WO2013139331A1

WO2013139331A1 - Connection system for solar generators

Info

Publication number: WO2013139331A1
Application number: PCT/DE2013/100100
Authority: WO
Inventors: Thomas Hoffmeister; Roland Pfeffer
Original assignee: Fpe Fischer Gmbh
Priority date: 2012-03-23
Filing date: 2013-03-14
Publication date: 2013-09-26
Also published as: DE102012104138B3

Abstract

The invention relates to a connection system for solar generators comprising a plurality of different modules from which connection units can be composed, which are used to make electrical contact with solar generators. A connection unit has at least one end module+ (1.1) and one end module- (1.2), each with at least one bore (5) designed such that it allows access to a connecting element (18), wherein the end modules (1.1, 1.2) can be mounted on the solar generator in such a way that a connecting cable from the solar generator can be connected from the front side of the end modules (1.1, 1.2) to the connection element (18). The bores (5) are sealed in a water-tight manner using a leg (10) from a bypass module (9) or a correspondingly formed plug, or by plugging in an electronic circuit board (16). Projections (4) corresponding to recesses (3) on the end module- (1.2) are formed on the upper side and/or on the side walls of the end module+(1.1), and said projections can be used to plug further modules onto the end modules (1.1, 1.2) by plugging either at least one projection (4) of the end module+ (1.1) into a recess (3) in said further module, or by plugging at least one projection (4) of said further module into a recess in the end module- (1.2).

Description

Connection system for solar generators

The invention relates to a connection system for solar generators, with which individual modules can be used to produce connection units which are individually adapted to the design and electrical properties of the solar generators to which the connection units are to be mounted. The connection units can also be easily equipped with electronic circuits for controlling and monitoring the solar generators.

Connection boxes for connecting and integrating solar generators (photovoltaic modules) in photovoltaic systems are usually used, in which the connection elements, the bypass diodes and possibly electronic boards for control and / or monitoring are accommodated in a single, compact housing (eg DE 10 2006 027 104 B3, DE 10 2008 022 298 B3). With such junction boxes very good electrical insulation values can be achieved; They can also ensure a good heat dissipation of the commonly used bypass diodes. However, the junction boxes have the disadvantage that they have to be preconfigured consuming, depending on the design and performance of the solar generators to which they are to be installed; Retrofitting with additional electronic components is relatively complicated.

In DE 20 2010 000 052 U1 a simply constructed connection device for photovoltaic modules is shown, which consists of a molded on the rear wall or welded to the rear wall, rear projecting jacket wall on which a plastic housing can be plugged and locked, creating a Cavity is formed, which allows contacting the ribbon cables of the photovoltaic modules. By introducing a plug into the cavity, it can be closed. An integration of bypass diodes or electronic circuits is not provided and due to design also not possible.

WO 2010/150173 A1 discloses a connection system for solar generators which has a plurality of different modules combined in a common housing, presented. The contacting of the connection lines of the solar generator via two end modules, each by connecting a connecting cable of the solar generator is connected to a terminal unit of the end modules. In a arranged between the end modules, another module, a bypass diode is housed. The individual modules can be closed separately using plugs / lids. Due to the placement of the modules in a common housing, the versatility of the connection system is reduced; The additional housing also causes increased production costs.

DE 10 2004 053 942 A1 and DE 20 2004 020 974 U1 describe connection systems for solar generators which comprise a plurality of different modules, it being possible to assemble terminal units which serve for electrically contacting solar generators from the modules. However, the connection systems do not have two separate end modules; the versatility of the connection systems is therefore limited.

DE 10 2007 037 797 B4 shows a connection system for solar generators, which comprises a plurality of different modules, wherein from the modules connection units, which serve for electrical contacting of solar generators, can be assembled. A connection unit has two end modules, which serve for the electrical contacting of the connection lines of the solar generator.

The invention has for its object to find a connection system can be constructed with the cost-effective connection units for solar generators, which are individually adaptable to the design and electrical properties of the solar generators, where the connection units are to be mounted. The connection units should also be easily equipped with electronic circuits for controlling and monitoring the solar generators.

The object of the invention is solved by the features of claim 1. Further advantageous embodiments of the invention will become apparent from the claims 2 to 10. According to the invention, the connection system for solar generators comprises a plurality of different modules, from which (according to a modular principle) connection units, which serve for the electrical contacting of solar generators, are put together.

In its simplest form, the connection unit has only one end module and one end module. On the top and / or on the side walls of Endmoduls + are as coupling elements projections, formed at the Endmodul- corresponding recesses, by means of which the end modules (Endmodule + or Endmodule-) other modules are plugged. For this purpose, either at least one protrusion of the end module + is plugged into a recess of another module or a protrusion of the other module into a recess in the end module. The projections and the recesses are geometrically adapted to each other so that they fit together form-fitting.

The invention is also intended to include solutions in which each of the end modules has protrusions and projections, e.g. in an alternating sequence.

The end modules, and also the intermediate modules which will be discussed later, are made of a weather resistant material, e.g. Plastic, and they typically have a flat cuboid shape (with rounded corners are possible), i. E. their height (distance from front to back) is smaller than their length and width. The modules may e.g. be designed as a rectangular plastic plate with rounded corners. The topology of the rear side of each end module is adapted to the topology of that side of a solar generator to which the mounting of the terminal unit is provided. Usually, the connection unit is mounted on the back of the solar generator, wherein both the back of the solar generator and the back of the end module are made flat.

Due to this adaptation of the topology, the connection unit can be attached to the relevant side of the (associated) solar generator, for example by gluing on, without causing larger gaps. Each end module comprises at least one electrical connection element, which serves to establish an electrical contact with at least one connecting line of the solar generator, and connecting elements with which the connection unit can be integrated into a photovoltaic system. The connection unit is always glued to the side of the solar generator on which the connecting cables are located.

Usually, the connecting cables are designed as ribbon cables, which are led out of the solar generator on the relevant side. Alternatively, the leads may also be covered with a laminate layer which, to expose the leads for contacting, e.g. by milling, is removed. An exact milling depth can be achieved by stopping the milling head at the moment when it comes in electrical contact with the relevant connecting line (voltage signal). If, as is generally customary, tinned connection lines are used, the tin layer can be milled off in addition to the laminate layer so that the connection lines can then be better welded to the connection elements.

Each end module is made so large (in this case, the geometry of the back) that with him (the back of Endmoduls) at least one of the openings through which a connection line is reached (ie either the opening through which the ribbon conductors are guided or the into the solar generator milled opening through which the connecting cable is exposed), can be covered.

In addition, at least one aperture / bore (preferably a single bore / aperture) is inserted in each end module which extends between the back and the front (opposite) thereof. Since almost exclusively bores are used for practical reasons, only the term "bore" will be used below, but it should also be understood to include any breakthroughs. The hole is chosen so large (designed) that it allows access to the connection element (= contact point for at least one connecting line). The end modules are attached to the solar generator in such a way that one (min. at least one) associated lead can be accessed through the bore (ie, either a ribbon conductor protrudes into the bore or an exposed lead is underneath the bore) and from the front of the end module concerned to the terminal (eg, by welding, soldering, screws or clamps ) can be electrically connected.

After making the electrical contact between the lead and the lead, usually the bore is made with a plug (or by means of a bypass module or by means of an electronic board), e.g. equipped with an O-ring seal, sealed waterproof, the plug is preferably chosen so large that the bore is largely filled by the stopper. In this way, the trapped air volume is minimized and the formation of condensation is suppressed.

In a preferred variant, the at least one protrusion is formed as a flat plate, wherein the flat surfaces of the plate parallel to the underside of the module, on which the projection is located run. The outline of the plate-shaped projection is mushroom-shaped, i.e. it is defined by a straight section adjacent the associated module with two parallel boundary lines and a curved section adjoining the straight section and having a curved (crowned) boundary line, e.g. the geometry of a circle section has defined, which connects the two straight boundary lines with each other.

The associated recesses, which correspond in their geometry but slightly larger than the projections (which is achieved by the fact that the projections fit into the recesses fit), are arranged on the tops of the modules and have a flat bottom surface parallel to the bottom of the module runs. The outline of the recess extends to the boundary line of the upper side of the module, ie, in addition to the recess in the upper side, a recess is formed in one of the side walls into which the straight region of the projection fits. With the connection system it is possible to construct a connection unit which comprises an end module + and an end module - which are pushed against one another by means of the coupling elements, and a U-shaped bypass module. The two legs of the bypass module may be in the form of plugs adapted to the shape of the holes in the modules and provided with sealing elements, the spacing of the legs of the bypass module corresponding to the spacing of the two holes in the assembled modules. Thus, the bypass module can be plugged into the two holes of the end modules, the holes are each sealed by a leg of the bypass module watertight and virtually all the air is displaced from the holes.

Preferably, both on each leg of the bypass module and in the bores of the end modules contact elements are arranged so that when plugging the bypass module in each case between a contact element of a leg and the contact element of a bore, an electrical connection is made. In the bypass modules is usually a bypass diode (with the term "bypass diode" should be included equally effective electronic components or circuits) and possibly an additional electronic circuit be integrated, the bypass diode (and possibly the electronic circuit) with the two contact elements is electrically connected to the legs of the bypass modules.

Another connection unit which can be constructed with the connection system according to the invention comprises two end modules and at least one intermediate module which contains an electronic component or an electronic circuit. Like the end modules, so is the at least one intermediate module with at least one coupling element (in the form of a projection or recess) equipped so that the at least one intermediate module with end modules and / or other intermediate modules can be plugged together. Also, the topology of the back of the at least one intermediate module is adapted to the topology of that side of the solar generator to which the mounting of the connection unit is provided. The geometric dimensions (length, width and height) of the end modules and intermediate modules preferably correspond, so that compact connection units can be formed from the end and intermediate modules by plugging together.

Like the end modules, the intermediate modules may also have bores with connection and / or contact elements which correspond both geometrically and functionally to the bores in the end modules. Preferably, the intermediate modules are provided with two holes, which, as well as the holes in the end modules can be used to connect the connecting lines of the solar generators with the connection elements. It has been shown that the connection lines of the solar generators of Einstringanlagen can best be contacted via the end modules of two- and multi-string systems in addition to the intermediate modules.

Two or more intermediate modules can also be combined integratively in one structural unit.

In order to be able to cascade the end modules and / or the intermediate modules in parallel and / or in series by means of the bypass modules, the geometry of the intermediate modules is selected such that in each case an intermediate module can be plugged together with one end module and / or with another intermediate module in such a way that in each case the distance between two adjacent holes corresponds to the distance between the two legs of a bypass module (ie, the bypass modules can be plugged).

As an alternative to the bypass modules (ie, the bypass modules can be completely dispensed with), an electronic board (possibly more) by means attached to the electronic board plug, which are provided with contact elements and which fit exactly into the holes, while the holes almost completely fill in (ie the plugs correspond functionally to the legs of the bridge modules) on which end and intermediate modules are plugged. On the electronic board on the one hand bypass solutions (ie the function of the bypass modules is the electronics board taken over) on the other hand electronic circuits, eg for monitoring, control or regulation of the solar generators implemented.

For mechanical protection of the connection units and / or for cooling of electronic components contained in the connection unit, at least one end module and one end module (preferably over all modules of the connection unit or correspondingly above an electronic circuit board) may have a metal profile (but also several metal profiles are conceivable ), eg an extruded aluminum profile can be arranged. Metal profiles may also be used to cool the electronic components, e.g. of bypass diodes in the bypass modules can be used by adjusting the surface of the metal profile, e.g. by means of cooling fins, is increased.

If an electronic board is used, the electronic board and the metal profile (mechanical protection, cooling) can also be combined in an integrative unit.

The invention will be explained in more detail with reference to several embodiments; show:

Fig. 1 a: a Endmodul- in plan view;

1 b: an end module in plan view,

1 c: a central part with two recesses and two protrusions in plan view, FIG. 1 d: a bypass module in a lateral sectional view,

2a shows a connection unit for single-strand and thin-film modules, serial arrangement with bypass module in plan view,

2b shows a connection unit for single-strand and thin-film modules, serial arrangement without bypass module in plan view,

2c: a connection unit for single-strand and thin-film modules, parallel arrangement with bypass module in plan view,

3a: a connection unit for three-string modules, with side cable exit in plan view, 3b: a connection unit for Dreist ngmodule, with vertical cable outlet in plan view,

4 shows a connection unit with an aluminum profile for cooling the bypass diodes in plan view,

5 shows a connection unit with an electronic circuit board in plan view,

6 shows a connection unit with an aluminum profile, which serves both for cooling and for mechanical protection, in perspective view,

7a shows the electrical connection between the connection lines of the solar generator and the connection unit in the case of a single-strand module,

Fig. 7b: the electrical connection between the connecting lines of the solar generator and the connection unit in a three-ring module.

1 a to 1 d show the modules of the connection system from which individually adapted connection units (also: MAPset, module connection point set) can be set up for any solar generators. The end modules 1 .1, 1 .2 (Fig. 1 a and Fig. 1 b) consist of a reinforcing ribs (not shown) provided plastic plate 2, in the edge either flat recesses 3 introduced with ball iger / mushroom-shaped cross-sectional area or at the edge of plate-shaped bulges 4 are formed (with a correspondingly mushroom-shaped cross-sectional area), which can be inserted into the recesses 3 (according to the principle of ball and pan).

The end modules 1 .1, 1 .2 each have a bore 5, which is used for contacting the connection lines of the solar generators, and connecting lines 6, via which the solar generators / connection units can be integrated in photovoltaic systems. In the middle of the modules and the recess 3 comprising a web-shaped thickening 7 is formed. Due to the ridge-shaped thickening 7, the bore 5 has a greater depth (than if it were in the surrounding plate), whereby a better grip for either a sealing plug (not shown) or for plugged-bypass modules 9 / electronic boards 16 is achieved. In addition, the mechanical stability of the module 1 is increased (for example, compared to bending). The intermediate modules 8 are like the end modules 1 .1, 1 .2, plate-shaped and have approximately their geometry, with the difference that they with two holes 5 (with the same geometry and function as in the end modules 1 .1, 1. 2) are provided, and the web-shaped thickening 7, which includes the two holes 5, is shorter.

The bypass modules 9 (Fig. 1 d) are U-shaped, wherein the two legs 10 of the U are provided with sealing rings 1 1 and inserted into the holes 5 (in the end modules 1 .1, 1 .2 and the intermediate modules 8) can be. By inserting the legs 10, the holes 5 are sealed watertight; At the same time an electrical connection between a arranged in the bypass module 9 bypass diode 12 and the end modules 1 .1, 1 .2 or intermediate modules 8 (not shown) arranged on the legs and in the holes contact elements.

For single-strand and thin-film modules, the terminal units used are in each case an end module + 1 .1 and an end module 1 .2 connected either with (FIG. 2 a) or without bypass module 9 / bypass diode 12 (FIG. 2 b) serially (in series) or with bypass module 9 / bypass diode 12 in parallel (FIG. 2C) are arranged to each other. The connection units are glued to the side of the solar generators for attachment to the solar generators (not shown) with their rear side (FIGS. 2a to 2c show the front side of the connection units, the rear side is the side concealed from the front side), at which the connection lines lead out or are exposed.

In order to set up connection units for two-string modules, an intermediate module 8 is in each case arranged between an end module + 1 .1 and an end module 1 .2, in three-string modules two intermediate modules 8 are arranged between two end modules 1 .1, 1 .2 (in the case of four-string modules, three intermediate modules 8, etc.). By inserting bypass modules 9, the end modules 1 .1, 1 .2 with the adjacent intermediate modules 8 and possibly adjacent intermediate modules 8 are electrically connected to each other, at the same time the holes are sealed. The end modules 1 .1, 1 .2 can be arranged either parallel to the intermediate modules 8 (FIG. 3 a), whereby a lateral Licher output of the connecting lines 6 is formed, or inserted at a 90 ° angle to the intermediate modules 8 (Fig. 3b), whereby a vertical output of the connecting lines 6 is formed.

To cool the bypass diodes 12 (in the bypass modules 9) of a connection unit, an aluminum profile 15 with cooling fins, which is in thermal contact with the bypass diodes 12, is arranged above the bypass modules 9 (FIG. 4).

For implementation of electronic circuits for monitoring, control and / or control of the solar generators, the connection unit is equipped with an electronic board 16 (shown in the drawing transparent), which also takes over the function of the bypass modules. In addition, the electronic board is equipped to protect it and protect the rest of the connection unit from mechanical damage with an aluminum profile that covers the entire electronic board 16 and virtually the complete connection unit (Fig. 5).

The use of an aluminum profile 17, which is provided on the one hand with cooling fins and on the other hand covers the complete connection unit (FIG. 6), achieves both mechanical protection of the connection unit and improved cooling of the bypass diodes. Such equipment of the connection units with aluminum profiles 16/17 enables UL certification.

For contacting the connection lines of the solar generators with connection elements 18, which are located in or below the holes 5 of the end modules 1 .1, 1 .2 or the intermediate modules 6, welded or soldered, and then the holes 5 with a leg 10 of a Bypass module 9 or with a correspondingly shaped plug (not shown) or plugged by attaching an electronic board 16 watertight. While in single-strand and thin-film modules, contacting takes place via the connection elements 18 of the end modules 1 .1, 1 .2 (FIG. 7a), multi-string modules also make contact via the connection elements 18 of the intermediate modules 6 (FIG. 7b). List of reference numbers used

1 .1 end module +

1 .2 end module

2 plastic plate

3 recess

4 bulge

5 hole

6 connection line

7 thickening

8 intermediate module

9 bypass module

10 legs of the bypass module

1 1 sealing ring / sealing element

12 bypass diode

15 aluminum profile for cooling

16 electronic board

17 Aluminum profile for cooling and mechanical protection

18 connection element

Claims

Patent claims

1 . Connection system for solar generators, which comprises several different modules, with the modules being able to be assembled into connection units that are used for the electrical contact of solar generators, and each connection unit having at least one end module (1.1) and one end module (1. 2) has,

- wherein the topology of the back of the end modules (1.1, 1.2) is adapted to the topology of that side of a solar generator on which the connection unit is intended to be mounted, whereby the backs of the end modules (1.1, 1.2) , can be attached to the relevant side of the solar generator without the formation of gaps,

- and the end modules (1.1, 1.2) each have at least one electrical connection element (18), which is used to establish electrical contact to at least one connection line of the solar generator, which is located on the side of the solar generator on which the Connection unit is provided, and each comprise at least one connecting element (6) which is used to integrate the connection unit into an associated photovoltaic system,

- whereby the geometry of the back of the end modules (1.1, 1.2) is selected such that the back can cover at least one opening in the solar generator, via which the at least one connecting cable can be reached,

- and the end modules (1.1, 1.2) have at least one hole (5) between the back and the front opposite it, the hole (5) being designed such that it enables access to the connecting element (18). , and the end modules (1.1), 1.2) can be mounted on the solar generator in such a way that at least one connection line can be connected from the front of the end modules (1.1, 1.2) to the associated connection element (18), wherein the bore (5) can be closed with a plug or by means of a bypass module (9) or by means of an electronic board (16), - and on the top and / or on the side walls of the end module (1 .2) as coupling elements recesses (3) and on the top and / or on the side walls of the end module + (1 .1) as coupling elements projections (4), which fit positively into the recesses (3), are shaped, whereby further modules can be plugged into the end modules (1.1, 1.2) by either inserting the at least one projection (4) of the end module+ (1.1) into a geometrically corresponding one Recess (3) in the further module or in at least one recess (3) of the end module (1.

2) a projection (4) of the further module is inserted.

Connection system according to claim 1, characterized in that the at least one projection (4) is formed in the shape of a plate, the flat surfaces of the plate running parallel to the underside of the module on which the at least one projection (4) is formed, the outline the at least one projection (4) has a straight section adjacent to the associated module, which is defined by two parallel boundary lines, and a curved section adjoining the straight section with a curved boundary line which connects the two straight boundary lines with one another, wherein the at least one recess (3) is arranged on the top of a module and has a flat bottom surface that runs parallel to the underside of the associated module, the geometries of the outline of the at least one recess (3) and the outline of the at least one projection (4) correspond to the extent that the

Projection (4) can be inserted in a form-fitting manner into the recess (3), the flat area of the outline of the recess

(3) ends with the lateral boundary line of the top of the associated module, whereby in addition to the recess in the top, a recess is also formed in one of the side walls.

Connection system according to claim 2, characterized in that the curved boundary line has the shape of a circular section.

4. Connection system according to one of claims 1 to 3, characterized in that the connection unit has an end module (1.1) and an end module (1.2), which are plugged together by means of the coupling elements (4, 5), and a bypass module - dul (9), wherein the bypass module is U-shaped, and the two legs (10) of the bypass module (9) have the shape of plugs that correspond to the shape of the holes (5) in the end modules (1 .1 , 1 .2) are adapted and which are provided with sealing elements (1 1), and the distance between the legs (10) of the bypass module corresponds to the distance between the two holes (5) in the assembled end modules (1 .1, 1 .2). , whereby the two bores (5) can each be closed watertight by means of a leg (10) of the bypass module (9) by plugging the bypass module (9) onto the two end modules (1.1, 1.2).

5. Connection system according to claim 4, characterized in that contact elements are installed both on each leg (10) of the bypass module (9) and in the bores (5) in the end modules (1.1, 1.2), whereby when plugging in of the bypass module (9) an electrical connection is established between a contact element of a leg (10) and the contact element of a bore (5), and in the bypass module (9) an electronic component that takes over the function of a bypass solution, and / or an electronic circuit is integrated, the electronic component or the electronic circuit being electrically connected to the two contact elements on the legs (10) of the bypass modules (9).

6. Connection system according to claim 5, characterized in that there is a bypass diode in the bypass module (9), the connections of which are electrically connected to one of the contact elements on the legs (10) of the bypass module (9).

7. Connection system according to one of claims 1 to 6, characterized in that the connection unit comprises an end module (1.1), an end module (1.2) and at least one intermediate module (8), the at least one intermediate module (8) is equipped with at least one coupling element (4, 5), which enables the at least one intermediate module (8) to be plugged together with end modules (1.1, 1.2) and/or other intermediate modules (8), and the topology of the The back of the at least one intermediate module (8) is adapted to the topology of that side of the solar generator to which the connection unit is intended to be mounted.

8. Connection system according to one of claims 1 to 7, characterized in that the intermediate modules (8) each have at least one bore (5), which is the at least one bore (8) in the end modules (1.1, 1.2). corresponds geometrically and functionally, wherein the intermediate module (8) can be plugged together with an end module (1.1, 1.2) and/or with another intermediate module (8) in such a way that the distance between two adjacent bores (5) corresponds to the Distance between the two legs (10) of a bypass module (9) corresponds, whereby the end modules (1.1, 1.2) and/or the intermediate modules (8) can be cascaded in parallel and/or serially by means of the bypass modules (9).

9. Connection system according to one of claims 1 to 7, characterized in that it has at least one electronic board (16) which can be plugged onto the end (1.1, 1.2) and intermediate modules by means of plugs attached to the electronic board (16). is, the plugs functionally corresponding to the legs (10) of the bridge modules (8), and on the one hand bypass solutions and on the other hand further electronic circuits are implemented on the electronic board.

10. Connection system according to one of claims 1 to 9, characterized in that the connection unit comprises a metal profile (15, 17) which can be arranged over at least one end module (1.1) and one end module (1.2), whereby mechanical protection of the connection unit and/or cooling of the electronic components contained in the connection unit is achieved.