PV Module Backplane Integration to Cut Converter-Junction Cabling
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Solution Overview
Problem
The high production costs of photovoltaic systems are attributed to the high costs of power converters and junction boxes, primarily due to the need for extensive external cabling between these components.
Innovation Solution
Integration of power converter boxes and junction boxes on the backplane of photovoltaic modules, utilizing solder ribbons and circuit board cables to reduce cable length and eliminate the need for external connections, while incorporating diodes for voltage regulation and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power converters and junction boxes are connected through external cables, then the system can function properly, but the production costs increase due to extensive cabling requirements
Solution Approach 1:
The patent integrates the power converter and junction box into a single integrated power converter box, eliminating the need for external cables between these components. This merging of previously separate components reduces cabling requirements and production costs while maintaining system functionality through internal circuit board connections.
2Adaptability or versatility
If external cables are used to connect power converters and junction boxes, then system assembly is flexible, but cable length and material requirements increase production costs
Solution Approach 1:
By combining the power converter and junction box into one integrated unit, the patent eliminates the need for external cables that would otherwise be required to connect these components. The internal integration removes the cable length requirement entirely while maintaining electrical connectivity through printed circuit board traces.
Solution Approach 2:
The patent extracts the cable connection function from the system by integrating the power converter and junction box internally. The cable connection is replaced by direct internal electrical connections within the integrated box, removing the need for external cabling infrastructure.
3Ease of operation
If power converters are positioned externally to photovoltaic modules, then installation is simplified, but the distance between components increases cable requirements and costs
Solution Approach 1:
The patent merges the power converter with the photovoltaic module by integrating it into the module's backplane structure. This integration eliminates the distance between components that would require cables, while the standardized integration method maintains installation simplicity through unified mounting procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces production costs, enhances security by preventing substrate damage from voltage issues, and simplifies the connection process by integrating power conversion modules for maximum power point tracking (MPPT) functionality.
Implementation Method 1
the first group of connection terminals of the power converter box and the second group of connection terminals of the junction box are coupled through a solder ribbon
Implementation Method 2
the first target connection terminal of the power converter box is coupled to an input terminal of the power conversion module through a circuit board cable
Implementation Method 3
the second target connection terminal of the junction box is coupled to an input terminal of the power conversion module through a first cable
Implementation Method 4
output terminals of the power conversion module are coupled to an inverter through a second cable, to transmit a second power processed by the power conversion module to the inverter
Implementation Method 5
the power converter box further includes a first diode corresponding to the first photovoltaic substring and at least one second diode corresponding to the second photovoltaic substring
Data Source
AI summary
A power converter box and at least one junction box are integrated on a backplane of the photovoltaic module as a whole, and there is a cable for connecting the power converter and the junction box. In this case, relative to the conventional technology in which a junction box is independent of a power converter, a length of a cable used when the junction box and the power converter box are taken as a whole is shorter than a length of a cable used in the conventional technology. In this case, compared with the conventional technology in which a cable is connected to an independently placed power converter, the power converter only needs to establish a connection relationship by using a solder ribbon, a circuit board cable, and the like with low costs, so that production costs are low.