Solar Module Local Management Units for MPPT Optimization

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Solution Overview

Problem

Traditional maximum power point tracking (MPPT) algorithms in solar arrays fail to optimize energy production due to differences in installation, fabrication, or degradation of solar modules, leading to reduced power output as weaker modules affect stronger ones in the same string or wiring section.

Innovation Solution

The implementation of local management units that periodically switch on and off weak modules, using electrical noise as a carrier signal for data transmission, allowing each module to operate on a different frequency, thereby reducing system noise and optimizing energy production by balancing current and voltage outputs across the string.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional MPPT algorithm treats solar array as single module and pulls/pushes current equally on all strings and modules, then the control system is simple, but the system cannot find maximum power point for each module and energy production is reduced

Engineering Contradiction:
Improveenergy productionVSAvoidcontrol system complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent divides the solar array into multiple independent strings and further segments each string into individual modules, with each module equipped with its own local management unit. This segmentation allows each module to independently track its maximum power point, preventing weaker modules from limiting stronger ones, thereby significantly improving energy production while distributing control complexity across multiple simple local units rather than one complex central controller.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements dynamic switching of module connections to the string bus, where local management units continuously adjust which modules are connected based on real-time performance conditions. This dynamic reconfiguration allows the system to adapt to changing environmental conditions and module degradation patterns, maintaining optimal power extraction from each module independently, thus improving productivity without requiring complex centralized control algorithms.

Inventive Principle:
Principle #15Dynamics

2Productivity

If local management units are implemented to periodically switch weak modules on and off, then energy production is optimized by isolating weak modules, but system complexity and component cost increase

Engineering Contradiction:
Improvepower outputVSAvoidsystem complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent introduces local management units at the module level, segmenting the control function from the power flow path. Each local management unit independently monitors and controls its associated module, enabling weak modules to be isolated without affecting the operation of stronger modules. This segmentation approach optimizes power output by ensuring that no single weak module limits the entire string, while distributing system complexity across multiple simple, identical local units.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The local management unit acts as an intermediary between the solar module and the string bus, providing intelligent switching control. This intermediary component enables weak modules to be periodically disconnected from the string bus without requiring complex centralized control, thereby optimizing energy production while keeping individual unit complexity low. The intermediary absorbs the control complexity locally rather than propagating it system-wide.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Ease of manufacture

If electrical noise is used as carrier signal for data transmission between modules and inverter, then communication infrastructure cost is reduced, but system noise increases

Engineering Contradiction:
Improvecommunication infrastructure costVSAvoidsystem noise
Core Design Contradiction:
Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful electrical noise generated by power switching operations into a useful carrier signal for data communication. Local management units modulate their switching operations to encode communication data, and the inverter detects these modulated signals to retrieve information from each module. This approach eliminates the need for separate communication wiring infrastructure while utilizing the existing electrical noise as the communication medium, thereby reducing manufacturing costs without significantly increasing overall system noise.

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

Data Source

PatentUS11171490B2System and method for low-cost, high-efficiency solar panel power feed
Publication Date: 2021.11.09 TIGO ENERGY INNOVATIONS LLC
  • US11171490B2 patent drawing
  • US11171490B2 patent drawing
  • US11171490B2 patent drawing

AI summary

A cascading regulation system connected to a number of serially connected power sources and uses multiple regulators having different cutoff voltages to provide an output for the local power consumption unit. Each of the regulators is connected to a subset of serially connected power sources and so configured that if the voltage generated at the lowest tap is no longer sufficient for a stable supply to the local power consumption unit, the next higher regulator takes over, and the output voltage drops in small steps reflective of that takeover of the next higher tap. When the voltage generated across a subsection grows, a lower connected tap may take over again, producing a slightly higher output voltage for the local power consumption unit. The cutover steps are chosen such that the output voltage range matches the range given as the acceptable input range for the local power consumption unit.