Power generator distributed inverter

A power generator configuration having a distributed inverter. A system is described that includes a plurality of solar modules coupled together in series to form a string; a plurality of combiner boxes, wherein each combiner box couples together a plurality of strings in parallel; and a plurality of DC-DC converters, wherein each DC-DC converter increases a direct current (DC) voltage output of an associated combiner box. Also provided are distributed maximum power point tracker (MPPT) controls that adjust for changing conditions at individual sets of strings.

BACKGROUND OF THE INVENTION

The invention relates generally to a distributed power generator system, and more particularly to a solar array configuration that utilizes a plurality of voltage boosters distributed throughout the array proximate associated strings of solar modules.

A solar (or photovoltaic) array is a linked collection of solar modules, which are in turn made of multiple interconnected solar cells. The cells convert solar energy into direct current (DC) electricity via the photovoltaic effect. Modules are linked together to form an array. The modules in a solar array are usually first connected in series to obtain the desired voltage, and then the individual strings are connected in parallel to allow the system to produce more current. At some point down the line, after all of the modules are coupled together in a single line, an inverter is utilized to convert the DC power produced by the modules into alternating current (AC).

FIG. 1depicts a typical configuration of a solar array system10. Solar array system10includes a solar array made up of a plurality of solar modules12. The solar array system10includes a plurality of combiner boxes14A,14B,14C,14D that couple sets of strings16in parallel. Each combiner box typically also includes a set of fuses17for each series string of modules. As noted, the parallel connections increase the current on each associated output line15A,15B,15C,15D. A second stage combiner box18may likewise be utilized to further combine the lines into a single DC line26. In many applications, the DC lines exiting the fused combiner boxes16,18may be hundreds or thousands of meters in length in order to carry the current from the solar modules (often located over many acres) to a terminal point.

Located near the terminal point is an inverter assembly20,22that receives the single DC line26and converts DC to AC, providing all necessary safety functions required for interconnection with AC switch gear24. The inverter assembly20,22includes two stages, a first stage20comprising a DC disconnect28and a DC-DC converter30and a second stage22comprising a isolating transformer32and an AC disconnect34. The DC and AC disconnects28,34are implemented as safety features. The first stage20utilizes the DC-DC converter30to boost the inputted array voltage on line26to supply a DC link voltage. The second stage24converts the DC link voltage to AC. In this case, the inverter assembly20,22ties directly into existing AC switch gear24. This is typically completed with a supply side tap located between the utility meter and the utility main. One of the drawbacks of this configuration in a large scale application is the amount of wire (typically copper) required to connect the combiner boxes14A,14B,14C,14D,18with the inverter assembly.

BRIEF DESCRIPTION OF THE INVENTION

A first aspect of the disclosure provides a distributed power generator system, comprising: a plurality of power generator modules coupled together in series to form a string; a plurality of combiner boxes, wherein each combiner box couples together a plurality of strings in parallel; and a plurality of DC-DC converters, wherein each DC-DC converter increases a direct current (DC) voltage output of an associated combiner box.

A second aspect of the disclosure provides a distributed power generator infrastructure, comprising: a plurality of modules arranged in a plurality of strings, wherein each string includes a subset of modules coupled together in series; a plurality of combiner boxes, wherein each combiner box couples together a set of strings in a parallel configuration and provides an output line, and wherein each combiner box provides a fuse for each string in the set; a plurality of DC-DC converters, wherein each DC converter is coupled to an output line of an associated combiner box in order to boost a voltage of the output line; and a plurality of maximum power point tracker (MPPT) controls, wherein each MPPT control is adjusts for a changing output at an associated combiner box.

A third aspect of the disclosure provides a system, comprising: means for obtaining direct current (DC) power from a plurality of power generating modules; means for forming strings by combining sets of the plurality of power generating modules in series; means for coupling sets of strings together in parallel at different locations in the solar array; means for boosting the DC voltage at an output line of each coupled set of strings; means for combining the outputs lines into a single DC line; and means for converting the single DC line into alternating current (AC).

DETAILED DESCRIPTION OF THE INVENTION

FIG. 2depicts a solar array system11that utilizes a distributed inverter configuration. In particular, the DC-DC converter circuitry has been removed from the inverter assembly (20,22ofFIG. 1) and distributed to the combiner boxes14A,14B,14C,14D within the array. Accordingly, each combiner box, which connects a set of strings16, has an associated DC-DC converter40A,40B,40C,40D that boosts the voltage output of the associated combiner box14A,14B,14C,14D. The booster voltage also results in a current drop. The DC-DC converters can be integrated into the combiner boxes or be implemented separately along the outputs15A,15B,15C,15D exiting each combiner box14A,14B,14C,14D. For the purposes of this disclosure, the term “combiner box” refers to any type of circuitry or harness for connecting strings of array modules. In addition, although described herein for use with a solar array system11, the distributed inverter configuration could be utilized with any other distributed power generator having a DC electrical output, such as a distributed wind generator.

As can be seen, the first stage42of the inverter assembly (42,22) inFIG. 2no longer provides a DC-DC converter, but instead only includes a DC disconnect28. Instead, as noted, the single DC-DC converter has been replaced with a plurality of DC-DC converters40A,40B,40C,40D, distributed throughout the array. In this embodiment, a DC-DC converter is associated with each coupled set of strings16. By boosting the voltage outputs at the combiner boxes14A,14B,14C,14D prior to the inverter assembly (42,22), various advantages are gained. One such advantage is that the higher voltage has less loss thereby allowing smaller gauge wires to be used between the combiner boxes14A,14B,14C,14D and inverter assembly (42,22). Given the run lengths in a large array application and cost of copper, significant savings can be realized. In a typical system, each combiner box/DC-DC converter is located proximate the associated solar module, e.g., less than 10 meters. Conversely, the run length from the combiner box/DC-DC converter to the inverter assembly (42,22) can be, e.g., hundreds of meters. Higher voltages along the longer run lengths mean less current and loss, thus allowing for a lower gauge wire to be used.

In addition, maximum power point tracker (MPPT) controls42A,42B,42C,42D can also be implemented in a distributed manner with the DC-DC converters40A,40B,40C,40D at the combiner boxes14A,14B,14C,14D to provide much more precise control. A maximum power point tracker (or MPPT) is utilized to provide an optimal electrical load for a power generator module, such as a photovoltaic (PV) cell or wind turbine. MPPT converts the power to a voltage or current level which is more suitable to whatever load the system is designed to drive. By locating MPPT controls42A,42B,42C,42D at the combiner boxes, adjustments at a much more granular level can be provided to account for changing outputs of discrete sets of strings in the solar array. Thus, for example, the impact of a passing cloud over a section of the array will only affect a small portion of the entire array.

FIG. 3depicts a flow diagram showing an illustrative method of the present invention. At S1, DC power is obtained from a plurality of solar modules and at S2strings are formed by combining modules in series. Next, sets of strings are coupled together in parallel at different locations in the solar array at S3, and the DC voltage on the output line of each coupling is boosted at S4. This increase in voltage results in a decrease in current. At S5, MPPT controls are utilized at each output line to adjust for changing conditions at an associated set of strings. Next, at S6, the output lines from each coupled set of strings are combined into a single DC line, and at S7, the single DC line is converted from DC to AC.

The terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context, (e.g., includes the degree of error associated with measurement of the particular quantity). The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including one or more of that term (e.g., the metal(s) includes one or more metals). Ranges disclosed herein are inclusive and independently combinable (e.g., ranges of “up to about 25 wt %, or, more specifically, about 5 wt % to about 20 wt %”, is inclusive of the endpoints and all intermediate values of the ranges of “about 5 wt % to about 25 wt %,” etc).

While various embodiments are described herein, it will be appreciated from the specification that various combinations of elements, variations or improvements therein may be made by those skilled in the art, and are within the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims