Power Transfer Plug for Non-Intrusive Grid Connection
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Solution Overview
Problem
The high labor costs and complexity associated with installing grid-tied inverter systems in existing structures, as they require extensive wiring and invasive procedures, hinder the widespread adoption of Micro Distributed Renewable Generation systems.
Innovation Solution
A power transfer plug system that allows for the rapid, safe, and cost-effective connection of renewable energy sources to a home or small business without the need for intrusive rewiring, enabling power distribution to all circuits from outside the structure, using a non-conductive plastic injection-molded power transfer plug with a system wire harness and alignment guide blocks for secure and efficient power routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring methods are used to connect grid-tied inverter systems in existing structures, then reliable power connection is achieved, but installation labor costs and time increase significantly
Solution Approach 1:
The patent introduces a plug as an intermediary device that connects between the inverter and the electrical panel. This plug contains built-in wiring and connection terminals, serving as a mediator that eliminates the need for extensive field wiring while ensuring reliable electrical connection. The plug pre-assembled wiring architecture allows for quick connection without compromising connection reliability.
Solution Approach 2:
The plug is pre-assembled with all necessary wiring, terminals, and connection elements before installation. The wiring harness, terminals, and insulating components are prepared in advance during manufacturing, eliminating the need for on-site wiring work and reducing installation time while maintaining connection reliability.
2Adaptability or versatility
If traditional wiring methods are used to connect grid-tied inverter systems, then complete power distribution is achieved, but installation complexity and labor costs increase
Solution Approach 1:
The patent combines multiple functions into a single plug device: the wiring harness, connection terminals, grounding elements, and insulating components are all integrated into one pre-assembled unit. This merging of components simplifies the installation process while maintaining the ability to distribute power to multiple circuits through the electrical panel.
Solution Approach 2:
The plug is designed as a universal connection device that can interface with standard electrical panels and support various inverter types. The multi-functional design includes power carrying terminals, grounding connections, and circuit distribution capabilities, allowing one device to perform multiple functions that would otherwise require separate wiring operations.
3Reliability
If extensive wiring is performed during installation, then code-compliant power connection is achieved, but installation cost increases
Solution Approach 1:
The plug is pre-assembled in a controlled manufacturing environment where code-compliant wiring practices can be ensured. All connections, insulation, and terminal attachments are performed during manufacturing under quality control, guaranteeing code compliance while eliminating costly on-site wiring labor.
Solution Approach 2:
The plug includes self-contained wiring and connection elements that perform the wiring function automatically during installation. The pre-assembled nature of the plug means the wiring work is self-performed during manufacturing, transferring the wiring task from the installation phase to the manufacturing phase, thereby reducing installation costs while maintaining code compliance.
Data Source
AI summary
A system and method that offers the provision too rapidly and safely connect electrical generation sources, including inverters used by solar collecting panels, or wind turbines, and backup hydrocarbon fueled generators or any other supplemental power sources including storage batteries, fuel cells and future electric automobiles. Thus enabling the feeding of power to all circuits in the home or small business, not just isolated circuits in a structure. The system is compliant with electric codes, requires no costly rewiring inside the structure or in the electrical circuit panel and can be accomplished entirely from the outside of the home or small business adjacent to the electric service meter for the home or small business structure. It offers owners, utilities and equipment manufacturers a simple, safe, cost effective method for interconnection of renewable generation and storage devices with the electric grid for participation in smart energy management and net metering initiatives with local utility companies.