Preconnected Power Device Chain for PV Deployment
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Solution Overview
Problem
The deployment of power devices in photovoltaic installations is costly, time-consuming, and complex due to the need for individual coupling to power units and the use of multiple connectors, which can lead to safety hazards.
Innovation Solution
Power devices are preconnected during manufacturing to form a chain, packaged as a single unit, and deployed by coupling them to photovoltaic generators, reducing the number of connectors and enabling easier, safer installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If power devices are deployed as individual units with separate connectors, then each device can be independently configured and replaced, but deployment costs increase, installation time increases, and complexity increases
Solution Approach 1:
Multiple power devices are pre-assembled into a single integrated module during manufacturing, with internal connections already established. This merging reduces the number of separate components that need to be handled and connected during deployment, thereby reducing deployment complexity while maintaining the functional capabilities of individual devices within the module.
Solution Approach 2:
The power devices are pre-configured and pre-connected during the manufacturing process rather than during field installation. This preliminary action includes establishing internal connections, configuring settings, and preparing the module for deployment, which eliminates the need for complex on-site assembly and reduces installation time and complexity.
2Adaptability or versatility
If multiple connectors are used to couple power devices to PV generators and to each other, then connection flexibility is improved, but safety hazards increase due to more connection points susceptible to overheating and arcing
Solution Approach 1:
Multiple connection points are consolidated into fewer connection points by pre-assembling the power devices into an integrated module. The internal connections within the module are established during manufacturing under controlled conditions, reducing the number of external connectors needed and thereby reducing the number of potential safety hazards during deployment.
Solution Approach 2:
The module design uses standardized connection interfaces that can be replicated across multiple modules while maintaining consistent safety standards. This standardization allows for flexible system configuration through module replication rather than through multiple individual connector connections, reducing overall safety risks.
3Productivity
If power devices are preconnected during manufacturing to form a chain, then deployment time is reduced and costs are reduced, but the ability to individually replace devices is limited
Solution Approach 1:
The power system is segmented into modular units that are pre-assembled during manufacturing. Each module contains multiple power devices that are internally connected, forming a self-contained unit. This segmentation allows the entire module to be deployed quickly as a single unit while still enabling replacement at the module level, balancing deployment speed with maintenance flexibility.
Solution Approach 2:
The power devices within each module are pre-configured and pre-connected during manufacturing with standardized interfaces. This preliminary preparation enables rapid deployment of the entire module while also facilitating easier replacement of entire modules in the field, as the internal complexity has already been resolved during manufacturing.
4Ease of operation
If connectors are used to connect power devices, then connection and disconnection is simplified, but the number of costly connector components increases
Solution Approach 1:
Multiple connector functions are merged into fewer connectors by pre-assembling the power devices into an integrated module. The internal connections that would otherwise require multiple connectors are established during manufacturing, reducing the total number of connectors needed in the system while maintaining ease of connection and disconnection at the module level.
Solution Approach 2:
The module is designed to be self-contained with internal connections already established, eliminating the need for multiple external connectors. The module interfaces with the PV generator and other modules through standardized connections, reducing the overall connector count while maintaining operational simplicity.
Data Source
AI summary
Various implementations described herein are directed to methods for connecting power devices prior to deployment in a photovoltaic installation, for cost savings and easy deployment. Some embodiments disclosed herein include manufacturing a chain of power devices already coupled by conductors, and providing a mechanical assembly for convenient storage and deployment.