Preconnected PV Power Chains to Cut Connector Count and Arcing
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Solution Overview
Problem
The deployment of power devices in photovoltaic systems is costly, time-consuming, and complex due to the need for individual coupling with power units and extensive use of connectors, which can lead to safety hazards and inefficiencies.
Innovation Solution
Power devices are preconnected in chains during manufacturing, with conductors permanently connecting adjacent devices, reducing the number of connectors needed and allowing for easier deployment by forming a single unit that can be quickly coupled to photovoltaic generators, thereby simplifying installation and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If power devices are individually coupled with power units using connectors during deployment, then each device can be independently installed and replaced, but deployment costs increase, installation time increases, and complexity increases
Solution Approach 1:
The system segments power devices into modular units that can be independently manufactured and tested, then pre-assembled into chains during manufacturing. This allows individual device replacement while reducing field deployment complexity, as broken chains can be replaced as single units rather than connecting multiple separate devices with multiple connectors.
Solution Approach 2:
Power devices are pre-connected to form chains during manufacturing before deployment. This preliminary assembly reduces on-site installation complexity and time, as the chains arrive ready-to-install with connections already made, eliminating the need for field technicians to handle multiple connectors and perform complex connection procedures.
2Adaptability or versatility
If extensive connectors are used to couple power devices during deployment, then flexible connections are achieved, but safety hazards increase due to more connection points susceptible to overheating and arcing
Solution Approach 1:
The invention extracts and eliminates connectors from the power device coupling system by using permanent bonded connections instead. This removal of connectors directly reduces the number of potential failure points for overheating and arcing, improving safety while maintaining connection reliability through permanent bonding techniques.
Solution Approach 2:
The patent replaces expensive, safety-risk-prone connectors with permanent bonded connections that eliminate the need for repeated connection and disconnection. This approach treats the connection as a permanent fixture rather than a disposable connector, reducing safety hazards associated with connector wear, loose connections, and arcing.
3Productivity
If power devices are preconnected in chains during manufacturing, then deployment time is reduced and installation is simplified, but manufacturing complexity increases
Solution Approach 1:
The invention merges multiple power devices and their interconnections into a single integrated chain unit during manufacturing. This combining of devices with their permanent connections creates a modular assembly that accelerates deployment while the manufacturing process is optimized for this specific assembly type, balancing the increased manufacturing complexity with significant field installation benefits.
Solution Approach 2:
Power devices are pre-connected and tested as complete chains during manufacturing before shipment. This preliminary assembly and testing ensures that chains arrive ready-to-install, dramatically reducing on-site deployment time. The manufacturing process is structured to perform these connections under controlled conditions, managing the complexity at the manufacturing stage to gain efficiency at the deployment stage.
4Ease of operation
If connectors are used to connect power devices, then connection and disconnection is easy, but the number of connection points increases leading to more safety risks
Solution Approach 1:
The invention removes connectors entirely from the system by implementing permanent bonded connections between power devices in chains. This extraction eliminates the trade-off between ease of connection and safety, as the permanent bonds provide both reliability and safety by eliminating the connection points where overheating and arcing could occur, while still allowing chain-level replacement if needed.
Data Source
AI summary
Methods for deploying connected power devices and systems of connected power devices prior to deployment in a photovoltaic installation are described. For example, a string of power devices pre-coupled by conductors is disclosed, which saves cost, provides convenient storage, reduces electromagnetic interference, and is easy to deploy. Various implementations described herein are also directed to employing photovoltaic strings including a photovoltaic power device with a specialized wiring configuration, which enables high string efficiency without incurring excessive wiring costs. Implementations may include a cable built into photovoltaic generators that carry one portion of the current, and other portions of the current may be carried by direct-current (DC) or alternating-current (AC) cables bypassing the photovoltaic generators.