Plug-In Power Connection for Utility-Scale Solar and Storage Equipment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and complexity of connecting large-scale electrical energy storage and solar photovoltaic equipment to destination equipment at power facilities require extensive on-site construction and skilled labor, involving hard-wiring and trenching, which is inefficient and labor-intensive.
Innovation Solution
A 'plug and play' system where source equipment is equipped with receptacles and cables have plugs, allowing for electrical connection without field terminations or hard-wiring, using asymmetrical shapes to prevent incorrect connections and seal against dust and water, with collection hubs aggregating power from multiple sources and destination equipment integrated on skids for easy deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hard-wiring methods are used to connect source equipment to destination equipment, then reliable electrical connection is achieved, but installation complexity and labor costs increase significantly
Solution Approach 1:
The electrical connection system is segmented into modular plug and receptacle components. The receptacle is integrated into the source equipment housing, while the plug is attached to the cable assembly. This segmentation allows for pre-fabricated connections to be made in controlled manufacturing environments rather than requiring complex field terminations, thereby maintaining reliability while reducing installation complexity.
Solution Approach 2:
Electrical connections are established in advance during equipment manufacturing and cable assembly fabrication. The receptacle is pre-installed in the source equipment housing, and the plug is pre-attached to the cable with all necessary terminations and connectors. This preliminary action eliminates the need for skilled electricians to perform field terminations, reducing both installation complexity and labor costs while maintaining connection reliability.
2Manufacturing precision
If skilled electricians perform field terminations to ensure proper electrical connections, then connection quality is improved, but installation time and labor costs increase
Solution Approach 1:
All electrical terminations, connector attachments, and cable preparations are completed during the manufacturing and assembly phases before the equipment is shipped to the installation site. This preliminary action ensures that connection quality is established under controlled conditions with proper quality assurance, eliminating the need for skilled electricians to perform time-consuming field terminations during installation.
Solution Approach 2:
The source equipment is designed with an integrated receptacle that is self-contained and ready to accept a plug without requiring additional tools, skills, or adjustments. The plug-and-receptacle system is designed to be inherently foolproof, allowing installation personnel to simply connect the components without needing specialized electrical knowledge, thereby dramatically reducing installation time while maintaining connection quality.
3Productivity
If plug and receptacle system is used for quick connection, then installation speed is improved, but protection against environmental factors may be compromised
Solution Approach 1:
The plug and receptacle are designed with asymmetrical features including a non-circular configuration and positioning protrusions that prevent incorrect insertion. This asymmetrical design ensures that the plug can only be connected in the correct orientation, guaranteeing proper alignment of electrical contacts and sealing surfaces. The result is that quick connection is achieved without compromising environmental protection, as the correct orientation ensures optimal sealing against dust and water.
Solution Approach 2:
A sealing mechanism acts as an intermediary between the plug and receptacle components. The seal is integrated into the connection interface and automatically engages when the plug is inserted into the receptacle. This intermediary sealing element provides protection against environmental factors such as dust and water while maintaining the simplicity and speed of the plug-and-receptacle connection system.
4Ease of manufacture
If pre-fabricated plug and receptacle systems are used, then labor costs are reduced, but adaptability to different configurations may be limited
Solution Approach 1:
The plug and receptacle system is designed with universal features that allow it to accommodate different cable types, sizes, and configurations. The receptacle is integrated into the source equipment housing in a standardized location, while the plug can be attached to various cable assemblies. This universal design maintains ease of manufacture through standardization while providing adaptability to different system configurations through the flexibility of the cable and connector interface.
Data Source
AI summary
Systems and methods of electrically connecting electrical energy storage or photovoltaic equipment with electrical destination equipment without performing any hard-wiring or installing any terminations in the field. A utility-scale electrical energy storage system and/or photovoltaic inverter is provided with a receptacle at its electrical output with a frame shaped and sized to secure to a first plug on a first cable to form an electrical connection between the first source equipment, first cable and the destination equipment.