Micro-inverter Assembly with Integrated DC Connector
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Solution Overview
Problem
Current photovoltaic (PV) systems face challenges with time-consuming and costly infield repairs due to complex DC connections, high installation costs, and efficiency losses from long AC wire harnesses, which also pose safety risks during installation.
Innovation Solution
The design includes a micro-inverter assembly with a housing containing a DC-to-AC micro-inverter and a DC connector positioned within a recess, allowing for plug-and-play or rotational engagement with a PV panel, reducing the need for wired connections and simplifying repairs, and an optimized AC wire harness configuration that minimizes cable length and resistance losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional DC wiring and junction boxes are used to connect PV panels to micro-inverters, then electrical connections can be established, but the system becomes complex and time-consuming to repair in the field
Solution Approach 1:
The patent combines the DC connector and micro-inverter into a single integrated assembly. The DC connector is built into the micro-inverter housing, eliminating the need for separate junction boxes and multiple discrete connection components. This merging reduces the number of parts that need to be accessed and manipulated during field repairs, directly addressing the contradiction between repair ease and device complexity.
Solution Approach 2:
The patent creates a modular micro-inverter assembly that can be easily separated from the PV panel as a complete unit. This segmentation allows technicians to remove and replace the entire micro-inverter assembly in one action rather than having to disassemble multiple connection points, reducing field repair time while maintaining manageable system complexity.
2Ease of manufacture
If separate junction boxes and DC cables are used to connect PV panels to micro-inverters, then electrical connections are established, but installation costs increase
Solution Approach 1:
The DC connector is integrated directly into the micro-inverter housing, eliminating the need for separate junction boxes and reducing the amount of DC cable required. This merging of functions reduces material costs and simplifies the installation process, directly addressing the contradiction between installation cost and wiring complexity.
3Loss of energy
If long AC wire harnesses are used to connect AC PV modules to the power grid, then electrical connections can be established, but voltage drops and power losses increase
Solution Approach 1:
The patent extracts the inverter function from a centralized location and places it at each individual PV module through the micro-inverter assembly. This extraction eliminates the need for long AC wire harnesses that traverse multiple modules, as each micro-inverter converts DC to AC locally. The result is reduced power loss in transmission while maintaining installation flexibility through modular deployment.
4Reliability
If multiple separate components (junction box, DC connectors, micro-inverter) are used in the DC connection path, then electrical connections can be established, but the number of potential fault points increases
Solution Approach 1:
The patent merges the DC connector, micro-inverter, and housing into a single integrated assembly. This consolidation reduces the number of discrete components in the DC connection path, thereby reducing the number of potential fault points and improving system reliability while maintaining manageable complexity through modular design.
Data Source
AI summary
A micro-inverter assembly for use in a photovoltaic system includes a housing, a direct current (DC)-to-alternating current (AC) micro-inverter disposed within the housing, and a DC connector electrically coupled to the DC-to-AC micro-inverter. The DC connector is positioned within a recess formed in a bottom surface of the housing such that at least one electrical contact of the DC connector is accessible from outside the housing. According to alternative embodiments, the DC connector comprises a plug-and-play connector constructed for one of a rotational engagement and a translational engagement with a DC connector of a photovoltaic (PV) panel.