Solar power monitoring and optimization equipment, systems and methods

Abstract

This invention discloses a device for monitoring and optimizing the power output of one or more solar panels, the device being coupled to the one or more solar panels. The device includes a processor configured to generate a periodic wave and apply the periodic wave to the output of the one or more solar panels. An analog-to-digital voltage-to-current converter receives voltage and current signals from the one or more solar panels and provides digital voltage and current signals to the processor. The processor is configured to: calculate the voltage amplitude and DC offset of the periodic wave applied to the output of the one or more solar panels; calculate the power and voltage difference of the one or more solar panels based on the voltage amplitude and DC offset; and modify the voltage of the one or more solar panels such that the power and voltage difference of the one or more solar panels is zero, or substantially zero.

Description

Technical Field

[0001] This invention relates to a solar power monitoring and optimization device, system, and related method. In particular, the invention relates to a device for monitoring and optimizing the power output of one or more solar panels, a communication and monitoring system comprising one or more such devices, and related methods. Specific embodiments of the invention relate to safety devices, systems, and methods related to solar panels. Background Technology

[0002] Solar panels and solar arrays are widely used to generate electricity in industrial, commercial, and residential environments. Optimizing the power output of solar panels is desirable to maximize the amount of electricity generated. It is also desirable to maximize the efficiency of solar panels and reduce losses due to factors such as heat.

[0003] Known problems with power switching devices used in conjunction with solar panels to generate electricity typically include slow switching speeds, unwanted harmonic interference and noise, heat generation requiring large heat sinks, and shortened lifespan under harsh environmental conditions. Another issue with power switching devices in known solar arrays is that many solar arrays are considered unsafe to use with water from fire hoses in the event of a fire.

[0004] Purpose of the invention

[0005] A preferred object of the present invention is to provide a solar power monitoring device and / or system and / or method that solves or at least improves one or more of the above-mentioned problems and / or provides a useful commercial option. Summary of the Invention

[0006] Embodiments of the present invention relate to a device for monitoring and optimizing the power output of one or more solar panels, the device being connected to the one or more solar panels. Embodiments of the present invention also relate to such devices including safety switches or safety devices. Other embodiments of the present invention relate to communication and monitoring systems including one or more such devices. Still other embodiments of the present invention relate to methods for monitoring and optimizing the power output of one or more solar panels.

[0007] According to one aspect, but not necessarily the broadest aspect, the present invention relates to an apparatus for coupling to one or more solar panels to monitor and optimize the power output of the one or more solar panels, the apparatus comprising:

[0008] A processor configured to generate a periodic wave and apply the periodic wave to the output of one or more solar panels;

[0009] An analog-to-digital converter (ADC) for receiving voltage signals from one or more solar panels; and

[0010] An analog-to-digital current converter used to receive current signals from one or more solar panels;

[0011] The processor is configured as follows:

[0012] It receives digital voltage signals from a voltage converter and digital current signals from a current converter;

[0013] Calculate the voltage amplitude and DC offset of the periodic wave applied to the output of one or more solar panels;

[0014] Calculate the power and voltage difference of one or more solar panels based on the output from the low-pass filter; and

[0015] Modify the voltage of one or more solar panels so that the difference between the power and voltage of the one or more solar panels is zero, or essentially zero, and thus maximized.

[0016] Suitablely, a periodic wave is any repeating wave of arbitrary shape and constant frequency. Preferably, a periodic wave is a sine wave. Alternatively, a periodic wave is a square wave, a sawtooth wave, or a periodic wave of another shape.

[0017] Appropriately, a periodic wave is a repetitive voltage wave or repetitive current wave applied to the output of one or more solar panels.

[0018] Appropriately, the periodic wave has a constant frequency between measurement periods. Alternatively, the frequency of the periodic wave differs between measurement periods.

[0019] In some embodiments, the processor is configured to apply a low-pass filter to a digital voltage signal and a low-pass filter to a digital current signal to calculate the voltage amplitude and DC offset of a periodic wave.

[0020] In other embodiments, the processor is configured to apply a low-pass filter and a band-pass filter to each of the digital voltage signal and the digital current signal to calculate the voltage amplitude and DC offset of the periodic wave.

[0021] In other embodiments, the processor is configured to apply a Fourier transform to a digital voltage signal and a Fourier transform to a digital current signal to calculate the voltage amplitude and DC offset of a periodic wave.

[0022] Preferably, the device includes a bidirectional or unidirectional power converter for receiving control signals from a processor to modify the voltage of one or more solar panels such that the difference between the power and voltage of the one or more solar panels is zero, or substantially zero, and thus maximized.

[0023] Preferably, the control signal is based on the output of the maximum power point controller module and the output of the periodic wave voltage or current controller module, such as the solar panel sinusoidal wave voltage or current controller module or square wave voltage or current controller module of the device.

[0024] Preferably, a periodic wave is applied by moving energy between an output energy storage device that communicates with a bidirectional or unidirectional power converter and an input energy storage device that communicates with the bidirectional or unidirectional power converter and one or more solar panels.

[0025] Preferably, the output energy storage device and / or the input energy storage device are in the form of capacitors.

[0026] Preferably, the device includes a printed circuit board (PCB) having a first control side containing a processor and a second opposing power side containing a plurality of power switching components, which are preferably arranged substantially in a U-shape or C-shape around a power inductor to maximize power switching speed and / or minimize harmonic noise and / or avoid the need for a heat sink.

[0027] Preferably, the device comprises an all-plastic housing.

[0028] Appropriately, the device detects the state of a solar circuit breaker or isolator switch coupled to the circuit by applying a voltage pulse to the circuit containing the device and one or more solar panels to look for current.

[0029] Appropriately, the circuit includes a capacitor on the load side of the solar circuit breaker or isolator switch, and the device detects the capacitor when the solar circuit breaker or isolator switch is closed.

[0030] According to another, but not necessarily the broadest, aspect of the present invention, the present invention relates to a method for monitoring and optimizing the power output of one or more solar panels by coupling a device to one or more solar panels, the method comprising:

[0031] A periodic wave is generated in the processor and applied to the output of one or more solar panels;

[0032] The device receives voltage signals from one or more solar panels in its analog-to-digital converter.

[0033] The device receives current signals from one or more solar panels in its analog-to-digital current converter.

[0034] The digital voltage signal is received in the processor coupled to the voltage converter;

[0035] The digital current signal is received in the processor coupled to the current converter;

[0036] The processor:

[0037] Calculate the voltage amplitude and DC offset of the periodic wave applied to the output of one or more solar panels;

[0038] Calculate the power and voltage difference of one or more solar panels based on the output from the low-pass filter; and

[0039] Modify the voltage of one or more solar panels so that the difference between the power and voltage of the one or more solar panels is zero, or essentially zero, and thus maximized.

[0040] The calculation of the voltage amplitude and DC offset of a periodic wave can include one of the following:

[0041] The processor applies a low-pass filter to the digital voltage signal and a low-pass filter to the digital current signal; or

[0042] The processor applies a low-pass filter and a band-pass filter to each of the digital voltage signal and the digital current signal; or

[0043] The processor applies the Fourier transform to the digital voltage signal and the Fourier transform to the digital current signal.

[0044] The method may involve applying a periodic wave to the output of one or more solar panels by moving energy between an output energy storage device that communicates with a bidirectional or unidirectional power converter and an input energy storage device that communicates with the bidirectional or unidirectional power converter and one or more solar panels.

[0045] Preferably, the method includes a bidirectional power converter that receives control signals from a processor to modify the voltage of one or more solar panels such that the difference between the power and voltage of the one or more solar panels is zero or substantially zero.

[0046] The method may include: the device applying a voltage pulse to a circuit containing the device and one or more solar panels to detect the state of a solar circuit breaker or isolator switch coupled to the circuit by looking for current.

[0047] Appropriately, the circuit includes a capacitor on the load side of the solar circuit breaker or isolator switch, and the method may be included in a device that detects the capacitor when the solar circuit breaker or isolator switch is closed.

[0048] According to another, but not necessarily the broadest, aspect of the invention relates to a solar communication and monitoring system comprising one or more of the aforementioned power monitoring and optimization devices coupled to one or more solar panels, wherein the one or more power monitoring and optimization devices are configured to modify the voltage of the one or more solar panels such that the difference between the power and voltage of the one or more solar panels is zero, or substantially zero, thereby maximizing the power output of the one or more solar panels.

[0049] Appropriately, each power monitoring and optimization device is coupled to one solar panel. Alternatively, each power monitoring and optimization device is coupled to multiple solar panels.

[0050] Preferably, the solar panels are connected in series, and the power monitoring and optimization equipment is also connected in series.

[0051] Preferably, the power monitoring and optimization device is coupled to the communication and security indicator device.

[0052] Preferably, the power monitoring and optimization equipment, as well as the communication and safety indicator equipment, are coupled to the inverter and / or battery via an isolator switch.

[0053] Appropriately, the device detects the status of the solar circuit breaker or isolator switch coupled to the circuit by applying voltage pulses to the circuit to look for current.

[0054] Appropriately, the circuit includes a capacitor on the load side of the solar circuit breaker or isolator switch, and the device detects the capacitor when the solar circuit breaker or isolator switch is closed.

[0055] According to another aspect, but not necessarily the broadest aspect, the present invention relates to a solar power monitoring and optimization kit comprising: one or more of the aforementioned power monitoring and optimization devices for coupling to one or more solar panels; and communication and safety indicator devices for coupling to the one or more power monitoring and optimization devices, to an inverter and / or a battery, and to a main power source.

[0056] According to another, but not necessarily the broadest, aspect, the present invention relates to a device for detecting the state of a solar circuit breaker or isolator switch coupled to a circuit containing one or more solar panels, wherein the device applies a voltage pulse to the circuit in which current is being sought.

[0057] Appropriately, the circuit includes a capacitor on the load side of the solar circuit breaker or isolator switch, and the device detects the capacitor when the solar circuit breaker or isolator switch is closed.

[0058] According to another, but not necessarily the broadest, aspect, the present invention relates to a method for detecting the state of a solar circuit breaker or isolator switch coupled to a circuit comprising one or more solar panels and communication and safety indicator devices, the method comprising applying a voltage pulse to a circuit for finding current.

[0059] Appropriately, the circuit includes a capacitor on the load side of the solar circuit breaker or isolator switch, and the method includes a device for detecting the capacitor when the solar circuit breaker or isolator switch is closed.

[0060] Other features and / or aspects of the invention will become apparent from the following detailed description. Attached Figure Description

[0061] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which the same reference numerals denote the same features. In the drawings:

[0062] Figure 1 This is a schematic diagram illustrating a plurality of power monitoring and optimization devices including a safety switch for monitoring and optimizing power output from a solar panel according to an embodiment of the present invention, showing devices coupled to a solar panel in a first system configuration;

[0063] Figure 2 This is shown as coupling to the solar panel in the second system configuration. Figure 1 A schematic diagram of the multiple devices shown;

[0064] Figure 3A This illustrates an embodiment of the present invention. Figure 1 A schematic diagram showing the power and signal paths between the device and the solar panel;

[0065] Figure 3B This illustrates another embodiment of the invention. Figure 1 A schematic diagram showing the power and signal paths between the device and the solar panel;

[0066] Figure 4 This is an image showing the control side of a printed circuit board of a power monitoring and optimization device according to an embodiment of the present invention;

[0067] Figure 5 It is shown Figure 4 The image shown is of the power supply side of the printed circuit board, without any power inductors attached.

[0068] Figure 6 It is shown Figure 5 The image shown is of the power supply side of the printed circuit board, which shows the attached power inductor;

[0069] Figure 7 It is a graph showing the changes in efficiency and power output of a solar panel under various input voltages and currents;

[0070] Figure 8 A power monitoring and optimization device operating as a safety switch in a power monitoring and optimization system is shown.

[0071] Figure 9A and 9B It shows the representation used for Figure 8 The graph shows the applied voltage pulses and measured current for the safety aspects of the power monitoring and optimization equipment.

[0072] Figure 10 It includes Figure 1 A perspective view of the power monitoring and optimization equipment for the safety switch shown;

[0073] Figure 11 yes Figure 1 Perspective view of the communication devices and safety indicators of the system shown;

[0074] Figure 12 yes Figure 1 Rear perspective view of the power monitoring and optimization equipment shown and the mounting bracket for coupling the equipment to the solar panel mounting frame;

[0075] Figure 13 It is shown Figure 1 An image of a power monitoring and optimization device coupled to a relatively small solar panel indicating the device is shown; and

[0076] Figure 14 This is a general flowchart illustrating a method for power monitoring and optimization equipment to monitor and optimize the power output of one or more solar panels.

[0077] Those skilled in the art will understand that the elements in the accompanying drawings are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the relative dimensions of some elements in the drawings may be distorted and / or some elements may be omitted to aid in understanding the embodiments of the invention. Detailed Implementation

[0078] Embodiments of the present invention relate to a device for monitoring and optimizing the power output of one or more solar panels, the device being connected to the one or more solar panels. Embodiments of the present invention also relate to such devices including safety switches. Other embodiments of the present invention relate to solar panel communication and monitoring systems and kits including one or more such devices. Still other embodiments of the present invention relate to methods for optimizing and monitoring the power output of one or more solar panels.

[0079] Embodiments of the present invention allow solar panels to be connected in series and have the benefits of series connection, while being mathematically connected in parallel and providing all the benefits of parallel connection. The communication system of the present invention uses radio frequency current instead of voltage, thus allowing communication signals to propagate through an electrically series system.

[0080] refer to Figure 1 and 2 The present invention illustrates a solar panel communication and monitoring system 100, 200 according to an embodiment of the present invention. Figure 1 A system 100 comprising a plurality of power monitoring and optimization devices 110 according to an embodiment of the present invention is shown. Each power monitoring and optimization device includes a safety switch coupled to a plurality of solar panels 112 in a first system configuration. The system 100 includes each power monitoring and optimization device 110 coupled to two solar panels 112. The solar panels are connected in series. The power monitoring and optimization devices 110 are coupled to a communication and safety indicator device 114. The power monitoring and optimization devices 110 and the communication and safety indicator device 114 are coupled to an inverter and / or a battery 118 via an isolator switch 116. The communication and safety indicator device 114 is coupled to a mains power supply.

[0081] Solar panel communication and monitoring system 200 is similar to Figure 1 The system 100 shown is an example of a second system configuration, but with power monitoring and optimization devices 110 and solar panels 112 coupled together. System 200 includes each power monitoring and optimization device 110 coupled to a single solar panel 112. The remaining configuration of system 100 is the same as that of system 100. The configuration of system 200 maximizes efficiency. It should be understood that system 200 includes twice the number of power monitoring and optimization devices 110.

[0082] It should be understood that, with Figure 1 and 2Compared to the quantities shown, the solar panel communication and monitoring system according to the present invention can include other quantities and configurations of power monitoring and optimization devices 110 and solar panels 112. For example, a single power monitoring and optimization device 110 can be coupled to three or more solar panels 112, or two or more power monitoring and optimization devices 110 can be coupled to four or more solar panels 112, etc.

[0083] Figure 3A The diagram illustrates the power and signal paths within a power monitoring and optimization device 110 and between a solar panel 112, according to an embodiment of the present invention. The power monitoring and optimization device 110 includes a voltage measuring device in the form of an analog-to-digital voltage converter 120 for receiving voltage signals from one or more solar panels 112 to which the device 110 is coupled. The device 110 also includes a current measuring device in the form of an analog-to-digital current converter 122 for receiving current signals from one or more solar panels 112 to which the device 110 is coupled.

[0084] Device 110 includes processor 124, which is configured to execute computer-readable program code stored in memory, such as any known type. Processor 124 is configured to generate a periodic voltage wave or a periodic current wave and apply the periodic wave to the output of one or more solar panels 112. The periodic wave with frequency f can be generated by periodic wave generator module 128.

[0085] The processor 124 is configured to receive a digital voltage signal from the voltage converter 120 and a digital current signal from the current converter 122.

[0086] Processor 124 is configured to calculate the voltage amplitude of a periodic wave applied to the output of one or more solar panels 112 and to calculate the DC offset of the periodic wave. Figure 3A In the illustrated embodiment, processor 124 is configured to apply a Fourier transform to a digital voltage signal and a Fourier transform to a digital current signal to calculate the voltage amplitude and DC offset of a periodic wave. Figure 3A In the illustrated embodiment, a Fourier transform is applied to a digital voltage signal in module 126. The output of module 126 is the Fourier amplitude of the DC voltage Vdc, i.e., the Fourier amplitude of the voltage Vf at zero frequency and at frequency f. A Fourier transform is applied to a digital current signal in module 130. The output of module 130 is the Fourier amplitude of the DC current Idc, i.e., the Fourier amplitude of the current Vf at zero frequency and at frequency f.

[0087] In other embodiments, processor 124 is configured to apply a low-pass filter to a digital voltage signal and a low-pass filter to a digital current signal to calculate the voltage amplitude and DC offset of the periodic wave, as referenced. Figure 3B As described.

[0088] In other embodiments, processor 124 is configured to apply low-pass and band-pass filters to each of the digital voltage and digital current signals to calculate the voltage amplitude and DC offset of the periodic wave.

[0089] Further reference Figure 3A The processor 124 is configured to calculate the differential dP / dV of the power and voltage of one or more solar panels 112 based on the calculated voltage amplitude and the DC offset of the periodic wave. Figure 3A In the embodiment shown, the calculation of the difference dP / dV occurs in module 129.

[0090] Processor 124 is configured to modify the voltage of one or more solar panels 112 such that the difference between the power and voltage of the one or more solar panels 112 is zero, or substantially zero, i.e., maximized. In some embodiments, processor 124 maximizes the difference between the power and voltage of the one or more solar panels 112 via maximum power point (MPPT) controller module 132 and periodic wave controller module 134.

[0091] In some embodiments, the power monitoring and optimization device 110 includes a bidirectional power converter 136 for receiving control signals from the processor 124 to modify the voltage of one or more solar panels 112 such that the difference between the power and voltage of the one or more solar panels is zero, or substantially zero, i.e., maximized. In alternative embodiments, it is envisioned that a unidirectional converter could be used instead of the bidirectional power converter 136 for most system operating points. However, in such embodiments, the periodic wave controller module 134 would lose control of the reverse power segment of the sine wave at some operating points and is therefore less preferred than the bidirectional power converter 136.

[0092] In some embodiments, a periodic wave is applied by moving energy between an output energy storage device 138 communicating with a bidirectional power converter 136 and an input energy storage device 140 communicating with the bidirectional power converter 136 and one or more solar panels 112. In a preferred embodiment, the output energy storage device 138 and the input energy storage device 140 are in the form of capacitors. Figure 3BA power and signal path between a power monitoring and optimization device 110 and a solar panel 112 according to another embodiment of the present invention is illustrated. The power monitoring and optimization device 110 includes an analog-to-digital voltage converter 120 for receiving voltage signals from one or more solar panels 112 to which the device 110 is coupled. The device 110 includes an analog-to-digital current converter 122 for receiving current signals from one or more solar panels 112 to which the device 110 is coupled. The device 110 includes a processor 124 coupled to receive digital voltage signals from the voltage converter 120. The processor 124 is coupled to receive digital current signals from the current converter 122.

[0093] Processor 124 is configured to execute computer-readable program code stored in, for example, any known type of memory. In this embodiment, processor 124 is configured to apply a periodic wave, such as a sine wave, and a low-pass filter module 126 to a digital voltage signal from voltage converter 120. The periodic wave can be generated by periodic wave generator module 128, such as sine wave generator module 128 generating a sine wave of the form A*sin(ωt), where A is the amplitude and ω = 2πν, where ν is the operating frequency. Low-pass filter module 126 can be a high-Q low-pass filter module, which operates according to the function ω 2 / (s 2 +(ω / Q)s+ω 2 The voltage signal is filtered, where Q is the filter mass = 1 / (2 * damping constant) and s is the Laplace operator, generated in the form V + V a The filtered voltage signal of *sin(ωt).

[0094] Processor 124 is configured to apply a periodic wave, such as a sine wave, and low-pass filter module 130 to a digital current signal from current converter 122. Low-pass filter module 130 may be a high-Q low-pass filter module, which operates according to a function ω. 2 / (s 2 +(ω / Q)s+ω 2 The current signal is filtered to generate a signal in the form of I+I. a The filtered current signal of *sin(ωt+q), where q is the current phase shift.

[0095] The processor 124 is configured at 129 to calculate the power and voltage difference dP / dV of one or more solar panels 112 based on the filtered voltage signal from the low-pass filter module 126 and the filtered current signal from the low-pass filter module 130.

[0096] The processor 124 is configured to modify the voltage of one or more solar panels 112 such that the difference between the power and voltage of the one or more solar panels 112 is zero, or substantially zero, i.e. maximized.

[0097] In some embodiments, the processor 124, via a maximum power point (MPPT) controller module 132 and a solar panel periodic voltage controller module 134, such as a solar panel sinusoidal voltage controller module 134, maximizes the difference between the power and voltage of one or more solar panels 112. The maximum power point controller module 132 applies a function (s... 2 +15s+60) / (s 2 +10s), and the solar panel sinusoidal voltage controller module 134 applies the function 1 / s, where s is the Laplace operator.

[0098] In some embodiments, the power monitoring and optimization device 110 includes a bidirectional power converter 136 for receiving control signals from the processor 124 to modify the voltage of one or more solar panels 112 such that the difference between the power and voltage of the one or more solar panels is zero, or substantially zero, i.e., maximized. In alternative embodiments, it is envisioned that a unidirectional converter could be used instead of the bidirectional power converter 136 for most system operating points. However, in such embodiments, the solar panel sinusoidal voltage controller 134 would lose control of the reverse power segment of the sine wave at some operating points and is therefore less preferred than the bidirectional power converter 136.

[0099] In some embodiments, a sine wave is applied by moving energy between an output energy storage device 138 communicating with a bidirectional power converter 136 and an input energy storage device 140 communicating with the bidirectional power converter 136 and one or more solar panels 112. In a preferred embodiment, the output energy storage device 138 and the input energy storage device 140 are in the form of capacitors.

[0100] In some embodiments, a 250 mV to 500 mV peak-to-peak 12.5 Hz sinusoidal voltage from a sinusoidal generator module 128 is applied to the solar panel 112 via a solar panel sinusoidal voltage controller module 134, via a bidirectional power converter 136 and an input energy storage device 140 and an output energy storage device 138 in the form of capacitors. The sinusoidal voltage generates an approximately sinusoidal current. Due to the nonlinear VI curve of the solar panel 112, the current is not perfectly sinusoidal. The approximately sinusoidal current is multiplied by a sinusoidal voltage that varies 180 degrees out of phase from the voltage wave phase when the voltage across the solar panel 112 is greater than the maximum power point to the phase phase phase when the voltage across the solar panel 112 is less than the maximum power point, and is zero when the voltage across the solar panel 112 is at the maximum power point. Therefore, the instantaneous power is calculated in terms of the phase change, and this phase change can be used to detect the maximum power point.

[0101] Both voltage and current signals pass through low-pass filter modules 126 and 130 with a resonant peak of 12.5 Hz, meaning the voltage and current signals have imaginary poles in the filter transfer function. This processing generates two parts of the signal: a constant part and a sinusoidal part. It can be shown that the change in power divided by the change in panel voltage equals a linear combination of the maximum and minimum values ​​of the sinusoidal voltage and the maximum and minimum values ​​of the sinusoidal current. This provides a direct and very fast measurement of the power point of solar panel 112, which can be used in a feedback controller comprising MPPT controller module 132 and solar panel sinusoidal voltage controller module 134 to very quickly move the voltage to the maximum power point.

[0102] Embodiments of the present invention can suppress unwanted voltage and current signals, for example, by using a narrow-bandwidth resonant filter at the measurement frequency, which solves some of the serious difficulties that existing solar panel management systems and devices have in noise suppression.

[0103] The output of the bidirectional power converter 136 is not limited by voltage or current. This makes the series connection of the solar panels 112 behave as if the solar panels were connected in parallel. By not limiting the voltage or current, a degree of freedom is added to the output of the bidirectional power converter 136. In contrast, known power management systems, methods, and devices limit the output voltage or output current, thus forming a completely limited system in which the system behaves only as a series system with generally poor power management. By not limiting the voltage or current at the output of the bidirectional power converter 136, the system voltage and current are determined by the connected load.

[0104] However, the voltage and current of the bidirectional power converter 136 must be limited within the system's operating limits. This is achieved by placing voltage and current controllers at the output of the bidirectional power converter, which disconnect the MPPT control loop and control the voltage or current to the maximum system value. At these operating points, the solar panel 112 cannot deliver all available power and will not operate at the maximum power point. The periodic wave controller module 134 can be considered a fast internal control loop, and the MPPT controller 132 can be considered a slower external control loop. When power is removed from the output of the bidirectional power converter 136, the control loop stabilizes very quickly to a new operating point for the voltage and current of the solar panel 112. The maximum power point calculation is discrete at the frequency of the periodic wave generator 128, which in some embodiments is 12.5 times per second. This allows for extremely fast tracking of the power point within a time frame of approximately 200 milliseconds.

[0105] Figure 4 , 5 Figures 6 and 7 show images of a printed circuit board (PCB) 142 of a power monitoring and optimization device 110 according to some embodiments. Figure 4 The control side 144 of the PCB 142, including the processor 124, is shown. Figure 5 The power supply side 146 of PCB 142 is shown; it is Figure 4 The other side of the control side 144 shown. Figure 6 It shows Figure 5 The power supply side 146 of the power inductor 148 is attached to the PCB 142 shown.

[0106] On the power supply side 146, the power switching component 150 is arranged in a tight C-shape around the terminals of the power inductor 148. This is the optimal arrangement to achieve the shortest possible connection between the power switching component 150 and the power inductor 148. The capacitor 152 is mounted very close to the power switching component 150, thus providing a near-optimal design. In some embodiments, this arrangement, together with the small surface-mount power component 150, enables very fast switching times on the order of 25 nanoseconds without generating unwanted harmonic interference. This very small power switching design in this embodiment provides very high switching speeds and very low power losses. Figures 4 to 6 The embodiment of PCB 142 shown has a rated power delivery capacity of 1000W and has no heat sink except for PCB 142 itself. Figures 4 to 6The illustrated embodiment of PCB 142 is only 90mm × 50mm and weighs approximately 400g, which is very small and light for a 1000W converter. Because the power components 150 generate very little heat, an all-plastic housing with highly thermally conductive silicone rubber can be used as the thermal connection between the PCB 142 and the housing. The all-plastic housing allows for safety standards at higher voltages and enables the power monitoring and optimization device 110 to be used in very harsh environmental conditions, including but not limited to solar farms built on the sea surface and ocean, where metal housings would corrode.

[0107] In the field of power engineering, this relative arrangement of power and control components on PCB 142 is somewhat counterintuitive because the electrical noise generated by the power switching circuitry is very tightly coupled to the measurement and control electronics. However, in embodiments of the present invention, the power switching arrangement is so electrically quiet that even a radio modem receiver placed 1 mm away from the power switching component can operate. The small size of the power monitoring and optimization device 110, the fast switching time, and the significantly reduced switching noise contribute to the actual power efficiency achieved in systems incorporating the power monitoring and optimization device 110, examples of which are shown in... Figure 7 As shown in the image.

[0108] Figure 7 The efficiency achieved using the power monitoring and optimization device 110 and system 100, 200 according to embodiments of the present invention is shown for different input and output voltages and currents. Figure 7 The image shows voltage curves for 40V, 45V, 50V, 55V, 60V, 65V, 70V, 75V, 80V, 85V, 90V, 95V, and 100V, and current curves for 10A, 12.5A, 15A, and 20A. If the voltage in(V) in ) less than voltage out(V out ), (V in <V out If the input I is zero, then the current limit is... in The maximum current at V, and if V in Greater than V out , (V in >V out If the current limit is the output I, then the current limit is... out The maximum current at that point. To find the operating point, take lower input and output voltages and find the intersection of that voltage with the desired operating power point.

[0109] The power monitoring and optimization device 110 is the first device capable of measuring whether the power output of the solar panel 112 is tracking the maximum power point. This is achieved by ramping up the voltage of the solar panel 112 by approximately 1V over approximately 2.5 seconds, then ramping down the voltage by approximately 2V over approximately 5 seconds, and then ramping up the voltage back to the level before the test began. If the power output of the solar panel 112 tracks the maximum power point, it is displayed as “W” on a power versus time graph. This is possible because the power point tracking of the MMPT controller module 132 is very fast.

[0110] refer to Figure 8 Another important aspect of the invention is the ability of the power monitoring and optimization device 110 to detect the state of the solar circuit breaker 154 or isolator switch by applying a small voltage pulse across the solar string that is searching for current. A capacitor 156 is placed on the load side of the solar circuit breaker 154, and the power monitoring and optimization device 110 can "see" the capacitor 156 when the solar circuit breaker 154 (switch) is closed. Because the measurement requires a capacitor, the measurement is unaffected by DC offset or resistance, and therefore does not detect, for example, water from a fire hose in the event of a fire. Reference will now be made to... Figure 9A and 9B This will be described in further detail.

[0111] The default state of the output of the power monitoring and optimization device 110 is "off," which is a safe state of zero volts. The operating voltage on the output of device 110 is managed by a state machine that checks the system state to ensure that the transition from the "off" state to the "on" state is safe. In the "off" state, each power monitoring and optimization device 110 transitions its output from 0V to approximately 0.7V, waits approximately 2 milliseconds, and then transitions the output back to zero volts, as... Figure 9A As shown. Current is measured during voltage transitions. The current is integrated from the time of the first rising voltage transition to the time of the falling voltage transition. The negative value of the current is integrated over the next two milliseconds, as shown. Figure 9BAs shown. The current integral will only be a large positive number when a large capacitor 156 is connected across the output terminals of the solar string. The current integral causes any offset between the output terminals, such as resistance (water, etc.), to have zero effect on the integral. When the capacitor is placed on the load side of the solar circuit breaker 154, the power monitoring and optimization device 110 sets its output voltage to the operating "on" voltage unless it can detect the capacitor 156, i.e., if the solar circuit breaker 154 is closed. Each device 110 places a pulse at random walk times of approximately 500 milliseconds, averaging the pulses executed by one device 110 at any given time. However, any overlapping pulses have no effect on the measurement. The integrated current is passed through a low-pass filter module, such as 130, and if the integrated current reaches a set threshold, the device 110 considers the solar circuit breaker 154 to be closed. Once the connection is established, the connection is maintained as long as there is a current flowing greater than a small threshold, such as 50 mA. If the current drops below the threshold, the power monitoring and optimization device 110 assumes that the solar circuit breaker 154 will open and reduce the output voltage to zero and restart the connection sequence.

[0112] Device 110 is responsible for connecting its power supply to the circuit, and it detects that the solar circuit breaker 154 has been continuously closed for, for example, five seconds before raising the output voltage to the operating voltage. This detection requires that all conductors connected to the string are correctly connected and undamaged. Device 110 will disconnect its power supply within five seconds, for example, when a string conductor breaks or the solar isolator switches to the off position. In accordance with Australian and New Zealand Standard AS / NZS 4777, Device 110 will also disconnect within five seconds, for example, when the inverter input current becomes zero, i.e., the main power supply has been disconnected and the inverter is off. The connection logic is based on differential measurements, which excludes constant bias on the string conductors, such as water from a fire hose, and will not connect if water short-circuits exposed conductors. Each device 110 has the following safety disconnection conditions that stop power delivery and bring the output to zero volts within 5 microseconds: output short circuit; reverse power; overcurrent; high input voltage; high output voltage; internal power supply failure. Recovery from these disconnection conditions is automatic, and Device 110 will automatically restart if this is possible.

[0113] Figure 10 This is a perspective view of a power monitoring and optimization device 110 according to an embodiment of the present invention. Figure 11 They are respectively in Figure 1 and 2The diagram shows a perspective view of the communication device and safety indicator 114 of systems 100 and 200. Devices 110, the communication device, and safety indicator 114 are designed to meet the Safety Integrity Level 2 (SIL2) safety standard. SIL2 is a requirement for electrical certification under IEC 61508. This allows for adoption in industries such as, but not limited to, mining sites, government sites, military sites, and solar farms.

[0114] According to some embodiments, the communication device and safety indicator 114 includes CAN hardware to support CAN devices where available. DeviceNet hardware may also be provided on the communication device and safety indicator 114 for connection to one or more smart measurement and control devices, as well as other equipment supporting DeviceNet. The communication device and safety indicator 114 may also include a 1 Mbps RS485 port for connection to any RS485-enabled device, including third-party inverters.

[0115] Figure 12 This is a rear perspective view of the power monitoring and optimization device 110 and the mounting bracket 158 ​​for coupling the device 110 to the solar panel mounting frame 160. A plurality of first fasteners pass through first holes in the mounting bracket 158 ​​and into alignment holes in the rear of the plastic housing of the power monitoring and optimization device 110. Second fasteners pass through second holes in the mounting bracket 158 ​​and into alignment holes in the solar panel mounting frame 160.

[0116] Figure 13 The image shows a power monitoring and optimization device 110 coupled to a standard 280W solar panel 112, thus indicating the relatively small size of the device 110.

[0117] It should be understood that another aspect of the present invention relates to a method 300 for monitoring and optimizing the power output of one or more solar panels 112 by coupling device 110 to one or more solar panels 112. (See reference...) Figure 14At 305, method 300 includes receiving a voltage signal from one or more solar panels 112 in an analog-to-digital voltage converter 120 of device 110. At 310, method 300 includes receiving a current signal from one or more solar panels 112 in an analog-to-digital current converter 122 of device 110. At 315, method 300 includes receiving a digital voltage signal in a processor 124 coupled to voltage converter 120. At 320, method 300 includes receiving a digital current signal in a processor 124 coupled to current converter 122. At 325, method 300 includes processor 124 applying a sine wave and a low-pass filter to the digital voltage signal. At 330, method 300 includes processor 124 applying a sine wave and a low-pass filter to the digital current signal. At 335, method 300 includes processor 124 calculating the power and voltage difference of one or more solar panels based on the output from the low-pass filter. At 340, method 300 includes processor 124 modifying the voltage of one or more solar panels 112 such that the difference between the power and voltage of the one or more solar panels is zero, or substantially zero, i.e., maximized. In a preferred embodiment, at 345, method 300 preferably includes bidirectional power converter 136 that receives control signals from processor 124 to modify the voltage of one or more solar panels 112 such that the difference between the power and voltage of the one or more solar panels is zero, or substantially zero.

[0118] It is conceivable that, in alternative embodiments of the invention, the sine wave generator module 128 can be replaced by a square wave generator module, a sawtooth wave generator module, or other periodic wave generator module to generate any repetitive wave of arbitrary shape and constant frequency. Preferably, the periodic wave is a sine wave, but the periodic wave can be a square wave, a sawtooth wave, or a periodic wave of other shapes. It should be understood that any waveform repeating at a constant frequency will have a principal Fourier component in the form of a sine wave of constant frequency. The constant frequency element provides the fundamental sine component, which produces a sine output when filtered by a low-pass filter, and thus performs the MPPT dP / dV calculation. In such embodiments, the Fourier component of the signal is primarily a sine wave. In such embodiments, the solar panel sine wave voltage controller module 134 can be replaced by a solar panel square wave voltage controller module or other waveform voltage controller. The signal processing described herein, particularly with reference to... Figure 3A and 3B It can be modified as needed so that the system, method and apparatus for monitoring and optimizing the power output of one or more solar panels will work with the square wave generator module, sawtooth wave generator module or other waveform generator module in apparatus 110 instead of sine wave generator module 128.

[0119] In some embodiments, the bidirectional power converter 136 or the unidirectional converter is connected to a battery or any voltage that is not zero at the output, such as a nearby energized solar string containing solar panels 112. The converter 136 calculates the internal switching time of the pulse width modulator (PWM) such that if the PWM is switched within the calculated switching time, the voltages in the input and output will match the current voltages. This allows the converter 136 to be started without causing a large current to flow in the input or output, thus allowing the converter 136 to start when connected to, for example, a battery 118 or a nearby energized solar panel string 112.

[0120] In some embodiments, device 110 includes a thermal fuse in the input to enhance the safety aspect of the invention. When the temperature of the power switching component 150 becomes greater than the manufacturer's specification for the power switching component 150, which is typically approximately 150 degrees Celsius, the thermal fuse disconnects the circuit. In the event of a fire or external heat source, the input of the power converter is then permanently removed from the power supply, thus ensuring that the power is disconnected at high temperatures.

[0121] Therefore, embodiments of the present invention address or at least improve upon the aforementioned problems of the prior art by providing a power monitoring and optimization device 110 that can provide very fast power switching and monitoring of the output power of one or more connected solar panels to maximize the power output of those solar panels. The arrangement of components on the PCB 142 maximizes power switching speed, minimizes harmonic noise, and eliminates the need for a heat sink, allowing the device to be small and lightweight. Typically, device 110 can adapt to changes in sunlight and adjust power within approximately 2 seconds. The very low heat generation of the power components allows device 110 to have an all-plastic housing, which allows for safety standards at higher voltages and enables use in very harsh environmental conditions. The ability of the power monitoring and optimization device 110 to detect the status of the solar circuit breaker 154 or isolator switch also allows the status of the solar array to be determined before the use of fire hoses in the event of a fire. According to some embodiments, using device 110 and communication devices and safety indicators 114 results in a 16% to 25% increase in power compared to the same solar array without device 110 and apparatus 114. When installed, each solar panel 112 delivers more power to the inverter while losing less heat on its own.

[0122] Once the emergency interlock is set, device 110 will not provide a lethal voltage under any circumstances. This state remains after a power outage, after disconnection from the solar array, or when device 110 is powered off (e.g., overnight). A potentially lethal voltage will only be generated if device 110 has a manually extinguishable emergency interlock. This can be set by turning off the main power supply and / or pressing the off button on the attached communication device and safety indicator 114.

[0123] Each device 110 monitors the status of the solar circuit, and an interruption in the circuit triggers device 110 to reduce the output to zero volts. Safety is ensured even if the central control circuit and communication with device 110 are not operational. When the main power is disconnected, device 110 disconnects and maintains the voltage in the solar circuit at zero. This allows for a breakpoint in emergency situations.

[0124] No additional data cables are required. Device 110, the communication device, and the safety indicator 114 can be installed anywhere solar panels can be mounted. All current solar inverters are supported, and device 110, the communication device, and the safety indicator 114 can be modified on all existing systems. Generic or different voltage panels can be used instead of current panels, and this invention will be applicable in such cases. This invention will also work with all current solar cells and can be directly connected to lead-acid batteries.

[0125] According to a preferred embodiment, data collection is continuous and accessible via a downloaded application (app). Panel-by-pane data is collected in real time and backed up locally to prevent data loss in the event of power or internet outages.

[0126] Device 110 is equipped with high-current, very low-forward-voltage Schottky bypass diodes mounted to the input and output terminals. The bypass diodes prevent incorrect connections and provide a current path in the event of a failure of solar panel 112 or device 110. A secondary 12V power supply can be used for remote installations where power supplies may be inconsistent.

[0127] In this specification, the terms "first," "second," etc., are intended to distinguish different features of the invention and are not intended to limit the invention to a particular order of embodiments, unless the context otherwise requires.

[0128] In this specification, the terms “comprises”, “comprising”, or similar terms are intended to indicate a non-exclusive inclusion, such that an apparatus comprising a list of elements may include not only those elements but also other elements not listed.

[0129] Any reference to prior art in this specification is not and should not be construed as an affirmation of or recommendation of any kind that forms part of the common knowledge of the prior art.

[0130] It should be understood that the present invention is not limited to the specific embodiments described herein. Those skilled in the art will recognize variations that still fall within the scope of the invention from the specific embodiments described herein, the scope of which is defined by the following claims.

Claims

1. An apparatus for coupling to one or more solar panels to monitor and optimize the power output of the one or more solar panels, the apparatus comprising: A processor configured to generate a periodic wave and apply the periodic wave to the output of the one or more solar panels; An analog-to-digital converter (ADC) for receiving voltage signals from the one or more solar panels; and An analog-to-digital current converter, the analog-to-digital current converter being used to receive current signals from the one or more solar panels; The processor is configured to: Receives digital voltage signals from the voltage converter and digital current signals from the current converter; By using signal processing techniques to separate the fundamental frequency component and the zero frequency component of the periodic wave, the voltage amplitude and DC offset of the periodic wave applied to the output of the one or more solar panels are calculated. Based on the voltage amplitude and DC offset of the periodic wave, calculate the power and voltage difference of the one or more solar panels; as well as Modify the voltage of the one or more solar panels such that the difference between the power and the voltage of the one or more solar panels is zero.

2. The device according to claim 1, wherein the periodic wave is any repeating wave of arbitrary shape.

3. The device according to claim 1, wherein the periodic wave is selected from the following: sine wave, square wave, sawtooth wave, or periodic wave of another shape.

4. The device of claim 1, wherein the periodic wave is a repetitive voltage wave applied to the output of the one or more solar panels.

5. The device of claim 1, wherein the periodic wave is a repetitive current wave applied to the output of the one or more solar panels.

6. The device according to claim 1, wherein the periodic wave has a constant frequency between measurement periods.

7. The device according to claim 1, wherein the frequency of the periodic wave differs between measurement periods.

8. The device of claim 1, wherein the processor is configured to apply a low-pass filter to the digital voltage signal and to the digital current signal to calculate the voltage amplitude and the DC offset of the periodic wave.

9. The device of claim 1, wherein the processor is configured to apply a low-pass filter and a band-pass filter to each of the digital voltage signal and the digital current signal to calculate the voltage amplitude and the DC offset of the periodic wave.

10. The apparatus of claim 1, wherein the processor is configured to apply a Fourier transform to the digital voltage signal and to the digital current signal to calculate the voltage amplitude and the DC offset of the periodic wave.

11. The device of claim 1, further comprising a bidirectional or unidirectional power converter that receives a control signal from the processor to modify the voltage of the one or more solar panels such that the difference between the power and the voltage of the one or more solar panels is zero.

12. The device of claim 11, wherein the control signal is based on the output of the maximum power point controller module and the output of the periodic wave controller module of the device.

13. The device according to claim 12, wherein the periodic wave controller module is a voltage controller module or a current controller module.

14. The device according to any one of claims 11 to 13, wherein the periodic wave is applied by moving energy between an output energy storage device communicating with the bidirectional or unidirectional power converter and an input energy storage device communicating with the bidirectional or unidirectional power converter and the one or more solar panels.

15. The device of claim 14, wherein the output energy storage device and / or the input energy storage device are in the form of a capacitor.

16. The device of claim 1, comprising a printed circuit board having a first control side including the processor and a second opposing power side including a plurality of power switching components.

17. The device of claim 16, wherein the plurality of power switching components are arranged in a U-shape or C-shape around the power inductor to maximize power switching speed and / or minimize harmonic noise and / or avoid the need for a heat sink.

18. The device of claim 1, wherein the device comprises an all-plastic housing.

19. The device of claim 1, wherein the device detects the state of a solar circuit breaker or isolator switch coupled to the circuit by applying a voltage pulse to a circuit comprising the device and the one or more solar panels to look for current.

20. The device of claim 19, wherein the circuit includes a capacitor on the load side of the solar circuit breaker or isolator switch, and the device detects the capacitor when the solar circuit breaker or isolator switch is closed.

21. A method for monitoring and optimizing the power output of one or more solar panels by coupling a device to one or more solar panels, the method comprising: A periodic wave is generated in the processor and the periodic wave is applied to the output of the one or more solar panels; The device receives voltage signals from the one or more solar panels in its analog-to-digital converter. The device receives current signals from the one or more solar panels in its analog-to-digital current converter. A digital voltage signal is received in the processor coupled to the voltage converter; A digital current signal is received in the processor coupled to the current converter; The processor: By using signal processing techniques to separate the fundamental frequency component and the zero frequency component of the periodic wave, the voltage amplitude and DC offset of the periodic wave applied to the output of the one or more solar panels are calculated. The power and voltage difference of the one or more solar panels are calculated based on the output from the low-pass filter; as well as Modify the voltage of the one or more solar panels such that the difference between the power and the voltage of the one or more solar panels is zero.

22. The method of claim 21, wherein the periodic wave is any repeating wave of arbitrary shape.

23. The method of claim 21, wherein the periodic wave is selected from: a sine wave, a square wave, a sawtooth wave, or a periodic wave of another shape.

24. The method of claim 21, wherein the periodic wave is a repetitive voltage wave or a repetitive current wave applied to the output of the one or more solar panels.

25. The method of claim 21, wherein the periodic wave has a constant frequency between measurement periods.

26. The method of claim 21, wherein the frequency of the periodic wave differs between measurement periods.

27. The method of claim 21, wherein calculating the voltage amplitude and the DC offset of the periodic wave comprises the processor applying a low-pass filter to the digital voltage signal and applying a low-pass filter to the digital current signal.

28. The method of claim 21, wherein calculating the voltage amplitude and the DC offset of the periodic wave comprises the processor applying a low-pass filter and a band-pass filter to each of the digital voltage signal and the digital current signal.

29. The method of claim 21, wherein calculating the voltage amplitude and the DC offset of the periodic wave comprises the processor applying a Fourier transform to the digital voltage signal and applying a Fourier transform to the digital current signal.

30. The method of claim 21, further comprising a bidirectional or unidirectional power converter receiving a control signal from the processor to modify the voltage of the one or more solar panels such that the difference between the power and the voltage of the one or more solar panels is zero.

31. The method of claim 30, further comprising applying the periodic wave to the output of the one or more solar panels by moving energy between an output energy storage device communicating with the bidirectional or unidirectional power converter and an input energy storage device communicating with the bidirectional or unidirectional power converter and the one or more solar panels.

32. The method of claim 21, wherein the device applies a voltage pulse to a circuit comprising the device and the one or more solar panels to detect the state of a solar circuit breaker or isolator switch coupled to the circuit by means of the device applying a voltage pulse to the circuit comprising the device and the one or more solar panels to look for current.

33. The method of claim 32, wherein the circuit includes a capacitor on the load side of the solar circuit breaker or isolator switch, and the method includes the device detecting the capacitor when the solar circuit breaker or isolator switch is closed.

34. A solar communication and monitoring system comprising one or more means for coupling to one or more solar panels in a circuit according to any one of claims 1 to 20 to monitor and optimize the power output of the one or more solar panels, wherein the one or more means for monitoring and optimizing the power output of the one or more solar panels is configured to modify the voltage of the one or more solar panels such that the difference between the power and the voltage of the one or more solar panels is zero, thereby maximizing the power output of the one or more solar panels.

35. The system of claim 34, wherein each device for monitoring and optimizing the power output of the one or more solar panels is coupled to a solar panel, or each device for power monitoring and optimization is coupled to multiple solar panels.

36. The system of claim 34, wherein the solar panels are connected in series, and the device for monitoring and optimizing the power output of the one or more solar panels is connected in series, and the device for monitoring and optimizing the power output of the one or more solar panels is coupled to a communication and safety indicator device.

37. The system according to any one of claims 34 to 36, wherein the device detects the state of a solar circuit breaker or isolator switch coupled to the circuit by applying a voltage pulse to the circuit to look for current.

38. The system of claim 37, wherein the circuit includes a capacitor on the load side of the solar circuit breaker or isolator switch, and the device detects the capacitor when the solar circuit breaker or isolator switch is closed.

39. A solar power monitoring and optimization kit comprising: a device according to one or more claims 1 to 20 for coupling to one or more solar panels to monitor and optimize the power output of the one or more solar panels; and a communication and safety indicator device for coupling to the one or more devices for monitoring and optimizing the power output of the one or more solar panels, coupling to an inverter and / or a battery, and coupling to a main power source.

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