Splice Box for Distributed Power Interconnection
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Solution Overview
Problem
The existing AC wiring systems for photovoltaic energy systems are time-consuming and costly to install due to the need for custom-made cables and are prone to errors during assembly.
Innovation Solution
A standardized AC wiring system using a splice box with plug pins, retention bars, and drop connectors that allows for prefabricated cable assemblies to be easily connected and cut to length, facilitating faster and more accurate installation by interconnecting DC-AC inverters in a photovoltaic energy system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-made cables are used to interconnect inverters, then the wiring system can be adapted to specific system requirements, but the installation time and cost increase significantly
Solution Approach 1:
The cable assembly is divided into modular segments with standardized connectors at each end. Each segment can be independently manufactured and then quickly assembled on-site by connecting multiple segments together, eliminating the need for custom-made continuous cables while maintaining adaptability to different system configurations.
Solution Approach 2:
The cable segments are pre-assembled with connectors attached in the manufacturing phase before delivery to the installation site. This preliminary preparation of connectors and cable segments eliminates time-consuming on-site assembly operations while allowing customization of segment lengths and configurations for different system requirements.
2Adaptability or versatility
If custom-made cables are assembled in the field, then the wiring can be customized for each installation, but the assembly process becomes costly and error-prone
Solution Approach 1:
The cable system is segmented into standardized modules that can be easily connected using simple connector interfaces. This segmentation transforms the complex custom assembly process into a series of simple, repeatable connection operations that are less error-prone and easier to manufacture.
Solution Approach 2:
The standardized connector design serves multiple functions: it provides mechanical connection, electrical contact, and alignment guidance. This universal connector type can be used across different cable segments and configurations, simplifying the manufacturing process while maintaining customization capability through different segment arrangements.
3Productivity
If standardized wiring systems are implemented, then installation speed increases, but the ability to adapt to different configurations may be limited
Solution Approach 1:
The standardized cable system is divided into modular segments that can be connected in various sequences and configurations. This segmentation enables fast standardized connection operations while providing the flexibility to adapt to different system layouts and requirements through different assembly patterns.
Solution Approach 2:
The standardized connector design incorporates dynamic elements such as flexible cable segments and adjustable mounting positions that allow the rigid standardized connection system to adapt to different installation configurations and spatial requirements.
Data Source
AI summary
A method and apparatus for power wiring. In one embodiment, the apparatus comprises a splice box comprising (i) a plug having a plurality of plug pins, each plug pin of the plurality of plug pins for coupling to a conductor within a cable adapted for coupling to a power line; (ii) a first pin receptacle for coupling to a first guide pin of a connector; and (iii) a first pair of retention bars disposed within the first pin receptacle, the first pair of retention bars for retaining the first guide pin.