Solar Charge Controller Protection Circuit for Battery Disconnects
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Solution Overview
Problem
Existing solar battery charging systems rely on human intervention to disconnect the solar panel from the controller before disconnecting the battery, leading to potential damage due to improper disconnection, and lack a fail-safe mechanism independent of battery voltage or active components.
Innovation Solution
A protective interconnection circuit using a relay or auxiliary loop mechanism that automatically disconnects the solar panel from the controller before the battery is disconnected and reconnects it after the battery is reconnected, incorporating a time delay to prevent transient damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the solar panel remains connected to the controller while the battery is disconnected, then the controller can be damaged due to inadequate or unstable voltage from the solar panel, but manually disconnecting the solar panel before the battery requires human memory and attention which is not reliable
Solution Approach 1:
The relay is configured to automatically disconnect the solar panel from the controller before the battery is disconnected. This preliminary action ensures that the controller is protected from voltage damage before the human operator completes the battery disconnection, eliminating the need for the operator to remember the correct sequence.
Solution Approach 2:
A relay is introduced as an intermediary device between the solar panel and the controller. The relay automatically executes the disconnection sequence based on the battery connection status, mediating between the operator's action and the controller's protection needs, thereby ensuring reliable operation without requiring complex control circuitry.
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
Ensures safe and reliable operation by automatically managing the connection and disconnection of solar panels and batteries, independent of battery voltage, reducing the risk of controller damage and ensuring seamless transitions.
Implementation Method 1
A relay or auxiliary loop mechanism that automatically disconnects the solar panel from the controller
Data Source
AI summary
A protective interconnection circuit for interconnecting a solar panel, a battery and a charge controller. One embodiment has a pair of post-mate, mating electrical connectors. The connectors have at least two primary conduction paths through the joined connectors and a first set of at least two auxiliary conduction paths through the joined connectors. The primary conduction paths electrically connect the battery to the charge controller. The auxiliary conduction paths of the battery side connector are connected together. The auxiliary conduction paths of the controller side connector are connected one to the solar panel and the other to the charge controller. Another embodiment has a relay with its coil terminals electrically connected the controller's battery terminals. The relay contacts are interposed in a conductive connection between the solar panel and the controller.