Inverter Box Quick Connectors for Assembly and Maintenance
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Solution Overview
Problem
The existing photovoltaic inverter box structures are inconvenient for assembly and disassembly, lack fool-proofing for wire connections, and are time-consuming and costly due to the need for precise screwdriver operation and potential misconnection risks.
Innovation Solution
The introduction of quick connectors on both the inverter accommodating box and the junction box allows for easy pluggable connections between outlet wires and inner wires, eliminating the need for individual terminal connections and enabling convenient assembly and disassembly, while also using angled screws for easier maintenance access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional screw connections and individual terminal connections are used, then the connection is stable and reliable, but the assembly and disassembly process is complex and time-consuming
Solution Approach 1:
The patent divides the connection system into modular components: quick connectors for wire connections, and standardized screw holes for box connections. This segmentation allows each component to be optimized independently, enabling rapid assembly and disassembly without compromising connection reliability.
Solution Approach 2:
The quick connectors are pre-assembled with terminals before installation. This preliminary action eliminates the need for on-site wire stripping, bending, and terminal attachment, significantly reducing assembly time while ensuring reliable electrical connections.
2Reliability
If traditional wire connection methods are used, then flexible wiring is possible, but the risk of misconnection increases and fool-proofing is lost
Solution Approach 1:
The quick connector design incorporates asymmetric features including shaped connection ends and positioning structures that only fit together in the correct orientation. This asymmetry provides fool-proofing against misconnection while maintaining simple plug-and-play operation.
Solution Approach 2:
The quick connectors include built-in positioning structures and alignment features that automatically guide correct wire pairing during connection. This self-service mechanism eliminates the need for operator judgment or reference to cable marks, preventing misconnection while simplifying the connection process.
3Strength
If vertically locked screws are used on side walls, then secure fixation is achieved, but maintenance access becomes difficult requiring specialized tools
Solution Approach 1:
The patent repositions screw holes from vertical side walls to horizontal top/bottom surfaces, changing the dimensional orientation of access. This allows maintenance personnel to access screws from the front or top using standard tools, maintaining fixation strength while dramatically improving maintenance accessibility.
4Manufacturing precision
If individual terminal connections are made one by one, then precise wire matching is possible, but the process is labor-intensive and costly
Solution Approach 1:
The patent merges multiple individual terminal connections into a single integrated quick connector assembly. This combining maintains precise wire matching through pre-assembly and positioning structures while increasing assembly speed by reducing the number of discrete connection operations from multiple individual terminations to a single plug-in action.
Data Source
AI summary
An inverter box structure includes an inverter accommodating box of an inverter circuit and a junction box. A first quick connector, disposed on the inverter accommodating box, includes a first connection end and a second connection end. The first connection end of the first quick connector is electrically with the inverter circuit. A second quick connector, disposed on the junction box or in the junction box, includes a third connection end and a fourth connection end. The third connection end of the second quick connector is connected to an inner wire of the junction box. A casing of the inverter accommodating box equipped with the first quick connector is opposite to a casing of the junction box equipped with the second quick connector, and the second connection end of the first quick connector matches with and is electrically connected to the fourth connection end of the second quick connector.