Segmented Power Cable Fixture for Shipping Stability
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Solution Overview
Problem
The existing cable systems for photovoltaic modules with microinverters are costly due to multiple AC connectors and face challenges in managing and uncoiling cables during installation, especially in limited spaces like rooftops, leading to entanglement issues.
Innovation Solution
A segmented cable management system with a single AC connector per microinverter and a fixture-based system that secures connectors with locking receptacles, allowing for compact shipping and easy partitioning, preventing entanglement by using a stacked configuration with interlocking tabs and ribs to stabilize the cable segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a long spool of cable with periodic splice box connectors is used, then the cable system can connect multiple microinverters in parallel, but the cable creates entanglement during installation and is difficult to manage in limited spaces
Solution Approach 1:
The cable system is divided into multiple pre-cut segments, each with a connector at one end. These segments are stored on individual spools and can be independently installed by connecting them to microinverters and to each other, eliminating the need to manage a single long spooled cable while maintaining the ability to connect multiple devices in parallel.
2Reliability
If a drop cable connector and molded splice box system is used, then cable connections can be established, but the cost overhead increases due to multiple AC connectors at each microinverter
Solution Approach 1:
The system merges the connector and splice box functions into a single integrated connector design. Each cable segment has a connector that directly interfaces with the microinverter, eliminating the need for separate splice boxes and reducing the number of AC connectors required at each installation point while maintaining reliable electrical connections.
3Stability of the object's composition
If cable segments are secured in a stacked configuration with interlocking tabs and ribs, then entanglement is prevented during shipping and storage, but the fixture structure becomes more complex
Solution Approach 1:
The fixture uses curved or rounded interlocking features (tabs and ribs) rather than sharp angular elements. The tabs and ribs are designed with smooth transitions and rounded profiles that interlock to prevent cable segment entanglement while distributing mechanical stresses evenly, reducing the risk of damage during shipping and storage.
Data Source
AI summary
Exemplary embodiments of the present invention are drawn to a method and apparatus for securing a segmented cable in manufacturing and for shipping and storage. In some embodiments, the apparatus comprises two or more fixtures, each comprising a plurality of locking receptacles along a body of each fixture, wherein each of the plurality of locking receptacles comprises a locking mechanism to secure a connector of a plurality of connectors on a power cable.