Microinverter Mounting Assembly With Locking DC Connector
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Solution Overview
Problem
Current photovoltaic (PV) systems with microinverters are time-consuming and costly to repair due to complex electrical connections and safety risks associated with high DC voltages, making infield repairs challenging and expensive.
Innovation Solution
A microinverter mounting assembly with a locking mechanism between the microinverter and PV panel DC connectors allows for easy attachment and detachment with minimal tool use, eliminating the need for wired connections and providing a secure, tool-free installation and replacement process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wired DC connections with junction boxes and multiple connectors are used, then reliable electrical connection is achieved, but installation and repair time increases significantly
Solution Approach 1:
The system segments the microinverter assembly from the PV panel by using a connector interface, allowing the microinverter to be independently attached and detached. This segmentation enables quick replacement without disturbing the PV panel or other system components, dramatically reducing repair time while maintaining connection reliability through the designed connector interface.
Solution Approach 2:
The connector interfaces are pre-configured and pre-positioned on both the microinverter and PV panel before assembly. The electrical contacts and locking mechanisms are prepared in advance, allowing for rapid connection by simply bringing the components together and engaging the connector, eliminating the need for on-site wiring or complex assembly procedures.
2Strength
If multiple unique tools and keys are required to remove junction box and microinverter components, then secure attachment is achieved, but ease of repair deteriorates
Solution Approach 1:
The connector design uses universal, standardized components that can be operated with common tools or even hand-operated. The locking mechanism and electrical contacts are integrated into a single connector assembly that serves multiple functions simultaneously, eliminating the need for multiple specialized tools while maintaining secure attachment through the unified connector design.
3Reliability
If approximately one to two feet of DC cable and junction box are used for wired connection, then electrical connection is established, but system cost increases
Solution Approach 1:
The connector integrates the electrical contact elements, locking mechanism, and structural support into a single unified component. This merging eliminates the need for separate DC cables and junction boxes, reducing the number of individual parts while maintaining reliable electrical connection through the integrated connector design.
4Object-affected harmful factors
If special DC wiring and grounding specifications are required to meet NEC code, then safety compliance is achieved, but installation complexity and cost increase
Solution Approach 1:
The connector is pre-designed and pre-configured to meet NEC code requirements for DC wiring and grounding specifications. The electrical contacts and grounding paths are established within the connector structure itself before installation, eliminating the need for complex on-site wiring procedures or additional grounding components, while ensuring safety compliance is built into the basic connector design.
Data Source
AI summary
A system and method for a microinverter mounting assembly including a microinverter assembly and a panel direct current (DC) connector. The microinverter assembly having a housing, a microinverter disposed within the housing, and a microinverter DC connector disposed within the housing and electrically coupled to the microinverter, the microinverter DC connector with a bottom panel having a locking recess formed therein and at least one electrical contact disposed within an opening formed in the bottom panel. The panel DC connector having a mounting substrate, a locking tab extending from the mounting substrate, and at least one electrical contact positioned on the mounting substrate. Further, the locking tab of the panel DC connector interfits within the locking recess of the microinverter DC connector to form a locking mechanism that prevents rotation of the microinverter DC connector when in a locked position.