Multi-path MPPT DC combiner box

Abstract

The utility model belongs to the technical field of direct current combiner boxes, and particularly discloses a multipath MPPT direct current combiner box, which comprises a box body and independent compartments, and the independent compartments comprise an input compartment, a main compartment, a radiator air duct and a modularized output compartment. The input compartment is used for connecting multiple paths of photovoltaic modules, the photovoltaic modules are connected with an MPPT power loop located in the main compartment through multiple paths of input loops, and the MPPT power loop is used for monitoring the output voltage and current of the photovoltaic modules in real time and adjusting the photovoltaic modules to work at a working point for outputting the maximum power; the radiator air channel is used for being in contact with a heat dissipation substrate of the MPPT power loop and dissipating heat of the MPPT power loop. The multipath MPPT DC combiner box provided by the utility model enables multipath photovoltaic assemblies to output maximum power under voltage and current conditions such as different installation positions, angles, shadow shielding and the like, thereby improving the power generation efficiency of a photovoltaic power generation system, and realizing rapid adaptation of various application scenes.

Description

Technical Field

[0001] This utility model relates to the field of DC combiner box technology, and in particular, to a multi-channel MPPT DC combiner box. Background Technology

[0002] Traditional DC combiner boxes simply combine the DC power generated by photovoltaic (PV) panels, failing to dynamically adjust based on the actual output characteristics of each PV string. In actual operation, the output characteristics of PV panels are significantly affected by factors such as sunlight and temperature, leading to variations in output voltage and current between different strings. When these strings are directly connected in parallel, some strings may not operate at their maximum power point, resulting in power loss. Furthermore, in large-scale PV power plants, the installation location, angle, and shading of PV panels vary, causing significant differences in output characteristics between different strings and resulting in parallel mismatch issues. Traditional combiner boxes cannot effectively address this problem, severely impacting the power generation efficiency and stability of the entire PV power generation system. Utility Model Content

[0003] To address the shortcomings of existing technologies, this utility model provides a multi-channel MPPT DC combiner box, which enables multiple photovoltaic modules to output maximum power under different installation positions, angles, and shading conditions, thereby improving the power generation efficiency of the photovoltaic power generation system. It features convenient installation and maintenance and is equipped with modular output compartments, allowing for flexible adjustment of output configurations to meet application needs and enabling rapid adaptation to various application scenarios.

[0004] The present invention adopts the following technical solution.

[0005] This utility model provides a multi-channel MPPT DC combiner box, comprising: a box body and independent compartments; each independent compartment includes: an input compartment, a main compartment, a heat sink duct, and a modular output compartment; wherein, the input compartment and the main compartment are both located on the front of the box body and respectively on both sides of the box body; the input compartment is used to connect multiple photovoltaic modules and connects the photovoltaic modules to the MPPT power circuit located in the main compartment through multiple input circuits, the MPPT power circuit is used to monitor the output voltage and current of the photovoltaic modules in real time and adjust the photovoltaic modules to operate at the maximum output power point; the heat sink duct is located on the back of the box body and is used to contact the heat dissipation substrate of the MPPT power circuit for heat dissipation of the MPPT power circuit; the modular output compartment is located on the side of the box body and is used for collecting and outputting the power generated by the photovoltaic modules.

[0006] Preferably, the input compartment includes: a multi-channel PV input interface, an input load switch, and a multi-channel input circuit; the multi-channel PV input interface and the input load switch are both located at the bottom of the input compartment; the multi-channel PV input interface is used to connect multiple photovoltaic modules and is electrically connected to the input load switch; the multi-channel input circuit is located at the top of the input compartment and is electrically connected to the input load switch.

[0007] Preferably, the multi-input circuit includes upper and lower layers, wherein the upper layer includes multiple DC busbars arranged in parallel, and the lower layer includes multiple EMI filter boards arranged in parallel; each DC busbar is electrically connected to an EMI filter board: the DC busbar is used for electrical connection to the input load switch, and the EMI filter board is used for connection to the MPPT power circuit.

[0008] Preferably, the input compartment further includes: a first turbulence fan, which is disposed on both sides of the input compartment for forced circulation and diffusion of heat within the input compartment.

[0009] Preferably, the main compartment further includes: a control and protection circuit, a soft start circuit, an insulation detection circuit, and an arc detection circuit; the control and protection circuit is connected to the MPPT power circuit, as well as the soft start circuit, insulation detection circuit, and arc detection circuit, to form a control system for the DC combiner box, used for data sampling and normal operation control of the control system.

[0010] Preferably, the main compartment further includes a second turbulence fan, which is disposed on the left and right sides of the MPPT power circuit to force the heat in the main compartment to circulate and diffuse.

[0011] Preferably, the input compartment is further provided with a communication interface connected to the control and protection circuit. The communication interface is located at the bottom of the input compartment and is used to connect to an external network cable.

[0012] Preferably, the heat sink air duct includes: a differential mode inductor, a cooling fan, a heat sink, and an air duct baffle; the cooling fan is located between the differential mode inductor and the heat sink, and its airflow direction is from the differential mode inductor to the heat sink; the air duct baffle is installed on the front side of the heat sink and fixedly connected to the back of the enclosure, and the air duct baffle is provided with air holes; a first slot is opened on the back of the enclosure corresponding to the position of the differential mode inductor, for electrically connecting the differential mode inductor to the MPPT power circuit and the EMI filter board of the multi-input circuit located inside the input compartment; a second slot is opened on the back of the enclosure corresponding to the position of the heat sink, for contacting the heat sink with the heat dissipation substrate of the MPPT power circuit.

[0013] Preferably, the side of the enclosure is provided with wiring terminals, and the modular output compartment is detachably connected to the side of the enclosure via the wiring terminals; the modular output compartment is provided with a DC surge protector and a circuit breaker with shunt trip for DC output, DC surge protection and active disconnection protection.

[0014] Preferably, the multi-channel MPPT DC combiner box further includes: a wall-mounted fixing structure, which is symmetrically arranged on the left and right sides of the back of the box and connected to the box through a connector; one side of the wall-mounted fixing structure is provided with an arc-shaped groove for quick connection with the fixing pin provided on the box.

[0015] The beneficial effects of this utility model are as follows: Compared with the prior art, the multi-channel MPPT DC combiner box provided by this utility model is functionally partitioned by setting up multiple independent compartments such as input compartment, main compartment, radiator duct, and modular output compartment, which facilitates installation and maintenance. In large-scale photovoltaic power plants and new energy DC collection and transmission scenarios, the MPPT power circuit in the MPPT DC combiner box can monitor the output voltage and current of photovoltaic modules in real time under different installation positions, angles, and shading conditions, calculate the current output power, and dynamically adjust the working voltage and current of each photovoltaic string according to the actual output characteristics of the photovoltaic panel to ensure that it always outputs maximum power. At the same time, by setting up input compartments, this utility model can connect multiple photovoltaic modules to form multiple MPPTs, so that photovoltaic panels in different positions and under different shading conditions can independently perform MPPT calculations, ensuring that more photovoltaic modules can always output maximum power, effectively solving the power loss and parallel mismatch problems existing in traditional combiner boxes, and improving the power generation efficiency of photovoltaic power generation systems by about 20%-30%. Furthermore, this invention can flexibly adjust the output characteristics of multi-channel MPPT DC combiner boxes by installing different modular output compartments to meet the needs of different application scenarios. It features convenient installation and maintenance and is equipped with a modular output format. It can achieve rapid adaptation to various application scenarios without changing the main body of the MPPT combiner box, further expanding the application fields of combiner boxes in multiple scenarios. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure and appearance of the multi-channel MPPT DC combiner box in the embodiment of this utility model;

[0017] Figure 2 This is a schematic diagram of the internal partitioning structure of the multi-channel MPPT DC combiner box in an embodiment of this utility model;

[0018] Figure 3 This is a schematic diagram of the back structure of the multi-channel MPPT DC combiner box in an embodiment of this utility model;

[0019] Figure reference numerals:

[0020] 1. Input compartment; 11. Multi-channel PV input interface; 12. Communication interface; 13. Input load switch; 14. Multi-channel input circuit;

[0021] 2. Main compartment; 21. MPPT power circuit; 22. Control and protection circuit; 23. Soft start circuit; 24. Insulation detection circuit; 25. Arc detection circuit;

[0022] 3. Heatsink airflow; 31. Common mode inductor; 32. Cooling fan; 33. Heatsink;

[0023] 4. Modular output compartment;

[0024] 5. Wall-mounted fixing structure. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. The embodiments described in this application are merely some embodiments of this utility model, not all embodiments. Based on the spirit of this utility model, other embodiments obtained by those skilled in the art without creative effort are all within the protection scope of this utility model.

[0026] refer to Figures 1 to 3 As shown, an embodiment of this utility model provides a multi-channel MPPT (Maximum PowerPoint Tracking) DC combiner box, comprising: a box body, the box body having an input compartment 1, a main compartment 2, a radiator duct 3, a modular output compartment 4, and a wall-mounting structure 5. The input compartment 1 and the main compartment 2 are both located on the front of the box body and on opposite sides. In a preferred but non-limiting embodiment of this utility model, the input compartment 1 is located on the lower side of the box body. The radiator duct 3 is located on the back of the box body, and the modular output compartment 4 is located on the side of the box body. The wall-mounting structure 5 is located on the back of the radiator duct 3. The combiner box has an overall protection rating of IP65. The overall layout is functionally partitioned, facilitating installation and maintenance and allowing for flexible output configuration according to application requirements.

[0027] like Figure 2 As shown, the input compartment 1 includes: a multi-channel PV input interface 11, a communication interface 12, an input load switch 13, a multi-channel input circuit 14, and a first turbulence fan.

[0028] The multiple input circuit 14 is located in the upper part of the input compartment 1 and includes an upper and lower structure. The upper layer includes multiple DC busbars arranged in parallel, and the lower layer includes multiple EMI shielding circuits arranged in parallel.

[0029] (Electromagnetic Interference) filter board; each DC busbar is electrically connected to one EMI filter board. Each DC busbar and each EMI filter board is an independent subunit, and the multi-input groups can be disassembled and reassembled according to maintenance needs, allowing for overall or partial replacement, thus improving installation and replacement efficiency. The multi-input circuit 14 achieves input protection, filtering, and grouping functions by setting up multiple DC busbars and EMI filter boards.

[0030] The communication interface 12, the multi-channel PV input interface 11, and the input load switch 13 are arranged sequentially from left to right at the bottom of the input compartment 1. The multi-channel PV input interface 11 is electrically connected to the input load switch 13, and the input load switch 13 is electrically connected to the DC combiner board of the multi-channel input circuit 14. The connection end of the multi-channel PV input interface 11 extends to the bottom surface of the enclosure for connecting the photovoltaic modules. The electrical energy output from the photovoltaic modules is transmitted to the multi-channel input circuit 14 of the input compartment 1 via the input load switch 13. The input load switch 13 serves to electrically isolate the internal components of the MPPT combiner box from the input of the photovoltaic strings.

[0031] The communication interface 12 uses RS485 to communicate with the control and protection circuit located in the main compartment 2. The interface end of the communication interface 12 extends to the bottom of the enclosure to connect to the external network cable, and plays the role of data transmission and receiving upper-level control commands.

[0032] The first turbulence fan is arranged on both sides of the input compartment 1. Through the fan turbulence, the heat generated by the operation of devices such as fuses and EMC common mode inductors in the input compartment 1 is forced to circulate and diffuse, thereby reducing the thermal stress of the devices and improving their service life and reliability.

[0033] The main compartment 2 includes: MPPT power circuit 21, control and protection circuit 22, soft start circuit 23, insulation detection circuit 24, arc detection circuit 25, and a second turbulence fan.

[0034] The power board of MPPT power circuit 21 is fixed to the wall of the main compartment 2 by studs. MPPT power circuit 21 is electrically connected to the EMI filter board located in the input compartment 1 through the differential mode inductor 31 located in the heat sink air duct 3, so as to realize the transformation and flow of energy from the input side to the output side.

[0035] The soft start circuit 23 is located on the right side of the MPPT power circuit 21 and close to the modular output compartment 4; the insulation detection circuit 24 is located on the lower left side of the main compartment 2; and the arc detection circuit 25 is located on the right side of the insulation detection circuit 24. The soft start circuit 23, the insulation detection circuit 24, and the arc detection circuit 25 are all relatively independent circuits, ensuring that the MPPT combiner box starts up and operates normally.

[0036] The control and protection circuit 22 is independently located on the upper left side of the main compartment 2, above the insulation detection circuit 24 and the arc detection circuit 25. The control and protection circuit 22 is electrically connected to the MPPT power circuit 21, as well as the soft start circuit 23, the insulation detection circuit 24, and the arc detection circuit 25. By sampling and controlling the data from the MPPT power circuit 21 and other functional circuits, it realizes system operation functions such as switching operating modes, executing control and protection logic, and processing data.

[0037] Under varying environmental conditions such as light intensity and temperature, the MPPT power loop 21 monitors the output voltage and current of the photovoltaic modules in real time and calculates the current output power. Based on the calculated power value, it compares it with the power at the previous moment or the preset maximum power point, and then adjusts the operating point of the photovoltaic modules through the power loop to gradually approach the maximum power point. In large-scale photovoltaic power plants, the installation location, angle, and shading of photovoltaic panels vary, leading to significant differences in output characteristics between different strings. The MPPT power loop 21 connects to multiple PV input interfaces 11 to form multiple MPPTs, allowing photovoltaic panels in different locations and with different shading conditions to perform MPPT calculations independently. This ensures that more photovoltaic modules can consistently output maximum power, effectively solving the power loss and parallel mismatch problems existing in traditional combiner boxes, and improving the power generation efficiency of the photovoltaic power generation system by approximately 20%-30%.

[0038] The second turbulence fan is set on the left and right sides of the MPPT power circuit 21 to form an air circulation path. It is used to force the heat generated by the device to circulate and diffuse, reduce the thermal stress of the device, and improve the service life and reliability of the device.

[0039] like Figure 3 As shown, the radiator air duct 3 is an independent compartment located at the back of the enclosure. The radiator air duct 3 includes: a differential mode inductor 31, a cooling fan 32, a radiator 33, and an air duct baffle. The cooling fan 32 is positioned between the differential mode inductor 31 and the radiator, drawing air from... Figure 3Viewed from the perspective of the heat sink duct 3, the differential mode inductor 31 is located below the heat sink duct 3, above which are the cooling fan 32 and the heat sink 33. The duct baffle is located on the front side of the heat sink 33 and is fixedly connected to the back of the enclosure, forming a semi-enclosed duct. The differential mode inductor 31 is connected to the internal MPPT power circuit 21 through a slot on the back of the enclosure. The differential mode inductor 31 and the area around the slot on the back of the enclosure are designed with IP65 protection to ensure the overall sealing of the enclosure. The heat sink 33 also contacts the heat dissipation substrate of the MPPT power circuit 21 through another slot on the back of the enclosure, which can carry away the heat generated by the device. The contact area between the heat sink 33 and the slot on the back of the enclosure is designed with a small groove with an embedded rubber sealing strip to ensure the overall protection level of the enclosure. The airflow direction of the radiator air duct 3 is bottom inlet and top outlet. The rotation of the cooling fan 32 creates a negative pressure inside the compartment, drawing in external cold air. The cold air first passes through the differential mode inductor 31, carrying away some heat, and is then blown by the fan towards the radiator 33. After passing through the air duct formed by the fins of the radiator 33 and the air duct baffle, the heat is discharged to the outside.

[0040] The wall-mounting fixing structure 5 is symmetrically arranged on the left and right sides of the back of the cabinet, forming a stable whole with the cabinet through a metal structure. The wall-mounting fixing structure 5 is made of a Z-shaped structural component. One end is designed as a quick-connect structure, which can be directly snapped onto the MPPT combiner box fixing pin through the arc-shaped slot. The other end is fixed with bolts to complete the installation, improving on-site installation efficiency.

[0041] Modular output compartment 4 is located on the side of the enclosure and houses a DC surge protector and a circuit breaker with shunt trip, providing DC output, DC surge protection, and active disconnection protection. In this example, modular output compartment 4 is an independent, detachable compartment structure. An adapter terminal is located on the side of the enclosure, allowing for detachable connection between modular output compartment 4 and the adapter terminal, which enables electrical connection to the main compartment 2. Furthermore, depending on the application scenario and requirements, different configurations of modular output compartments can be installed to add functions such as output chopping, expanding the application range and adaptability of the combiner box to various scenarios.

[0042] This invention functionally partitions the layout, with each functional area divided into a compartment. The vulnerable components within each compartment are designed as a whole composed of multiple sub-units, allowing for complete or partial replacement as needed for maintenance. Simultaneously, the modular output compartment 4 is an independent, detachable structure. Its specific configuration can be modified according to different application scenarios and requirements. Replacing the modular output compartment without altering other parts of the MPPT combiner box adds functions such as output chopping, changing the MPPT combiner box's output characteristics and further expanding its application range and adaptability to multiple scenarios.

[0043] The beneficial effects of this utility model are as follows: Compared with the prior art, the multi-channel MPPT DC combiner box provided by this utility model is functionally partitioned by setting up multiple independent compartments such as input compartment, main compartment, radiator duct, and modular output compartment, which facilitates installation and maintenance. In large-scale photovoltaic power plants and new energy DC collection and transmission scenarios, the MPPT power circuit in the MPPT DC combiner box can monitor the output voltage and current of photovoltaic modules in real time under different installation positions, angles, and shading conditions, calculate the current output power, and dynamically adjust the working voltage and current of each photovoltaic string according to the actual output characteristics of the photovoltaic panel to ensure that it always outputs maximum power. At the same time, by setting up input compartments, this utility model can connect multiple photovoltaic modules to form multiple MPPTs, so that photovoltaic panels in different positions and under different shading conditions can independently perform MPPT calculations, ensuring that more photovoltaic modules can always output maximum power, effectively solving the power loss and parallel mismatch problems existing in traditional combiner boxes, and improving the power generation efficiency of photovoltaic power generation systems by about 20%-30%. Furthermore, this invention can flexibly adjust the output characteristics of multi-channel MPPT DC combiner boxes by installing different modular output compartments to meet the needs of different application scenarios. It features convenient installation and maintenance and is equipped with a modular output format. It can achieve rapid adaptation to various application scenarios without changing the main body of the MPPT combiner box, further expanding the application fields of combiner boxes in multiple scenarios.

[0044] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and not to limit it. Although the utility model has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of this utility model. Any modifications or equivalent substitutions that do not depart from the spirit and scope of this utility model should be covered within the protection scope of the claims of this utility model.

Claims

1. A multi-channel MPPT DC combiner box, comprising: The enclosure and independent compartments are characterized by: The independent compartments include: an input compartment (1), a main compartment (2), a radiator duct (3), and a modular output compartment (4); The input compartment (1) and the main compartment (2) are both located on the front of the box and on the two sides of the box respectively. The input compartment (1) is used to connect multiple photovoltaic modules and connect the photovoltaic modules to the MPPT power circuit (21) located in the main compartment (2) through the multiple input circuit (14). The MPPT power circuit (21) is used to monitor the output voltage and current of the photovoltaic modules in real time and adjust the photovoltaic modules to work at the operating point of maximum output power. The radiator air duct (3) is located on the back of the housing. The radiator air duct (3) is used to contact the heat dissipation substrate of the MPPT power circuit (21) to dissipate heat from the MPPT power circuit (21). The modular output compartment (4) is located on the side of the box and is used to collect and output the power generated by the photovoltaic module.

2. The multi-channel MPPT DC combiner box according to claim 1, characterized in that: The input compartment (1) includes: a multi-channel PV input interface (11), an input load switch (13), and a multi-channel input circuit (14); The multi-channel PV input interface (11) and the input load switch (13) are both located at the bottom of the input compartment (1); the multi-channel PV input interface (11) is used to connect multiple photovoltaic modules and is electrically connected to the input load switch (13); the multi-channel input circuit (14) is located at the top of the input compartment (1) and is electrically connected to the input load switch (13).

3. The multi-channel MPPT DC combiner box according to claim 2, characterized in that: The multi-input circuit (14) includes upper and lower layers. The upper layer includes multiple DC busbars arranged in parallel, and the lower layer includes multiple EMI filter boards arranged in parallel. Each DC busbar is electrically connected to an EMI filter board. The DC busbar is used to electrically connect to the load switch (13), and the EMI filter board is used to connect to the MPPT power circuit (21).

4. The multi-channel MPPT DC combiner box according to claim 2, characterized in that: The input compartment (1) further includes: a first turbulence fan, which is disposed on both sides of the input compartment (1) for forced circulation and diffusion of heat in the input compartment (1).

5. The multi-channel MPPT DC combiner box according to any one of claims 1-4, characterized in that: The main compartment (2) also includes: a control and protection circuit (22), a soft start circuit (23), an insulation detection circuit (24), and an arc detection circuit (25); The control and protection circuit (22) is connected to the MPPT power circuit (21), soft start circuit (23), insulation detection circuit (24), and arc detection circuit (25) to form the control system of the DC combiner box, which is used for data sampling and normal operation regulation of the control system.

6. The multi-channel MPPT DC combiner box according to claim 5, characterized in that: The main compartment (2) also includes a second turbulence fan, which is located on the left and right sides of the MPPT power circuit (21) to force the heat in the main compartment (2) to circulate and diffuse.

7. The multi-channel MPPT DC combiner box according to claim 5, characterized in that: The input compartment (1) is also provided with a communication interface (12) connected to the control and protection circuit (22). The communication interface (12) is located at the bottom of the input compartment (1) and is used to connect to an external network cable.

8. The multi-channel MPPT DC combiner box according to any one of claims 1-4, characterized in that: The heat sink air duct (3) includes: differential mode inductor (31), heat sink fan (32), heat sink (33) and air duct baffle; the heat sink fan is located between the differential mode inductor and the heat sink, and its air path direction is from the differential mode inductor to the heat sink (33); the air duct baffle is installed on the front side of the heat sink and is fixedly connected to the back of the housing. The first slot is opened at the position corresponding to the differential mode inductor (31) on the back of the enclosure, which is used to electrically connect the differential mode inductor (31) to the MPPT power circuit (21) and the EMI filter board of the multi-input circuit (14) located inside the input compartment (1); A second slot is opened on the back of the housing corresponding to the position of the heat dissipation fan (32) to allow the heat dissipation fan (32) to contact the heat dissipation substrate of the MPPT power circuit (21).

9. The multi-channel MPPT DC combiner box according to any one of claims 1-4, characterized in that: The side of the enclosure is provided with wiring terminals for connecting the modular output compartment (4); the modular output compartment (4) is detachably connected to the side of the enclosure via the wiring terminals; The modular output compartment (4) is equipped with a DC surge protector and a circuit breaker with shunt trip for DC output, DC surge protection and active disconnection protection.

10. The multi-channel MPPT DC combiner box according to any one of claims 1-4, characterized in that: The multi-channel MPPT DC combiner box also includes: a wall-mounted fixing structure (5), which is symmetrically arranged on the left and right sides of the back of the radiator air duct (3) and connected to the main compartment (2) through a connector; The wall-mounted fixing structure (5) has an arc-shaped groove on one side for quick connection with the fixing pin set in the box.

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