GB2602615A - Smart covering system - Google Patents

Abstract

A smart photovoltaic (PV) roof tile system comprising at least one power and data conductive tape assembly 8 that is mounted to a roof batten 5; and at least one PV roof tile having means to allow the tile to be fastened to the power and conductive assembly thereby allowing electric and data transfer between the two units. The system is monitored to allow faulty or inefficient tiles such as tiles positioned in the shade to be bypassed. The tape is secured and folded around the top of a roof batten and connected via end caps. The tape has data and electric conductive channels and grooves that engage with the tile locking system, securing the tiles and aligning the tape and tiles data/electric channels (fig 2e). Each tile has guides 12 and electric conduits on periphery, front and back to assist alignment and the connectivity of the tiles to each other; and control and monitoring means (voltage and light monitoring). Performance and maintenance requirements are monitored to allow the most efficient circuit to set, allowing faulty and inefficient tiles to be bypassed. Excess energy may be stored in a power collector e.g. battery, or sent to the national grid.

Description

Smart Covering System by Damian Roslaniec Background informaflon 1 Standard industry practises for structure coverings commonly used, still rely on traditional methods of construction, and involve extraction of crude materials used for fabrication of such, those include stone and clay. There has also been an increase in use of metals and plastic which aim at compensating for the weaknesses and sustainability of using traditional materials. The technique of securing them still consists of individual fastening through means of nails or screws, a time consuming process during which many shingles get damaged and wasted. This results in higher landfill demand and increase in pollution.

Over the years market has seen an increase in inventions and demand for utilising solar energy whilst incorporating those into new and existing structures. Most common uses for existing structure coverings have been based on stand alone solar panels, with some innovative ideas that incorporate electrical buss circuit track systems, built mainly for roof covering replacement. Those can act as both; moulded mechanical fastening mechanism and electrical conduits. Providing ability for one single photovoltaic cell to connect in parallel to pre determined series circuit as standard. This eliminates the need of traditional electrical plug or soldering connections.

Photovoitaic roofing systems have become ever more popular and are rnainly composed of metal, plastic and polymer materials, those are combined with photovoltaic cells to produce substitute for regular roof covering. Such can resemble regular structure without the need of having a bulky new platform being built on existing covering. In practise they act as both weather shield to the structure, and electricity generating system. Thus having a huge impact on the environment.

With the increased use of solar and other renewable energy power, large power plants are finding it ever so harder to manage and plan energy fluctuations. This leads to plants having to increase or decrease their power production in response to fluctuations in demand more often. More often then not, such power plants are not designed in a way as to act this fast. In turn they are forced to either use expensive and not sustainable means to temporarily compensate for under production while generators increase output, or having to work at its minimum loads when the demand is low to manage substantial flow. Neither of which are feasible or environmentally friendly. As a result, blackouts are often the outcome of problems associated with managing of the above.

Photovoltaic cells can be wired in two basic circuits or combination of both. Each has its advantages and disadvantages. Most solar systems in the market use pre determined circuits for optimal performance and power supply. Those have pre set limitations to voltage supply and are prone to power loss through resistance, and travel distance in not so favourable conditions. While maintenance to solar systems isn't expensive monitoring of such is usually done as a whole system, this means that damage to separate circuits, individual output malfunctions or damage to cells can be overlooked and difficult to trace.

Over the time ways of connecting and attaching the photovoltaic cells have evolved. While the most common way of achieving this is still wire and plug system, patent no 11,643,825 proposes a railing with integrated wire connection. It can act as both solar shingle electric attachment coupling and fastening mechanism. Such evolved from previous US Pat. Nos, 6,065,255, 6,111,189, 6,465,724, 7,012,188 & 6,672,018. None of which proposes integrated mid way between the new and the old. Al present the installations of such type require extensive labour training to handle the task, those are also designed mainly to replace the covering entirely or be installed on top of it, not integrate within. Many of system's basic components are not widely available, such as railings and brackets. Meaning little room for quantity errors which might result in logistic and environmental issues.

Summary

The current construction market has large number of highly trained and qualified tradespeople who still use traditional skilis and widely available materials. Having future of solar revolution at sight but being unable to train the workforce and setup the manufacture process to accomplish the target, we are left needing a transition product, where widely available skills and construction materials can be used. Utilising simplistic design and ability to transfer skills of already available workforce, yet combining new adaptive smart technology, would be a prime success in producing and fitting the product on a mass scale. "8

The first part of the invention comes in a form of a power and data conductor assembly. Such would be made out of variety of flexible materials and incorporate buss, flat wire conduit or similar moulded in to its form. The smart assembly also referred to as smart tape, acts as a collar over widely available and standardised covering support structure, such as roofing battens. This however might be adapted to incorporate a factory produced standardised supports in future. It then acts as power and digital information conduit. This eliminates the need for high end manufacturing process of bulk rail support systems or brackets, and can be simply rolled and packed in to the box. While the structure of the roof is still built traditionally power and data module creates smart network and power connections direct or indirectly to Photovoltaic cells. Thus can be easily incorporated in to existing structures for improvement and as addition any on going or future project, as well as provide fully stand alone system. Such module resembling a tape product, vvould be easy to install through size match of structural supports it will cover, and such wili incorporate pre marked supported fixing points. This will allow use of screws, automated nailer systems or similar, being widely available and automated it would act as a way of fastening the power and data module to the structure.

Using roils of power and data transfer module instead of pre built railings, offers unique opportunity to speed up the process of design and installation of an electric circuit. This would be achieved through; roll out, attach and cut to required length type of process. Each end of the module is connected further through a. slot on connector, which transfers the conduits through standardised cable connector in to the buildings system. This embodiment could be changed to incorporate soldering or similar for connection purposes instead of sot on connector. Joining peaces of smart tape wouid be avoided as much as possible but for minimising wastage and environmental purposes, this process will use pin in connectors, slide over jointers, combination of both or other ways such as soldiering. "10

Photovoitaic soar cells are incorporated in tne form to look alike roofing tile or other required covering, through widely available methods such as extrusion, moulding or other. Those will be able to resembie flies, shingles, slates already in the market. Making it easy to incorporate in to existing structures. Minimising aesthetics changes to both, already existing structures and future planned projects. The system has also the ability to be used as full stand alone covering, comprising fully of solar covering. The smart tape mentioned above will be equipped with an easy guided snap in lock, which enables easy alignment over the entire roof sub structure. This will enable each tile to be positioned exactly as it would be in traditional way. "11

The click on lock, for each shingle or similar will incorporate piercing, spring loaded pins or other electrical conduits. This will altogether not be limited to this and might be improved depending on continuous development of the product. When the lock is engaged through applied downwards pressure over the smart tape, which in turn is attached to solid structure, the piercing pins and or spring loaded pins or similar achieve contact and as such electrical power and data connection is created. The electrical conduits within the lock system will be protected by rubber or similar seals that would provide electrical and weather safe enclosure once engaged in to lock position. (not shown on the diagrams). Dismantling the device is as simple as applying upward force to it, what in turn disengages the circuit. "12

In this embodiment each tile has a photovoltaic cell soldered inside, that is wire connected to a smart digitally controlled 10 way relay board (final design may change the numbers of such and evolve as the development is still during its progress). It would also include a current flow detector. The 10 way relays have 2 output connectors situated at each side of the tile (x4) and one to the lock mechanism. The smart board within the unit has pre built circuit, connecting photovoltaic cell to 4 sides of the tile and total of 8 relays which are by default set to OFF (circuit broken) and the two relays to the Lock Mechanism with by default are switched to ON (circuit complete') position. 'The board itself is powered by energy produced by the Photovoltaic cell that also holds a person& identification number. Smart board within devices data stream is directly wired in to piercing pins, spring pins or similar, situated at the top of the fastening bracket. This creates circuit connection with the smart tape that carries it down to the wire and finally receiver at the other end, The device which in this instance of design is a shingle that is laid out in a traditional fashion, each tile overlapping one another from bottom to the top, and butting up against each other on the sides. The shingles are grooved towards the ends of both sides as to interlock one another. Within those grooves are seals that crate weather protection, grooves will also incorporate positive and negative connections able to electronically connect each tile along the sides in series. Likewise tiles will also have electrical connectors underside of the bottom of the tile and its face towards the top, providing possible series connection diagonally. Once the fastening lock on the tile is engaged, by default, each device will direct its gathered energy to smart tape as a main structure conduit. Also at the same time feed data down data stream on the same smart tape identifying itself and confirming charge being generated on constant or intermittent basis. Receiver on the other end is then able to gather the information while interpreting it, and produce a report. This can be done for each and individual device connected to crate an overview of entire system.

The systems algorithm at the receiving end is able to map the entire structure through data collected. This will involve combination of time it takes for individual devices to communicate back and fourth, similarity in current production, .fallowed by automated series and parallel circuit check. Through disconnecting the tile thought to be next to one another, will confirm if its actually there by studying the overall voltage drop etc. This will aiso provide exact position of each individual device on the structure and as such a map of solar power grid is created. This along with daylight sensor partnered, can chose most power efficient circuits to be created for least resistance in any weather conditions, meaning least possible power lost. The system in turn then sends signal to those individual devices and requests that relays partner up with those specified while releasing default relays if necessary, This Action can be performed automated, manually or wirelessly depending on the setup, "15 The system continues to monitor the output of individual devices and stores average production rates in the system to any given daylight at the time. It is then able to produce an automated request for maintenance should any device fall bellow the threshold, and using built in algorithm distinguish whether the device needs cleaning or if its faulty and needs replacing, producing exact placement of such device. This eliminates the need for any manual checkups, and produces automated detailed maintenance request. *16 ;The working system is further connected to electric supply powering at home appliances etc. Excess energy produced is stored in power collector (usually batteries) as per usual solar installation, with further excess energy ove.rflowing ir to the local power and if necessary. Combination of all above or single components can also be used depending on the setup. "17 ;Individual systems in turn are remotely monitored by "master renewal power generation system"(MRPGS) for power production, maintenance issues as well as energy demand. This system exchanges information together with power plants energy production monitoring system currently in use. Together they can easily plan and act on power fluctuation in any given area. ;While currently power plants are required to quickly switch between power production levels, using information from the mRpcs will allow the process to be slowed down hence decrease pressure on over stretched systems. This would be achieved by remotely re directing individual systems (both current energy production, energy that is already collected in storage and the available power in the national grid), as a combination or individual depending on the requirement. This will either temporarily boost under production while Power Plant builds up the speed, through accessing systems storage energy and/or energy in current production. On the other hand when over production in the national grid occurs, the power can be easily re directed in to individual power storages to be used later. "19 ;The algorithm of the MRPGS will gather down information, and over time produce an optimal way of collecting, using and sharing the energy produced over general day. This allows every system to be synchronised together with optimal Power plant energy production and demand. For instance it will only collect and store the energy produced during the morning hours when demand is lowest, allowing the Power Plant to operate above its minimum. Making it more profitable rather then operating at a lose. During the day when the demand is greater the solar system would direct the power produced and stored in to the grid, allowing the Power giant to slowly build up its power production to match the demand. As night comes and the power demand decreases, again the system allows for power plant to slowly clump its excess energy by charging the individual systems power storages, allowing the Power Plant to gradually slow down and so on. This allows the Power Plants to work at more constant pace while compensating for demand levels. ;Drawings "20-Figure 1.a to 1.d shows smart transfer tape/wire rolled up as it would be in transit, now its fixed, folded over, its shape, conduits and preliminary fastening groves. "21--Figure 2.a to 2.g shows embodiment of the tile from many angles, preliminary fastening mechanism, guides and electrical conduits "22-Figure 3a to 3d shows alternative embodiment of fastening mechanism '4'23-Figure 4 shows internal structure of the tile and its components "24-Figure 5.a-5.g shows how system is tied together both structurally and electronically 25-Figure 6.a-6.b shows end-power and data transfer connector/blanking cap "26-Figure 7.a Lb explains control of smart solar roof system. ""27 ;Description ;As portrayed in embodiment, the roiled up smart tape/wire body Fig 1.a (8) made of flexible/playable material such as fibre, polymer or other (metal would also be considered depending on design), that incorporates flat copper or similar electronically conductive wires (1 & 3). It shows electric transfer conduits (1) both positive and negative, as well as digital data transfer conduits (3) in the centre of it. Once rolled over length of roofing covering structure such as roofing battens (5) it folds over its sides, this is shown in fig lb and 1.c. It is then nailed or screwed through the top as per Fig 1.c (6) what in turn secures the body (8). Further Fig 1.c shows a cut section of a product (8) fitted on a roofing batten (5) with a fixing through the top (6), sides incorporate power conductors (1) and a data transfer wires at the top (3). On both sides of the centre section there are small cut outs (4) that allow the smart tape to fold over without risk of it breaking if less playable material is used to manufacture the body (8). Towards the top of the covering there are two the slotting groves (2 & 7) which are used as fastening system. Fig 1.d shows a possible addition in a form of a tooth system (9) inside a grove fit (7) with corresponding reverse system on tile locking clip (not shown) that will prevent tile from sliding side ways. "28 ;Tile/shingle design top and the body in Fig 2.a (10) in this embodiment. For purpose of iilustration and new structure this is a preliminary design, however the moulds, shape and similar, of a body choice would resemble product currently on a market and popular requests as well as new designs. Within the mould is a space for a photovoltaic cell (14) that is internally soldered or similar further as explained later. There are two visible current conduits (11.2) positive and negative on its face for pairing with overlapping tile (not shown), further two towards its right side (11,1) for overlap pairing with next device. Each side at the top of the tile incorporates guides (12) for easy alignment of higher row and ensuring connectors are within reach of one another Underside of the device Fig Lb in turn shows further six electrical conduits. Two on the left side (114) for side pairing, two at the bottom (11.3) for lower device pairing, and two within fastening bracket plates (19 & 20) explained in detail later for direct main parallel circuit connection. Underside of the connection conduits (11.3 & 11.4) incorporate spring pins/ piercing pins/pressure plates (17) or similar for purposes of achieving secure connection during upwards and downwards device movements. There is also a reverse slot (16) at the bottom that fits with aligning guides (12) of lower row tiles. Profile of the tile shown in Fig 2.c shows side overlaps (15) and underlap,s (13) on its sides for achieving close fits and electrical connection alignment with other tiles. "30 ;The fastening mechanism Fig 2.d comes in pre formed bracket with two plates (19 &20) and body (10). Top of the mechanism within body (10) has internally wired digital transfer wires (3.2) coming of relay board explained in detail later, further let out through pins (17) for connection to digital transfer framework wire (3). Similarly bracket plates (19 & 20) have internally soldered electrical conduits (11.5) to pins or similar (17) for connection contact circuit placed on tapes main body (3). Within the side plates (19 &20) there are also fastening guides (21 & 13) that fit direct on to groves (2) within tapes body (8). Fig 2.e shows tile device engaged with the Tape body (8) as a whole. Fig 2.f offers a view of a fastening bracket in more detail. With guides (21 & 18) formed in a clip-in fashion which might be changed and adjusted depending on requirements and modifications. In contrast to guide mould (21) change is shown on appendix 2.g so have the groves (2) on main body (10). The change also incorporates slides (22) on the main body (10) for easy slotting of device while applying downwards force. All pins (17) are also shown in engaged mode connecting all conduit plates as guided with hallow space (17.1) towards the back representing spring chamber. ;An alternative embodiment to click-in fastening system to described in Fig 2.a-2g is that of a liver pressure type as per Fig 3.a incorporating a grooved bar (25) solidly attached to a sliding plate (19) which as a whole in turn slides closer to mounting plate (20). This is achieved through as shown in Fig 3.b leverage action of a tile's main body (10) being pushed down. As action of lowering the far end of the tile (10) along pin (28) is performed, the solid gear (27) incorporated in main body (10) mechanically slides the plate (25) in. Allowing connector bolts/pins (17) to engage both ends and the top. When system reaches the closed position catch (26) engages catch (24) and prevents the system from re opening, unless it is intended to by use of sufficient upwards force. Fig 3,c & provides an overall view of the system in both open and closed position. *39

Internal embodiment in appendix 4 of the tile consists of a photovoltaic cell (14) directly connected to a digital voltage and resistance measuring device (30.1) and digital electric relay board (29.1) as per current design. It will be an aim to integrate the two in to one component in the future. Powered directly by the photovoltaic cell (14) the device will send its digital signature and voltage measurements through its digital conduits (30.2) like an USB cable does, straight in to smart tapes digital conductors (3). The digital relay board (29.1) will be set by default to direct the generated electricity straight through main parallel circuits (11.5) on to smart tapes power stream (1), creating parallel circuit.The digital connector for the relay board (29.2) is able to receive instructions from a system control module (not shown) and switch in to different circuit modes as requested, directing power through any of shown pairing connectors (11.1, 11.2, 11,3, 11.4 & 11.5) using any of its positive or negative receptors, "33 Once the devices are fitted and fastened, the higher row overlaps the lower and connections are made in all points as per Fig 5,a. Although the groves and guides (12, 16, 15 & 13) ensure really precise tile placement, all conduits (11.1 -11.5) in the devices are made slightly longer and wider then necessary to allow for small margin of tile displacement, this can be seen on Fig 5,a to 5.c. Part of entire matrix connection between the tiles can be seen in appendix 5.d with additional digital power relays (29) joining rows of tape (8) The smart relay board previously mentioned allows for circuits to be remotely manipulated in to anything one pleases given its requested through end device/computer or system. For example Fig 5.e shows a request for all tiles to relay itself creating a series circuit through out A-H, while Fig 5.f shows executed request to relay all tiles in to default mode of parallel circuit Fig 5.g shows an execution of a mix request where devices A,B,C,H,I & J have been instructed in to a series circuit while D,E,F & G stayed in parallel. Overall in combination of relays in devices which join conduits that of smart tapes (not shown) the structure can build one large solar pane.: or divide itself in to two or more separate systems made of either parallel or series circuits independently or as a mixture of both.

Fig 6.a ties off the ends of main body (8) streams with end cap (31) and sends it off as a cable (32) for likes of ordinary solar setup (not shown) or advanced setup explained below. The cap simply slots on to the tape using groves as shown in fig 6.b and similarly to tile fastening system itself connection is achieved through pins directed in to soldered or similar transfer of conduits (33 & 34) within to the cable, (32) output "35 The entire system (fig 7.a) is connected as any other solar panel system would be including but not limited to inverter (not shown) with addition of a device/computer (36.1) being able to receive and act on information received along digital data transfer (3) in the systems setup. The main module control (39) which controls and diverts different sources of power supply in and out of the property including solar (35), battery (37) and national grid (38). The system also incorporates light detection device (41) which is either installed separate with direct connection to interpreting device (36:1) or within a tile and data transferred through data connection (3). Computer (36.1) is in direct contact with control module (39) through data stream (40), and is able to request that the module (39) either diverts the solar power (35.1) to the property(35.2), national arid (38) or battery storage (37). Divert the battery power (37) in to the property(35.2) or national grid (38). It can also divert national grids (38) power supply to the property (35.2) or to battery storage (37) for charging purposes. Actions can be performed individually or as a combination depending on request. The entire system is monitored by computer device (36.1) which transmits live data stream through streaming device (36.2.). Such as internet or independent connection. The streaming/receiving device (36.2) is also able to receive remote communications and instructions passed on for a computer device (36.1) to act on.

Computer System The computer system (36.1) receives data along digital transfer conduits (3), direct from every device connected to it. Using combination of response time from each device. localised voltage differences and parallel/series test through relays its able to determine exact position of every device fitted to the structure and create entire grid systems map. Using light level data from light sensor (41) and voltage production per Cell data (30.2) the system is able to use its algorithm to build most efficient power transfer circuits for least power lose. Once a decision is obtained it is able to communicate with relay boards (29.2) and rearrange circuits to its requirements. This can be done automatically through system or overridden manually through computer device (36;1) input or remotely through streaming/receiving device (36.2) which will pass instructions on to computer device (36.1). ""37

The data sharing is recorded live both on computer device (36.1), out server communication (43) as on Fig 7.)3 and monitored for changes compared to data collected. Through data collection and comparison the system is able to determine whether any particular device is malfunctioning, needs cleaning or requires replacement as a whole, in an instant of an issue, the program would generate a callout for re.pair/re.olacement, provide device name/number and its position on the structure, or simply produce performance report comparing its output on the day compared to similar day in the past. "38

The system also collects the data on households/projects daily consumptions routine throughout the year and builds a consumption statistics calendar for production, supply, overflow and storage of charge. This information is then recorded and sent over to server communication (43) for further analysis by the computer device (36:I) through direct link device (362).

On the bigger picture as shown in Fig Tb the server communication (43) gathers system information including daily demand calendar schedule from each property (42) under its management. Overall it builds singe demand schedule for all included system divided in to areas as per power grid supply and stores t for future communications. ""39

Power grid regulator (45) collects demand information from local stations (47) against supply of power by the power plants (46) It then instructs when the power stations has to increase or decrease on supply of production. ""40

In turn grid regulator (45) communicates with server communication (43) through dedicated network (40) to provide status of individual systems and its daily calendar demand. The grid regulator (45) can use the information to plan power plants (46) operation schedule so that no over producing or under producing of electricity occurs. Furthermore, should fluctuations occur in power grid the grid regulator (45) can instruct communication server (43) to direct its systems (42) to either redirect production and storage power (37) directly in to the grid or to consume and allow excess grid power to be dumped in to storage batteries (37). In practise when demand is high and National grid needs more energy it has the ability to barrow it from individual systems and replace it when demand is low. Allowing the grid to operate without the need for immediate changes to production. 2

Once the layout of structure is covered with such said smart tape, a network is created for solar power generation as described above. Such solar power shingles can be replaced easily with another type of shingles such as ones equipped with light detectors or anything else technologically advancements bring in the future, given fastening connectors keep its alignments and connection points to match those there. Essentially the structure becomes a Mather board allowing anything of use being attached to it. ""41

Claims (1)

1. System Of Claim claim Claim 1. Smart power generating adaptive structure covering system comprising: at least one power and data conductor assembly that is secured to the structure at least one tile with a way of fastening such to power and data assembly providing electrical connection between the two.Claim 2. Smart roof covering power relay adaptive system comprising: at least one power and data conductor assembly able transfer information or current at least one photovoltaic cell at least one digital electric relay; and a device able to gather and analyse the information with a lity to automatically or manually make requests for at least one relay to act on.Claim 3. Smart solar roof tile system comprising at least one photovoltaic cell at least one digital power relay way of fastening at least one tile to the structure while achieving electrical connection with at least one electrical assembly mentioned in claim 1: and ability of t east one tile making electrical connection with at least one more tile Claim 4. A smart solar tile comprising a require.d shape embodiment Photovo faic cell; and at least one digital device able to transmit information Claim 5. A structure controlling module and process device system comprising: Information input from a smart structure covering processing device able to understand the information control module able to act on requests produced by processing device; and at least one electronic relay Claim 6. A smart maintenance system comprising: monitoring device roof covering system; and reporting software Ciaim 7. A smart power fluctuation control system comprising: national power grid supply at least one solar system at least one Relay controi device; and data collecting device Claim 8.data conductor assembly with ability of it being rolled up and/or being folded comprising: flexible body at least one electrical conductor; and method of attaching the body to a roof structure Claim 9, a tile locking system comprising: at ieast two sides and way of fastening those to the structure and; at least one electronic connection Claim 10 where a tile is attached to the structure through leverage action causing fastening plates to compress on to structure or sub structure material indirectly or directly Claim 11 where a tile is securely attached to the structure through push in action fastening on to locking pins: and kept at its position through use of e guide pins and tapes body corresponding groves Claim 1 where tile and the body are manufactured using moulding or extrusion process Claim 13 where system can create energy supply, storage and demand schedule Claim 14 where system can program individual device relays to act on schedule for energy conservation Claim 15 where system can integrate in to existing structures without the need for major alternations to the said structure Cain 16 Guiding system for roof tiles comprising: at least one tile at!east one guide and at least one tra k within the tile that corresponds to at east one guide Claim if where a tape covering said structure, is able to at least one electrical connection with at least one tile through any form of Ponta Claim 18 where described, a solar device tile or other can be removed and replaced with another form of device or blank in its place