AU2019202170A1 - A solar array assembly - Google Patents

Abstract

A SOLAR ARRAY ASSEMBLY A photovoltaic block array of photovoltaic panel modules is described. The array comprises one or more master photovoltaic sub-block array modules configured to be connected to a grid, the master photovoltaic sub-block array modules in cluding: a plurality of electrically-connected photovoltaic panels mounted on panel mounts; a plurality of inverters in electrical communication connected with one or more of the photovoltaic panels; a control cubicle connected to the inverters, the control cubicle including: a transformer for stepping up the voltage from the inverters to HV; at least one HV controller and an HV circuit breaker, configured to control generated power from the master photovoltaic sub-block array and one or more slave photovoltaic sub-block arrays; one or more slave photovoltaic sub-block array modules configured to be connected in se ries, the slave photovoltaic sub-block array modules including control cubicles which do not include an HV controller or an HV circuit breaker; wherein a first one of the one or more slave photovoltaic sub-block array modules is electrically connected to the master photovoltaic sub-block array downstream of the master photovoltaic sub-block array. Distribution Network Mine Site jSite Main SwitchroornIc2 (t T 416 1c 1)0 t Figure1

Description

A SOLAR ARRAY ASSEMBLY

1. Priority is claimed from associated Australian provisional patent application nos 2018901041, and 2018901040, and it is to be considered that the entirety of both documents, including their Appendices, are hereby incorporated in this specification by this reference to them.

TECHNICAL FIELD

2. The present invention generally relates to solar array assemblies and more particularly but not exclusively to solar array assemblies deployable in remote locations and sites that may be temporary in nature.

BACKGROUND ART

3. Modern societies are heavily reliant on electricity to function. Communities in isolated locales, such as mine sites, farmsteads and isolated villages are no exception. Given the expense involved in connecting remote communities to a power grid, there is demand for a cost-efficient means for creating a localised 'micro-grid'.

4. Remote communities are known to generate electricity using fossil fuel generators. Diesel generators in particular are a mature technology with a low capital cost. The systems are also relatively simple to transport, install, and to redeploy if need be. However, the main disadvantages of diesel power generation are in the operating cost - the price of diesel itself, combined with the costs of transporting it to the given remote community - and logistical challenges, which lead to high electricity costs. Furthermore, there has been a move away from fossil-fuel power generation and in the direction of renewable energy sources.

5. Renewable energy sources provide a clear advantage over fossil-fuel energy sources in that the operating cost is significantly lower and can reduce the reliance on fossil fuel logistics.

- 2 2019202170 28 Mar 2019

6. However, there are significant disadvantages associated with the most common renewable energy sources. Both wind turbines and photovoltaic panels currently represent a higher capital expenditure; they are 'stick built' and require higher site labour and equipment; they have greater planning and development time; the individual components are quite delicate; and it is generally not economically viable to relocate once installed. Both clean energy sources also typically require specialised hardware for installation as well as a large labour force that is not likely to be present in small, isolated communities, in areas of low socioeconomic status or in a multitude of other situations wherein the importation of fuel may be problematic, contributing to increased capital expenditure associated with importing the technical expertise.

7. Traditional design and construction methods for wind and photovoltaics mean they are not economically relocatable once installed - wind turbines are large and require large footings and heavy-duty crane equipment, and photovoltaic panels require placement into fixed ground mounting assemblies on site. However, there are situations wherein relocation of an electricity generating source may be beneficial. For example, mine sites will change location over time as older deposits are exhausted and new faces are opened; communities may need to relocate for reasons such as natural disasters; geographies with geopolitical challenges may become unattractive to asset owners; and settlements such as refugee camps may be forced to move due to changes in the local political situation. In this regard, diesel generators are better suited to relocation and/or recovery as they tend to be far more durable and require less permanent infrastructure to set up.

8. One particular characteristic of photovoltaic panels that inhibits their mobility is the sheer area and size involved. While the prior art does disclose many forms of highly mobile photovoltaic solar panel, these tend to be small, personal units for use during camping or travel for powering personal electronic devices. The size of photovoltaic panels that are for providing power to buildings or communities tend to be much larger in surface area. These large solar panels, designed for

- 3 2019202170 28 Mar 2019 power output on the scale of homes and businesses, must be transported in a gentle manner and require careful preparation. This further inhibits the ability for an installed photovoltaic system to be recovered and redeployed without extensive planning.

9. There are clear advantages to either electricity source. Photovoltaic panels provide electricity without requiring ongoing expenditure on fuel and have far less of an impact on the environment. Fossil fuel generators (such as diesel generators) are durable and are widely available in compact, portable forms that are simple to deploy and relocate.

10. However, there are also disadvantages to utilising either power source. The present technology seeks to provide a large scale solar array, and/ or mountings and components therefor, that ameliorates at least one of the abovementioned disadvantages.

DISCLOSURE OF THE TECHNOLOGY

11. In one broad form the technology provides a modular photovoltaic system that is adapted to provide power on a utility scale as opposed to a personal device scale, yet can be deployed, demounted and redeployed as necessary.

12. The objective of the technology is to broadly provide a photovoltaic array for a photovoltaic panel module and a controller network suitable for use in a photovoltaic array.

13. In accordance with one aspect of the present invention there is provided a photovoltaic block array of photovoltaic panel modules, the block array comprising:

one or more master photovoltaic sub-block arrays configured to be connected to a grid;

one or more slave photovoltaic sub-block arrays configured to be connected in series;

wherein a first one of the one or more slave photo2019202170 28 Mar 2019

- 4 voltaic sub-block arrays is configured to be connected in series to the master photovoltaic sub-block array.

14. In one embodiment one of the sub-block array assemblies is configured to generate up to 100MW of power.

15. In one embodiment one of the sub-block array assemblies is configured to generate up to 10MW of power.

16. In one embodiment the master sub-block array is configured to generate up to 1MW of power.

17. In one embodiment one of the slave sub-block arrays is configured to generate up to 90MW of power.

18. In one embodiment one of the slave sub-block arrays is configured to generate up to 9MW of power.

19. In one embodiment one of the one or more slave sub-block arrays includes a plurality of photovoltaic modules, wherein one of the plurality of photovoltaic modules includes a plurality of photovoltaic module arrays.

20. In one embodiment a photovoltaic module array includes a plurality of photovoltaic panels.

21. In one embodiment the photovoltaic module array is electrically connected together.

22. In one embodiment the photovoltaic module array is demountable and is configured to be mounted on a mounting system substantially as described in the Appendix.

23. In one embodiment each sub-block array includes a plurality of invert- ers.

- 5 2019202170 28 Mar 2019

24. In one embodiment each sub-block array includes a substation. In one embodiment the master sub-block array substation is configured to connect to a ring main. In one embodiment the master sub-block array substation configuration includes HV metering and circuit-breaker protection.

25. In one embodiment the one or more slave sub-block arrays are configured to connect in series to the master sub-block array.

26. In one embodiment the slave blocks do not include HV metering and circuit-breaker protection.

27. In one embodiment the master sub-block arrays are configured to protect and convert the output from up to fifty slave sub-block arrays to that which is acceptable to a ring main.

28. In one embodiment the master sub-block arrays are configured to protect and convert the output from up to ten slave sub-block arrays to an output that is acceptable to a ring main.

29. In accordance with one aspect of the present technology there is provided a controller system for use in a photovoltaic panel array, the controller system including a plurality of controllers including a master controller and one or more slave controllers wherein the slave controller is connected to the master controller when the photovoltaic panel array provides more than 1MW of power.

30. In one embodiment there is provided a generator controller configured to be attached to respective non-renewable power generators and energy storage units.

31. In accordance with one aspect of the present technology there is provided a system for selecting a cable characteristic, the system including a computing processor which comprises a cable characteristic selection

- 6 2019202170 28 Mar 2019 engine configured to receive data relating to a solar photovoltaic panel array, including type and configuration of components in the array, and automatically select cable characteristics.

32. In one embodiment an output of the selection engine includes data relating to a distance between components of the solar photovoltaic array.

33. In one embodiment an input to the selection engine includes data relating to a distance between components of the solar photovoltaic array.

34. In one embodiment the input to the engine includes data relating to the plurality and characteristics of components in the array such as for example, number and arrangement of master sub-block arrays, number of slave sub-block arrays, arrangement of subs-block arrays.

35. In one aspect the present invention provides a method for optimising cable size and capacity, the method including the steps of receiving in a computing processor which comprises a cable characteristic selection engine, data relating to a solar photovoltaic panel array, including type and configuration of components in the array, and automatically select cable characteristics, processing the data to select an optimal cable for the type and configuration of components in the array.

36. In a third aspect, the present invention provides a computing program that includes at least one instruction, which, when executed on a computing system, performs the method steps in accordance with the abovementioned aspect of the invention.

37. In a fourth aspect, the present invention provides a computer readable medium incorporating a computer program in accordance with the abovementioned aspect of the invention.

38. In accordance with another aspect of the present invention there is provided a controller kit suitable for use in a photovoltaic panel array, the controller comprising:

- 7 2019202170 28 Mar 2019 a set of one or more master photovoltaic sub-block array controllers, the one or more master controllers being configured to be in electrical communication with a respective master photovoltaic subblock array for controlling the output of the master photovoltaic subblock array;

a set of one or more slave sub-block array controllers, one or more being configured to be in electrical communication with a slave photovoltaic sub-block array, the slave sub-block array controller being configured to receive and execute commands from the master photovoltaic sub-block array controller, wherein the set of one or more of the sub-block arrays includes a master photovoltaic sub-block array controller and one or more slave photovoltaic sub-block array controllers, such that a first one of the one or more slave photovoltaic sub-block arrays is configured to be connected to the master photovoltaic sub-block array.

39. In one embodiment the controller kit includes a network controller configured to electrically communicate with an external electrical grid connection.

40. In one embodiment the controller kit includes a generator controller connected with a non-photovoltaic electrical generator.

41. In one embodiment there is provided an energy storage controller.

42. In one embodiment, a regulation or stabilisation module is provided which in use controls the use of energy storage in anticipation of either variations in demand or power generation.

43. In one embodiment, the regulation or stabilisation module controls the use of non-photovoltaic power generation in anticipation of either variations in demand or power generation.

44. A method for modular installation of a controller network suitable for use in a photovoltaic array comprising the steps of:

- 8 BRIEF

45.

46.

47.

48.

49.

connecting a set of one or more master photovoltaic subblock array controllers to a master photovoltaic sub-block array for controlling the output of the master photovoltaic sub-block array;

connecting a set of one or more slave sub-block array controllers to one or more slave photovoltaic sub-block arrays, the slave sub-block array controller being configured to receive and execute commands from the master photovoltaic sub-block array controller, wherein the set of one or more of the sub-block arrays includes a master photovoltaic sub-block array controller and one or more slave photovoltaic sub-block array controllers, such that a first one of the one or more slave photovoltaic sub-block arrays is configured to be connected to the master photovoltaic sub-block array.

DESCRIPTION OF DRAWINGS

Figure 1 shows a plan view of a site to which an embodiment of the present invention is deployed;

Figure 2 shows an aerial view of a site to which an embodiment of the present invention is deployed;

Figure 3 shows several optional connection configuration embodiments of the present invention;

Figure 4 is a schematic view of interconnection of photovoltaic sub-block array substations in accordance with an embodiment of the present invention;

Figure 5 shows a schematic (detail view of a portion of Figure 4) showing the configuration of a master photovoltaic sub-block array substation in accordance with a component of an embodiment of the present invention;

- 9 2019202170 28 Mar 2019

50. Figure 6 shows a further detailed schematic view of the arrangement of a master photovoltaic sub-block array substation in accordance with a component of an embodiment of the present invention;

51. Figure 7 shows the arrangement of a master sub-block array controller and electrical topography arrangement in accordance with a component of an embodiment of the present invention;

52. Figure 8 shows a schematic arrangement of a slave photovoltaic subblock array substation in accordance with a component of an embodiment of the present invention;

53. Figure 9 shows the arrangement of a slave sub-block array controller in and electrical topography of same in accordance with a component of an embodiment of the present invention;

54. Figure 10 shows the arrangement of a network monitor in accordance with a component of an embodiment of the present invention;

55. Figure 11 shows the arrangement of a generator controller in accordance with a component of an embodiment of the present invention;

56. Figures 12A to 12F show different controller arrangements in accordance with embodiments of the present invention; and

57. Figures 13 and 14 show an output of a cable characteristic selection algorithm which is part of an embodiment of the present technology.

DETAILED DESCRIPTION OF AN EMBODIMENT

58. In this specification, unless the context clearly indicates otherwise, the term comprising has the non-exclusive meaning of the word, in the sense of including at least rather than the exclusive meaning in the sense of consisting only of. The same applies with corresponding

2019202170 28 Mar 2019

- ίο grammatical changes to other forms of the word such as comprise, comprises and so on.

59. Those skilled in the art will appreciate that the embodiments described herein are susceptible to obvious variations and modifications other than those specifically described and it is intended that the broadest claims cover all such variations and modifications.

60. Where definitions for selected terms used herein are found within the detailed description of the invention, it is intended that such definitions apply to the claimed invention. However, if not explicitly defined, all scientific and technical terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the invention belongs.

61. Referring to the drawings, Figure 1 illustrates the application of a demountable, movable and modular photovoltaic or microgrid system 100 for the generation of power for a mine site 102. The photovoltaic block array includes one or more photovoltaic sub-block array assemblies. A photovoltaic sub-block array assembly includes at least a master photovoltaic sub-block array 104 and optional slave photovoltaic sub-block arrays 106. The photovoltaic block array may include up to ten, twenty, thirty or forty sub-block array assemblies, each sub-block array assembly including a master sub-block arrays and an optional plurality of slave sub-block arrays.

62. It can be seen that there may be up to nine slave sub-block arrays connected to each master sub-block array in the embodiment shown. Each sub-block array is 1MW in generation capability but it is contemplated that the sub-block arrays may be configured to be 0.5MW, 2MW, 3MW, 5MW, or other sizes.

63. The second and further subsequent photovoltaic sub-array modules are slave photovoltaic sub-arrays 106. The slave photovoltaic sub-ar-

	ray modules 106 are connected to the master photovoltaic sub-array 104 in a high voltage circuit.
64.	Each master photovoltaic sub-array 104 and slave photovoltaic subarray 106 will have a series of Direct Current (DC) to Alternating Current (AC) inverters 107 which convert the DC current generated by the photovoltaic sub-array to AC current.
65.	An embodiment may include multiple photovoltaic arrays connected in a parallel circuit, where each of the photovoltaic arrays includes one master photovoltaic sub-array and one or more slave photovoltaic sub-arrays.
66.	The master photovoltaic sub-array 104 includes a master sub-block array controller 108, connected thereto for controlling the output of the master photovoltaic sub-block array 104. The master sub-block array controller 108 also communicates with a slave sub-block array controller 110, itself connected to a slave photovoltaic sub-array 106, where the operation of the slave photovoltaic sub-array is controlled by the slave sub-block array controller 110 by executing the commands received from the master photovoltaic sub-array controller 108.
67.	The master sub-array controller 108 and slave sub-array controller 110 communicate via a communication link 112, which connects all controller modules in the microgrid system 100. In the embodiment shown, the communication link 112 encircles the boundary of microgrid system 100 and consists of a fibre optics communication network. However, such an embodiment is purely for demonstrating the workings of the invention, and as such, other modes of network communication and arrangements are contemplated such as coaxial cable or wireless network connections.
68.	The fibre optic communication link 112 also may connect to a generator controller 114 connected with a non-photovoltaic electrical gener-

- 12 2019202170 28 Mar 2019 ator 116, such as a fossil fuel electrical power generator. The generator controller 114 controls the operation of the generator 116, and controls the level of power generation. This is also used to monitor the sources of generation in the Microgrid to ensure the PV plant supplies appropriate amounts of power to prevent any detrimental effect

69. The fibre optics communication link 112 also may connect to a network monitor 118. The network monitor 118 is in communication with an external electrical grid connection 120 and monitors the grid conditions of power flow.

70. The master sub-block array controller includes a regulation engine which, through a communication link, is in communication with at least the slave controller(s), network controller, and generator controller and controls the operation of each of the controllers in accordance with selected algorithms disposed in its memory.

71. The regulation engine includes a plurality of modules which are configured to receive external sensor data related to one or more external events, and then autonomously determine the commands to be issued to the controller network in order for the microgrid system to respond or adjust to the one or more external events.

72. Due to the modular nature of the microgrid system, individual modules of the regulation engine can be switched partially on or off, or added, removed or scaled in a modular fashion in response to external events that affect the microgrid system.

73. The modules of the regulation engine shown include a Control and monitor module, an Environmental module, and a Stabilisation module. The various modules may be combined or applied in the various embodiments as set out below. Effectively, for each individual source of generation on site there is a monitor. That monitoring information is then fed back to the master sub-block array controller which ad-

- 13 2019202170 28 Mar 2019 justs the output of the inverters such that the power exported does not cause substantial problems in the rest of the network.

Control and monitor module

74. The Control and monitor module controls renewables to seek to achieve a condition that the maximum power point on the inverters is controlled to curtail output in the event that there is insufficient demand or spinning reserve within the microgrid system. Additionally, the Control and monitor module also monitors any generators connected to the microgrid to ensure that there is sufficient spinning reserve to enable the system to respond to an external event, wherein the spinning reserve is the extra generating capacity available to be provided by increasing the power output of generators connected to the microgrid. This allows generators to operate at peak efficiency for longer, increasing fuel efficiency and asset life and to improve the power response by reducing high ramp events relatively small energy capacity systems, such as lithium-ion power batteries and small flywheels. The Control and monitor module sends instructions to the master sub-array controller to adjust photovoltaic power generation in the slave sub-block arrays and/or the master sub-block arrays in relation to the external event.

Environmental module

75. The Environmental module monitors environmental conditions relevant to photovoltaic power generation and anticipates future variation in power generation or power demand. The Environmental module may also communicate with the generator controllers and sends instructions to the generator controllers to turn them on and off in response to environmental conditions. For example, the Environmental module may include a skyward directed light sensor or camera for cloud monitoring is used detect and to predict cloud movement and lighting conditions in order to anticipate variations or fluctuations in photovoltaic power generation. When anticipating variations or fluctuations in photovoltaic power generation, the Environmental module sends instructions to the generator controller to turn on the genera-

- 14 2019202170 28 Mar 2019 tors. Additionally, due to the predictive features of the module, the generator is provided with instructions in advance of the change in sunlight which allows the generators to slowly increase or decrease the torque required to accommodate the change without changing the overall power generated by the microgrid. This also reduces the required spinning reserve demands placed on the generators.

Master Controller modules

Stabilisation module application for small-scale grids

76. The Stabilisation module controls the operation of additional supply of dispatchable power in anticipation of either variations in demand or power generation. As such the Stabilisation module manages the combination of power supply from the different sources in the microgrid. For example, when connected to a small-scale external grid including a thermal power station, the Stabilisation module balances the different sources of power on the microgrid to seek to achieve a condition wherein the power on the external grid is stable and the spinning reserve requirement of the thermal power plant is reduced.

Stabilisation module application for supply matching

77. The Stabilisation module may also automatically match power demand to the renewable power sources based on their supply capacity. For example, when a small fluctuation of power is anticipated for a grid including multiple photovoltaic arrays of different generating capacities, the Stabilisation module will communicate with the master sub-array controllers to switch up or switch down the power supplied by the sub-arrays to match the current and anticipated photovoltaic array power generation to the magnitude of the power fluctuation. The client can send a command for the photovoltaic block array to ramp down (known as a curtailment event) by reducing output from the inverters if they are in a low load scenario.

Stabilisation module application for large scale grids

78. In another example, when the microgrid is part of a grid-connected site with local thermal power generation, the Stabilisation module balances the different sources of power on the microgrid to seek to provide that the

- 15 2019202170 28 Mar 2019 power to the grid is stable, where energy storage is used for grid stabilisation rather than any thermal plant response, without compromising grid stability. In such cases, the thermal plant can be turned off in during the daytime operation, and some night time operation, of the microgrid.

Stabilisation module application for reduction of use of thermal plant

79. In another example, when the microgrid is connected to a grid which includes a thermal power plant, the Stabilisation module manages an increase of generation and storage capacity to entirely replace thermal plant during day and some night operations.

Stabilisation module application for removal of thermal plant

80. In another example, when the microgrid is connected to a grid which includes a thermal power plant, the Stabilisation module manages an increase in generation and storage capacity to entirely replace thermal plant at all times. In this example, thermal plant is no longer needed for the supply of power to the grid.

81. Referring to Figure 2, there is provided an example of a layout 200 for implementing the different stages of implementation of the above controller modules and their applications. Stage 1 202, includes a single master photovoltaic sub-array. There are nine slave photovoltaic sub-arrays 204.

82. The implementation and layout may be varied or staged to suit the individual demands placed on the microgrid.

83. Furthermore, due to the modularity of the modules and their applications, different permutations or combinations of the modules or applications may be combined in order to suit a specific demand on the microgrid. The stages provided above are merely an example application to demonstrate the workings and modular features of the invention.

84. Figure 3 provides a further example layout 300 of the integration of three different integration embodiments of photovoltaic arrays with a thermal power station 302. Such layouts may be used when the Stabilisation mod-

- 16 2019202170 28 Mar 2019 ule is applied in applications where the grid includes a thermal power station.

85. Accordingly, the arrangement shown in Figure 3 may include a power station which includes a HV ring main connection or busbar 304, which is a metallic strip for local high voltage power distribution along multiple circuits at one distribution point. A first integration option 306 is connected to the HV ring main 304, where the integration embodiment is similar to a stage two implementation including a slave photovoltaic sub-array 308 in series with the master photovoltaic sub-block array 310. A transformer is also provided to transform the voltage generated by the PV arrays. Each of the master and slave photovoltaic sub-block arrays includes a DC/AC inverter 312 and a respective master sub-array controller 314 or slave subarray controller 316, wherein the photovoltaic array is directly connected to the HV ring main via one or more safety elements, such as a circuit breaker, plug-in circuit breaker, fuse or switch or a combination of safety elements. Due to the modularity of the invention, it is likely that the circuit breaker and or fuse may be a plug-in style.

86. Alternatively, another integration embodiment is shown at 318, akin to the application described in stage one, where a single master photovoltaic sub-array 320 is connected to the HV ring main 304 via a DC/AC inverter 322 and a second Low voltage bus bar 324. The second bus bar 324 may include one or more load devices, such as a motor 326 and may be formed as part of a Low Voltage main switch board (LV -MSB). The connection between the two HV ring mains may also include a transformer to vary the alternating current generated by the photovoltaic array and a safety element such as a circuit breaker, plug in circuit breaker, fuse or switch or a combination of safety elements.

87. A further integration embodiment is provided at 328, which is similar to a stage two implementation, whereas 328 includes a slave photovoltaic subarray (not shown) in parallel with the master photovoltaic sub-array 332. A transformer 333 is provided to vary the alternating current generated by the photovoltaic arrays. Each of the master and slave photovoltaic sub-ar-

- 17 2019202170 28 Mar 2019 rays include a DC/AC inverter 334 and the respective master sub-array controller 332 or slave sub-array controller (not shown), wherein the photovoltaic array is connected in parallel with one or more load elements 336, such as a motor or compressor, wherein that circuit is connected to the HV ring main via one or more safety elements, such as a circuit breaker, plug in circuit breaker, fuse or switch 337 or a combination of those safety elements. Due to the modularity of the invention, it is considered advantageous that the circuit breaker and or fuse be a plug-in style.

88. Figure 4 shows an embodiment of a photovoltaic array 400 including a master photovoltaic sub-array 402 connected in series to nine slave photovoltaic sub-arrays 404. The arrangement shown in Figures 1, 2, 3 and 4 is described in more detail in the associated Australian provisional patent application no 2018901041, in the Appendix, the entirety of which is incorporated by this reference to it here. At a high level, the circuitry for both master and slave photovoltaic arrays are similar.

89. More detail of the modular PV array arrangement is shown in Figure 5, wherein, only the master photovoltaic array connections (and panels, inverters and combiner boxes) are shown. They include a low voltage cubicle 502 and a high voltage cubicle 504, connected by a transformer 503 to shift up the voltage. There is also one or more protection elements 514 in the HV cubicle, a power meter 506 in the low voltage cubicle, and one or more photovoltaic arrays 508, each with their respective inverter 509. This is connected to a high voltage connection 510 via the one or more safety elements 514.

90. The differences between the master photovoltaic sub-array and slave photovoltaic sub-array are more clearly illustrated in Figures 6 to 9. In Figure 6, there is provided a more detailed technical schematic of an example of a master photovoltaic array block 600 which includes a connection to a HV ring main 602, which connects the photovoltaic arrays 604 and their respective inverters. The output energy is provided to the high voltage connection point 622; the master photovoltaic array 600 is also connected in series at 606 to any slave photovoltaic sub-arrays.

- 18 2019202170 28 Mar 2019

91. The photovoltaic arrays 604, and their respective inverters, are connected to the low voltage circuit 610, which may form part of the LV-MSB (main switchboard). The low voltage circuit 610 also includes a plurality of secondary modules, including Low Voltage Control and Meter 612, High Voltage Control, Protection and Power Quality 614, Communications system 616, and Distribution Network Service Provider 618. Basically, the comms/ control equipment is powered from that main switchboard, as well as any metering/monitoring equipment the client may want to install. The low voltage circuit 610 is connected to the high voltage connection point 606 via a LV/MV transformer 620, which is isolated by means of the High Voltage Ring Main Unit (HV-RMU) 622, which is a modular, prefabricated set of enclosed switches, which include three switch settings; open, closed and earth.

92. Further detail on the master sub-block array circuitry is provided in Figure 7, which is located inside the compact secondary substation (CSS) 700. The inverters 702 connected to each photovoltaic sub-array are all in communication with each other and a Human Machine Interface (HMI) and Industrial Personal Computer (IPC) 712 via an electrical interface. The inverters 702 are also connected to the master sub-array controller 706 using an electrical interface, wherein the electrical interface described the electrical characteristics of drivers and receivers used in serial communication. For example, the electrical interface may include, but is not limited to the standard interface RS-485 over twisted pair in a bus configuration. Electrical interfaces, such as RS-485 do not require a particular communication protocol. However, for the purpose of illustrating the workings of the invention, the inverters 702 communicate with the HMI and IPC 712, and the master sub-array controller 706 using the Aurora and Mod-bus communication protocols respectively.

93. Both the HMI and IPC 712, and the master sub-array controller 706, are connected to an Ethernet switch 708 which enables the transmission of data packets from any device connected to a port on the Ethernet switch 708 to any other port without any interference. The Ethernet switch 708

- 19 2019202170 28 Mar 2019 may also be connected to one or more protection elements or earth terminals 710.

94. The Ethernet switch 708 is connected to the communications link, which connects the master sub-array controller to the rest of the controller network for the microgrid, which enables the transmission of data to and from the other controllers on the controller network and allows the master subarray to receive commands from the network controller and provide commands to the one or more slave sub-array controllers.

95. Moreover, the Ethernet switch 708 is also in communication with an analytics IPC 714 for data collection, analytics and monitoring, which may be further connected to a data logging device or other sensor 715, such as but not limited to a weather station for the collection of data related to environmental conditions related to the generation of photovoltaic power. In operation, a camera detects clouds moving overhead towards the array 700 and then ramps the inverters down 702 ahead of time so there isn't a sudden of loss of power; instead it is a gradual decline. The Ethernet switch may also be connected to one or more protection elements or earth terminals 710. Moreover, additional features may be provided and connected to the master sub-array controller 706, such as safety sensors such as CSS internal temperature sensors 716, or a revenue grade meter 718, which measures the power produced and subsequently billed to a client.

96. Figure 8 provides an embodiment of an example of circuitry layout for a slave photovoltaic sub-array 800. Unlike the master sub-array controller, the slave sub-array controller does not include the same level of system intelligence or complexity. The master sub-array circuits include HV control, and HV switchgear, whereas the slave sub-array controller does not include that functionality. An advantage this provides is lower cost and reduced installation time when increasing capacity of the solar array.

97. So, the slave photovoltaic sub-array 800 includes a HV ring main connection 802, which connects the photovoltaic array 804 and their respective inverters to the HV ring main. Each slave photovoltaic sub-array 800 is

- 20 2019202170 28 Mar 2019 connected to either the master photovoltaic sub-array upstream, or a further slave photovoltaic sub-array at connection points 806.

98. The photovoltaic arrays 804, and their respective inverters, are connected to the low voltage circuit 808, which may form part of the LV-MSB (main switchboard). The low voltage circuit 808 may also include Low Voltage Control and Metering module 810. The other secondary modules included in the master photovoltaic sub-array are not provided in the slave photovoltaic sub-array. The low voltage circuit 808 is connected to the connection points 804 via a LV/MV transformer 812.

99. Further detail on the slave sub-array circuitry is provided in Figure 9, which is located inside the local control panel 900 (which is part of the LV control and metering 901), which is removably attachable to the slave photovoltaic sub-array. The inverters 902 connected to each photovoltaic sub-array are all in communication with each other and a computer 904, such as a temporary laptop which is used during commissioning, wherein the installer plugs it in to configure local settings on the controller. The laptop is connected via an electrical interface. The inverters 902 are also connected to the slave sub-array controller 906 using an electrical interface, wherein the electrical interface described the electrical characteristics of drivers and receives used in serial communication. For example, the electrical interface may include, but is not limited to the standard interface RS-485 over twisted pair in a bus configuration. Electrical interfaces, such as RS-485 do not require a particular communication protocol. However, for the purpose of illustrating the workings of the invention, the inverters communicate with the computer 904, and the slave sub-array controller 906 using the Aurora and Modbus communication protocols respectively.

100. Both the computer 904, and the slave sub-array controller 906 are connected to an Ethernet switch 908 which enables the transmission of data packets from any device connected to a port on the Ethernet switch 908 to any other port without any interference. The Ethernet switch 908 may also be connected to one or more protection elements or earth terminals 910.

101. Moreover, additional features may be provided and connected to the master sub-array controller 906, such as safety sensors such as CSS internal temperature sensors 912, or a revenue-grade meter.

102. The Ethernet switch 908 is connected to the communications link, which connects the slave sub-array controller to the rest of the controller network for the microgrid, which enables the transmission of data to and from the other controllers on the controller network and allows the slave subarray to receive commands from the master sub-array controller.

103. In Figure 10, an embodiment is provided where the controller network for the microgrid includes a network controller. The network controller may be housed in a network local control panel 1000 at or proximate to the junction between the microgrid and the external grid. The network controller 1002 is connected to an existing metering device 1004, to interface with the existing grid monitoring equipment and an Ethernet switch 1006. The network controller monitors the grid when a grid is connected thereto.

104. The Ethernet switch 1006 is connected to the communications link 1008, which connects the network controller to the rest of the controller network for the microgrid, which enables the transmission of data to and from the other controllers on the controller network and enables the network controller to send commands to the other controllers in accordance with the optimization rules determined by the hybridisation engine. The hybridisation engine is described in more detail in a co-pending patent application entitled A system and method for monitoring and controlling a hybrid power supply arrangement, filed by Sunshift Pty Ltd, which is fully incorporated herein by reference as if reproduced in full herein.

105. In Figure 11, an embodiment is provided where the controller network for the microgrid includes one or more generator controllers, for each generator connected to the microgrid. In the embodiment shown, two generator controllers 1102 and 1104 are provided corresponding to two generators 1105 and 1106, wherein each generator controller may be housed in a generator local control panel 1100, at or proximate to the generators con-

- 22 2019202170 28 Mar 2019 nected to the microgrid. In the embodiment described, two generators 1104 and 1106 are provided. However, as would be understood by the person skilled in the art, any number of generators may be provided.

106. The generator controllers 1102 and 1104 are both connected to an Ethernet switch 1006. The Ethernet switch 1006 is connected to the communications link 1110, which connects the generator controller to the rest of the controller network for the microgrid, which enables the transmission of data to and from the other controllers on the controller network and enables the generator controllers to receive commands from the network controller in accordance with the optimization rules determined by the hybridisation engine.

107. Due to the modularity of the controllers on the microgrid network, many different network configurations are facilitated and contemplated. The flexibility of such a system is advantageous in providing a great deal of flexibility in order to overcome unconventional operational environments or power demands. Accordingly, a number of different arrangements of controllers is provided. However, the following examples are for the purpose of demonstrating the workings of the invention, and the arrangements provided are not taken to be limiting as all possible arrangements and permutations of the modules are contemplated within the working of the present invention.

108. Figure 12A provides an embodiment showing a first arrangement of the microgrid controller network 1200, including a master sub-block array controller 1202 and generator controller 1204 linked by communication link 1206. This arrangement is advantageous when there is thermal generation on site.

109. Figure 12B provides a further embodiment showing a further arrangement of the microgrid controller network 1208, including a master sub-block array controller 1210 and generator controller 1212 linked by communication link 1214. This arrangement is advantageous when the system is feeding power direct to the grid.

- 23 2019202170 28 Mar 2019

110. Figure 12C provides a further embodiment showing a further arrangement of the microgrid controller network 1216, including a master sub-array controller 1218, generator controller 1220 and network controller 1222 linked by communication link 1224. This arrangement is advantageous when there is a grid connection but it is unreliable (often the case in remote areas) and they perform some generation locally

111. Figure 12D provides a further embodiment showing a further arrangement of the microgrid controller network 1224, including a master sub-block array controller 1228, a slave sub-array controller 1230, a generator controller 1232 and a potential future energy storage controller 1234, where the potential future energy storage controller 1234 may be housed in an energy storage local control panel on or proximate to a energy storage device such as a battery, wherein each of the controllers is linked by communication link 1238. When the overall percentage of solar power in a power generation mix gets higher, this arrangement is beneficial to provide storage for stability reasons.

112. Figure 12E provides a further embodiment showing a further arrangement of the microgrid controller network 1240, including a master sub-block array controller 1242, a slave sub-block array controller 1244, a network controller 1246 and a potential future energy storage controller 1248 linked by communication link 1250. This arrangement is advantageous when we want to feed into the grid but with storage to boost overall output (i.e. if we are curtailed by the grid we can put some of that power into the battery to export later).

113. Figure 12F provides a further embodiment showing a further arrangement of the microgrid controller network 1252, including a master sub-block array controller 1254, a slave sub-block array controller 1256, a generator controller 1258, a network controller 1260, and a potential future energy storage controller 1262 linked by communication link 1264. This is advantageous when all the situations in Figures 12A to E are combined.

- 24 2019202170 28 Mar 2019

ADVANTAGES

114. The features of the present invention provide a number of advantages, including single point connection to grid and reduced cost and complexity. Firstly, the modularity of the microgrid allows for the microgrid to be set up in any configuration to suit any difficult site, or around existing fixed equipment or plants. This allows for easy integration within existing operations, especially in cases where a staged renewable energy solution is desired to be implemented without experiencing any period of shut down for the operation. This is particularly useful for remote mine sites who cannot afford to experience downtime that would be required to set up non-modular conventional microgrid systems.

115. Secondly, the modular nature of the system facilitates prefabrication off site which minimizes set up time and improves quality control. It also allows for easy and efficient repairs as different modules and controllers are removable such that if any modular component breaks, repair and restoring the operational capacity merely requires changing the broken component. It also provides for efficient debugging of the system due to the modular nature of the interacting components and modules.

116. Thirdly, the modularity of the microgrid provides commercially advantageous scalability such that additional modules and functionalities are added or removed only once they are needed. For example, when in the initial stages, the microgrid may only include a single master photovoltaic sub-array, and a stabilization module is not required. However, as the system grows, the modules are specifically designed to automatically address the issues of complex modular systems and managing a grid with multiple different power sources and loads that have different capacities throughout their period of use, for example photovoltaic units at night.

117. Finally, the analytical and predictive capability of the microgrid controller system allows for the optimization of the output and deployment of elements of the microgrid system which reduces wear on generator and load components by seeking to provide that power supply fluctuations are min-

- 25 2019202170 28 Mar 2019 imized and the microgrid remains stable. It also reduces wear from insufficient spinning reserves and inefficient run cycles.

CLARIFYING DEFINITIONS

118. Those skilled in the art will appreciate that the embodiments described herein are susceptible to obvious variations and modifications other than those specifically described and it is intended that the broadest claims cover all such variations and modifications. Those skilled in the art will also understand that the inventive concept that underpins the broadest claims may include any number of the steps, features, and concepts referred to or indicated in the specification, either individually or collectively, and any and all combinations of any two or more of the steps or features may constitute an invention.

119. Where definitions for selected terms used herein are found within the detailed description of the invention, it is intended that such definitions apply to the claimed invention. However, if not explicitly defined, all scientific and technical terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the invention belongs.

120. It will also be appreciated that where methods and systems of the present invention and/or embodiments are implemented by computing systems or partly implemented by computing systems then any appropriate computing system architecture may be utilised without departing from the inventive concept. This includes standalone computers, networked computers and dedicated computing devices that do not utilise software as it is colloquially understood (such as field-programmable gate arrays).

121. Where the terms computer, industrial personal computer, controller and sensor are used in the specification, these terms are intended to cover any appropriate arrangement of computer or electrical hardware for implementing the inventive concept and/or embodiments described herein.

- 26 2019202170 28 Mar 2019

122. Where reference is made to communication standards, methods and/or systems, it will be understood that the devices, computing systems, servers, etc., that constitute the embodiments and/or invention or interact with the embodiments and/or invention may transmit and receive data via any suitable hardware mechanism and software protocol, including wired and wireless communications protocols, such as but not limited to second, third and fourth generation (2G, 3G and 4G) telecommunications protocols (in accordance with the International Mobile Telecommunications-2000 (IMT-2000) specification), Wi-Fi (in accordance with the IEEE 802.11 standards), Bluetooth (in accordance with the IEEE 802.15.1 standard and/or standards set by the Bluetooth Special Interest Group), or any other radio frequency, optical, acoustic, magnetic, or any other form or method of communication that may become available from time to time.

123. The present technology also includes aspects and embodiments and features described and disclosed in the attached Appendix, which should be read in conjunction with this specification.

Claims (31)

The claims defining the invention are as follows:

1. A photovoltaic block array of photovoltaic panel modules, the array comprising:

one or more master photovoltaic sub-block array modules configured to be connected to a grid, the master photovoltaic sub-block array modules including:

a plurality of electrically-connected photovoltaic panels mounted on panel mounts;

a plurality of inverters in electrical communication connected with one or more of the photovoltaic panels;

a control cubicle connected to the inverters, the control cubicle including:

a transformer for stepping up the voltage from the inverters to HV;

at least one HV controller and an HV circuit breaker, configured to control generated power from the master photovoltaic sub-block array and one or more slave photovoltaic sub-block arrays;

one or more slave photovoltaic sub-block array modules configured to be connected in series, the slave photovoltaic sub-block array modules including control cubicles which do not include an HV controller or an HV circuit breaker;

wherein a first one of the one or more slave photovoltaic sub-block array modules is electrically connected to the master photovoltaic sub-block array downstream of the master photovoltaic sub-block array.

2. The photovoltaic block array in accordance with claim 1 wherein there are provided 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 slave photovoltaic sub-block array modules of about 1MW each.

3. The photovoltaic block array in accordance with claim 1 or 2 wherein the photovoltaic module array is demountable and includes a base upon which is mounted a plurality of photovoltaic panels.

4. The photovoltaic block array in accordance with claim 1, 2 or 3 wherein each slave sub-block array includes a plurality of inverters.

5. The photovoltaic block array in accordance with any one of claims 1 to 4 wherein the master sub-block array HV controllers are configured to protect and convert the output from up to fifty slave sub-block arrays to that which is acceptable to a ring main.

6. The photovoltaic block array in accordance with any one of claims 1 to 5 wherein the HV controller in the master photovoltaic sub-block array module includes a regulation engine which is in electrical or wireless communication with at least the slave photovoltaic sub-array module, to control the operation of each of the sub-block array modules in accordance with selected algorithms.

7. The photovoltaic block array in accordance with any one of claims 1 to 6 wherein the regulation engine includes a plurality of control modules.

8. The photovoltaic block array in accordance with any one of claims 1 to 7 wherein the HV controller also monitors and controls one or more generators connected to the microgrid to seek to provide sufficient spinning reserve to enable the system to respond to an external event.

9. The photovoltaic block array in accordance with any one of claims 1 to 8 wherein an environmental module is provided which is operatively connected to a light sensor or camera for cloud monitoring so as to receive data therefrom.

10. The photovoltaic block array in accordance with any one of claims 7 to 9 wherein a stabilisation module is provided to control the operation of additional supply of dispatchable power in anticipation of variations in demand or power generation.

11. The photovoltaic block array in accordance with claim 10 wherein the stabilisation module also automatically match power demand to the renewable power sources based on their supply capacity.

12. The photovoltaic block array in accordance with any one of claims 1 to 8 wherein when the microgrid is connected to a grid which includes a thermal power plant, the Stabilisation module manages an increase in generation and storage capacity to entirely replace thermal plant.

13. The photovoltaic block array in accordance with any one of claims 1 to 8 wherein one of the master photovoltaic sub-arrays is connected to an HV ring main via a DC/AC inverter and a low voltage bus bar.

14. The photovoltaic block array in accordance with claim 13 wherein the low voltage bus bar is connected to one or more load devices and is formed as part of a Low Voltage main switch board.

15. The photovoltaic block array in accordance with any one of claims 1 to 14 wherein the connection to an HV ring main includes a transformer to vary the alternating current generated by the photovoltaic array, and a safety element such as a circuit breaker, plug in circuit breaker, fuse or switch.

16. The photovoltaic block array in accordance with any one of claims 1 to 15 wherein one or more of the slave photovoltaic sub-array modules are connected in parallel with the master photovoltaic sub-array.

17. The photovoltaic block array in accordance with any one of claims 1 to 16 wherein the master photovoltaic array module includes a low voltage cubicle and a high voltage cubicle, connected by a transformer to shift up the voltage.

18. The photovoltaic block array in accordance with any one of claims 1 to 17 further including one or more protection elements in the HV cubicle, and a power meter in the low voltage cubicle.

19. The photovoltaic block array in accordance with any one of claims 1 to 18 wherein the photovoltaic array modules and their respective inverters are connected to a low voltage circuit.

20. The photovoltaic block array in accordance with any one of claims 1 to 19 wherein the low voltage circuit also includes a plurality of secondary modules which include Low Voltage Control and Meter, High Voltage Control, Protection and Power Quality, Communications system, and Distribution Network Service Provider.

21. The photovoltaic block array in accordance with any one of claims 1 to 20 wherein the master sub-block array control cubicle circuitry is located inside a compact secondary substation (CSS).

22. The photovoltaic block array in accordance with any one of claims 1 to 21 wherein an Ethernet switch is connected to the communications link, which connects a network controller to a controller network, which enables the transmission of data to and

23. The photovoltaic block array in accordance with any one of claims 1 to 22 wherein one or more of the generator controllers are both connected to an Ethernet switch, which is connected to the communications link, which connects the generator controller to the rest of the controller network for the microgrid, which enables the transmission of data to and from the other controllers on the controller network and enables the generator controllers to receive commands from the network controller in accordance with optimization rules determined by a hybridisation engine.

24. The photovoltaic block array in accordance with any one of claims 1 to 23 wherein cable characteristics for connection to the components in the module are selected by a method for optimising cable size and capacity, the method including the steps of:

receiving in a computing processor which includes a cable characteristic selection engine, data relating to a solar photovoltaic panel array, including type and configuration of components in the array, and automatically select cable characteristics, processing the data to select an optimal cable for the type and configuration of components in the array.

25. The photovoltaic block array in accordance with claim 24 wherein an input of the selection engine includes data relating to a distance between components of the solar photovoltaic array.

26. The photovoltaic block array in accordance with claim 25 wherein an input to the selection engine includes data relating to the plurality and characteristics of components in the array including number and arrangement of master sub-block arrays, number of slave sub-block arrays, and geometric spacing and arrangement of sub-block arrays.

27. A method for modular installation of a photovoltaic array comprising the steps of:

connecting a set of one or more master photovoltaic sub-block array controllers to a master photovoltaic sub-block array for controlling the output of the master photovoltaic sub-block array;

2019202170 28 Mar 2019

- 28 2019202170 28 Mar 2019

- 29 2019202170 28 Mar 2019

- 30 2019202170 28 Mar 2019 from other controllers on the controller network and enables the network controller to send commands to the other controllers in accordance with optimization rules determined by a hybridisation engine.

- 31 connecting a set of one or more slave sub-block array controllers to one or more slave photovoltaic sub-block arrays, the slave sub-block array controller being configured to receive and execute commands from the master photovoltaic sub-block array controller, wherein the set of one or more of the sub-block arrays includes a master photovoltaic sub-block array controller and one or more slave photovoltaic sub-block array controllers, such that a first one of the one or more slave photovoltaic sub-block arrays is configured to be connected to the master photovoltaic sub-block array.