US20190123682A1 - Functionally integrated detachable photovoltaic module junction box - Google Patents
Functionally integrated detachable photovoltaic module junction box Download PDFInfo
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- US20190123682A1 US20190123682A1 US15/837,141 US201715837141A US2019123682A1 US 20190123682 A1 US20190123682 A1 US 20190123682A1 US 201715837141 A US201715837141 A US 201715837141A US 2019123682 A1 US2019123682 A1 US 2019123682A1
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- 238000012544 monitoring process Methods 0.000 claims abstract description 48
- 238000005457 optimization Methods 0.000 claims abstract description 48
- 238000004891 communication Methods 0.000 claims abstract description 20
- 238000006243 chemical reaction Methods 0.000 claims description 8
- 238000009434 installation Methods 0.000 claims description 7
- 230000004308 accommodation Effects 0.000 claims description 6
- 239000003292 glue Substances 0.000 claims description 3
- 238000005452 bending Methods 0.000 claims description 2
- 238000003780 insertion Methods 0.000 claims description 2
- 230000037431 insertion Effects 0.000 claims description 2
- 239000002184 metal Substances 0.000 claims description 2
- 229910052751 metal Inorganic materials 0.000 claims description 2
- 238000012423 maintenance Methods 0.000 abstract description 8
- 238000004519 manufacturing process Methods 0.000 abstract description 7
- 238000010248 power generation Methods 0.000 description 10
- 230000002159 abnormal effect Effects 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 230000017525 heat dissipation Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 241000196324 Embryophyta Species 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
- H02S40/345—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes with cooling means associated with the electrical connection means, e.g. cooling means associated with or applied to the junction box
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/03—Cooling
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/081—Bases, casings or covers
- H02G3/083—Inlets
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/14—Fastening of cover or lid to box
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S50/00—Monitoring or testing of PV systems, e.g. load balancing or fault identification
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the invention relates to a photovoltaic module junction box and, in particular, to a detachable photovoltaic module junction box that integrates functions of component optimization, monitoring, communication and shutdown.
- PV photovoltaic
- Shutdown the output of the module can be shut down automatically or remotely, thereby protecting the safety of the module and the surrounding components.
- Cost more functions can be integrated while the cost is reduced.
- the functionally integrated detachable PV module junction box includes a base part and an upper cover part that electrically and detachably connects to the base part.
- the base part has a base in which a plurality of string ports, a positive electrical port, and a negative electric port are provided.
- the upper cover part has an upper cover provided with a circuit board therein.
- the circuit board has an optimizing and monitoring circuit and a plurality of electrical connection pieces that electrically connect to the optimizing and monitoring circuit. Each of the electrical connection pieces matches with a respective one of the string ports, the positive electrical port, and the negative electrical port on the base part for connections.
- the base part is applied to be mounted on a PV module.
- Each of the string ports, the positive electrical port, and negative electrical port electrically connect to the strings of the PV module.
- each of the electrical connection pieces of the upper cover part correspondingly match with the string ports, the positive electrical port and the negative electrical port and form electrical connections.
- the optimizing and monitoring circuit of the upper cover part connects to the strings of the PV module via the electrical connection pieces, thereby performing power optimization and performance monitoring on each of the strings.
- the optimizing and monitoring circuit sends out a notification and shuts down the corresponding string.
- the optimizing and monitoring circuit that has various processing functions is integrated on the circuit board of the upper cover part, the functions of power optimization, monitoring, communications and shutdown are all integrated on the junction box, thereby satisfying function requirements of PV power generation products by the market.
- the base part is mounted on the PV module.
- the upper cover part is detachably combined with the base part to increase the assembly efficiency and reducing the assembly cost.
- the junction box needs to be repaired, only the upper cover part of the junction box needs to be replaced. This quickly completes the repair and reduces the maintenance cost.
- FIG. 1 shows a perspective view of a junction box of the invention
- FIG. 2 is an exploded perspective view showing a base part and an upper cover part of the junction box
- FIG. 3 is a locally exploded view of the base part of the invention.
- FIG. 4 is a planar view of a string port of the base part of the invention.
- FIG. 5 is an exploded view of the upper cover part of the invention.
- FIG. 6 is a cross-sectional view of the invention.
- FIGS. 7A and 7B are block diagrams of an optimizing and monitoring circuit.
- FIG. 8 is another cross-sectional view of the invention.
- a junction box in a PV module comprises a base part 1 and an upper cover part 2 that is detachably mounted on the base part 1 .
- the base part 1 has a base 10 and a plurality of through holes 101 formed on a bottom of the base 10 for copper belts to go through.
- the copper belts electrically connect to strings of the PV module.
- Both sides of the base 10 are provided respectively with a cable 100 for serial connections of the junction boxes of adjacent PV modules.
- a lower wall 102 is formed around the bottom of the base 10 .
- a plurality of string ports 11 , a positive electrical port 12 , and a negative electrical port 13 are provided inside the lower wall 102 .
- the positive electrical port 12 and the negative electrical port 13 electrically connect to the two cables 100 , respectively.
- a plurality of buckles 103 are provided outside the lower wall 102 on the bottom of the base 10 for the connection with the upper cover part 2 . In this embodiment, each buckle 103 is in an inverted U shape.
- the upper cover part 2 has an upper cover 20 .
- the upper cover 20 has a top, around which an upper wall 202 is formed.
- the space formed within the top and the upper wall 202 is provided with a circuit board 21 .
- the circuit board 21 is provided with a plurality of electrical connection pieces 22 and an optimizing and monitoring circuit (not shown).
- the electrical connection pieces 22 match with the string ports 11 , the positive electrical port 12 and the negative electrical port 13 on the base 10 , thereby forming electrical connections through insertions.
- the top of the upper cover 20 is provided with a plurality of engaging blocks 203 outside the upper wall 202 . Each of the engaging blocks 203 corresponds to a respective buckle 103 on the base 10 , thereby achieving a detachable connection.
- FIG. 3 shows the structures of the string ports 11 , the positive electrical port 12 , and the negative electrical port 13 inside the base 10 . Moreover, the string ports 11 , the positive electrical port 12 , and the negative electrical port 13 have the same structure. In the following, one of the string ports 11 is taken as an explicit example to describe in detail the structure thereof
- the string port 11 is formed by bending a conductive metal sheet, with one end forming a U-shaped inserting part 111 .
- the inserting part 111 has two pinnacles, with one pinnacle extending toward the interior of the inserting part 111 to form a contact spring 112 and the other pinnacle extending horizontally to form a saddle part 113 .
- the saddle part 113 is formed with two fixing holes 114 .
- the saddle part 113 is formed with an L-shaped electrical connection part 115 on the end opposite to the inserting part 111 . That is, the inserting part 111 and the electrical connection part 115 are on opposite ends of the saddle part 113 .
- the electrical connection part 115 corresponds to the through holes 101 on the base 10 for being soldered on the copper belts passing through the through holes 101 .
- the inserting part 111 allows the electrical connection pieces 22 of the upper cover part 1 to be inserted in between. Each electrical connection piece 22 is in electrical contact with one side wall of a corresponding inserting part 111 and the contact spring 112 . The opposite outer sidewalls of the inserting part 111 are punched to form a protruding piece 116 to reinforce fixing effects.
- the inner surface of the bottom of the base 10 is formed with a plurality of installation platforms 14 .
- Each of the installation platforms 14 comprises a concave accommodation chamber 141 and a wall part 142 protruding from one edge of the accommodation chamber 141 .
- the accommodation chamber 141 accommodates the inserting parts 111 of the string ports 11 .
- Two side walls of the accommodation chamber 141 are formed with concave grooves 143 .
- the two grooves 143 correspond to the protruding pieces 116 on the two opposite outer sidewalls of the inserting part 111 .
- the protruding pieces 116 are inserted to enhance the fixing effect.
- the wall part 142 is formed with two protruding pillars 144 .
- the saddle part 113 of the string port 11 strides across the wall part 142 .
- the protruding pillars 144 of the wall part 142 protrude through the fixing holes 114 on the saddle part 113 , thereby firmly fixing the string port 11 on the installation platform 14 .
- the structure of the positive electrical port 12 and the negative electrical port 13 are the same as that of the string port 11 .
- the base 10 is also formed with the same installation platform 14 to fix the positive electrical port 12 and the negative electrical port 13 .
- the inner surface of the upper wall 202 of the upper cover 20 is formed with a plurality of limiting sheets 204 and a plurality of limiting blocks 205 .
- the circuit board 21 is disposed within the limiting sheets 204 inside the upper wall 202 , supported by the limiting blocks 205 to maintain a height over the upper wall 202 .
- the circuit board 21 is formed with a plurality of sets of paired conductive holes 211 in order to have electrical connections with pins 220 protruding from the bottom end of the electrical connection pieces 22 .
- Each of the conductive holes 211 is connected to the optimizing and monitoring circuit provided on the circuit board 21 .
- the optimizing and monitoring circuit on the circuit board 21 performs power optimization on the strings that are connected to the string ports 11 , the positive electrical port 12 , and the negative electrical port 13 .
- Parameters such as voltage and temperature of the PV module are monitored. When any parameter is abnormal, a notification is sent out and the strings are shut down automatically or remotely.
- the upper cover 20 in this embodiment is further provided with a heat sink 23 .
- the heat sink 23 is formed with a plurality of protruding parts 230 , each of which is close to primary elements (such as MCU) on the optimizing and monitoring circuit of the circuit board 21 for heat dissipation.
- the upper cover 20 is further injected with a glue with high thermal conductivity, thereby firmly fixing the circuit board 21 and the heat sink 23 therein.
- the highly thermal conductive glue also helps heat dissipation. In addition, it is resistant to water and dusts.
- a waterproof ring 40 is inserted between the upper cover 20 and the base 10 so that the junction box has better water resistance.
- the structure of the optimizing and monitoring circuit on the circuit board 21 is shown in FIGS. 7A and 7B .
- the optimizing and monitoring circuit inside a single junction box comprises a micro control unit 30 , a plurality of optimization modules 31 ⁇ 33 , a driving module 34 , a voltage collecting unit 35 , a temperature collecting unit 36 , and a power line communication (PLC) module 37 .
- PLC power line communication
- the optimization modules 31 ⁇ 33 connect respectively to the power input terminals of the strings PV 1 , PV 2 , and PV 3 of the PV module. More explicitly, the optimization modules 31 ⁇ 33 electrically connect to the string ports 11 , the positive electrical port 12 , and the negative electrical port 13 on the base part 1 via the electrical connection pieces 22 on the circuit board 21 , thereby connecting to the power output terminals of PV 1 , PV 2 , and PV 3 .
- the optimization modules 31 ⁇ 33 perform maximum power point tracking (MPPT) on each of the strings PV 1 , PV 2 , and PV 3 . This achieves the goal of power optimization at the smallest power generation unit (string level).
- MPPT maximum power point tracking
- the voltage collecting unit 35 has a set of input terminals and an output terminal.
- the input terminals are connected to a positive power source VO+and a negative power source VO ⁇ of the PV module via the positive electrical port 12 and the negative electrical port 13 , thereby detecting the voltage of the PV module.
- the output terminal of the voltage collecting unit 35 is connected to the micro control unit 30 to transmit the detected voltage to the micro control unit 30 .
- the temperature collecting unit 36 collects an environmental temperature of the optimizing and monitoring circuit, and transmits the detected environmental temperature to the connected micro control unit 30 .
- the PLC module 37 is a power line communication device connected to power loops of the micro control unit 30 and the PV module. Therefore, the micro control unit 30 communicates with an external system terminal device 50 via power lines.
- the invention further provides a shutdown function.
- Each of the optimization modules 31 ⁇ 33 has a shutdown end EN, which is connected to the output terminal of the driving module 34 .
- the input terminal of the driving module 34 is connected with the micro control unit 30 .
- the micro control unit 30 determines that the PV module or any of the strings is abnormal, in addition to sending a notification via the PLC module 37 to the system terminal device 50 , the micro control unit 30 can automatically send a command or accept a command from the system terminal device to shut down any one or all of the strings via the driving module 34 .
- the abnormal strings are isolated from the power loop to protect the system safety of other normal strings of the PV module or other PV modules.
- the power supplied to the junction box and the optimizing and monitoring circuit comes from the power output from the PV module without the need of any additional power supply systems. That is, the optimizing and monitoring circuit further includes a DC/DC conversion unit 38 , whose input terminal is connected to the power output terminal of the PV module via the electrical connection pieces 22 and the string ports 11 . Therefore, the DC/DC conversion unit 38 performs DC to DC voltage conversion on the power output from the PV module, thereby supplying a stable working voltage to the micro control unit 30 .
- each of the strings PV 1 ⁇ PV 3 of the PV module are connected in series via the optimization modules 31 ⁇ 33 , the input terminal of the DC/DC conversion unit 38 then connects to the positive power output terminal of the string PV 3 and the negative power output terminal of the string PV 1 via the electrical connection pieces 22 and the string ports 11 , thereby obtaining electrical power from the PV module.
- each of the PV modules can be connected in series.
- Each of the PV modules can also make use of the junction box to have power optimization, monitoring, and shutdown functions.
- the optimizing and monitoring circuit of each junction box communicates with the system terminal device 50 via power lines.
- the system terminal device 50 connects to the power lines via a demodulator 51 in order to demodulate carrier waves on the power line to the system terminal device 50 .
- the upper cover part 2 is detachably connected to the base part 1 .
- the upper cover 20 of the upper cover part 2 is provided with a circuit board 21 with the optimizing and monitoring circuit to perform optimization, communications, monitoring and shutdown functions.
- the junction box is easier to assemble. When the junction box requires maintenance, one merely takes off the upper cover part 2 and replaces it with a new upper cover part 2 , making the repair quick and easy.
- Use of the power lines for communications can reduce the costs of wiring and materials. This also reduces difficulty in assembly.
Abstract
Description
- The invention relates to a photovoltaic module junction box and, in particular, to a detachable photovoltaic module junction box that integrates functions of component optimization, monitoring, communication and shutdown.
- With the rise of green energy, photovoltaic (PV) power generation receives more and more attention on the market. With technological developments, PV systems that can provide the maximum power generation efficiency are more welcomed by the market.
- Owing to limitations in production processes, there are subtle differences among power generation units. Constrained by the cost and the current level of electrical and electronic components manufacturing, it is impossible to achieve an overall optimization of the power plant level in power optimization.
- With developments in the technology, power optimization is gradually pushed toward smaller power generation units. Currently, group serial power optimization is most likely to achieve. Also as time goes on, the market has posed more demanding requirements for PV power generation systems, as listed below.
- Optimization: power optimization is required at the level of the smallest power generation unit in order to have the maximum power output. When the devices are blocked by tree branches and weeds, have inconsistent orientations, or mismatched components, it is still designed to have its maximum power output.
- Monitoring: such parameters as voltage, current and temperature, of the power generation unit are measured at maximum precision.
- Communication: reliable communications are achieved within the ISM band, with a minimal frequency band and radio wave interference, while resistant to surrounding radio interference;
- Shutdown: the output of the module can be shut down automatically or remotely, thereby protecting the safety of the module and the surrounding components.
- Production: the product production cycle is shortened as much as possible, thereby reducing space occupancy.
- Maintenance: difficulties in repair and maintenance are reduced so that problems can be solved once and for all.
- Cost: more functions can be integrated while the cost is reduced.
- From the above description, it is seen that the market currently imposes a lot of requirements on the PV power generation system, such as the specification, performance and cost. However, related products on the market at the moment emphasize more on power optimization. Nothing of integration type has appeared to integrate various functions in a single module to reduce production, assembly and maintenance costs.
- It is an objective of the invention to provide a functionally integrated detachable PV module junction box. Functions of group serial optimization, monitoring, communication and shutdown are integrated to a single device to meet market requirements. At the same time, a detachable structure is employed to increase the efficiencies in production, assembly and maintenance, thereby relatively reducing the costs.
- To achieve the objective, the functionally integrated detachable PV module junction box includes a base part and an upper cover part that electrically and detachably connects to the base part.
- The base part has a base in which a plurality of string ports, a positive electrical port, and a negative electric port are provided.
- The upper cover part has an upper cover provided with a circuit board therein. The circuit board has an optimizing and monitoring circuit and a plurality of electrical connection pieces that electrically connect to the optimizing and monitoring circuit. Each of the electrical connection pieces matches with a respective one of the string ports, the positive electrical port, and the negative electrical port on the base part for connections.
- The base part is applied to be mounted on a PV module. Each of the string ports, the positive electrical port, and negative electrical port electrically connect to the strings of the PV module. When the upper cover part and the base part are connected, each of the electrical connection pieces of the upper cover part correspondingly match with the string ports, the positive electrical port and the negative electrical port and form electrical connections. As a result, the optimizing and monitoring circuit of the upper cover part connects to the strings of the PV module via the electrical connection pieces, thereby performing power optimization and performance monitoring on each of the strings. When an abnormal activity happens, the optimizing and monitoring circuit sends out a notification and shuts down the corresponding string.
- Since the optimizing and monitoring circuit that has various processing functions is integrated on the circuit board of the upper cover part, the functions of power optimization, monitoring, communications and shutdown are all integrated on the junction box, thereby satisfying function requirements of PV power generation products by the market. Moreover, the base part is mounted on the PV module. The upper cover part is detachably combined with the base part to increase the assembly efficiency and reducing the assembly cost. On the other hand, when the junction box needs to be repaired, only the upper cover part of the junction box needs to be replaced. This quickly completes the repair and reduces the maintenance cost.
-
FIG. 1 shows a perspective view of a junction box of the invention; -
FIG. 2 is an exploded perspective view showing a base part and an upper cover part of the junction box; -
FIG. 3 is a locally exploded view of the base part of the invention; -
FIG. 4 is a planar view of a string port of the base part of the invention; -
FIG. 5 is an exploded view of the upper cover part of the invention; -
FIG. 6 is a cross-sectional view of the invention; -
FIGS. 7A and 7B are block diagrams of an optimizing and monitoring circuit; and -
FIG. 8 is another cross-sectional view of the invention. - As shown in
FIG. 1 , a junction box in a PV module comprises abase part 1 and anupper cover part 2 that is detachably mounted on thebase part 1. Thebase part 1 has abase 10 and a plurality of throughholes 101 formed on a bottom of thebase 10 for copper belts to go through. The copper belts electrically connect to strings of the PV module. Both sides of thebase 10 are provided respectively with acable 100 for serial connections of the junction boxes of adjacent PV modules. - As shown in
FIG. 2 , alower wall 102 is formed around the bottom of thebase 10. A plurality ofstring ports 11, a positiveelectrical port 12, and a negativeelectrical port 13 are provided inside thelower wall 102. The positiveelectrical port 12 and the negativeelectrical port 13 electrically connect to the twocables 100, respectively. A plurality ofbuckles 103 are provided outside thelower wall 102 on the bottom of thebase 10 for the connection with theupper cover part 2. In this embodiment, eachbuckle 103 is in an inverted U shape. - The
upper cover part 2 has anupper cover 20. Theupper cover 20 has a top, around which anupper wall 202 is formed. The space formed within the top and theupper wall 202 is provided with acircuit board 21. Thecircuit board 21 is provided with a plurality ofelectrical connection pieces 22 and an optimizing and monitoring circuit (not shown). Theelectrical connection pieces 22 match with thestring ports 11, the positiveelectrical port 12 and the negativeelectrical port 13 on thebase 10, thereby forming electrical connections through insertions. The top of theupper cover 20 is provided with a plurality of engagingblocks 203 outside theupper wall 202. Each of the engagingblocks 203 corresponds to arespective buckle 103 on thebase 10, thereby achieving a detachable connection. -
FIG. 3 shows the structures of thestring ports 11, the positiveelectrical port 12, and the negativeelectrical port 13 inside thebase 10. Moreover, thestring ports 11, the positiveelectrical port 12, and the negativeelectrical port 13 have the same structure. In the following, one of thestring ports 11 is taken as an explicit example to describe in detail the structure thereof - With reference simultaneously to
FIGS. 3 and 4 , thestring port 11 is formed by bending a conductive metal sheet, with one end forming a U-shaped insertingpart 111. The insertingpart 111 has two pinnacles, with one pinnacle extending toward the interior of the insertingpart 111 to form acontact spring 112 and the other pinnacle extending horizontally to form asaddle part 113. Thesaddle part 113 is formed with two fixingholes 114. Besides, thesaddle part 113 is formed with an L-shapedelectrical connection part 115 on the end opposite to the insertingpart 111. That is, the insertingpart 111 and theelectrical connection part 115 are on opposite ends of thesaddle part 113. Theelectrical connection part 115 corresponds to the throughholes 101 on thebase 10 for being soldered on the copper belts passing through the throughholes 101. The insertingpart 111 allows theelectrical connection pieces 22 of theupper cover part 1 to be inserted in between. Eachelectrical connection piece 22 is in electrical contact with one side wall of a corresponding insertingpart 111 and thecontact spring 112. The opposite outer sidewalls of the insertingpart 111 are punched to form a protrudingpiece 116 to reinforce fixing effects. - In order to more firmly combine the
string ports 11, the positiveelectrical port 12 and the negativeelectrical port 13, the inner surface of the bottom of thebase 10 is formed with a plurality ofinstallation platforms 14. Each of theinstallation platforms 14 comprises aconcave accommodation chamber 141 and awall part 142 protruding from one edge of theaccommodation chamber 141. Theaccommodation chamber 141 accommodates the insertingparts 111 of thestring ports 11. Two side walls of theaccommodation chamber 141 are formed withconcave grooves 143. The twogrooves 143 correspond to the protrudingpieces 116 on the two opposite outer sidewalls of the insertingpart 111. The protrudingpieces 116 are inserted to enhance the fixing effect. - The
wall part 142 is formed with two protrudingpillars 144. Thesaddle part 113 of thestring port 11 strides across thewall part 142. The protrudingpillars 144 of thewall part 142 protrude through the fixingholes 114 on thesaddle part 113, thereby firmly fixing thestring port 11 on theinstallation platform 14. As described before, the structure of the positiveelectrical port 12 and the negativeelectrical port 13 are the same as that of thestring port 11. Thebase 10 is also formed with thesame installation platform 14 to fix the positiveelectrical port 12 and the negativeelectrical port 13. - As shown in
FIG. 5 , the inner surface of theupper wall 202 of theupper cover 20 is formed with a plurality of limitingsheets 204 and a plurality of limitingblocks 205. Thecircuit board 21 is disposed within the limitingsheets 204 inside theupper wall 202, supported by the limitingblocks 205 to maintain a height over theupper wall 202. - The
circuit board 21 is formed with a plurality of sets of pairedconductive holes 211 in order to have electrical connections withpins 220 protruding from the bottom end of theelectrical connection pieces 22. Each of theconductive holes 211 is connected to the optimizing and monitoring circuit provided on thecircuit board 21. When theupper cover part 20 and thebase part 10 are connected, and theelectrical connection pieces 22 are respectively connected to thestring ports 11, the positiveelectrical port 12, and the negativeelectrical port 13 on thebase 10, the optimizing and monitoring circuit on thecircuit board 21 performs power optimization on the strings that are connected to thestring ports 11, the positiveelectrical port 12, and the negativeelectrical port 13. Parameters such as voltage and temperature of the PV module are monitored. When any parameter is abnormal, a notification is sent out and the strings are shut down automatically or remotely. - When the optimizing and monitoring circuit provided on the
circuit board 21 performs power optimization, monitoring, and communications, it may generate a high temperature. To ensure that the operation of the optimizing and monitoring circuit is not affected by the high temperature, theupper cover 20 in this embodiment is further provided with aheat sink 23. As shown inFIG. 5 , theheat sink 23 is formed with a plurality of protrudingparts 230, each of which is close to primary elements (such as MCU) on the optimizing and monitoring circuit of thecircuit board 21 for heat dissipation. In this embodiment, theupper cover 20 is further injected with a glue with high thermal conductivity, thereby firmly fixing thecircuit board 21 and theheat sink 23 therein. The highly thermal conductive glue also helps heat dissipation. In addition, it is resistant to water and dusts. As shown inFIG. 6 , a waterproof ring 40 is inserted between theupper cover 20 and the base 10 so that the junction box has better water resistance. - The structure of the optimizing and monitoring circuit on the
circuit board 21 is shown inFIGS. 7A and 7B . The optimizing and monitoring circuit inside a single junction box comprises amicro control unit 30, a plurality ofoptimization modules 31˜33, a drivingmodule 34, avoltage collecting unit 35, atemperature collecting unit 36, and a power line communication (PLC)module 37. - The
optimization modules 31˜33 connect respectively to the power input terminals of the strings PV1, PV2, and PV3 of the PV module. More explicitly, theoptimization modules 31˜33 electrically connect to thestring ports 11, the positiveelectrical port 12, and the negativeelectrical port 13 on thebase part 1 via theelectrical connection pieces 22 on thecircuit board 21, thereby connecting to the power output terminals of PV1, PV2, and PV3. Theoptimization modules 31˜33 perform maximum power point tracking (MPPT) on each of the strings PV1, PV2, and PV3. This achieves the goal of power optimization at the smallest power generation unit (string level). - The
voltage collecting unit 35 has a set of input terminals and an output terminal. The input terminals are connected to a positive power source VO+and a negative power source VO− of the PV module via the positiveelectrical port 12 and the negativeelectrical port 13, thereby detecting the voltage of the PV module. The output terminal of thevoltage collecting unit 35 is connected to themicro control unit 30 to transmit the detected voltage to themicro control unit 30. - The
temperature collecting unit 36 collects an environmental temperature of the optimizing and monitoring circuit, and transmits the detected environmental temperature to the connectedmicro control unit 30. - The
PLC module 37 is a power line communication device connected to power loops of themicro control unit 30 and the PV module. Therefore, themicro control unit 30 communicates with an externalsystem terminal device 50 via power lines. - In addition to the above-mentioned functions of power optimization, monitoring, and communications, the invention further provides a shutdown function. Each of the
optimization modules 31˜33 has a shutdown end EN, which is connected to the output terminal of the drivingmodule 34. The input terminal of the drivingmodule 34 is connected with themicro control unit 30. When themicro control unit 30 determines that the PV module or any of the strings is abnormal, in addition to sending a notification via thePLC module 37 to thesystem terminal device 50, themicro control unit 30 can automatically send a command or accept a command from the system terminal device to shut down any one or all of the strings via thedriving module 34. The abnormal strings are isolated from the power loop to protect the system safety of other normal strings of the PV module or other PV modules. - The power supplied to the junction box and the optimizing and monitoring circuit comes from the power output from the PV module without the need of any additional power supply systems. That is, the optimizing and monitoring circuit further includes a DC/
DC conversion unit 38, whose input terminal is connected to the power output terminal of the PV module via theelectrical connection pieces 22 and thestring ports 11. Therefore, the DC/DC conversion unit 38 performs DC to DC voltage conversion on the power output from the PV module, thereby supplying a stable working voltage to themicro control unit 30. Since each of the strings PV1˜PV3 of the PV module are connected in series via theoptimization modules 31˜33, the input terminal of the DC/DC conversion unit 38 then connects to the positive power output terminal of the string PV3 and the negative power output terminal of the string PV1 via theelectrical connection pieces 22 and thestring ports 11, thereby obtaining electrical power from the PV module. - Through the above-mentioned junction box, each of the PV modules can be connected in series. Each of the PV modules can also make use of the junction box to have power optimization, monitoring, and shutdown functions. The optimizing and monitoring circuit of each junction box communicates with the
system terminal device 50 via power lines. Thesystem terminal device 50 connects to the power lines via ademodulator 51 in order to demodulate carrier waves on the power line to thesystem terminal device 50. - The explicit structure of the invention is described above. The following describes how to use the invention.
- As shown in
FIGS. 6 and 8 , theupper cover part 2 is detachably connected to thebase part 1. Theupper cover 20 of theupper cover part 2 is provided with acircuit board 21 with the optimizing and monitoring circuit to perform optimization, communications, monitoring and shutdown functions. Through the detachable electrical connections between theelectrical connection pieces 22 and thestring ports 11, the positiveelectrical port 12, and the negativeelectrical port 13, the junction box is easier to assemble. When the junction box requires maintenance, one merely takes off theupper cover part 2 and replaces it with a newupper cover part 2, making the repair quick and easy. Use of the power lines for communications can reduce the costs of wiring and materials. This also reduces difficulty in assembly. - While the invention has been described by way of example and in terms of the preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
Claims (20)
Applications Claiming Priority (3)
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CN201721385537U | 2017-10-25 | ||
CN201721385537.X | 2017-10-25 | ||
CN201721385537.XU CN207304475U (en) | 2017-10-25 | 2017-10-25 | The integrated detachable photovoltaic component terminal box of function |
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US10250185B1 US10250185B1 (en) | 2019-04-02 |
US20190123682A1 true US20190123682A1 (en) | 2019-04-25 |
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US15/837,141 Expired - Fee Related US10250185B1 (en) | 2017-10-25 | 2017-12-11 | Functionally integrated detachable photovoltaic module junction box |
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US (1) | US10250185B1 (en) |
JP (1) | JP3215385U (en) |
CN (1) | CN207304475U (en) |
AU (1) | AU2017101770A4 (en) |
DE (1) | DE202017107738U1 (en) |
TW (1) | TWM558488U (en) |
Cited By (2)
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US10530292B1 (en) * | 2019-04-02 | 2020-01-07 | Solarmass Energy Group Ltd. | Solar roof tile with integrated cable management system |
US10658969B2 (en) | 2014-12-04 | 2020-05-19 | Solarmass Energy Group Ltd. | Photovoltaic solar roof tile assembly |
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CN110593566A (en) * | 2019-09-02 | 2019-12-20 | 中冶天工集团天津有限公司 | Novel pre-buried wire box and construction method |
CN111497767A (en) * | 2020-04-23 | 2020-08-07 | 上海沪工汽车电器有限公司 | Protective cover structure for lower cover of central electric junction box for vehicle |
CN114833538B (en) * | 2022-04-02 | 2023-03-24 | 扬州朗日新能源科技有限公司 | Solar photovoltaic junction box production and processing device |
CN115224646B (en) * | 2022-07-08 | 2023-12-22 | 中国华冶科工集团有限公司 | Junction box device |
CN116865666B (en) * | 2023-09-05 | 2023-11-17 | 江苏泽润新能科技股份有限公司 | Photovoltaic metal junction box |
CN116995614B (en) * | 2023-09-27 | 2024-01-26 | 广东电网有限责任公司肇庆供电局 | Outdoor termination of low pressure photovoltaic |
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JP2005312130A (en) * | 2004-04-19 | 2005-11-04 | Auto Network Gijutsu Kenkyusho:Kk | Electric connection box |
US7649731B2 (en) * | 2007-01-31 | 2010-01-19 | Tyco Electronics Corporation | Power distribution module using buss bar |
FR2915345B1 (en) * | 2007-04-20 | 2009-07-03 | Imphy Alloys Sa | BATI SUPPORT OF AN ELECTRICALLY ACTIVE PANEL SUCH AS A PHOTOVOLTAIC PANEL |
DE202007012096U1 (en) * | 2007-08-29 | 2009-01-08 | Weidmüller Interface GmbH & Co. KG | Electrical connection device for conductive contacts, in particular blade contacts |
DE102007043178A1 (en) * | 2007-09-11 | 2009-03-12 | Yamaichi Electronics Deutschland Gmbh | Junction box, solar panel, contact device and procedure |
DE102008003448B4 (en) * | 2008-01-08 | 2017-01-05 | Yamaichi Electronics Deutschland Gmbh | Junction box, use, solar panel, contact element, and procedure |
CN101651262B (en) * | 2008-08-12 | 2012-03-21 | 凡甲电子(苏州)有限公司 | Solar battery panel connecting box |
DE102009033481B4 (en) * | 2009-07-15 | 2012-07-05 | Phoenix Contact Gmbh & Co. Kg | Connection and connection device |
DE102010029714A1 (en) * | 2010-04-08 | 2011-10-13 | Tyco Electronics Amp Gmbh | Electrical spring clamp, punched grid, busbar and electrical connection device |
CN102386259A (en) * | 2010-09-02 | 2012-03-21 | 国琏电子(上海)有限公司 | Wiring box |
JP6117661B2 (en) * | 2013-09-19 | 2017-04-19 | 日立オートモティブシステムズ株式会社 | Electronic control unit |
CN207304483U (en) * | 2017-10-26 | 2018-05-01 | 江苏英迈能源科技有限公司 | The monitoring cutoff device of solar photovoltaic assembly |
-
2017
- 2017-10-25 CN CN201721385537.XU patent/CN207304475U/en active Active
- 2017-11-03 TW TW106216374U patent/TWM558488U/en not_active IP Right Cessation
- 2017-12-11 US US15/837,141 patent/US10250185B1/en not_active Expired - Fee Related
- 2017-12-19 AU AU2017101770A patent/AU2017101770A4/en not_active Ceased
- 2017-12-19 DE DE202017107738.1U patent/DE202017107738U1/en active Active
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2018
- 2018-01-04 JP JP2018000005U patent/JP3215385U/en not_active Expired - Fee Related
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10658969B2 (en) | 2014-12-04 | 2020-05-19 | Solarmass Energy Group Ltd. | Photovoltaic solar roof tile assembly |
US10756669B2 (en) | 2014-12-04 | 2020-08-25 | Solarmass Energy Group Ltd. | Solar roof tile |
US11626829B2 (en) | 2014-12-04 | 2023-04-11 | Solarmass Energy Group Ltd. | Methods of manufacturing and installing a solar roof tile assembly |
US10530292B1 (en) * | 2019-04-02 | 2020-01-07 | Solarmass Energy Group Ltd. | Solar roof tile with integrated cable management system |
US10998848B2 (en) | 2019-04-02 | 2021-05-04 | Solarmass Energy Group Ltd. | Method of routing and securing electrical power cables for a solar roof installation |
Also Published As
Publication number | Publication date |
---|---|
AU2017101770A4 (en) | 2018-02-01 |
JP3215385U (en) | 2018-03-15 |
CN207304475U (en) | 2018-05-01 |
TWM558488U (en) | 2018-04-11 |
US10250185B1 (en) | 2019-04-02 |
DE202017107738U1 (en) | 2018-03-27 |
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