This invention generally relates to modular solar systems that comprise one or more module units that are connectable into a system/assembly for convenient installation on a roof or other surface that receives solar insolation. The modules are adapted for electrical, and preferably also mechanical, connection into a module assembly, with the number of modules and types of modules selected to handle the required loads. Each module is adapted and designed to handle the entire power of the assembly and to provide or receive control signals for cooperative performance between all the modules and for monitoring and communication regarding the assembly performance and condition.
For AC power systems (and all power systems where there is a load and a supply), the generation (supply power) and demand (load) must be equal. In other words, the Utility Supply must equal the Customer Load. If there is ever a power outage, the re-connection of the circuits after the fault is cleared must be done carefully to assure that the loads are connected in a phased or staged fashion. This assures that the required balance is maintained while restoring power.
AC distribution systems are designed in such a way to allow this. There are distribution systems (with protection in the form of fuses and circuit breakers) with switches to allow each part of the system to be isolated and controlled.
On both sides (supply and demand) of a conventional Utility Grid, the system is designed in sections or blocks of power to allow for this distribution and equalization. These divisions are isolated by circuit breakers, load centers, distribution panels, transformers and utility substations. This is because the power needs to be carefully distributed from available generation systems that are in turn delivered to quantified loads that are supplied over wiring and distribution circuiting sized to handle the specific power for each circuit.
Solar-powered autonomous devices have been designed for emergency use (for example, during power outage in a hurricane or other catastrophe), or for other non-grid-tied applications, wherein “autonomous” herein means the device is designed for, and relies solely on, solar-panel charging of batteries or other energy-storage devices, without a grid tie. Such conventional autonomous devices do not include the balance of supply and demand that is included in certain embodiments of the invention, and are not modularly-expandable, by connecting multiple modules, as are certain embodiments of the invention. Such conventional autonomous devices are built in a specific system, or “emergency box”, size, and cannot be expanded beyond that single size and power-producing capability. So, such conventional autonomous devices cannot be expanded to serve a larger load than the single “box” size is designed for. The only choice for serving larger loads with such conventional autonomous systems is to buy a bigger system, that is, a bigger, single “emergency box” with higher load-serving capacity.
This invention has been developed in response to the present state of the art and, in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available systems and methods. Features and advantages of different embodiments of the invention will become more fully apparent from the following description and appended claims, or may be learned by practice of the invention as set forth hereinafter.
Consistent with the foregoing, a system is disclosed for a solar-powered module, and assemblies of solar-power modules, wherein the modularity allows easy transport and installation on a building roof or other surface where solar insolation occurs. The modules are each adapted for electrical, and preferably also mechanical, connection into a module assembly, wherein additional modules are added, possibly in the form of subordinate modules, primary modules, main modules, or some other module type, to handle the required loads and to provide control of each of the modules, for example, to control how the solar panels charge the energy-storage devices of each and all the modules via a DC system, and to load-shed according to predetermined outlet/load priorities. Each module is adapted and designed to handle the entire load of the assembly and to provide or receive control signals for cooperative performance between all the modules and for monitoring and communication regarding the assembly performance and condition.
Each module in the preferred system is designed with a higher system load rating than what would normally be required for a single module, so that future applications/uses may be served even when the total served load changes. Each individual module is therefore “ready” to accept these higher loads, if and when the individual module is placed in a larger system, that is, placed in an assembly of connected modules. Thus, while, in certain embodiments, some or all of the modules are operable and effective in single-module applications, the preferred modules are “pre-sized” or “pre-adapted” to handle combined loads of several modules connected together. In other words, each preferred module is sized to accommodate the loads of multiple modules and will act as a sub-panel within the assembly of modules, but the preferred modules are electrically, and preferably mechanically, connectable and operable, without requiring any conventional AC system service panel or sub-panel to be added to the assembly of modules, and without requiring the services of an electrician.
Many objects of certain embodiments of the invention will become apparent from the following description, to solve needs for conveniently-packaged and shipped modules of uniform dimensions, convenient and clear electrical and mechanical connectability, as well as convenient and clear status and performance monitoring and reporting.
In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through use of the accompanying drawings, in which:
The description that follows includes systems, methods, techniques, instruction sequences, and computing machine program products that embody illustrative embodiments of the disclosure. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide an understanding of various embodiments of the inventive subject matter. It will be evident, however, to those skilled in the art, that embodiments of the inventive subject matter may be practiced without these specific details. In general, well-known instruction instances, protocols, structures, and techniques are not necessarily shown in detail.
In various embodiments, a system as described herein determines how a customizable modular solar power system is functionally accomplished.
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.
Furthermore, the described features, advantages, and characteristics of the embodiments may be combined in any suitable manner. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.
These features and advantages of the embodiments will become more fully apparent from the following description and appended claims, or may be learned by the practice of embodiments as set forth hereinafter. As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method, and/or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module,” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having program code embodied thereon.
Many of the functional units described in this specification have been labeled as modules, in order to more particularly emphasize their implementation independence.
For example, a module may be implemented as a hardware circuit comprising custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components. A module may also be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.
Modules may also be implemented in software for execution by various types of processors. An identified module of program code may, for instance, comprise one or more physical or logical blocks of computer instructions which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.
Indeed, a module of program code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network. Where a module or portions of a module are implemented in software, the program code may be stored and/or propagated on in one or more computer readable medium(s).
The computer readable medium may be a tangible computer readable storage medium storing the program code. The computer readable storage medium may be, for example, but is not limited to, an electronic, magnetic, optical, electromagnetic, infrared, holographic, micromechanical, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing.
More specific examples of the computer readable storage medium may include but are not limited to a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a portable compact disc read-only memory (CD-ROM), a digital versatile disc (DVD), an optical storage device, a magnetic storage device, a holographic storage medium, a micromechanical storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, and/or store program code for use by and/or in connection with an instruction execution system, apparatus, or device. Computer readable storage medium excludes computer readable signal medium and signals per se.
The computer readable medium may also be a computer readable signal medium. A computer readable signal medium may include a propagated data signal with program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electrical, electro-magnetic, magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport program code for use by or in connection with an instruction execution system, apparatus, or device. Program code embodied on a computer readable signal medium may be transmitted using any appropriate medium, including but not limited to wire-line, optical fiber, Radio Frequency (RF), or the like, or any suitable combination of the foregoing.
In one embodiment, the computer readable medium may comprise a combination of one or more computer readable storage mediums and one or more computer readable signal mediums. For example, program code may be both propagated as an electro-magnetic signal through a fiber optic cable for execution by a processor and stored on RAM storage device for execution by the processor.
Program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++, PHP or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
The computer program product may be shared, simultaneously serving multiple customers in a flexible, automated fashion. The computer program product may be standardized, requiring little customization and scalable, providing capacity on demand in a pay-as-you-go model. The computer program product may be stored on a shared file system accessible from one or more servers.
The computer program product may be integrated into a client, server and network environment by providing for the computer program product to coexist with applications, operating systems and network operating systems software and then installing the computer program product on the clients and servers in the environment where the computer program product will function.
In one embodiment software is identified on the clients and servers including the network operating system where the computer program product will be deployed that are required by the computer program product or that work in conjunction with the computer program product. This includes the network operating system that is software that enhances a basic operating system by adding networking features.
Furthermore, the described features, structures, or characteristics of the embodiments may be combined in any suitable manner. In the following description, numerous specific details are provided, such as examples of programming, software modules, user selections, network transactions, database queries, database structures, hardware modules, hardware circuits, hardware chips, etc., to provide a thorough understanding of embodiments. One skilled in the relevant art will recognize, however, that embodiments may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of an embodiment.
Aspects of the embodiments are described below with reference to schematic flowchart diagrams and/or schematic block diagrams of methods, apparatuses, systems, and computer program products according to embodiments of the invention. It will be understood that each block of the schematic flowchart diagrams and/or schematic block diagrams, and combinations of blocks in the schematic flowchart diagrams and/or schematic block diagrams, can be implemented by program code. The program code may be provided to a processor of a general purpose computer, special purpose computer, sequencer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the schematic flowchart diagrams and/or schematic block diagrams block or blocks.
The program code may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the schematic flowchart diagrams and/or schematic block diagrams block or blocks.
The program code may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the program code which executed on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
The schematic flowchart diagrams and/or schematic block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of apparatuses, systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the schematic flowchart diagrams and/or schematic block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions of the program code for implementing the specified logical function(s).
It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the Figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more blocks, or portions thereof, of the illustrated Figures. [0040] Although various arrow types and line types may be employed in the flowchart and/or block diagrams, they are understood not to limit the scope of the corresponding embodiments. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the depicted embodiment. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted embodiment. It will also be noted that each block of the block diagrams and/or flowchart diagrams, and combinations of blocks in the block diagrams and/or flowchart diagrams, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and program code.
Certain embodiments of the invented Customizable Modular Solar Power System (CMSPS) are for meeting the needs of an individual home, apartment building, individual business building, or other individual building, to supplement, or supply entirely, said home's or building's energy needs. While the CMSPS is of a scale and structure that is efficiently shipped, installed, and operated on a single home or building, the CMSPS is specially adapted to have features similar to those of a much larger power system, that is, of a AC Utility Power Grid/System. More specifically, said features comprise that the system is divided into individual modules that can be controlled and balanced with each other, the solar supply power, and the loads they are serving.
The CMSPS comprises, consists essentially of, or consists of, at least one module, and preferably multiple of said modules, that can each operate and function independently. The module is a complete solar powered power supply with energy storage that is completely self-contained. Even in an individual module, the supply and demand must be managed and controlled.
The preferred system comprises, consists essentially of, or consists of, multiple modules connected together to increase the overall power of the system in order to serve larger loads. A single module may be only capable of serving a 10 amp, 120V load. However, multiple modules when connected together would be capable of serving much larger loads (60 amps at 240 volts).
The Inventor has determined that multiple solar power supplies cannot be just “simply connected” together, and so connection of multiple of the CMSPS modules is specially designed and structured to include features that are not included in conventional “solar in a box”, “plug and play solar panels”, or “emergency solar box generators”. The inventor has determined that each sub-system (module) of the CMSPS must be integrated through a distribution system that: 1) Assures that each power generating system is balanced with the energy storage system(s), and the electrical loads within the module; 2) Has circuit protection to protect against and isolate faults; and 3) Actively manages the power between the modules (system balancing).
The approach taken to assure that this is done properly is to design each module with the interfacing bus bar or wiring, for electrically connecting the multiple modules, being sized to accommodate the full load of the combined system (once multiple modules are connected together). The bus bar may comprise a solid or tubular cross-sectional shape selected from the group consisting of circles, conic sections, and polygons, such as circles, cones, ellipse, ovals, squares, rectangles, triangles, hexagons, octagons, and pentagons to maximize the efficiency of the connection. The bus bar may be a solid or a tube having such cross-sectional shape. The circuit protection, monitoring and control are also designed to allow the balancing of the system, along with isolating faults in the system to allow the system to continue to operate when there is a failure in one of the system components. For example, if one battery bank is failing, the system isolates this bank from the rest of the system in order to allow the remaining battery banks to operate without having the bad bank bringing down the entire system (potentially lowering the voltage to a point that the loads can no longer be served).
Either the main module, the primary module, or other module type used for systems requiring higher power, contains all of the system power, monitoring and control features for a complete and operational system. Additional subordinate modules can be connected to the primary module in order to increase the overall power of the system. Each module has a specific rating called the load rating that corresponds to the size of the load that it is capable of supplying. Each module has both a local load rating and a system load rating. The local load rating corresponds to the amount of power that the individual module can supply directly, while the system load rating corresponds to the size of the load that the entire system of connected modules can supply. In other words, if the largest load to be expected from the system after all modules are connected together will be 5 kW, then the primary and subordinate modules must all have a system load rating equal to or greater than 5 kW, even though the local load ratings of the individual modules may be less than that, for example 1 kW. This assures that, once all of the modules are connected together, the combined load over the bus bar and/or interconnection wiring is large enough to handle this maximum load. The monitoring and control system prevents the electrical interconnection of modules with incompatible local and system load ratings. The local and system load ratings are determined when the module is manufactured and do not change after that. In other words, the system load rating of a subordinate module will not increase if the module is connected to a system of modules that supplies a very large load.
For individual modules, there also exists ratings for power production and storage capabilities. These are called local production rating and local storage rating. These correspond to how much solar power each module can produce and how much power each module can store, respectively. Both of these ratings are determined when the module is manufactured and do not change after that unless the module is altered in some way, for example the energy-storage device is replaced by one with greater storing capacity. Unlike the system load rating mentioned previously, there is not a manufacturable system production rating or system storage rating since these ratings will both change depending on the size of the system into which the individual modules are connected. Thus, individual modules do not have a system rating for either production or storage but the system of modules as a whole, once all connected, will have system ratings for production and storage.
As an example, the local storage rating of a single module may be 2.5 kWh (storage capacity) with a local production rating of 500 W, and a system load rating of 5 kW. If four (4) of these modules are connected into a system, the system load ratings of each module would be high enough to allow the electrical interconnections of the modules to occur. The system storage rating would be 10 kWh (4 modules at 2.5 kWh each) and the system production rating would be 2 kW (4 modules at 500W each).
The modules are electrically connected by means of interconnection bus bars (which preferably also mechanically connect the modules) and/or wiring, which allow the sharing of power between the modules. While bus bars are preferred in certain embodiments, wiring by means of electrically-conductive wire or cable may be the interconnection means, or may supplement a bus bar interconnection means. The bus bar may comprise a solid or tubular cross-sectional shape selected from the group consisting of circles, conic sections, and polygons, such as circles, cones, ellipse, ovals, squares, rectangles, triangles, hexagons, octagons, and pentagons to maximize the efficiency of the connection. The DC electrical connection is shared over the bus bar or wiring interconnection. In addition to DC interconnection, the monitoring or network interconnected is also done by means of said interconnection bus bars or wiring. See
The primary (P) module can be viewed as an electrical load center or main service panel that serves the load(s). All of the subordinate (S) modules feed into the P module in order to supply the combined power required for the system. Thus, the load(s) served via the P module are supported by the power capacity of the total system. For example, 4 modules at 500 watts each connected together would be able to serve 2 kW of load.
The P module has circuit protection (fuses and/or circuit breakers) as well as controls to allow the isolation and control of each of the interconnected S modules. Both supply and load power, within each module and also within the system (that is, the combined system of P module and S modules), are able to be controlled, balanced and modified (if required—load shedding or isolating faults) by the control system (or “controller”) of the P module.
For embodiments that require more power than a single P module with multiple S modules can provide, then 2 or more P modules can be connected to serve these larger loads. If multiple, connected P modules are not enough, certain embodiments are designed to allow the integration of 2 CMSPS systems. This is accomplished by adding a main (M) module that has higher load ratings than the P modules. So, for example, if the system is maxed out with (4) 2 kW P modules (for a total of 8 kW) and more power is needed, an M module with a system load rating of 20 kW could be added to the system. For example, each of 4 P modules would be connected to the M module, and additional P modules (with attached S modules) could then be added to the entire assembly in order to achieve the higher capacity. The M module would be the only component that would need to have the highest rating, since each system would be feeding into M module, and would only be exposed to the lower rating. Module M, along with its output receptacle, would be rated for the highest capacity as required. The module naming convention and the associated numbers given in this example are not meant to be limiting in scope but are only meant to illustrate the expandability of the solar modular system. There may be a module with load ratings higher than the M module given in this example that could be used in a system to produce as much power as needed, according to specifications.
The inventor has determined that there are 2 requirements in order to combine multiple modules according to preferred embodiments of the invention:
Structural changes in the modules that are required in certain embodiments so that each module is adapted and designed to handle the entire load of the assembly, may include one or more, and typically all, of the following:
From a safety and control standpoint, there are also requirements. Each circuit must be protected from an electrical fault. This is done with fuses and/or circuit breakers. For control, each subsystem/component must have a method of being connected to or disconnected from the system. This is done with relays, switches and/or electronic control systems (with transistors and the like). This applies locally (to one module) and to the whole system (whole assembly). Once the modules are physically connected (and electrically connected) this isolation and control extends across the whole system/assembly.
The control system is comprised of a main controller located in the P module or the M module. Each module that is connected to the main controller also has a controller that connects that module to the main controller, and controls everything within that individual module. The part of the control system that is down at ground level is the user interface device to the control system. It allows the user to monitor and control the system from there, without having to climb up on the roof R (schematically shown in
With a small system (only P modules), the P module's controller is the main controller of the system. Once the P module(s) are connected to an M module, the M module becomes the main controller. All controllers are networked to the main controller, and any global monitoring or control actions are carried out through this main controller.
The control system (CS, or also “controller”) monitors and controls the connection of additional modules. In order to connect multiple modules, the P module is the first one in the system. The P module can operate by itself with no other modules connected to it. In order to increase the total system power, additional S modules can be connected to the P module. As each S module is connected to the system (placed in line with a number of S modules with P at the head of the system), the control system will confirm that the S modules are compatible and will make the electrical connections required in order to incorporate the additional S module into that system. Additional S modules can be placed into the system until the total rated system power has been reached (or, a “full” system). If an additional module is attempted to be placed into a full system, the CS will alert the user with audible and/or visual notifications that the max has been reached. If the user ignores the warnings, the CS will not allow the module to be electrically connected (even if it is mechanically connected). For every system, there is a limit to the number of modules that can be connected to that system. In the example shown in
The CS monitors and controls all of the system functions, as are described herein and/or as will be understood by one of skill in the art after reading and viewing this document and the drawings. The CS is connected by wiring (data wiring, Ethernet or similar) to the control unit. While the solar modules are typically placed up on the roof or in an otherwise elevated position, the control system user interface device is typically down at ground level so that it is accessible to the user. The CS can also be connected via wireless (WIFI, Bluetooth, or similar) to the internet so that the user interface device is remote such as a phone or computer.
In certain embodiments, if there are problems with the system that cannot be resolved by the user locally, the CS can be accessed by personnel at a remote help desk. In certain embodiments, all of the system functions (both monitoring and control) can be done remotely provided that there is an internet connection. The local connection to the internet can also be powered by the CMSPS to assure that this feature is always available (even when there is a utility power outage).
Every system issue that arises (faults, under-voltage, over-voltage, over-current, battery failure, etc.) may be reported to the CS and a notification is sent to the user interface device based on the nature of the issue. For serious issues (fault or complete system failure) there are default settings that immediately and automatically cause the CS to take required actions. For example, for a catastrophic event (for example, tree falls on module and completely crushes it), the CS will shut down all systems immediately to prevent further electrical damage to the system. All circuits would be “opened” by switches and other means to disconnect and shut down the electrical system. Other less serious issues may be reported to the CS and a notification sent to the user interface device (for example, a “trouble”, “notification”, or “alarm” notification, etc.) and an audible and/or visual alarms would sound based on the nature and severity of the problem.
In order to maintain the total storage capacity of the system, the CS continuously monitors the health of the batteries. The Energy Management System (EMS) monitors the power production (from solar) and controls how much power is delivered to the loads. There are many factors that affect the storage capacity of the system. How much solar energy is available on any given day is one of the main factors. If there are multiple cloudy days, the CS will conserve the amount of power that is delivered to the loads in order to maintain the most important operational features/apparatus if there is minimized energy production.
Temperature can also influence battery health. The EMS is equipped with temperature sensors that report the temperature of the electronics and the batteries. Cooling systems for overheating are preferably included, and can be turned on when temperatures exceed a maximum level (pre-set at the factory based on the battery type). When temperatures drop below a minimum, actions are taken to keep the battery healthy in these conditions. Some of these actions preferably include turning off a “fresh air” electronics cooling fan, and turning on an internal “re-circulating” fan that distributes the electronics compartment air into the battery compartment.
In addition to insulation around the batteries, phase change material may also be utilized to even out the temperature swings from day to night. This prevents both temperature extremes (too hot or too cold). In addition to these components, the batteries may be placed on a conductive plate (copper or aluminum or other conducting material) that is shared with the electronic components compartment. During the summer or hot days, the amount of heat transferred from the electronics compartment to the battery compartment will be minimal. This is due in part to the fact that the fresh air fan will be keeping the electronics compartment cool when it is hot outside. When the air is cold outside, the heat from the electronics compartment will be conducted through the base plate to the batteries to help them stay warm.
Batteries do produce a small amount of heat when they are charging and discharging. By connecting several modules together, it is possible to use batteries from one module to charge batteries from another module in this case. There can also be a small heater in the battery compartment for geographic locations that are extremely cold.
The way load shedding is controlled is via a load shedding (LS) feature that is selected by the user. There is a minimum of two power outlets (or receptacles) at the module(s), and preferably at three power outlets (or receptacles). The priority of each receptacle is indicated to, and known by, the user in advance, and the user plugs-in/connects the loads accordingly depending on the user's perception of the importance/priority of the loads. For example, if there were three receptacles and levels of load shedding ranked as A—Highest importance to C—Lowest priority loads, the user would determine the load importance/priority and plug-in/connect them accordingly to the receptacles. Thus, in the event of a shortage of solar/battery power, the LS system would “shed” the lowest priority loads first by disconnecting (turning off a switch or relay) the C receptacle. All loads plugged into this circuit would be turned off if the stored power dropped below a preset level. After turning off load C, the second level would turn off the B loads before the highest priority loads were at risk of being turned off.
Under normal conditions, all three circuits would be fully operational. In addition to the circuit management explained above, there are also lighting circuits that could be dimmed to conserve energy. Any and all of the circuits (A, B and C) can be programmed as dimming circuits, and the dimming parameters can be pre-set to dim as required when energy needs to be conserved.
LED indicators at the user interface device show the system status. For example, if all circuits are fully charged and operational, the LEDs would show a Green illuminated LED for circuit A, Yellow for B, and Red for C. In the case where load shedding is occurring, a flashing LED shows that it is in transition, and once circuit C is turned off, the Red LED would no longer be illuminated.
The interconnection of the modules can be done primarily over the DC power system wiring. The preferred method is to have DC wiring systems shared between the modules.
Shared DC connections allows for sharing of the stored energy between the modules on the DC system, along with allowing the energy produced from the solar panels to be allocated across several modules for storage as needed. If one module is not collecting enough solar energy to keep its batteries charged, the other connected modules can charge the batteries of any and all batteries within the connected system. The control system determines not only which battery bank(s) within the individual module are to be charged, but also allows battery banks in any of the connected modules to be charged by any of the other connected modules.
From a power delivery standpoint, shared DC power between modules allows more energy to be delivered to connected loads, both instantaneous power (in rush current, for example) and total power capabilities are increased according to the number of modules connected together. All energy available can be delivered to any of the connected loads. So if there is only one module rated for 500 watts of power and an instantaneous current maximum of 5 amps, once two of these modules are connected together, they will have double the capacity (1kW of power and 10 amps current).
The CMSPS is equipped with the load shedding capabilities as described above. In a small CMSPS with one or a few modules, the power is distributed to the loads via the plug strip as shown in
For a larger CMSPS, the connection to the loads served is made via an electrical sub-panel. All circuits that are to be served by the CMSPS are connected to the CMSPS sub-panel. In an autonomous system (not grid-connected) these circuits are isolated from (not connected to in any way) any and all of the normal grid-connected circuits. When both types of circuits are present, the outlets or receptacles connected to the CMSPS are identified (color corresponding to priority levels for load shedding) so that the user can identify which circuits are available for CMSPS loads to be plugged into.
All loads served by the small CMSPS are plugged into the power strip that allows each circuit to be managed by the control system. Load shedding is done by switching on or off each receptacle in the plug strip. Each receptacle in the plug strip has an indicator light next to it showing whether or not that individual receptacle or circuit is active or not. The color of each indicator light identifies which circuit and which priority each receptacle serves. Lower priority circuits are shed first, keeping the higher circuits active.
It may be noted that the term “modular” means that a system is expandable in order to increase the total system power by adding modules, for example, meaning that each module is compatible with the other modules in the system and can be connected (both electrically and mechanically) together. Modules are interchangeable and compatible with each other without any modification, except that, preferably, there are “right” and “left” modules, however, to connect in a manner as shown and described for
The cross-section of the interface (here, “interconnection” including mechanical and electrical connection) between two adjacent modules is shown in
As shown in
The row of modules in
The row of modules in
In
The rows of modules in
Certain embodiments of the invention may be described as a customizable modular solar power system, preferably for installation on a roof or other elevated location that receives solar insolation. The preferred system comprises multiple modules each having photovoltaic cells/panel(s), wherein a certain type of module (a primary module) is designed so that it can operate on its own, as a single, self-contained solar module providing DC power to one or more loads. The primary module, in addition to a solar panel(s) and elements to produce DC power, also comprises control and/or monitoring and/or communication/wireless apparatus for the entire assembly (the entire “system”). Additional, subordinate module(s) may also be provided for mechanical and electrical attachment to the primary module, to increase DC power production. Therefore, preferably each module (both primary and subordinate) is designed to connect to and work with other modules, for higher power output, by means of each module being adapted to work at the full system load rating of the entire system. Therefore, up to a predetermined number of subordinate modules may be connected electrically in parallel to the primary module, and preferably also mechanically connected, to be secured into a single structural unit. Further, in certain embodiments, multiple of the primary-module-plus-subordinate-module assemblies (P plus S assemblies) may be connected in parallel to a main module, that may comprise additional of said control and/or monitoring and/or communication/wireless apparatus for the entire assembly (entire system of two or more P plus S assemblies connected to M).
In the assemblies/systems of the above paragraph, each module preferably comprises a module housing that holds the solar panel(s) on one or more of its surfaces (preferably on a top, broad and flat surface), wherein the solar panel(s) may be of any type such as a flexible solar panel or rigid solar panels or cells, and of any composition currently known or developed in the future. The module housing contains in its interior space the other elements needed for the module operation, control, and protection, wherein the housing is further adapted to include ports for required operative connections (via the “outlets” or other electrical connection sites) to other modules and/or to loads. The modules, therefore, may be described in many embodiments as separate boxes, all of the same or approximately the same dimensions, that can be stacked in a courier-approved-size package, and shipped to a user. Then, the modules may easily be placed on a roof or other support and connected together and made operative without significant knowledge except to read instructions included with the package. Preferably, the connection is a convenient slide-together or snap-together connection that serves both mechanical and electrical connection, but, alternatively, the modules may be mechanically connected together by fasteners, clips, plates, racks, or other connectors, and plug-in wiring may be used to make the electrical connections.
The elements in and on each module for operation of each module of the above two paragraphs may comprise, consist essentially of, or consist of, elements to generate and store solar energy, and to provide DC power, to a load(s) that is/are outside the module but electrically connected (typically plugged into a receptacle) to a power outlet of the module or to a power outlet of the system/assembly of modules. Said elements in each module may include the solar cells/panel(s) (such as photovoltaic cells/panel(s)), one or more batteries or other energy storage devices, a Maximum Power Point Tracker (MPPT) such as one available commercially and understood in the art, a charge controller (CC), a control system (CS), relays to isolate the battery/storage-device from the DC power bus, an electronics compartment temperature sensor, a battery/energy-storage compartment temperature sensor, heater, DC circuit protection and control, and a wireless device connected to the control system to allow remote wireless monitoring and control of the system.
Certain embodiments may comprise, consist essentially of, or consist of, the elements schematically portrayed in
These elements, of the previous three paragraphs, are provided and operationally connected, when multiple of the modules are connected into the multiple-module system, so that each individual module is able to collect (via the solar panel), store (in batteries or other energy storage system), and deliver to external loads the energy collected by the solar panel, with the capacity to handle a total higher load than just one module. Said elements of the module and their particular operational connection are important because each module of the system must be: 1) compatible with the other modules (mechanically and electrically), and 2) have a system load rating high enough to handle all of the power over the entire system, and 3) have a control system to manage the power (since it is shared over the entire system). Regarding the item no. 1 compatible electrical operational connections, it is necessary to electrically connect the DC wiring of each module to the DC wiring of the other modules in a given group/assembly of modules. Regarding the item no. 2 system load rating for each module being high enough to handle all of the power over the entire system, this is important because: a) one cannot combine multiple systems or modules unless the total system is capable of supporting the combined loads, b) the combined loads vary depending on how many modules are connected together, and c) the modules and their operational connection must be designed to accommodate this variance. Regarding the item no. 3 control of operational connection, the system comprises a control system and (preferably wireless) communication to a control station/unit, to manage operations of each module (“in-box” or “within a given module”) and also of the system as a whole (that is, control of functions “out of the box”, that is, “between modules of the system” and “between the system and the loads”), for example, energy storage in the batteries/energy-storage and load shedding. Load shedding on the load side of the system allows energy management that conserves power when the energy storage system (batteries or the like) is low.
Certain embodiments, such as those described in the five paragraphs immediately above, may include one or more of the following features:
Certain embodiments, such as those described in the six paragraphs immediately above, may include one or more of the following features:
Certain embodiments may be described as: A solar-powered modular system comprising: a plurality of modules, each comprising a housing, a solar panel on at least one outer surface of the housing that is adapted to produce power from solar insolation, a DC system comprising an energy-storage device, a charge controller that controls charging of the energy-storage device from energy produced by the solar panel, DC wiring and a DC outlet, each of the plurality of modules being electrically connected in parallel to form a module assembly for connection to power one or more electrical loads; wherein the DC systems of the modules are electrically connected in parallel; and wherein each of the modules has a system load rating equal to or greater than a sum of maximum power production of each of the electrically-connected modules, so that the module assembly is adapted to be connected to, and to power, said one or more electrical loads that total to be a higher total load than each of said modules is adapted to power individually. Therefore, in certain embodiments there may be subordinate modules operatively (electrically) connected in parallel to a primary module that comprises control capability, wherein all the modules of such an assembly are preferably in parallel; and, in certain embodiments, multiple of such primary modules (with the connected subordinate modules) may be connected in parallel to a main module that has further control capability, wherein all the modules of such an assembly are in parallel.
Certain embodiments may be described as: a solar-powered modular system comprising: a first set of modules, each comprising a housing, a solar panel on at least one outer surface of the housing that is adapted to produce power from solar insolation, a DC system comprising an energy-storage device, a charge controller that controls charging of the energy-storage device from energy produced by the solar panel, DC wiring and a DC outlet; each of the plurality of modules being electrically connected in parallel to form a module assembly for connection to power one or more electrical loads; wherein the DC systems of the modules are electrically connected in parallel; and wherein said first set of modules comprises one primary module and subordinate modules, wherein the primary module further comprises a control system adapted to monitor and control the energy-storage device of each of the subordinate modules; and the solar-powered modular system further comprising a second set of modules comprising subordinate modules that are connected in parallel to said primary module of said first set in parallel to the subordinate modules of said first set, wherein said control system of the primary module is adapted to monitor and control the energy-storage device of each of the subordinate modules of said second set; and wherein each of the subordinate modules of said first set has a system load rating equal to or greater than a sum of maximum power production of each of the first set subordinate modules and the primary module, wherein each of the subordinate modules of said second set has a system load rating equal to or greater than a sum of maximum power production of each of the second set subordinate modules and the primary module, and the primary module has a system load rating equal to or greater than a sum of all of the modules of said first set and said second set, so that the primary module is adapted to be connected to, and to power, said one or more electrical loads that total to be a higher total load than each of said modules of the first set and the second set is adapted to power individually.
Although this invention has been described above with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to these disclosed particulars, but extends instead to all equivalents within the scope of the following claims.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 15/485,824 filed on Apr. 12, 2017 which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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Parent | 15485824 | Apr 2017 | US |
Child | 15591504 | US |