Rapid Shutdown Module Heartbeat Control for Fault Localization

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Solution Overview

Problem

Existing methods for testing and controlling rapid shutdown devices in photovoltaic systems are inefficient, leading to potential safety hazards and difficulties in locating malfunctioning devices.

Innovation Solution

A method involving the transmission of heartbeat signals of varying signal strengths to rapidly switch on/off rapid shutdown devices, coupled with a tester that includes a main control chip, communication component, and voltage measuring components to efficiently test and control these devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If rapid shutdown devices are plugged in and unplugged one by one to locate malfunctioning devices, then the malfunctioning device can be identified, but the process is time-consuming and inefficient

Engineering Contradiction:

Improvemalfunction location accuracyVSAvoidtesting time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system segments the testing process by assigning unique identification codes to different rapid shutdown devices and uses a display device to show which specific device is malfunctioning, eliminating the need for manual one-by-one testing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system implements feedback through the display device that provides real-time information about malfunctioning rapid shutdown devices, allowing operators to immediately identify and locate the problematic device without systematic manual testing

Inventive Principle:

Principle #23Feedback

2Device complexity

If the controller is arranged inside the inverter, then the system structure is compact, but the controller stops operating when the inverter is switched off, resulting in failure to control the rapid shutdown device

Engineering Contradiction:

Improvesystem structureVSAvoidcontrol reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The controller is extracted from the inverter and positioned independently, allowing it to continue operating and controlling rapid shutdown devices even when the inverter is switched off, ensuring continuous safety control

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The controller acts as an intermediary between the monitoring device and the rapid shutdown devices, receiving monitoring information and independently controlling the rapid shutdown devices without requiring the inverter to be operational

Inventive Principle:

Principle #24Intermediary (Mediator)

3Power

If high voltage direct current power is generated by series-connected photovoltaic modules, then the power output is sufficient, but safety and fire hazards increase

Engineering Contradiction:

Improvepower outputVSAvoidsafety hazards

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The rapid shutdown device is activated in advance through the monitoring device to reduce voltage on direct current cables before maintenance or emergency situations occur, preventing safety hazards while maintaining high power output capability during normal operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system converts the potentially harmful high voltage direct current into a safety feature by using the monitoring device to detect arcs and trigger rapid shutdown, transforming the high voltage risk into a controlled safety mechanism

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 approach enables rapid and efficient testing and control of rapid shutdown devices, reducing safety hazards and improving operational efficiency by quickly locating malfunctions and ensuring continuous control even when the inverter is switched off.

Implementation Method 1

transmitting a heartbeat signal of first signal strength to a target rapid shutdown device... transmitting a heartbeat signal of second signal strength to the target rapid shutdown module

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250130280A1Shutdown device detection and control method, and detector

Publication Date: 2025.04.24 ALTENERGY POWER SYST

AI summary

A method for testing and controlling a rapid shutdown device, and a tester are provided. The method includes: transmitting a heartbeat signal of first signal strength to a target rapid shutdown device in a target rapid shutdown module to switch the target rapid shutdown device on and testing the target rapid shutdown device using a preset testing program t, on receipt of a rapid shutdown device testing request, where all rapid shutdown devices in the target rapid shutdown module are previously off; and transmitting a heartbeat signal of second signal strength to the target rapid shutdown module to switch the rapid shutdown devices on or off, on receipt of a rapid shutdown device control request, where the first signal strength is lower than the second signal strength. The rapid shutdown devices can be tested and controlled efficiently, thereby effectively avoiding safety hazards and thus protecting workers.