Inline DC Step-Up Harness for 1,500 V PV String Retrofit
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Solution Overview
Problem
Existing photovoltaic (PV) solar facilities with 600 or 1,000 volts direct current (DC) modules face challenges in efficiently combining multiple strings into a higher system voltage, as current technologies limit the ability to upgrade to higher voltage ratings without complex and costly infrastructure changes.
Innovation Solution
The Inline DC Feeder DC/DC Voltage Step-up Harness (IDF-VSH) electrically combines multiple PV strings, utilizing flyback DC/DC converters to increase voltage to 1,500 Vdc and regulate output to a predetermined amperage, allowing for the retrofit of older systems by replacing combiner boxes with higher voltage-rated components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple PV strings are combined into higher system voltage using traditional combiner boxes, then system voltage is limited to 600 or 1,000 Vdc, but upgrading to higher voltage requires complex and costly infrastructure changes
Solution Approach 1:
The patent changes the electrical parameters of the system by introducing DC/DC voltage step-up converters that transform multiple low-voltage PV strings (600 or 1,000 Vdc) into a single high-voltage output (1,500 Vdc). This parameter transformation allows the system to operate at higher voltage without requiring complete infrastructure replacement, as the converters are integrated into the existing combiner box structure
Solution Approach 2:
The DC/DC voltage step-up converters act as intermediary devices between the PV strings and the inverter. These converters galvanically isolate and electrically combine multiple input strings while stepping up the voltage, serving as a mediator that enables high-voltage operation without direct connection between low-voltage strings and the inverter, thereby simplifying infrastructure changes
2Adaptability or versatility
If traditional combiner boxes are used to combine PV strings, then installation is straightforward, but the ability to upgrade to higher voltage ratings is limited
Solution Approach 1:
The combiner box is designed with multi-functionality by integrating DC/DC voltage step-up converters that can handle multiple input voltage configurations (600 Vdc or 1,000 Vdc strings) and produce a unified high-voltage output (1,500 Vdc). This universal design allows the same combiner box structure to serve both traditional and upgraded high-voltage systems, enhancing adaptability while maintaining installation simplicity
Solution Approach 2:
The system incorporates dynamic voltage conversion capability where the DC/DC converters can adaptively step up voltage from different input configurations to a standardized high-voltage output. This dynamic transformation allows the combiner box to accommodate future voltage upgrades without structural changes, making the system adaptable while preserving ease of installation
3Power
If multiple PV strings are electrically combined without galvanic isolation, then connection is simple, but voltage regulation and amperage control are difficult
Solution Approach 1:
The DC/DC voltage step-up converters serve as galvanic isolators and electrical mediators between PV strings and the inverter. Each converter independently regulates its input string's voltage and current while providing galvanic isolation, then combines the outputs to achieve precise overall voltage regulation (1,500 Vdc) and amperage control (30 A maximum). This intermediary approach enables sophisticated power control without direct electrical connection between strings
Solution Approach 2:
The DC/DC converters incorporate feedback control mechanisms that continuously monitor input voltage, output voltage, and current levels. This feedback enables the converters to dynamically adjust their operation to maintain precise voltage regulation at 1,500 Vdc and enforce amperage limits at 30 A, ensuring safe and efficient operation while managing the complexity through intelligent control algorithms
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient voltage escalation and amperage regulation, facilitating the upgrade of older PV systems to higher voltage configurations, enhancing system efficiency and reducing the need for extensive infrastructure modifications.
Implementation Method 1
utilizing flyback DC/DC converters to increase voltage to 1,500 Vdc
Data Source
AI summary
An inline DC feeder DC/DC voltage step-up harness for photovoltaic solar facilities includes a housing, a plurality of PV input connectors, an at least one PV output connector. The housing incorporates a DC/DC converter, and has an input and an output. The plurality of PV input connectors are operatively connected to the housing at the input. The PV output connector is operatively connected to the housing at the output.