Redundant electrical architecture for photovoltaic modules

• US 9,768,725 B2
• Filed: 11/04/2014
• Issued: 09/19/2017
• Est. Priority Date: 01/18/2008
• Status: Active Grant

• Current Assignee: Spectrum Solar, LLC
• Original Assignee: Tenksolar, Inc.
• Inventors: Meyer, Dallas W.
• Primary Examiner(s): Porta, David
• Assistant Examiner(s): VALENTINER, JEREMY SCOTT
• Application Number:
  US14/532,305
• Publication Number:
  US 20150047689A1
• Time in Patent Office: 1,050 Days
• CPC Class Codes: H01L 31/02008 for solar cells or solar cell modules
• CPC Class Codes: H01L 31/042 PV modules or arrays of single PV cells supporting structures for PV modules H02S20/00
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02S 50/00 Monitoring or testing of PV systems, e.g. load balancing or fault identification
• CPC Class Codes: H02S 50/10 Testing of PV devices, e.g. of PV modules or single PV cells testing of semiconductor devices during manufacturing H01L22/00
• CPC Class Codes: H02S 50/15 using optical means, e.g. using electroluminescence
• CPC Class Codes: Y02E 10/56 Power conversion systems, e.g. maximum power point trackers

Abstract

One example embodiment includes a PV module comprising a conductive backsheet, a substantially transparent front plate, a plurality of PV cells, a plurality of conductive spacers, and a power conversion device. The PV cells can be disposed between the conductive backsheet and the front plate and can be arranged in a plurality of rows. The PV cells within each row can be connected to each other in parallel and the rows can be connected in series. The PV cells can be interconnected between the conductive spacers. The power conversion device can be redundantly connected to the PV cells via a last conductive spacer connected to a last row. The power conversion device can substantially maintain a maximum peak power of the PV module and can convert a lower voltage collectively generated by the PV cells to a predetermined stepped up voltage greater than or equal to 12 volts.

Claims

1. A method of calibrating a photovoltaic module, comprising:

downloading a first set of computer executable instructions onto a non-transitory computer-readable medium within a photovoltaic module comprising an array of photovoltaic cells, the photovoltaic module further comprising a power conversion device redundantly connected to the array of photovoltaic cells, the power conversion device including a plurality of redundant power conversion circuits, the first set of computer executable instructions configured to control operation of the photovoltaic module during calibration;

exposing the photovoltaic module to multiple illumination intensities;

exposing the photovoltaic module to multiple ambient temperatures including, during exposure of the photovoltaic module to each of the multiple illumination intensities, exposing the photovoltaic module to each of the multiple ambient temperatures such that the photovoltaic module is exposed to each of the multiple ambient temperatures during exposure to each given one of the multiple illumination intensities,

generating measurement data for each illumination intensity and ambient temperature, the measurement data representative of one or more of;

an electrical resistance of each power conversion circuit;

a power output of each power conversion circuit;

a peak power current of each power conversion circuit;

a peak power voltage of each power conversion circuit; and

a local circuit phase of each power conversion circuit;

generating a plurality of calibration curves from the measurement data;

storing the plurality of calibration curves in a memory of the photovoltaic module, the plurality of calibration curves allowing a control module of the photovoltaic module to transform measurements in an operating environment into representative data; and

replacing the first set of computer executable instructions stored on the non-transitory computer-readable medium with a second set of computer executable instructions configured to control operation of the photovoltaic module in the operating environment.

2. The method of claim 1, wherein the measurement data is generated internally within the photovoltaic module.

3. The method of claim 1, wherein the measurement data includes data representative of one or more of:

normalized maximum power output of the photovoltaic module, short circuit current of the photovoltaic module, open circuit voltage of the photovoltaic module, maximum peak power current of the photovoltaic module, maximum peak power voltage of the photovoltaic module, parasitic resistance of the photovoltaic module, shunt resistance of the photovoltaic module, reverse current bias of the photovoltaic module, reverse voltage bias of the photovoltaic module, frequency response of each power conversion circuit, capacitance of each power conversion circuit, inductance of each power conversion circuit, circuit tuning parameters of each power conversion circuit, switching times of each power conversion circuit, or phasing of each power conversion circuit.

4. The method of claim 3, further comprising collecting and storing trend analysis data representative of one or more of:

a time and date, an ambient temperature of the photovoltaic module, an operating temperature of each of the power conversion circuits, an illumination intensity onto the photovoltaic module, an output voltage of the power conversion device, an amount of current imbalance between a supply line and a neutral line of the power conversion device, an amount of power drawn from the output of the power conversion device by an active-row balancing device, or a failure rate of the power conversion circuits.

5. The method of claim 4, wherein the measurement data and trend analysis data is generated internally within the photovoltaic module.

6. The method of claim 4, wherein at least some of the measurement data and trend analysis data is generated by and collected from a loopback device connected to the power conversion device.

7. The method of claim 6, wherein the loop back device comprises one or more of:

a global positioning system device, a voltage calibration device, a current calibration device, an Ethernet port, a wireless communication port, or an illumination calibration device.

8. A method of calibrating a photovoltaic module, comprising:

executing a first set of computer executable instructions stored on a non-transitory computer-readable medium within a photovoltaic (PV) module, the photovoltaic module comprising an array of PV cells and a power conversion device redundantly connected to the PV cells, the power conversion device including a plurality of redundant power conversion circuits, the first set of computer executable instructions configured to control operation of the photovoltaic module during calibration;

generating measurement data for each of multiple illumination intensities to which the PV module is exposed by generating the measurement data while exposing the PV module to each of the multiple illumination intensities one at a time and during exposure to each of the multiple illumination intensities exposing the PV module to each of multiple ambient temperatures;

generating a plurality of calibration curves from the measurement data;

storing the plurality of calibration curves in a memory of the PV module, the plurality of calibration curves allowing a control module of the PV module to transform measurements in an operating environment into representative data; and

replacing the first set of computer executable instructions stored on the non-transitory computer-readable medium with a second set of computer executable instructions configured to control operation of the PV module in the operating environment.

9. The method of claim 8, wherein the measurement data is generated internally within the PV module.

10. The method of claim 8, wherein the generating the measurement data includes generating measurement data that is representative of one or more of:

an electrical resistance of each of the plurality of power conversion circuits;

a power output of each of the plurality of power conversion circuits;

a peak power current of each of the plurality of power conversion circuits;

a peak power voltage of each of the plurality of power conversion circuits; and

a local circuit phase of each of the plurality of power conversion circuits.

11. The method of claim 8, wherein the measurement data includes data representative of one or more of:

normalized maximum power output of the PV module, short circuit current of the PV module, open circuit voltage of the PV module, maximum peak power current of the PV module, maximum peak power voltage of the PV module, parasitic resistance of the PV module, shunt resistance of the PV module, reverse current bias of the PV module, reverse voltage bias of the PV module, frequency response of power conversion circuits, capacitance of the power conversion circuits, inductance of the power conversion circuits, circuit tuning parameters of the power conversion circuits, switching times of the power conversion circuits, or phasing of the power conversion circuits.

12. The method of claim 11, further comprising collecting and storing trend analysis data representative of one or more of:

a time and date, an ambient temperature of the photovoltaic module, an operating temperature of each of the power conversion circuits, an illumination intensity onto the photovoltaic module, an output voltage of the power conversion device, an amount of current imbalance between a supply line and a neutral line of the power conversion device, an amount of power drawn from the output of the power conversion device by an active-row balancing device, or a failure rate of the power conversion circuits.

13. The method of claim 12, wherein the measurement data and trend analysis data is generated internally within the photovoltaic module.

14. The method of claim 12, wherein at least some of the measurement data and trend analysis data is generated by and collected from a loopback device connected to the power conversion device.

15. The method of claim 14, wherein the loop back device comprises one or more of:

a global positioning system device, a voltage calibration device, a current calibration device, an Ethernet port, a wireless communication port, or an illumination calibration device.