Inline DC Feeder Harness for 1500 V PV String Step-Up
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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 using traditional combiner boxes, then the system can handle higher current, but the system voltage remains limited to 600 or 1,000 Vdc and cannot be upgraded to higher voltage configurations
Solution Approach 1:
The patent applies parameter changes by using DC/DC converters to transform the electrical parameters of the PV strings, specifically converting multiple lower-voltage strings (600 or 1,000 Vdc) into a single higher-voltage output (1,500 Vdc). This allows the system to operate at higher voltages without requiring complete system replacement, thereby resolving the contradiction between maintaining power handling capability and achieving voltage upgrade capability.
2Productivity
If older PV systems are upgraded to higher voltage configurations, then system efficiency is enhanced, but extensive infrastructure modifications are required
Solution Approach 1:
The patent applies segmentation by dividing the voltage conversion function into modular DC/DC converter units that can be integrated into the existing combiner box infrastructure. Rather than requiring complete system overhaul, the solution segments the upgrade into manageable components (converters, control circuits) that can be added to existing 600V or 1000V combiner boxes to enable 1500V operation, thus reducing infrastructure modification scope while achieving efficiency gains.
3Power
If multiple PV strings are electrically combined into a single harness, then voltage can be increased to 1,500 Vdc, but the system requires galvanic isolation and amperage regulation
Solution Approach 1:
The patent applies the intermediary principle by introducing DC/DC converters as mediating devices between the multiple PV string inputs and the single high-voltage output. These converters provide galvanic isolation through their inherent transformer architecture, acting as an intermediary barrier that allows voltage transformation while maintaining electrical isolation. This resolves the contradiction by making galvanic isolation an integrated feature of the voltage boosting process rather than an additional complexity.
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, 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.