8 includes a voltage regulator submodule 81 and an isolation submodule 82. The voltage regulator submodule 81 is used to output a stable voltage, and the isolation submodule 82 is used to prevent voltage backflow during normal output. The input terminal of the voltage regulator submodule 81 is electrically connected to the positive input terminal PVin+, the output terminal of the voltage regulator submodule 81 is electrically connected to the isolation submodule 82, and the isolation submodule 82 is electrically connected to the positive output terminal PVout+.

[0033] Preferably, the voltage regulator submodule 81 includes a series voltage regulator circuit, and the isolation submodule 82 includes an isolation diode D2. The input terminal of the series voltage regulator circuit is electrically connected to the positive terminal PVin+, the output terminal of the series voltage regulator circuit is electrically connected to the anode terminal of the isolation diode D2, and the cathode terminal of the isolation diode D2 is electrically connected to the positive terminal PVout+.

[0034] Please see Figure 3 The series voltage regulator circuit includes a current-limiting resistor R1, a base drive resistor R2, output feedback sampling resistors R3 and R4, and an adjustable precision parallel regulator. The output feedback sampling resistors R3 and R4 provide output voltage feedback and provide output voltage regulation feedback signals to the adjustable precision parallel regulator.

[0035] Preferably, the bypass protection module 7 includes a bypass diode D1, with the anode of the bypass diode D1 electrically connected to the negative terminal PVout- of the output terminal, and the cathode of the bypass diode D1 electrically connected to the positive terminal PVout+ of the output terminal.

[0036] Preferably, the shutdown execution module 2 includes a switch SW1, which is located between the positive input terminal PVin+ and the positive output terminal PVout+. In practical applications, the switch SW1 is not limited to semiconductor switching devices and mechanical switching devices.

[0037] Usage: When the component is working normally, the switch SW1 of the shutdown execution module 2 is in the closed state, and the current of the solar panel string flows through the switch SW1 of the shutdown execution module 2. The voltage between the positive terminal PVout+ and the negative terminal PVout- is equal to the voltage of the battery string. When the component has abnormal conditions, such as excessive temperature, excessive voltage, or other conditions, the shutdown control module 6 locates the abnormal component by comparing the information of other normally working components in the string, displays the abnormal solar component through the display module, and provides an abnormal reminder through the alarm module.

[0038] When the shutdown control module 6 issues a shutdown command, the PLC transceiver module 3 transmits the received shutdown command to the MCU control module 4 for conversion. The MCU control module 4 then transmits the converted shutdown command to the shutdown execution module 2, causing the switch SW1 of the shutdown execution module 2 to be in the off state. At this time, the series voltage regulator circuit of the voltage regulator submodule 81 outputs a regulated voltage and keeps the output voltage at a safe level.

[0039] After shutdown, the output voltage value of the step-down output module 8 can be detected to determine whether shutdown is complete, and the user will be warned by sound and light to avoid electric shock.

[0040] This invention discloses an electrical fault detection and shutdown circuit for a solar module junction box. By incorporating a sensor module, it effectively monitors the module's operating information in real time. An MCU control module converts the received information, facilitating subsequent information reception and identification by other modules. Electrically connecting a PLC transceiver module to a shutdown control module transmits real-time module operating information to the shutdown control module. The shutdown control module detects and judges the received information, promptly marking any abnormal components. Sending a shutdown command from the shutdown control module disconnects the shutdown execution module, ensuring the safety of the solar module. The circuit is simple in structure and easy to use.

[0041] The present invention has been described in the above-described embodiments; however, these embodiments are merely examples for implementing the present invention. It must be noted that the disclosed embodiments do not limit the scope of the present invention. Conversely, any modifications and refinements made without departing from the spirit and scope of the present invention are within the scope of patent protection of the present invention.

Claims

1. An electrical fault detection and shutdown circuit for a solar module junction box comprising an input positive terminal, an input negative terminal, an output positive terminal, and an output negative terminal, characterized in that, The circuit also includes: A power module is provided for supplying power to the solar panel junction box. The power module is located between the positive input terminal and the negative input terminal. A shutdown execution module is located between the positive input terminal and the positive output terminal, and the shutdown execution module is electrically connected to the power supply module. A PLC transceiver module, wherein the PLC transceiver module is electrically connected to the power supply module; An MCU control module is electrically connected to the power supply module, the PLC transceiver module, and the shutdown execution module. The sensor module is electrically connected to the MCU control module; A step-down output module, connected in parallel with the shutdown execution module, includes a voltage regulator submodule for outputting a stable voltage and an isolation submodule for preventing voltage backflow during normal output. The input terminal of the voltage regulator submodule is electrically connected to its positive terminal, the output terminal of the voltage regulator submodule is electrically connected to the isolation submodule, and the isolation submodule is electrically connected to its positive output terminal. A shutdown control module, which is electrically connected to the PLC transceiver module; The MCU control module transmits the received operating information from the sensor module to the PLC transceiver module, which in turn transmits the received operating information to the shutdown control module. The shutdown control module detects and judges the received operating information and marks abnormal components when an anomaly occurs. When the shutdown control module sends a shutdown command, the PLC transceiver module transmits the received shutdown command to the MCU control module, which then transmits the shutdown command to the shutdown execution module. The shutdown execution module is in a disconnected state, and the buck output module operates to maintain the output voltage at a safe level. After shutdown, the shutdown completion can be determined by detecting the output voltage value of the buck output module.

2. The electrical fault detection and shutdown circuit for a solar module junction box as described in claim 1, characterized in that, The voltage regulator submodule includes a series voltage regulator circuit, and the isolation submodule includes an isolation diode. The input terminal of the series voltage regulator circuit is electrically connected to the positive terminal of the input terminal, the output terminal of the series voltage regulator circuit is electrically connected to the anode terminal of the isolation diode, and the cathode terminal of the isolation diode is electrically connected to the positive terminal of the output terminal.

3. The electrical fault detection and shutdown circuit for a solar module junction box as described in claim 1, characterized in that, The sensor module includes a voltage sensing submodule and a temperature sensing submodule, both of which are electrically connected to the input terminal of the MCU control module.

4. The electrical fault detection and shutdown circuit for a solar module junction box as described in claim 1, characterized in that, It also includes a bypass protection module, which is located between the positive terminal of the output terminal and the negative terminal of the output terminal.

5. The electrical fault detection and shutdown circuit for a solar module junction box as described in claim 4, characterized in that, The bypass protection module includes a bypass diode, the anode of which is electrically connected to the negative terminal of the output terminal, and the cathode of which is electrically connected to the positive terminal of the output terminal.

6. The electrical fault detection and shutdown circuit for a solar module junction box as described in claim 1, characterized in that, It also includes a display module, the input of which is electrically connected to the shutdown control module.

7. The electrical fault detection and shutdown circuit for a solar module junction box as described in claim 1, characterized in that, It also includes an alarm module, the input of which is electrically connected to the shutdown control module.

8. The electrical fault detection and shutdown circuit for a solar module junction box as described in claim 1, characterized in that, The shutdown execution module includes a switch located between the positive input terminal and the positive output terminal.

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