Patent Application
20110028008
In the manufacturing of products that are electronically controlled, particularly when the electronic control includes a microcontroller or other logic that can be variously configured, inventories are increased by variations between similar product models wherein the controller is customized for each such variation. In some cases the basic control method of the controller is fixed, with certain parameters being the only difference between two product models. Thus the controller is programmed to include the appropriate parameters for the instant controller product and the two mated during manufacturing. For product held in inventory, the quantity to be held is increased to shorten delivery time after an order is received. For product that is customized as an order is received, delivery time is increased by the time required for customization.
For example, solar panels are tested when they complete manufacturing to determine such parameters as output voltage and current at test conditions. In some systems each panel is mated to a controller, wherein the controller must be programmed to reflect the parameters determined in testing. The controller and panel are electrically connected using a junction box.
The disclosure of the 534 application provides for an electromechanical system somewhat similar to the fashion in which an electric light bulb is connected to its base, power, and on/off switch. According to the 524 application, a base unit is connected securely to the structure of a first electronic device and electrical connections brought into the base unit. The base unit includes one or more threaded surfaces, wherein the threaded surfaces are conductive or include an area that is conductive. A second electronic device to be connected to the first electronic device is manufactured and secured inside an insertable unit that has threads matching those of the base unit. The threads of the insertable unit are also conductive, or include an area that is conductive. The second electronic device is electrically connected to the threads of the insertable unit. Later, such as at the end of a production line or during field installation, the insertable unit is screwed into the base unit, thereby providing the second electronic device with electrical contact with the base unit (thereby to the first electronic device). The base unit and the insertable unit are manufactured such that when the two are screwed together a tight seal is formed. Should the electronics in the insertable unit fail, the insertable unit may be unscrewed and a new unit screwed in. If the first electronic device should fail, the insertable unit can be removed and used with a different first electronic device.
The first electronic device can be any electronic or electrical device, for example a solar panel.
For the purpose of illustration, the discussion of the invention will be presented as for a solar panel module, however the concept may be extended to any controlled product that requires customization of a controller. Likewise, the structure according to the 524 application will be used as an illustration of one embodiment of the present invention, though it is clear that the present invention may be practiced with any similar structure wherein a controller within a second substructure is mechanically and electrically connected to a first substructure, the combination thereby forming a complete structure for controlling an apparatus connected with the second substructure. In the context of the present invention, the combination of the two substructures will be referred to as a “junction box.”
According to the present invention, a junction box first substructure is attached and electrically connected with a solar panel during manufacturing, wherein the first substructure includes an electronic memory that is programmed with parameters or customization flags. A controller, configured to be mated to the junction box within a junction box second substructure, is preprogrammed with a control algorithm, but the program does not include all parameters needed by the control program. That is, the program of the controller does not change between a one or more different models except for the definition of certain parameters specific to a given model.
When the controller and junction box are mated, electrical contact is made between the controller and the electronic memory in the first substructure. The controller interrogates the memory device in the first junction box subsystem, thereby to receive the parameters related to the instant solar panel. The controller is then capable of controlling the solar panel in that all parameters needed by the control algorithm are available to the controller.
The following description is an example of one structure in which the invention may be practiced. It is presented in detail for clarity. However one skilled in the art will know of many different configurations wherein two substructures may be mated.
Looking to
Around at least part of the inside perimeter of the outer shell 110 are threads 104. The threads 104 may be formed during molding of the outer shell 110 and conductive inserts later placed in the threads 104. In some embodiments the outer shell inside perimeter is smooth, and the threads 104 are a separate, threaded metal piece that fits into the outer shell 110. In similar fashion, the a center piece 112 includes threads 106, wherein the threads 1106 maybe be molded into the center piece material 112 and conductive material added, or the center piece is smooth and the threads 106 are a threaded cylindrical metal piece that slides down over the smooth center piece 112. Other methods will be known to one familiar with the art, wherein a threaded outer and inner (112) part may be constructed such that at least some portion of the threads are electrically conductive.
In some embodiments the threads 104/202 or 106/208 of the base 100 and the insertable unit 200 are somewhat tapered, similar to pipe threads, wherein the threads will bind and tighten down when the insertable unit 200 is screwed into the base unit 100 a desired amount. In some embodiments the threads 104/202 or 106/208 are like machine threads, having the same diameter along the center axis of the body 100 and insertable unit 200. One skilled in the art will know of other means for forming threads on the two units 100,200 such that they may later be taken apart nondestructively, while providing a tight fit in service.
In some circumstances it may be necessary for the insertable until to have a particular orientation relative to the base unit 100, hence the structure of the first electronic device. This is sometimes accomplished by manufacturing base 100/insertable unit 200 pairs that are a particular orientation when screwed together. In one embodiment the threads 104/106 comprise a plurality of thread sets and the appropriate thread set selected when screwing the insertable unit 200 into the base unit 100 to provide the desired final orientation. For example, in one embodiment there are four sets of threads 104/106 on the base unit 100 provided, each with a thread entry point that is ninety (90) degrees apart from the thread entries on either side. If each thread goes around a whole number of times, for example two, then one may select the final orientation of an insertable unit 200 upon installation by selecting a thread set 104,106 with its opening corresponding to the final orientation.
For example, consider a configuration wherein the conductive threads 104 on the inner surface of the outer ring 110 of the base unit 100 are segmented, rather than a continuous thread around the inner surface, the threads 104 comprising four segments, each electrically isolated from the other, and each with a unique connection to the first electrical device. Now consider that the electrically conductive threads 202 of the insertable unit 200 are similarly segmented. By selecting which set of threads 104 to engage when screwing the two units 100, 200 together one would also select how the two electronic devices are connected. Of course one would be able to vary how many segments, what connections, and such are designed into a given device set to provide for a variety of electrical connection possibilities.
Continuing with
The NVM 408 has one electrical connection 412 to the outer surface of the center post 410, thereby making electrical connection to the conductor 404, wherein the conductor 404 further connects to the first electronic device (not shown). The conductor 404 may be connected to system ground/return path. In one embodiment, using a one-wire memory device 408, a second conductor 414 is connected to a connector pad 416. In other embodiments the conductor 414 is brought out sideways (relative to the drawing) and connected to conductive tape (not shown) similar to 404, the conductive tape extending up to the top of the post 410, then electrically connected to the connector pad 416.
Looking now to
The NVM 408 is programmed with data specific to the first set of electronics to which it is connected. For example, for the scenario wherein the base unit 100 is affixed to a solar panel, the NVM 408 is programmed with characteristic data obtained by end of line testing of the solar panel. When the insertable unit 200 is screwed into the base unit 100, the connector 508 makes electrical contact with the matching connector 416, thereby enabling the control electronics 504 to receive data from the NVM 408 by providing the proper control signals to the NVM 408. In some embodiments the control electronics 504 include NVM as well, and once the electronics 504 has received the data from the base unit 100 NVM 408, no further data exchange between the two is necessary. In one embodiment the insertable unit 200 is removed due to failure or other reasons, and a new insertable unit 200 is connected to the base 100, and again the NVM 408 provides the new electronic unit 504 with the stored data.
In some embodiments the electronic unit 504 does not have NVM of its own, and instead receives data from the NVM 408 whenever needed.
In some embodiments the data provided by the NVM is not parametric, but is configuration flags. In other embodiments the data included in the NVM is a serial number, production date, or other static information unique to the first electronics connected to the base 100.
If any disclosures are incorporated herein by reference and such incorporated disclosures conflict in part or whole with the present disclosure, then to the extent of conflict, and/or broader disclosure, and/or broader definition of terms, the present disclosure controls. If such incorporated disclosures conflict in part or whole with one another, then to the extent of conflict, the later-dated disclosure controls.
This application is related to commonly-owned U.S. patent application Ser. No. 12/502,524 submitted Jul. 14, 2009 by Kent Kernahan, which application is incorporated herein in its entirety. This application will be referred to as “the 524 application.”
