US20220407314A1 - Cable integrated solar inverter - Google Patents
Cable integrated solar inverter Download PDFInfo
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- US20220407314A1 US20220407314A1 US17/804,810 US202217804810A US2022407314A1 US 20220407314 A1 US20220407314 A1 US 20220407314A1 US 202217804810 A US202217804810 A US 202217804810A US 2022407314 A1 US2022407314 A1 US 2022407314A1
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H02J3/00—Circuit arrangements for ac mains or ac distribution networks
- H02J3/38—Arrangements for parallely feeding a single network by two or more generators, converters or transformers
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H02J1/00—Circuit arrangements for dc mains or dc distribution networks
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H02J3/00—Circuit arrangements for ac mains or ac distribution networks
- H02J3/38—Arrangements for parallely feeding a single network by two or more generators, converters or transformers
- H02J3/381—Dispersed generators
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H02J3/00—Circuit arrangements for ac mains or ac distribution networks
- H02J3/38—Arrangements for parallely feeding a single network by two or more generators, converters or transformers
- H02J3/40—Synchronising a generator for connection to a network or to another generator
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
- H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
- H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
- H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
- H02M7/53—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
- H02M7/537—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
- H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
- H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
- H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
- H02M7/53—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
- H02M7/537—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
- H02M7/5387—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration
-
- 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
- H02S40/32—Electrical components comprising DC/AC inverter means associated with the PV module itself, e.g. AC modules
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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
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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
- H02S40/38—Energy storage means, e.g. batteries, structurally associated with PV modules
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- H—ELECTRICITY
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- 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
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H02J2300/00—Systems for supplying or distributing electric power characterised by decentralized, dispersed, or local generation
- H02J2300/20—The dispersed energy generation being of renewable origin
- H02J2300/22—The renewable source being solar energy
- H02J2300/24—The renewable source being solar energy of photovoltaic origin
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M1/00—Details of apparatus for conversion
- H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
- H02M1/007—Plural converter units in cascade
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M1/00—Details of apparatus for conversion
- H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
- H02M1/0077—Plural converter units whose outputs are connected in series
-
- 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
-
- 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
- Y02E10/56—Power conversion systems, e.g. maximum power point trackers
Definitions
- PV cells Photovoltaic (PV) cells are currently used to harvest solar energy for use in both commercial and residential environments. To enable more widespread adoption of solar power, however, it is important to minimize the cost per watt for the power harvested. This requires all elements of a solar power system to be designed with both cost and system energy requirements taken into account. As solar power systems comprise several components in addition to the PV cell, development of these components also affects the evolution of the entire solar power system.
- DC direct current
- AC alternating current
- Various embodiments of the present invention are directed to an improved solar inverter system for generating AC power from photovoltaic solar panels or other DC power sources.
- a cable integrated solar inverter is provided for converting DC power from solar modules to AC power for supplying a grid.
- power converter cartridges are integrated into trunk cable and connected to solar panels. The power converter cartridges are connected in series via the trunk cable, which then provides the combined output from the plurality of power converters to a grid interface unit.
- the grid interface unit receives a rectified (half-sine) wave and converts the rectified wave into a pure AC signal.
- the grid interface unit may include fault detection systems, monitoring systems, synchronization systems, unfolding circuitry, interface and communication circuitry and/or the like.
- FIG. 1 A shows a residential environment having a photovoltaic power system according to one embodiment
- FIG. 1 B is shows a schematic of a cable integrated solar inverter system according to one embodiment
- FIG. 2 A shows an isometric view of a power converter cartridge and housing in which the power converter cartridge is detached from the housing according to one embodiment
- FIG. 2 B shows an isometric view of the power converter cartridge and housing of FIG. 2 A in which the power converter cartridge is secured to the housing;
- FIG. 3 shows isometric view of a cable integrated power converter according to another embodiment
- FIG. 4 A shows a plan view of cable integrated power converter according to yet another embodiment
- FIG. 4 B shows a plan view of cable integrated power converter according to yet another embodiment
- FIG. 5 A is an exemplary schematic diagram of a cabling system according to one embodiment
- FIG. 5 B depicts an exemplary electrical signal transformation at an exemplary unfolding bridge according to one embodiment
- FIG. 6 is an exemplary control system block diagram according to one embodiment
- FIG. 7 is an exemplary schematic diagram of a cabling system according to another embedment
- FIG. 8 A depicts an exemplary combined synchronization and serial communication electrical signal
- FIG. 8 B depicts a serial representation of an exemplary combined synchronization and serial communication electrical communication packet.
- a cable integrated solar inverter system for converting DC power received from photovoltaic cells into AC power suitable for supply to a power grid.
- the cable integrated solar inverter system can be used in conjunction with a variety of photovoltaic power systems, including systems in both commercial and residential environments.
- FIG. 1 A shows a building structure 5 having a photovoltaic power system interconnected with an AC power grid 9 .
- the photovoltaic power system includes a photovoltaic solar array 10 .
- the solar array 10 is configured to generate power in combination with a wind turbine 20 , which can be stored in an energy storage unit (e.g., comprised of the illustrated battery array 22 and a fuel cell array 24 ).
- a fuel operated generator 26 is also provided for emergency operation.
- the photovoltaic solar array 10 of FIG. 1 A comprises a plurality of photovoltaic solar panels 11 - 18 .
- the building structure 5 has been shown as a residential building structure, it should be understood that the photovoltaic solar array 10 may be mounted on virtually any type of building structure or on a ground surface.
- each of the plurality of photovoltaic solar panels 11 - 18 is made from a multiplicity of photovoltaic solar cells 19 .
- Each of the photovoltaic solar cells 19 may generate, for example, approximately 0.5 volts. When connected in series—parallel, the cells 19 together may provide, for example, approximately 300 watts of power at 30 volts.
- individual photovoltaic solar panels 11 - 18 are mounted on equatorial mounts (not shown) for following the movement of the sun throughout the day.
- FIG. 1 B shows a schematic diagram of a cable integrated solar inverter system 102 according to one embodiment.
- the cable integrated solar inverter system 101 includes a trunk cable 102 , a plurality of distributed power converters 206 , each distributed along the trunk cable 102 , and a grid interface unit 106 .
- the power converters 206 are each electrically connected to one of a plurality of photovoltaic modules 11 - 18 .
- the power converters 206 are also connected to one another in series via the trunk cable 102 .
- the power converters 206 are each configured to function as a half-sine wave power converter.
- the power converters 206 convert DC power received from the photovoltaic modules 11 - 18 into rectified half-sine wave signals, which are added and delivered to the grid interface unit 106 via the trunk cable 102 .
- the grid interface unit 106 then converts the signals received from the power converters 206 into a full AC sine-wave power signal suitable for delivery to a power grid.
- the power converters are integrated into the trunk cable 102 , which connects the power converters 206 in series.
- the trunk cable 102 comprises a 30-ampere rated AC cable.
- the trunk cable 102 extends between the integrated power converters 206 , which can be embedded, enclosed, or otherwise integrated into the cable in a variety of ways.
- trunk cable ends 110 a and 110 b are both connected to grid interface unit 106 . In other embodiments, trunk cable end 110 b is connected to grid interface unit 106 and terminal 110 a is terminated.
- grid interface unit 106 includes elements that are not required to be in close proximity to photovoltaic modules 11 - 18 .
- the grid interface unit 106 may include fault detection systems, monitoring systems, synchronization systems, unfolding circuitry, interface and communication circuitry and/or the like.
- the grid interface unit 106 supplies the grid with AC power.
- the distributed power converter system is configured for converting DC Power (e.g., produced by solar panels and/or photovoltaic panels) into AC power suitable for supplying a power grid.
- the power converters 206 are connected in series to one another and each power converter is connected to a photovoltaic panel.
- FIG. 2 A shows an isometric view of a cable integrated distributed power converter according to one embodiment.
- the power converter 206 comprises a removable cartridge 211 that can be selectively removed from the trunk cable 102 .
- the power converter cartridge 211 is configured to be selectively secured to a housing 208 .
- the housing 208 may be constructed from a thermally conductive material (e.g., metals, metal alloys, thermally conductive plastic, a combination of plastics and metals and/or the like).
- the housing 208 may be constructed from thermally conductive plastic and include a metal heat-sink.
- the power converter cartridge 211 may be constructed from similar thermally conductive materials and in similar manner.
- the housing 208 is a generally rigid member defining a generally horizontal, flat base and a central recessed area 214 configured for receiving the removable power converter cartridge 211 .
- Opposing ends of the housing 208 are attached to the trunk cable 102 .
- the trunk cable 102 is secured to the housing 208 in a weather-proof manner (e.g., via weather-proof rubber grommets 213 a , 213 b , or by overmolding the housing onto the trunk cable).
- the power converter cartridge 211 defines a generally rigid exterior shell configured for insertion into the recessed area 214 of the housing 208 . As explained in greater detail below, the power converter's electronic components are sealed within the cartridge 211 and thereby shielded from outside weather. As shown in FIG. 2 A , the power converter cartridge 211 includes positive and negative terminals 202 , 204 configured for connection to the photovoltaic modules 11 - 18 . In particular, the terminals 202 , 204 enable the power converter 206 to receive DC power from the photovoltaic modules 11 - 18 , which the power converter 206 then converts into a rectified half-sine signal as described below.
- the power converter cartridge 211 also includes connection terminals 210 b on its opposing ends for providing an electrical connection between the power converter cartridge 211 its housing 208 .
- the housing 208 includes corresponding connection terminals 210 a , which protrude inwardly into the housing's recessed area 214 .
- the power converter cartridge's connector terminals 210 b are conductive cavities configured for reviving the housing's connector terminals 210 a .
- the connecters 210 a and 210 b help secure the power converter cartridge 211 in housing 208 .
- the power converter cartridge 211 and housing 208 each include two connecters.
- the power converter cartridge 211 and housing 208 include a single connector or multiple connecters (e.g., three connecters, four connecters, five connecters and/or the like).
- the connecters may comprise flat electrical contacts that are merely in contact with one another.
- the electrical connectors are configured to provide dedicated electrical connections between the power converter 206 , adjacent power converters 206 , and the above-described grid interface unit 106 .
- the electrical connectors comprise a power connection line, a fault detection line, and a synchronization line between the power converters 206 and grid interface unit 106 .
- the power converter cartridge is configured to be removably secured within the housing 208 .
- FIG. 2 B shows the power converter cartridge 211 secured within housing 208 .
- the housing 208 may include a latch or other fastening device (not shown) for securing and/or releasing the power converter cartridge.
- the shape of the housing 208 facilitates the power converter cartridge 211 snapping in place when inserted into the housing.
- power converters 206 may include a light emitting diode (LED) to indicate that status of the power converter.
- the LED may display a green light if the power converter is properly secured in place.
- the LED may display a red light if the power converter is loose and/or not properly secured within housing 208 .
- power converters 206 may be configured to measure the amount of power being outputted by the power converter and display the measurement as an LED output.
- the LED be configured to flash up to 10 times where each flash represents a percentage of measured power output compared to total power output. For example, 2 flashes corresponds to a measurement of 20 percent of total power output up and 9 flashes corresponds to 90 percent of total power output for the power converter
- the power converter 206 electronics are contained within the power converter cartridge 211 .
- a jumper cartridge may be inserted to bridge the gap left by the power converter cartridge.
- a set of connectors may be provided to connect the power converter to the cable. The connectors left on the cable after removal of the power converter can then be directly connected together, thereby connecting the gap left from removal of the converter.
- a power converter 206 is determined to be faulty, it may be easily replaced by inserting a new power converter cartridge 211 into a respective housing 208 .
- each of the power converters 206 shown in FIG. 1 B may take the configuration shown and described with respect to FIGS. 2 A and 2 B .
- the cable integrated solar inverter system may comprise numerous power converters 206 (e.g., 10 power converters) spread evenly along a length of the trunk cable 102 in order to facilitate ease of connection to photovoltaic modules.
- the power converters 206 may not be integrated directly into the trunk cable 102 .
- the power converters may be configured such that individual sections of trunk cable can be removably secured to each power converter 206 .
- the trunk cable 102 is comprised of numerous sections of cable.
- FIG. 3 shows an isometric view of a cable integrated power converter according to another embodiment.
- the power converter's electronics are contained within a housing 311 , which may be sealed for weather proofing.
- the power converter's housing includes positive and negative terminals 305 , 308 , which are configured to enable the power converter to be connected to a photovoltaic module.
- the housing 311 also includes terminals 302 a , 302 b , and 302 c disposed on its opposing ends.
- the terminals 302 a , 302 b , and 302 c configured to provide a detachable electrical connection with the trunk cable 102 at both ends of the housing 311 .
- FIG. 3 shows an isometric view of a cable integrated power converter according to another embodiment.
- the power converter's electronics are contained within a housing 311 , which may be sealed for weather proofing.
- the power converter's housing includes positive and negative terminals 305 , 308 , which are configured to enable the power converter
- the trunk cable 102 includes corresponding connection terminals 304 a , 304 b , and 304 c .
- the opposite end of the power converter 206 (obstructed from view in FIG. 3 ) is connected to a second section of the trunk cable 102 in the same fashion.
- the corresponding pairs of power converter and trunk cable connection terminals 302 a / 304 a ; 302 b / 304 b ; and 302 c / 304 c are configured to provide dedication electrical connections between the power converter 206 , adjacent power converters 206 , and the above-described grid interface unit 106 .
- the terminals 302 a / 304 a connect a power connection line
- the terminals 302 b / 304 b connect a fault detection line
- the terminals 302 c / 304 c connect a synchronization line, each of which is established between the power converters 206 and grid interface unit 106 .
- the terminals 302 a / 304 a , 302 b / 304 b , and 302 c / 304 c may be integrated into a single multi-pin interface.
- a faulty power converter 206 may be replaced by disconnecting the trunk cable 102 from the power converter 206 and connecting the trunk cable 102 to a new power converter 206 of the same type.
- the practical operation of the cabling system of FIG. 3 is similar to the operation described above with reference to FIG. 2 A and FIG. 2 B .
- the illustrated housing 311 may be an expanded housing configured to house two or more power converters 206 .
- each of the connections 304 a - 304 c would be repeated such that each of the two or more power converters 206 has a dedicated connection to the trunk cable.
- the two or more power converters 206 in the expanded housing would share a controller.
- FIGS. 4 A and 4 B show an overhead view of a cable integrated power converter according to another embodiment.
- the power converter's electronics are contained within a power converter cartridge 411 configured for being removably secured between brackets 404 and 402 disposed at ends of sections of the trunk cable 102 .
- the power converter cartridge 411 is configured for being connected via positive and negative terminals (not shown) to a photovoltaic module 11 - 18 as described above.
- brackets 404 and 402 is configured for removable attachment to opposite ends of the power converter cartridge 411 .
- bracket 404 includes protruding elements 404 a and 404 b for removably attaching trunk cable 102 to the power converter cartridge 411 .
- bracket 402 includes protruding elements 402 a and 402 b for removably attaching trunk cable 102 to the power converter cartridge 411 .
- the shape of the edges of brackets 404 and 402 correspond to the shape of the edges of the power converter cartridge 411 . Inserting the power converter cartridge 411 into bracket 402 secures the power converter cartridge 411 between elements 402 a and 402 b .
- bracket 402 secures the power converter cartridge 411 between elements 404 a and 404 b .
- the protruding elements 404 a,b ; 402 a,b may be configured to partially surround and engage the power converter cartridge 411 using a press-fit configuration, snap-fit configuration, a latch, a magnetic attachment, or by other suitable means.
- FIG. 4 A shows the power converter cartridge 411 disconnected from trunk cable 102
- FIG. 4 B shows the power converter cartridge 411 connected and secured to the trunk cable 102
- the trunk cable 102 is electrically connected to the brackets 404 and 402 (e.g., with weather-proof rubber grommets 413 a , 413 b to secure the connection).
- the brackets 404 , 402 are configured for electrically connecting the power converter cartridge 411 to the trunk cable 102 via projecting terminals 406 a and 408 a .
- the projecting terminals 406 a and 408 a are configured for insertion into corresponding terminals 406 b and 408 b of the power converter cartridge 411 .
- inserting the terminals 406 a into the terminals 406 b establishes an electrical connection between a first section of the trunk cable 102 and the power converter cartridge 411
- inserting the terminals 408 a into the terminals 408 b establishes an electrical connection between a second section of the trunk cable 102 and the power converter cartridge 411
- the connected terminals 408 and 406 help secure the power converter cartridge 411 to the brackets 402 , 404 and trunk cable 102 .
- the corresponding pairs of power converter cartridge 411 and trunk cable 102 connection terminals 408 a / 408 b , and 406 a / 406 b are configured to provide dedicated electrical connections between the power converter 206 , adjacent power converters 206 , and the above-described grid interface unit 106 .
- the three prongs of the electrical connections 408 a,b and 406 a,b shown in FIGS. 4 A and 4 B represent a power connection line, a fault detection line, and a synchronization line, respectively.
- the connection terminals may be integrated into a single multi-pin interface or any other suitable electrical connection interface.
- the power converter cartridge 411 and housing 208 may include a single connector or multiple connecters (e.g., four connecters, five connecters and/or the like). Additionally, in further embodiments, the connecters may comprise flat electrical contacts that are merely in contact with one another.
- FIG. 5 A shows a schematic circuit diagram of a cable integrated solar inverter system according to one embodiment.
- the photovoltaic modules 11 - 18 are each connected to a respective power converter 206 .
- each power converter 206 may be a cable integrated power converter having any of the various configuration described herein (e.g., as shown in FIGS. 2 A- 4 B ).
- the power converters 206 are connected to one another in series and are synchronized to ensure that the output of each power converter 206 is in-sync with the other converters 206 (as described in relation to FIG. 8 A-B ).
- each power converter 206 is added to produce a power converter output 510 , as indicated in FIG. 5 A .
- the output of each power converter is similar to the output 510 .
- the synchronization ensures that when the output of each converter is added, the wave form 510 is maintained.
- the DC power from a photovoltaic module 11 - 18 is delivered to a buck converter within each power converter 206 .
- the buck converter is configured to produce a half-sine wave (or rectified wave).
- the buck converters each utilize pulse width modulation and an output filter to produce a half-sine wave from the input DC power signal.
- the output voltages are added to produce a half-sine wave at the end of the trunk cable that is the sum of the voltage output from each power converter.
- this configuration allows the use of smaller components that are rated for lower voltage than would ordinarily be required to convert or invert the same amount of power.
- this configuration may utilize smaller components rated to block only the voltage on the photovoltaic modules 11 - 18 .
- the components do not necessarily have to be rated to block the entire voltage of the string, which allows for the use of lower cost components (e.g., in comparison to a design requiring a higher rating).
- the power converters 206 are configured to independently control their output to draw maximum power from their respective photovoltaic modules while also maintaining a smooth half-sine wave shape (e.g., sine wave without significant electrical fluctuations or spikes).
- FIG. 6 shows a circuit diagram for a power converter 206 according to one embodiment. The boxes marked in phantom within FIG. 6 show different circuit operation steps associated with control system 600 . The voltage from each photovoltaic module is first measured and filtered, and the difference between the voltage at the panel and the known maximum power point voltage (Vmp) is calculated circuit operation step 602 .
- Vmp maximum power point voltage
- the control system 600 receives a voltage reading from the photovoltaic module and then subtracts the received voltage from the voltage determined from a maximum power point tracking (MPPT) routine.
- MPPT maximum power point tracking
- the output from circuit operation step 602 is then fed into a proportional-integral (PI) controller as shown in circuit operation step 604 .
- PI proportional-integral
- the PI controller multiplies the determined difference (e.g., error) by a first constant gain and a second gain multiplied by an integral term that increases over time at circuit operation step 604 .
- first and second products above are then added.
- the added sum above is then multiplied by a rectified sine-wave to modulate the sum into a rectified sine wave shape at circuit operation step 606 .
- the product of this multiplication is then compared to the actual output current flowing through the string of power converters and the trunk cable circuit operation step 606 . For example, the actual current flow through the string of power converters is subtracted from the current determined at circuit operation step 606 .
- the difference between these two signals represents an error signal, which is fed into a second PI controller at circuit operation step 608 .
- the second PI controller is generally similar to the PI controller described above.
- the output of the second PI controller is then fed into the power width modulation (PWM) software routine, which continuously modulates switching transistors in the power converters to generate a smooth half-sine output at circuit operation step 610 .
- PWM power width modulation
- the two level filtering process optimizes the voltage and current independently and simultaneously. This ensures that the control system achieves the smooth desirable power results in a fast and an efficient manner.
- the control system 600 achieves a steady state the power output remains optimized. When unexpected events that affect the power output occur the system will automatically adjust in a manner similar to the described above.
- a control system similar to exemplary control system 600 may be implemented in each power converter (e.g., power converter cartridges 211 , 311 , and 411 ).
- a blocking diode 506 is connected in series with the power converters 206 to prevent electrical signals from propagating towards the power converters 206 and photovoltaic modules.
- the power converter output 510 is then transmitted to an unfolding bridge 504 for conversion to a pure or a full AC signal.
- the unfolding bridge 504 is housed within the grid interface unit 106 (shown in FIG. 1 B ). Generally, the unfolding bridge is configured to convert the output signal 510 generated collectively by the power converters 206 into an AC power signal (e.g., suitable for supply to a power grid). In particular, as shown in FIG. 5 B , the unfolding bridge 504 is configured to convert the half-sine wave 510 output by the power converters 206 into a full sine wave 512 (illustrated as the unfolding bridge output). The unfolding bridge output 512 is then transmitted back to a power grid 508 .
- the circuitry within the grid interface unit 106 functions as an H-bridge configured to reverse the polarity of the power converter output signal 510 on alternate sine pulses. Reversing the polarity, in turn, converts the rectified half-sine wave shape 510 into a pure sine wave shape 512 suitable for delivery to a power grid.
- sine wave may be used to refer to a cosine wave, a shifted sine wave, a shifted cosine wave, any sinusoidal signal, any sinusoidal combination of signals or the like.
- half-sine wave may refer to a half-cosine wave, a shifted half-sine wave, a shifted half-cosine wave, any half-sinusoidal signal, half-sinusoidal combination of signals or the like.
- the grid interface unit 106 (including its unfolding circuitry) is located remotely from the power converters 206 and the photovoltaic modules 11 - 18 .
- the power converters 206 and photovoltaic modules 11 - 18 may be located in an outdoor environment
- the grid interface unit 106 may be located in an indoor environment or secured within a separate weather resistant housing.
- FIG. 7 shows a schematic circuit diagram of a cable integrated solar inverter system according to a different embodiment.
- the power converters 206 collectively construct an output 510 , similar to FIG. 5 A .
- a first power converter may produce the base portion of output 510
- a second power converter produces a middle portion of output 510
- a third power converter produces a top portion of output 510 .
- the output from the 3 power converters may be added to produce power converter output 510 .
- a first power converter 206 in order to construct the rectified (half-sine) wave 510 , a first power converter 206 generates base portion 510 c of the rectified (half-sine) wave, a second power converter 206 generates middle portion 510 b of the rectified (half-sine) wave, and a third power converter 206 generates top portion 510 a of the rectified (half-sine) wave.
- the power converters 206 are connected to one another in series and are synchronized to ensure that the output of each power converter 206 is in-sync with the other converters 206 . Therefore the signals 510 a , 510 b and 510 c are added to one another to create the rectified (half-sine) wave 510 .
- the converters output 510 is constructed by three different converters 206 .
- the converters output 510 may be constructed by more or less power converters 206 .
- the output 510 may be constructed by 2, 5, or 10 power converters 206 .
- the photovoltaic system 7 has been set described as a single phase 120 volt 60 hertz electrical system, it should be understood that the present invention is suitable for use with other types of electrical systems including 240 volt 50-60 hertz grid systems. In addition, it should be understood that the present invention is suitable for with other types of renewable energy sources such as windmills, water wheels, geothermal and is suitable for with other types energy storages devices such as fuel cells, capacitor banks and/or the like.
- communication and synchronization data between the grid interface unit 106 and power converters 206 may be sent as signals along one combined synchronization and communications wire in the trunk cable 102 .
- the output power 510 must be correctly synchronized to the grid as described in relation to FIGS. 5 - 7 .
- the grid interface unit 106 is configured to synchronize the output power 510 to the grid.
- the grid interface unit 106 is configured to monitor the grid 508 and detect the zero crossing point in grid 508 's AC voltage.
- the grid interface unit 106 then broadcasts a synchronization signal in the form of a square wave on a dedicated synchronization wire, in trunk cable 102 , to each of the power converters 206 connected to the trunk cable.
- Each of the power converters 206 are configured to synchronize each of their individual outputs to output 510 by monitoring the incoming synchronization signal square wave broadcast by grid interface unit 106 on the dedicated synchronization wire in trunk cable 102 .
- the current or voltage on the communications wire is sourced by the grid interface unit 106 and can vary between a high and low state.
- Each power converter 206 is configured to detect the zero crossing point of grid 508 by sensing a transition from high to low (or alternatively low to high) in the synchronization signal. As each power converter 206 receives the synchronization signal, each power converter is configured to begin creating the half sine voltage signal in synchronization with the other power converters and grid 508 .
- this command data is used for system monitoring and control and may include requests for status of the power converters 206 , addressing commands of the power converters 206 , requests for voltage, current, or power levels being measured by the power converters 206 , and/or fault or shutdown commands.
- this data is transferred through a dedicated serial communications line, in addition to the line used for synchronization.
- the serial communication signal and the synchronization signal are combined into a single signal on one wire by reserving certain periods of time for the synchronization signal, with the remainder of the time reserved for serial data transmission.
- FIG. 8 A depicts an exemplary combined synchronization and serial communication electrical signal 802 broadcast on a combined synchronization and communication line.
- grid 508 may operate at a nominal 60 Hz rate, thus the zero crossing signal happens twice per cycle at approximate 8.33 millisecond intervals.
- the synchronization signal produced by grid interface unit 106 will thus switch between high and low at approximately every 8.33 millisecond at as depicted at times 804 .
- the power converters 206 will observe guard bands 808 around the zero crossing transition during which no data can be sent down the line. For example, this guard band can be approximately 2 milliseconds around each zero crossing.
- the power converters 206 are configured to monitor the combined serial communication and synchronization signal to measure the timing of each transition.
- This transition is used to synchronize the power converters 206 to the power line to produce a synchronized output, such as output 510 .
- the grid interface unit 106 sends other relevant or command data to the power converters 206 .
- the synchronization signal is included as part of a communication packet.
- the grid interface unit may be configured to utilize a standard Universal Asynchronous Receiver Transmitter (UART) Non Return to Zero Encoding (NRZ) physical layer and a link layer carrying a packet of information.
- UART Universal Asynchronous Receiver Transmitter
- NRZ Non Return to Zero Encoding
- FIG. 8 B depicts a serial representation of an exemplary combined synchronization and serial communication electrical communication packet 820 utilizing a standard UART.
- a first zero crossing synchronization happens at the first edge of the Start Bit 822 , during the change from Idle to Start Bit.
- a microcontroller I/O port in each power converter 206 is configured both as an external edge triggered interrupt and a as a UART Receiver Port. This allows the first edge change, Start Bit 822 , of combined packet 820 to the power converters 206 , to be used as a synchronization trigger for the power converters 206 to start outputting a rectified sine wave.
- an external Edge Interrupt Service Routine (ISR) located in each power converter 206 may begin the process of the rectified sine wave building.
- the microcontroller I/O port is also configured as a UART Receiver, all bytes 824 , corresponding to the command data from the grid interface unit to the power converters 206 , can also be received.
- the edge interrupt capability is disabled for a certain period of times, such as approximately 8 ms in the case of a 120 Hz half sine waves, so that all the bytes of the packet can arrive without falsely triggering zero crossing signaling.
- the packet of information is smaller than the period of the rectified sine wave. This results in an idle time allowing the power convert 206 to enable the edge interrupt again or to allow the reserved time for synchronization signal.
- the power converters 206 can respond by either sending pulses of current or voltage along the same wire at a designated period within the cycle, or across a different wire in trunk cable 102 .
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Abstract
Description
- This application is a continuation of a U.S. continuation patent application Ser. No. 17/174,771 filed on Feb. 12, 2021, which is a continuation of U.S. non-provisional patent application Ser. No. 15/383,647, entitled “Cable Integrated Solar Inverter” and filed on Dec. 19, 2016, which claims priority from provisional U.S. Application No. 62/269,754, entitled “Cable Integrated Solar Inverter” and filed on Dec. 18, 2015, each of which is herein incorporated by reference in its entirety.
- Photovoltaic (PV) cells are currently used to harvest solar energy for use in both commercial and residential environments. To enable more widespread adoption of solar power, however, it is important to minimize the cost per watt for the power harvested. This requires all elements of a solar power system to be designed with both cost and system energy requirements taken into account. As solar power systems comprise several components in addition to the PV cell, development of these components also affects the evolution of the entire solar power system.
- In order to produce power useable for most purposes, the direct current (DC) produced by a PV cell must be converted to alternating current (AC) having the frequency of the local utility. This conversion is typically accomplished by an inverter. A stand-alone inverter is used in totally isolated systems that normally do not interface with the utility grid. More sophisticated inverters convert the DC to AC at the utility frequency and ensure maintaining the AC inverter output in phase with the utility grid AC phase.
- As the DC to AC conversion of power harvested from PV cells is a necessary function of solar power systems, there is on-going need in the art to reduce the cost associated with inverter systems, their installation, and long-term maintenance.
- Various embodiments of the present invention are directed to an improved solar inverter system for generating AC power from photovoltaic solar panels or other DC power sources. In various embodiments, a cable integrated solar inverter is provided for converting DC power from solar modules to AC power for supplying a grid. In one embodiment, power converter cartridges are integrated into trunk cable and connected to solar panels. The power converter cartridges are connected in series via the trunk cable, which then provides the combined output from the plurality of power converters to a grid interface unit. In one embodiment, the grid interface unit receives a rectified (half-sine) wave and converts the rectified wave into a pure AC signal. According to various embodiments, the grid interface unit may include fault detection systems, monitoring systems, synchronization systems, unfolding circuitry, interface and communication circuitry and/or the like.
- Particular embodiments of the subject matter described herein can be implemented so as to realize one or more of the following advantages: allow for embedding and/or incorporating power converters and/or converter circuitry within a cabling system and for more efficient power conversion from solar energy systems; reduce the cost and resources required for installing and maintaining solar energy systems; provide an easy to service system improving the user experience of customers and service personnel; eliminate unnecessary service interruptions; and provide a more efficient and improved optimization process and capabilities.
- The details of one or more embodiments of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description and the drawings.
- Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
-
FIG. 1A shows a residential environment having a photovoltaic power system according to one embodiment; -
FIG. 1B is shows a schematic of a cable integrated solar inverter system according to one embodiment; -
FIG. 2A shows an isometric view of a power converter cartridge and housing in which the power converter cartridge is detached from the housing according to one embodiment; -
FIG. 2B shows an isometric view of the power converter cartridge and housing ofFIG. 2A in which the power converter cartridge is secured to the housing; -
FIG. 3 shows isometric view of a cable integrated power converter according to another embodiment; -
FIG. 4A shows a plan view of cable integrated power converter according to yet another embodiment; -
FIG. 4B shows a plan view of cable integrated power converter according to yet another embodiment; -
FIG. 5A is an exemplary schematic diagram of a cabling system according to one embodiment; -
FIG. 5B depicts an exemplary electrical signal transformation at an exemplary unfolding bridge according to one embodiment; -
FIG. 6 is an exemplary control system block diagram according to one embodiment; -
FIG. 7 is an exemplary schematic diagram of a cabling system according to another embedment; -
FIG. 8A depicts an exemplary combined synchronization and serial communication electrical signal; and -
FIG. 8B depicts a serial representation of an exemplary combined synchronization and serial communication electrical communication packet. - Various embodiments of the present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The term “or” is used herein in both the alternative and conjunctive sense, unless otherwise indicated. Like numbers refer to like elements throughout.
- According to various embodiments, a cable integrated solar inverter system is provided for converting DC power received from photovoltaic cells into AC power suitable for supply to a power grid. The cable integrated solar inverter system can be used in conjunction with a variety of photovoltaic power systems, including systems in both commercial and residential environments. As an example,
FIG. 1A shows a building structure 5 having a photovoltaic power system interconnected with an AC power grid 9. In the illustrated embodiment, the photovoltaic power system includes a photovoltaicsolar array 10. In particular, thesolar array 10 is configured to generate power in combination with awind turbine 20, which can be stored in an energy storage unit (e.g., comprised of the illustratedbattery array 22 and a fuel cell array 24). In the illustrated embodiment, a fuel operated generator 26 is also provided for emergency operation. - The photovoltaic
solar array 10 ofFIG. 1A comprises a plurality of photovoltaic solar panels 11-18. Although the building structure 5 has been shown as a residential building structure, it should be understood that the photovoltaicsolar array 10 may be mounted on virtually any type of building structure or on a ground surface. In one embodiment, each of the plurality of photovoltaic solar panels 11-18 is made from a multiplicity of photovoltaicsolar cells 19. Each of the photovoltaicsolar cells 19 may generate, for example, approximately 0.5 volts. When connected in series—parallel, thecells 19 together may provide, for example, approximately 300 watts of power at 30 volts. In some instances, individual photovoltaic solar panels 11-18 are mounted on equatorial mounts (not shown) for following the movement of the sun throughout the day. -
FIG. 1B shows a schematic diagram of a cable integratedsolar inverter system 102 according to one embodiment. In the illustrated embodiment, the cable integratedsolar inverter system 101 includes atrunk cable 102, a plurality of distributedpower converters 206, each distributed along thetrunk cable 102, and agrid interface unit 106. As shown inFIG. 1B , thepower converters 206 are each electrically connected to one of a plurality of photovoltaic modules 11-18. Thepower converters 206 are also connected to one another in series via thetrunk cable 102. As explained in greater detail herein, thepower converters 206 are each configured to function as a half-sine wave power converter. In operation, thepower converters 206 convert DC power received from the photovoltaic modules 11-18 into rectified half-sine wave signals, which are added and delivered to thegrid interface unit 106 via thetrunk cable 102. Thegrid interface unit 106 then converts the signals received from thepower converters 206 into a full AC sine-wave power signal suitable for delivery to a power grid. - As shown in
FIG. 1B , the power converters are integrated into thetrunk cable 102, which connects thepower converters 206 in series. As an example, in one embodiment thetrunk cable 102 comprises a 30-ampere rated AC cable. Thetrunk cable 102 extends between theintegrated power converters 206, which can be embedded, enclosed, or otherwise integrated into the cable in a variety of ways. - In some embodiments, trunk cable ends 110 a and 110 b are both connected to
grid interface unit 106. In other embodiments,trunk cable end 110 b is connected togrid interface unit 106 and terminal 110 a is terminated. - In some embodiments,
grid interface unit 106 includes elements that are not required to be in close proximity to photovoltaic modules 11-18. For example, thegrid interface unit 106 may include fault detection systems, monitoring systems, synchronization systems, unfolding circuitry, interface and communication circuitry and/or the like. In one embodiment, thegrid interface unit 106 supplies the grid with AC power. The distributed power converter system is configured for converting DC Power (e.g., produced by solar panels and/or photovoltaic panels) into AC power suitable for supplying a power grid. Thepower converters 206 are connected in series to one another and each power converter is connected to a photovoltaic panel. - As one example,
FIG. 2A shows an isometric view of a cable integrated distributed power converter according to one embodiment. In the illustrated embodiment, to facilitate ease of maintenance and replacement of faulty devices, thepower converter 206 comprises aremovable cartridge 211 that can be selectively removed from thetrunk cable 102. In particular, as shown inFIG. 2A , thepower converter cartridge 211 is configured to be selectively secured to ahousing 208. According to various embodiments, thehousing 208 may be constructed from a thermally conductive material (e.g., metals, metal alloys, thermally conductive plastic, a combination of plastics and metals and/or the like). For example, thehousing 208 may be constructed from thermally conductive plastic and include a metal heat-sink. Likewise, thepower converter cartridge 211 may be constructed from similar thermally conductive materials and in similar manner. - As shown in
FIG. 2A , thehousing 208 is a generally rigid member defining a generally horizontal, flat base and a central recessedarea 214 configured for receiving the removablepower converter cartridge 211. Opposing ends of thehousing 208 are attached to thetrunk cable 102. For example, in the illustrated embodiment, thetrunk cable 102 is secured to thehousing 208 in a weather-proof manner (e.g., via weather-proof rubber grommets - In the illustrated embodiment, the
power converter cartridge 211 defines a generally rigid exterior shell configured for insertion into the recessedarea 214 of thehousing 208. As explained in greater detail below, the power converter's electronic components are sealed within thecartridge 211 and thereby shielded from outside weather. As shown inFIG. 2A , thepower converter cartridge 211 includes positive andnegative terminals terminals power converter 206 to receive DC power from the photovoltaic modules 11-18, which thepower converter 206 then converts into a rectified half-sine signal as described below. - The
power converter cartridge 211 also includesconnection terminals 210 b on its opposing ends for providing an electrical connection between thepower converter cartridge 211 itshousing 208. As shown inFIG. 2A , thehousing 208 includescorresponding connection terminals 210 a, which protrude inwardly into the housing's recessedarea 214. As such, the power converter cartridge'sconnector terminals 210 b are conductive cavities configured for reviving the housing'sconnector terminals 210 a. In the illustrated embodiment, theconnecters power converter cartridge 211 inhousing 208. Moreover, in the illustrated embodiment, thepower converter cartridge 211 andhousing 208 each include two connecters. However, in various other embodiments, thepower converter cartridge 211 andhousing 208 include a single connector or multiple connecters (e.g., three connecters, four connecters, five connecters and/or the like). In further embodiments, the connecters may comprise flat electrical contacts that are merely in contact with one another. - According to certain embodiments, the electrical connectors are configured to provide dedicated electrical connections between the
power converter 206,adjacent power converters 206, and the above-describedgrid interface unit 106. For example, in one embodiment, the electrical connectors comprise a power connection line, a fault detection line, and a synchronization line between thepower converters 206 andgrid interface unit 106. - As noted above, the power converter cartridge is configured to be removably secured within the
housing 208.FIG. 2B shows thepower converter cartridge 211 secured withinhousing 208. According to various embodiments, thehousing 208 may include a latch or other fastening device (not shown) for securing and/or releasing the power converter cartridge. In other embodiments, the shape of thehousing 208 facilitates thepower converter cartridge 211 snapping in place when inserted into the housing. - In certain embodiments,
power converters 206 may include a light emitting diode (LED) to indicate that status of the power converter. For example, the LED may display a green light if the power converter is properly secured in place. Alternatively, the LED may display a red light if the power converter is loose and/or not properly secured withinhousing 208. Additionally,power converters 206 may be configured to measure the amount of power being outputted by the power converter and display the measurement as an LED output. For example, the LED be configured to flash up to 10 times where each flash represents a percentage of measured power output compared to total power output. For example, 2 flashes corresponds to a measurement of 20 percent of total power output up and 9 flashes corresponds to 90 percent of total power output for the power converter - As explained below, the
power converter 206 electronics are contained within thepower converter cartridge 211. In certain embodiments, when thepower converter cartridge 211 is removed from thehousing 208, a jumper cartridge may be inserted to bridge the gap left by the power converter cartridge. In other embodiments, a set of connectors may be provided to connect the power converter to the cable. The connectors left on the cable after removal of the power converter can then be directly connected together, thereby connecting the gap left from removal of the converter. Moreover, when apower converter 206 is determined to be faulty, it may be easily replaced by inserting a newpower converter cartridge 211 into arespective housing 208. - As will be appreciated from the description herein, in one embodiment, each of the
power converters 206 shown inFIG. 1B may take the configuration shown and described with respect toFIGS. 2A and 2B . In particular, the cable integrated solar inverter system may comprise numerous power converters 206 (e.g., 10 power converters) spread evenly along a length of thetrunk cable 102 in order to facilitate ease of connection to photovoltaic modules. However, as will be appreciated from the description herein, in various other embodiments thepower converters 206 may not be integrated directly into thetrunk cable 102. In such embodiments, the power converters may be configured such that individual sections of trunk cable can be removably secured to eachpower converter 206. In this configuration, thetrunk cable 102 is comprised of numerous sections of cable. - As another example,
FIG. 3 shows an isometric view of a cable integrated power converter according to another embodiment. In the illustrated embodiment ofFIG. 3 , the power converter's electronics are contained within ahousing 311, which may be sealed for weather proofing. The power converter's housing includes positive andnegative terminals housing 311 also includesterminals terminals trunk cable 102 at both ends of thehousing 311. For example, as shown inFIG. 3 , thetrunk cable 102 includescorresponding connection terminals FIG. 3 ) is connected to a second section of thetrunk cable 102 in the same fashion. - In one embodiment, the corresponding pairs of power converter and trunk
cable connection terminals 302 a/304 a; 302 b/304 b; and 302 c/304 c are configured to provide dedication electrical connections between thepower converter 206,adjacent power converters 206, and the above-describedgrid interface unit 106. For example, in one embodiment, theterminals 302 a/304 a connect a power connection line, theterminals 302 b/304 b connect a fault detection line, and theterminals 302 c/304 c connect a synchronization line, each of which is established between thepower converters 206 andgrid interface unit 106. As will be appreciated from the description herein, theterminals 302 a/304 a, 302 b/304 b, and 302 c/304 c may be integrated into a single multi-pin interface. - With respect to the illustrated embodiment of
FIG. 3 , afaulty power converter 206 may be replaced by disconnecting thetrunk cable 102 from thepower converter 206 and connecting thetrunk cable 102 to anew power converter 206 of the same type. As a result, the practical operation of the cabling system ofFIG. 3 is similar to the operation described above with reference toFIG. 2A andFIG. 2B . - The illustrated
housing 311 may be an expanded housing configured to house two ormore power converters 206. In this embodiment, each of the connections 304 a-304 c would be repeated such that each of the two ormore power converters 206 has a dedicated connection to the trunk cable. In some examples of this embodiments, the two ormore power converters 206 in the expanded housing would share a controller. - As yet another example,
FIGS. 4A and 4B show an overhead view of a cable integrated power converter according to another embodiment. In the illustrated embodiment ofFIG. 4A , the power converter's electronics are contained within apower converter cartridge 411 configured for being removably secured betweenbrackets trunk cable 102. According to various embodiments, thepower converter cartridge 411 is configured for being connected via positive and negative terminals (not shown) to a photovoltaic module 11-18 as described above. - Each of
brackets power converter cartridge 411. For example,bracket 404 includesprotruding elements trunk cable 102 to thepower converter cartridge 411. Similarly,bracket 402 includesprotruding elements trunk cable 102 to thepower converter cartridge 411. As shown inFIGS. 4A and 4B , the shape of the edges ofbrackets power converter cartridge 411. Inserting thepower converter cartridge 411 intobracket 402 secures thepower converter cartridge 411 betweenelements power converter cartridge 411 intobracket 402 secures thepower converter cartridge 411 betweenelements elements 404 a,b; 402 a,b may be configured to partially surround and engage thepower converter cartridge 411 using a press-fit configuration, snap-fit configuration, a latch, a magnetic attachment, or by other suitable means. -
FIG. 4A shows thepower converter cartridge 411 disconnected fromtrunk cable 102, whileFIG. 4B shows thepower converter cartridge 411 connected and secured to thetrunk cable 102. As illustrated in the figures, thetrunk cable 102 is electrically connected to thebrackets 404 and 402 (e.g., with weather-proof rubber grommets brackets power converter cartridge 411 to thetrunk cable 102 via projectingterminals terminals corresponding terminals power converter cartridge 411. As can be appreciated formFIGS. 4A and 4B , inserting theterminals 406 a into theterminals 406 b establishes an electrical connection between a first section of thetrunk cable 102 and thepower converter cartridge 411, while inserting theterminals 408 a into theterminals 408 b establishes an electrical connection between a second section of thetrunk cable 102 and thepower converter cartridge 411. In addition, the connectedterminals power converter cartridge 411 to thebrackets trunk cable 102. - In one embodiment, the corresponding pairs of
power converter cartridge 411 andtrunk cable 102connection terminals 408 a/408 b, and 406 a/406 b are configured to provide dedicated electrical connections between thepower converter 206,adjacent power converters 206, and the above-describedgrid interface unit 106. For example, in one embodiment, the three prongs of theelectrical connections 408 a,b and 406 a,b shown inFIGS. 4A and 4B represent a power connection line, a fault detection line, and a synchronization line, respectively. However, as will appreciated from the description herein, the connection terminals may be integrated into a single multi-pin interface or any other suitable electrical connection interface. Indeed, in various other embodiments, thepower converter cartridge 411 andhousing 208 may include a single connector or multiple connecters (e.g., four connecters, five connecters and/or the like). Additionally, in further embodiments, the connecters may comprise flat electrical contacts that are merely in contact with one another. -
FIG. 5A shows a schematic circuit diagram of a cable integrated solar inverter system according to one embodiment. As indicated inFIG. 5 a , the photovoltaic modules 11-18 are each connected to arespective power converter 206. As will be appreciated from the description herein, eachpower converter 206 may be a cable integrated power converter having any of the various configuration described herein (e.g., as shown inFIGS. 2A-4B ). In the illustrated embodiment, thepower converters 206 are connected to one another in series and are synchronized to ensure that the output of eachpower converter 206 is in-sync with the other converters 206 (as described in relation toFIG. 8A-B ). The output of eachpower converter 206 is added to produce apower converter output 510, as indicated inFIG. 5A . In one embodiment, the output of each power converter is similar to theoutput 510. The synchronization ensures that when the output of each converter is added, thewave form 510 is maintained. - In one embodiment, the DC power from a photovoltaic module 11-18 is delivered to a buck converter within each
power converter 206. As explained in greater detail below, the buck converter is configured to produce a half-sine wave (or rectified wave). The buck converters each utilize pulse width modulation and an output filter to produce a half-sine wave from the input DC power signal. As thepower converters 206 are connected in series, the output voltages are added to produce a half-sine wave at the end of the trunk cable that is the sum of the voltage output from each power converter. Notably, this configuration allows the use of smaller components that are rated for lower voltage than would ordinarily be required to convert or invert the same amount of power. For example, this configuration may utilize smaller components rated to block only the voltage on the photovoltaic modules 11-18. In other words, the components do not necessarily have to be rated to block the entire voltage of the string, which allows for the use of lower cost components (e.g., in comparison to a design requiring a higher rating). - According to various embodiments, the
power converters 206 are configured to independently control their output to draw maximum power from their respective photovoltaic modules while also maintaining a smooth half-sine wave shape (e.g., sine wave without significant electrical fluctuations or spikes).FIG. 6 shows a circuit diagram for apower converter 206 according to one embodiment. The boxes marked in phantom withinFIG. 6 show different circuit operation steps associated with control system 600. The voltage from each photovoltaic module is first measured and filtered, and the difference between the voltage at the panel and the known maximum power point voltage (Vmp) is calculatedcircuit operation step 602. For example, atcircuit operation step 602, the control system 600 receives a voltage reading from the photovoltaic module and then subtracts the received voltage from the voltage determined from a maximum power point tracking (MPPT) routine. The output fromcircuit operation step 602 is then fed into a proportional-integral (PI) controller as shown incircuit operation step 604. - The PI controller multiplies the determined difference (e.g., error) by a first constant gain and a second gain multiplied by an integral term that increases over time at
circuit operation step 604. In turn, first and second products above are then added. The added sum above is then multiplied by a rectified sine-wave to modulate the sum into a rectified sine wave shape atcircuit operation step 606. The product of this multiplication is then compared to the actual output current flowing through the string of power converters and the trunk cablecircuit operation step 606. For example, the actual current flow through the string of power converters is subtracted from the current determined atcircuit operation step 606. The difference between these two signals represents an error signal, which is fed into a second PI controller at circuit operation step 608. - The second PI controller is generally similar to the PI controller described above. The output of the second PI controller is then fed into the power width modulation (PWM) software routine, which continuously modulates switching transistors in the power converters to generate a smooth half-sine output at
circuit operation step 610. The two level filtering process optimizes the voltage and current independently and simultaneously. This ensures that the control system achieves the smooth desirable power results in a fast and an efficient manner. Once the control system 600 achieves a steady state the power output remains optimized. When unexpected events that affect the power output occur the system will automatically adjust in a manner similar to the described above. As will be appreciated from the description herein, a control system similar to exemplary control system 600 may be implemented in each power converter (e.g.,power converter cartridges - Referring back to
FIG. 5A , a blockingdiode 506 is connected in series with thepower converters 206 to prevent electrical signals from propagating towards thepower converters 206 and photovoltaic modules. Thepower converter output 510 is then transmitted to an unfoldingbridge 504 for conversion to a pure or a full AC signal. - In the illustrated embodiment of
FIG. 5A , the unfoldingbridge 504 is housed within the grid interface unit 106 (shown inFIG. 1B ). Generally, the unfolding bridge is configured to convert theoutput signal 510 generated collectively by thepower converters 206 into an AC power signal (e.g., suitable for supply to a power grid). In particular, as shown inFIG. 5B , the unfoldingbridge 504 is configured to convert the half-sine wave 510 output by thepower converters 206 into a full sine wave 512 (illustrated as the unfolding bridge output). The unfoldingbridge output 512 is then transmitted back to apower grid 508. - According to one embodiment, the circuitry within the
grid interface unit 106 functions as an H-bridge configured to reverse the polarity of the powerconverter output signal 510 on alternate sine pulses. Reversing the polarity, in turn, converts the rectified half-sine wave shape 510 into a puresine wave shape 512 suitable for delivery to a power grid. It is understood that the term “sine wave” may be used to refer to a cosine wave, a shifted sine wave, a shifted cosine wave, any sinusoidal signal, any sinusoidal combination of signals or the like. Similarly, the term “half-sine wave” may refer to a half-cosine wave, a shifted half-sine wave, a shifted half-cosine wave, any half-sinusoidal signal, half-sinusoidal combination of signals or the like. - Referring back to the illustrated embodiment of
FIG. 1B , the grid interface unit 106 (including its unfolding circuitry) is located remotely from thepower converters 206 and the photovoltaic modules 11-18. For example, while thepower converters 206 and photovoltaic modules 11-18 may be located in an outdoor environment, thegrid interface unit 106 may be located in an indoor environment or secured within a separate weather resistant housing. -
FIG. 7 shows a schematic circuit diagram of a cable integrated solar inverter system according to a different embodiment. In this illustrated embodiment, thepower converters 206 collectively construct anoutput 510, similar toFIG. 5A . However, in this embodiment a first power converter may produce the base portion ofoutput 510, while a second power converter produces a middle portion ofoutput 510 and a third power converter produces a top portion ofoutput 510. The output from the 3 power converters may be added to producepower converter output 510. For example, in order to construct the rectified (half-sine)wave 510, afirst power converter 206 generates base portion 510 c of the rectified (half-sine) wave, asecond power converter 206 generates middle portion 510 b of the rectified (half-sine) wave, and athird power converter 206 generates top portion 510 a of the rectified (half-sine) wave. In the illustrated embodiment, thepower converters 206 are connected to one another in series and are synchronized to ensure that the output of eachpower converter 206 is in-sync with theother converters 206. Therefore the signals 510 a, 510 b and 510 c are added to one another to create the rectified (half-sine)wave 510. In the illustrated embodiment, theconverters output 510 is constructed by threedifferent converters 206. However, in other embodiments theconverters output 510 may be constructed by more orless power converters 206. For example, theoutput 510 may be constructed by 2, 5, or 10power converters 206. - Although the photovoltaic system 7 has been set described as a single phase 120 volt 60 hertz electrical system, it should be understood that the present invention is suitable for use with other types of electrical systems including 240 volt 50-60 hertz grid systems. In addition, it should be understood that the present invention is suitable for with other types of renewable energy sources such as windmills, water wheels, geothermal and is suitable for with other types energy storages devices such as fuel cells, capacitor banks and/or the like.
- According to various embodiments, communication and synchronization data between the
grid interface unit 106 andpower converters 206, may be sent as signals along one combined synchronization and communications wire in thetrunk cable 102. In general, in order for the system described in the above to function correctly, theoutput power 510 must be correctly synchronized to the grid as described in relation toFIGS. 5-7 . In various embodiments, thegrid interface unit 106 is configured to synchronize theoutput power 510 to the grid. For example, in one embodiment, thegrid interface unit 106 is configured to monitor thegrid 508 and detect the zero crossing point ingrid 508's AC voltage. Thegrid interface unit 106 then broadcasts a synchronization signal in the form of a square wave on a dedicated synchronization wire, intrunk cable 102, to each of thepower converters 206 connected to the trunk cable. Each of thepower converters 206 are configured to synchronize each of their individual outputs tooutput 510 by monitoring the incoming synchronization signal square wave broadcast bygrid interface unit 106 on the dedicated synchronization wire intrunk cable 102. The current or voltage on the communications wire is sourced by thegrid interface unit 106 and can vary between a high and low state. Eachpower converter 206 is configured to detect the zero crossing point ofgrid 508 by sensing a transition from high to low (or alternatively low to high) in the synchronization signal. As eachpower converter 206 receives the synchronization signal, each power converter is configured to begin creating the half sine voltage signal in synchronization with the other power converters andgrid 508. - In addition to the synchronization among the power converters, there also is a requirement to exchange serial data or command data between the
power converters 206 and thegrid interface unit 106. In some embodiments, this command data is used for system monitoring and control and may include requests for status of thepower converters 206, addressing commands of thepower converters 206, requests for voltage, current, or power levels being measured by thepower converters 206, and/or fault or shutdown commands. In some embodiments this data is transferred through a dedicated serial communications line, in addition to the line used for synchronization. However, it is advantageous to combine the synchronization line and the serial communications line into one line or wire, to reduce the wiring needs and overall system cost. - In one embodiment, the serial communication signal and the synchronization signal are combined into a single signal on one wire by reserving certain periods of time for the synchronization signal, with the remainder of the time reserved for serial data transmission.
-
FIG. 8A depicts an exemplary combined synchronization and serial communicationelectrical signal 802 broadcast on a combined synchronization and communication line. For example,grid 508 may operate at a nominal 60 Hz rate, thus the zero crossing signal happens twice per cycle at approximate 8.33 millisecond intervals. The synchronization signal produced bygrid interface unit 106 will thus switch between high and low at approximately every 8.33 millisecond at as depicted attimes 804. Thepower converters 206 will observeguard bands 808 around the zero crossing transition during which no data can be sent down the line. For example, this guard band can be approximately 2 milliseconds around each zero crossing. Duringbands 808 surrounding each transition in the signal, thepower converters 206 are configured to monitor the combined serial communication and synchronization signal to measure the timing of each transition. This transition is used to synchronize thepower converters 206 to the power line to produce a synchronized output, such asoutput 510. Outside of theguard bands 808, incommunication time 806, thegrid interface unit 106 sends other relevant or command data to thepower converters 206. - In one embodiment, the synchronization signal is included as part of a communication packet. For example the grid interface unit may be configured to utilize a standard Universal Asynchronous Receiver Transmitter (UART) Non Return to Zero Encoding (NRZ) physical layer and a link layer carrying a packet of information.
-
FIG. 8B depicts a serial representation of an exemplary combined synchronization and serial communicationelectrical communication packet 820 utilizing a standard UART. - For example, a first zero crossing synchronization happens at the first edge of the Start Bit 822, during the change from Idle to Start Bit. In some examples, a microcontroller I/O port in each
power converter 206 is configured both as an external edge triggered interrupt and a as a UART Receiver Port. This allows the first edge change, Start Bit 822, of combinedpacket 820 to thepower converters 206, to be used as a synchronization trigger for thepower converters 206 to start outputting a rectified sine wave. For example, an external Edge Interrupt Service Routine (ISR) located in eachpower converter 206 may begin the process of the rectified sine wave building. Furthermore, because the microcontroller I/O port is also configured as a UART Receiver, allbytes 824, corresponding to the command data from the grid interface unit to thepower converters 206, can also be received. - Furthermore, inside of the ISR, the edge interrupt capability is disabled for a certain period of times, such as approximately 8 ms in the case of a 120 Hz half sine waves, so that all the bytes of the packet can arrive without falsely triggering zero crossing signaling. In some examples, the packet of information is smaller than the period of the rectified sine wave. This results in an idle time allowing the
power convert 206 to enable the edge interrupt again or to allow the reserved time for synchronization signal. In some examples, to respond to messages sent by thegrid interface unit 106, thepower converters 206 can respond by either sending pulses of current or voltage along the same wire at a designated period within the cycle, or across a different wire intrunk cable 102. - While this specification contains many specific embodiment details, these should not be construed as limitations on the scope of any inventions described herein, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described herein in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations, one or more features from a combination can in some cases be excised from the combination, and the combination may be directed to a sub-combination or variation of a sub-combination.
- Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single product or packaged into multiple products.
- Thus, particular embodiments of the subject matter have been described. Other embodiments are within the scope of the specification above. In some cases, the actions recited in the specification can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain embodiments, multitasking and parallel processing may be advantageous.
- Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the application.
Claims (19)
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CN108633320A (en) | 2018-10-09 |
US10951161B2 (en) | 2021-03-16 |
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TW201801437A (en) | 2018-01-01 |
WO2017106842A1 (en) | 2017-06-22 |
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TWI788194B (en) | 2022-12-21 |
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