Preconnected PV Power Device Chains With Fewer Field Connectors
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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 installation and safer operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If power devices are deployed as individual units requiring individual coupling and multiple connectors, then each device can be independently installed, but deployment costs increase, installation time increases, and safety hazards increase
Solution Approach 1:
Power devices are pre-assembled into chains during manufacturing with conductors pre-connected between adjacent devices. This preliminary assembly eliminates the need for field technicians to individually connect each device during installation, significantly reducing installation time and complexity while maintaining the ability to deploy multiple devices efficiently.
Solution Approach 2:
Multiple power devices are merged into a single chain assembly during manufacturing, with conductors internally connected between adjacent devices. This merging reduces the number of separate connection operations required during deployment from four connectors per device to only two connectors per chain, reducing both installation time and safety hazards.
2Adaptability or versatility
If multiple connectors are used to couple power devices, then individual device flexibility is maintained, but deployment costs increase and safety hazards increase due to more connection points
Solution Approach 1:
Adjacent power devices are merged into chains with pre-connected conductors, reducing the number of connectors from four per device to two per chain. This merging maintains the electrical and functional flexibility of individual devices while significantly reducing the total number of connection points, thereby lowering deployment costs and safety hazards.
Solution Approach 2:
The connector function is extracted from individual device assembly and relocated to the manufacturing process. Conductors are pre-connected between adjacent power devices during factory assembly, removing the need for field technicians to install multiple connectors and reducing the overall connector count while maintaining device flexibility.
3Productivity
If power devices are preconnected during manufacturing, then deployment costs reduce and installation time reduces, but manufacturing complexity increases
Solution Approach 1:
Power devices are pre-assembled into chains during manufacturing with conductors pre-connected between adjacent devices. This preliminary assembly, performed in the controlled manufacturing environment, shifts the complexity of precise connections from field installation to factory production, where automated equipment and standardized procedures can efficiently handle the increased manufacturing complexity while dramatically improving deployment efficiency.
4Ease of operation
If connectors are used to connect power devices, then installation flexibility is maintained, but safety hazards increase due to susceptibility to overheating, arcing and fire
Solution Approach 1:
The connection function is extracted from field installation and relocated to manufacturing, where conductors are pre-connected between adjacent power devices. This eliminates the need for field technicians to create potentially unsafe connections and reduces the total number of connection points from four per device to two per chain, directly reducing safety hazards while maintaining installation flexibility through standardized chain interfaces.
Solution Approach 2:
Connections between power devices are established in advance during manufacturing under controlled conditions, eliminating the need for field connection operations that pose safety risks. The pre-connected chains arrive at installation sites ready-to-deploy, reducing the number of hot work operations and connection points where overheating, arcing, and fire hazards could occur.
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.