Abstract:
A controller for a plurality of solar panels is provided. An input connector is configured to receive (a) power from the plurality of solar panels, and (b) information from the individual solar panels. An output is configured to forward from the input connector the power from the plurality of solar panels. A controller is configured to receive the information, and based on the information selectively enable or disable the flow of power from the input to the output. The controller enables the flow of power when (a) a number of solar panels connected to the input is within a first threshold, and (b) the total rated output of solar panels connected to the input is within a second threshold. The controller disables the flow of power when (a) a number of solar panels connected to the input exceeds the first threshold, and/or (b) the total rated output of solar panels connected exceeds the second threshold.

Description:
FIELD OF THE INVENTION 
     The various embodiments described herein relate generally to the installation of solar panels. More specifically, the instant application relates to a methodology for installing solar panels that minimizes or eliminates the need for specialized training or knowledge in electrical power systems. 
     BACKGROUND 
     Solar technology presents a viable green source of energy as an alternative to fossil fuels. This is particularly the case for geographic areas that have a high amounts of daylight and/or higher than average fuel costs, such as Hawaii. 
     An ongoing obstacle to the adoption of solar panels as a home energy solution remains the expense, particularly in the purchase of the components and the installation. A typical residential solar system, will include a number of solar panels connected by electrical cables to a junction box. The output of the junction box is then fed to load distribution center for internal use. Electrical cable between the solar panels and the junction box are cut to length, and spliced ends of the wires are connected to terminals using generally known methodologies familiar to the field of electricians. 
     A drawback of the above system is that the total maximum output of the panels must not exceed the capacity of the home&#39;s existing electrical service, in that having an output in excess of capacity can damage the system and/or present a safety hazard. However, different solar panels have different outputs and different homes have different capacities. The underlying calculations on the appropriate number of panels are generally known by electricians and professional solar panel installers, but are not typically known by a typical consumer. Many consumers are also not familiar with how to make safe electrical grade connections between components and/or lack the tools to do so. Jurisdictions thus often require professional installers to install solar panel systems to ensure safe and proper installation, which adds to the overall installation costs. In general any wired in place solar or electrical system must be installed by a licensed electrical contractor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various embodiments in accordance with the present disclosure will be described with reference to the drawings, in which: 
         FIG. 1  illustrates an environment of an embodiment of the invention. 
         FIG. 2  illustrates a solar panel according to an embodiment of the invention. 
         FIG. 3  illustrates a cable connecting to various components according to an embodiment of the invention. 
         FIG. 4  illustrates a table of possible shapes of connectors based on system capacity according to an embodiment of the invention. 
         FIG. 5  illustrates an embodiment of a smart station. 
         FIG. 6  illustrates a flowchart of the operation of a smart station according to an embodiment of the invention. 
         FIG. 7  illustrates a more detailed end-to-end embodiment of the invention 
         FIG. 8  illustrates a data store and accompanying components according to an embodiment of the invention. 
         FIG. 9  illustrates an environment of another embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, various embodiments will be illustrated by way of example and not by way of limitation in the figures of the accompanying drawings. References to various embodiments in this disclosure are not necessarily to the same embodiment, and such references mean at least one. While specific implementations and other details are discussed, it is to be understood that this is done for illustrative purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the scope and spirit of the claimed subject matter. 
     Because of safety concerns, any wired in place solar or electrical system is typically installed by a licensed electrical contractor. Embodiments herein provide methodologies and architecture that address those safety concerns. Embodiment herein can thus this reduce or eliminate the need for onsite engineering and allow anyone to safely connect and install a solar panel system. 
     Embodiments of the invention herein provide a “plug and play” solar panel installation methodology that requires little or no reliance on professional electricians or installers. End consumers can thus install the systems on their own, thereby reducing the overall installation costs. 
     Referring now to  FIG. 1 , an embodiment of a deployed solar panel system is shown. Solar panels  102  are an originating source of electrical power. Each panel  102  includes an interface adaptor  104  that connects to branches of a cable  106 . Cable  106  also connects to smart station  108 , discussed in more detail below. Smart station  108  in turn connects to a home load center  110  through a connector  109 , which in turn connects to a utility meter  112  and/or other electrical leads  114 . 
     Referring now to  FIG. 2 , an embodiment of solar panel  102  and adaptor  104  is shown (not to scale—panel  102  would typically be considerably larger). Adaptor  104  is preferably the only electrical conduit through which power from panel  102  is sent downstream. Adaptor  104  is also preferably mounted to or otherwise integral with panel  102 . 
     Referring now to  FIG. 3 , an embodiment of adaptor  104  relative to cable  106  is shown. Adaptor  104  may include a data source  302 . Data source  302  preferably is a programmed integrated circuit, but this need not be the case and data source  302  may be any other form of hardware and/or software data source. The invention is not limited to any physical embodiment of data source  302 . 
     Data source  302  preferably includes information about the solar panel  102  to which data source  302  is connected, such information being stored or generated on an as needed basis. Such information may include the rated wattage of the solar panel  102  that data source  302  is associated with. In addition and/or the alternative, such information may include an identifier or marker. Such information may also contain other identification information that may be of use, such as the manufacturer, although such information may not be necessary for operation of the embodiment. The invention is not limited to any particular type of data stored and/or generated by data source  302 , or the format of such data. Data source  302  may receive power from the panel  102  directly, through a local battery, or via feedback from smart station  108  or other downstream elements. Data source  302  may also be a passive device that require no independent power, but which can impart its information by modulating other signals that react therewith. 
     Adaptor  104  also preferably includes a connector  304  with various pins and/or slots configured to mate with a corresponding branch connector  306  of cable  106 . The various pathways provided by the pins will be appropriate to convey power from panels  102  to smart station  108 , as well as the requisite information from data source  302 . 
     The shape of the connectors  304 / 306  may have various generic or unique features. At a minimum, each connector combination  304 / 306  is preferably of a plug in type, i.e., connector  306  can mate with connector  304  by simply physical contact or insertion, and without the need to strip any wires. This provides a “plug and play” feature that allows installation without specific knowledge of safely stripping and connecting electrical cable with electrical terminals. 
     Connectors  306  may be at preset positions along cable  106 . In the alternative, connectors  306  may be snap on components that the consumer can connect to the cable during installation at desired customized positions. 
     The shape and configuration of connectors  304 / 306  could be universal to any particular solar panel  102  with adaptor  104 . In the alternative the combination could be unique to panels of common rated outputs. By way of non-limiting example, a square arrangement of connectors  304 / 306  could be used for a panel rated for 50 watts, while a triangular arrangement could be for panels of 100 watts. The number of branch connectors  306  in combination with the unique shape of the connectors can collectively limit the total output of an array of panels  102  to smart station  108 . By way of non-limiting example, a cable  106  with sixteen (16) branch points with connectors  306  having a shape specific to 200 watt panels  102  would have a maximum limit of 3.2 kW, and could be used safely with systems that could handle such capacity. Not every connector  306  need be connected to panels, and unused connectors  306  are preferably covered by a weather resistant cap. 
     Cable  106  also includes a connector  310  at the end that connects to smart station  108 , which has a mating connector  312 . At a minimum, each connector combination  310 / 312  is preferably of a plug in type, i.e., connector  310  can mate with connector  312  by simple physical contact or insertion, and without the need to strip any wires. This provides a “plug and play” feature that allows installation without specific knowledge of how to safely strip and connect electrical cable with electrical terminals. 
     Cable  106  may also include an equipment-grounding conductor as well as optional grounding electrode conductor. The equipment ground conductor would connect to the equipment ground that comes out of the module&#39;s power source and ultimately be grounded through the grounding of the home&#39;s existing electrical system. The grounding electrode conductor, which grounds the panel/racking system that supports the panels  102 , and would connected to a separate ground connection attached to the array and will ultimately be grounded through a separate grounding rod not attached to the home&#39;s existing electrical service. 
     The shape and configuration of connectors  310 / 312  could be universal to any smart station  108 . In the alternative, connector combination  310 / 312  is preferably unique to the system size as dictated by the smart station  108 . By way of non-limiting example, a trapezoid arrangement could be used for a system rated for 3.8 kilowatts, while a hexagon could be for systems of 13.4 kilowatts.  FIG. 4  shows a table  400  of non-limiting examples of different connector configurations for different system ratings. The invention is not limited to any particular design or system size. The only guiding principles are that preferably (1) different system sizes have different shaped connectors  310 / 312 , and (2) connectors  310 / 312  have different shapes than connectors  304 / 306  that connect panels  102  and cable  106 . In addition and/or alternative to different shapes, different colors could also be used. 
     The number of branched connectors  306  in combination with a unique connection mechanism collectively limit the total output of an array of panels  102  to smart station  108 . By way of non-limiting example, a cable  104  with sixteen (16) branch points with connectors  306  specific to 200 watt panels  102  would have a maximum limit of 3.2 kW, and could be used safely with systems that could handle such capacity. 
     As shown in  FIG. 5 , smart station  108  may have multiple connectors  312  to connect to multiple cables  106 . Three are shown in  FIG. 5 , but there may be any number of connectors  312  (including only a single connector  312 ) as appropriate for the system. Each of the connectors  312  preferably has the same structure; along with the specific cables  106 , this would ensure that each connector  312  connects to the same maximum array of panels  102 . However, this need not be the case, and different connectors  312  may be used. The total number of connectors  312  is preferably system specific, e.g., if a smart station  108  can handle 60 panels of a certain type, then three connectors  312  configured to mate with cables  106  that support 20 panels of that type may be appropriate. However, this need not be the case, and there may be more connectors  312 . 
     Alternatively, smart station  108  might have connectors  312  of different types/structures. The smart station would allow the user to select just one, or an appropriate subset, of the multiple connectors  312 . Selecting a single connector  312  or an appropriate subset of connectors  312  would preferably disable the other connectors  312 . This potentially allows a universal smart station  108  that could be used safely for different system sizes. 
     Referring now to  FIG. 5 , a schematic of various control elements of smart station  108  is shown. The smart station  108  has at least one connector  312  to connect to different cables  106  as appropriate. Connectors  312  preferably connect to connector  109  through a power pathway  520 ; connector  109  ultimately connects to the home load center  110  through a regulation component  524  to deliver power from the array of solar panels  102  for end use. Connector  109  preferably also has a unique shape that is matched to the system, but this need not be the case, and may represent conventional electrical leads. A ground  528  also connects to power pathway  520  via ground pathway  526  for grounding purposes as discussed herein. 
     Smart station  108  also may include a controller  502 , a communications module  506 , and a display  504 . Controller  502  may include a processor  508  and a memory  510 . The various components may be any combination of electronic computer hardware and/or software as needed to effectuate the functionality of smart station  108  as discussed herein. The components, which may be integral or distinct, are connected using known methodologies and are not discussed further herein. 
     As noted above, cable  106  includes structure to carry information signals from the data sources  302  in the panels  102 . These signals reach controller  502  via a signal pathway  522 . As discussed in more detail below, controller  502  analyzes the signals and may enable or disable the system based upon system status. Signal pathway  522  is shown as a bidirectional pathway, but it may be unidirectional. 
     Controller  502  may be programmed with certain maximum/minimum parameters of the system. For example, controller  502  may be programmed with a maximum number of panels  102  and/or maximum amount of wattage that the system can support. Controller  502  may also be in communication with the data sources  302  of the panels  102 . Since the data source  302  may include information about the corresponding panel  102 , system controller  502  can determine whether the complete system connections are within the maximum parameters, and disable the system when this is not the case. For example, system controller  502  can determine whether too many panels  102  are connected, or whether the total rated wattage of the connected panels  102  exceed what the system can handle. Controller  502  can also monitor the presence of ground fault errors, loss of grounding continuity, over-current and/or over-voltage. These are exemplary only, and the invention is not limited to any particular system parameter(s) that controller  502  monitors and/or reacts to. 
     Regulator element  524  can be used for system control. Regulator  524  may be a simple switch under control from controller  502 . Controller  502  can thus enable or disable the flow of power through smart station  108 . Alternatively, controller  502  could instruct panel  102  to shutdown via data source  302 . The structure of such components are known to those of skill and not further detailed herein. 
     Controller  502  also may be programmed to monitor the output current of the array of panels  102 . As discussed below, it is possible for the array of panels  102  to generate higher output than system capacity. In such a case, controller  502  could disable the system, or otherwise govern the output fed to home load center  110  back to within acceptable levels. In theory some element would need to monitor this collective power flow for controller  502  to make the appropriate decision; regulator element  524  could by way of non-limiting example include an ammeter that monitors the collective power flow and informs controller  502 . 
     Controller  502  could also attempt to rectify the problem by altering the electrical layout of the system. For example, control  502  could shut down one or more of connectors  312 . In another example, control  502  could instruct one or more adaptors  104  to disconnect or reduce the power flow from their corresponding panels  102 ; selective deactivation of adaptors  104  may identify a “problem” panel  102 . In addition and/or the alternative, adaptors  104  could monitor the flow of electricity of the panel and on its own authority shut down the power connection if the output of the panel exceeds the rated wattage. Such intelligent capability may also be incorporated in the same integrated circuitry of adaptor  104  that supports data source  302 . 
     Referring now to  FIG. 6 , a flowchart of an example of a methodology for controller  502  is shown. At step  600 , the system starts and initializes. As part of this initialization, the continuity of the equipment grounding conductor between smart station  108  and panels  102  may be tested. At step  602 , controller  502  detects whether or not at least one panel is connected to the system; such detection may be via information of the data sources  302  of an attached panel  102 , or the simple detection of a power output from a panel  102 . If no panel is connected, the user is prompted at step  604  to attach additional panels, and control returns to step  602 ; this cycle loops until a panel is detected, at which point control passes to step  606 . The prompt at  604  may be via display  504 , or a signal sent through communications module  506  to a remote device. In another embodiment, steps  602  could be configured to determine if a pre-set number of panels  102  have been reached, and prompts the user to add panels until that number is achieved. 
     At step  606 , controller  502  confirms that the connected panels  102  are within the operating system parameter(s). The controller  502  preferably determines this based on the information from the connected data sources  302  relative to a stored threshold, which may be a data table. For example, if the parameter is number of panels, then controller  502  counts the number of data sources  302  that it receives signals from (this may a direct count, or an indirect count based on data taken from the information received from the data sources  302 ). If the parameter is the total rated wattage, then controller  502  adds the rated wattages of the panels as received from data sources  302 . These accumulated value(s) are then compared against the threshold as stored. If the value(s) are within acceptable limits, then the user is prompted at step  608  that the system can be enabled. If one or more of the values are not within acceptable limits (e.g., there are too many panels, and/or the total rated wattage is above system capacity), then the system is disabled at step  612  and the user is prompted of the nature of the problem at step  614 . Additional checks may also be occurring for system abnormalities, e.g., grounding fault, over-voltage, over-current, etc. 
     Steps  606  and  608  continue in a loop until the user activates the system at  610 ; this gives the user the opportunity to add more panels while the system monitors changes to confirm that the installation remains within system parameters. Once the user engages the system at  610  (which in  FIG. 6  only occurs if the system is not exceeding some value at  606 ), normal system operation engages at step  611 . 
     During normal system operation, controller  502  continues to monitor the status of the data sources  302  for changes in the connected panels  102 , and potentially other system abnormalities. If a configuration change occurs that exceeds system parameter(s) at step  616 , then controller  502  disables or governors the system at step  612  as discussed above. 
     Optionally, the system can as a fallback at step  618  determine whether the total output of the array of panels  102  exceeds a safety level; this safety level could be the same threshold as used for the total rated wattage, or some other value. If such an excess is detected, controller  502  disables or governors the system at  612 . In the alternative, control  502  can communicate with the adaptors  104  to shut down individual panels. 
     Referring now to  FIG. 7 , a more detailed schematic of a system  700  according to an embodiment of the invention is shown. 
     As noted above, it is possible that overages can occur despite the above safety measures. One such reason is simple mechanical failure. Another such reason would be if the user defies the instructions and connects multiple panels  102  in series or parallel through connections other than adaptor  104 , referred to herein as a “cluster” of panels. Yet another would be if a user damaged the system by cutting and splicing wires together. In such a case the information from data store  302 , which is specific to a particular panel, would not accurately represent the number of panels or the output characteristics of the cluster. 
     There are a variety of methodologies to prevent the formation of clusters. One such methodology is to exclude connectors on panels  102  other than adaptor  104  bearing specific connectors  304 . Another methodology for when other connections are present is to physically or electrically disable such other connections when adaptor  104  is used. For example, insertion of connector  306  into  304  physically flips a switch that disconnects other connectors. By way of another example, adaptor  104  includes a cap that may be inserted into other connectors inherent to panel  102 . 
     Referring now to  FIG. 8 , a schematic of an embodiment of data store  302  on adaptor  104  relative to panel  102  is shown. At a minimum, data store preferably includes a memory  802  with the information about panel  102 . Memory  802  can communicate with cable  106  via a signal pathway  804  that terminates in connector  304 . 
     If “smart” functions are desired, a processor  806  may also be provided. One optional smart function is for processor  806  to control power output from panel  102  via switch  810  on power lines  808 . Another optional smart function is for processor  806  to control other power connections  812  via a switch  814 . As noted above, data store  302  can, either on its own control or under instruction from smart station  108 , enable and disable the various power conduits to prevent daisy chaining and/or to isolate potential problem areas. 
     According to another embodiment of the invention, the functionality of smart station  108  can be separated into distinct components, which may have distinct or overlapping functionality. By way of non-limiting example,  FIG. 9  shows smart combiner  402  that connects to a station  404 . Smart combiner  402  may be mounted on the roof or otherwise in close proximity of the panels  102 ; the racking (not shown) for the array of solar panels  102  may be an appropriate attachment structure. The closer proximity allows for shorter cables  106 , as cables  106  do not need to run the full length to the station  404 . A single cable/connection  406  can then connect smart combiner  402  and smart station  404 . 
     The cable  106 &#39;s will feed into the smart combiner  402  via connectors  312  consistent with the description of  FIG. 1 . Smart combiner  402  may have components similar to those discussed with respect to  FIG. 5  to monitor and react to system parameters. This will give the user real-time feedback (such as LED lights) regarding connections about how many panels  102  can be safely connected as the user is connecting panels on the roof. The smart combiner box may also ground the panels and racking system by biting into the racking. In this embodiment, other functions of the smart station  108  of  FIG. 1 —including shutting off the power or reducing power produced by the solar panels, cutting off the flow of power into the home&#39;s electrical system, recognizing ground faults, over-voltage, and over-current situations, etc.—would be part of station  404 . Smart combiner  402  and station  404  could be connected by custom end cables in the manner discussed herein, or more conventional electrical wiring. Smart combiner  402  could serve a grounding function by clipping directly on to the racking for the panels. The smart combiner  402  could ground the racking by running a grounding wire back through the cable from the smart connector to the smart station  108 . 
     The various system monitoring and diagnostics of the embodiment of  FIG. 9  preferably run according to the same flowchart as shown in  FIG. 6 . However, the functionality of controller  502  in the decision making can be implemented in smart combiner  402  and/or station  404 . If both combiner  402  and station  404  have controllers, the two may consult with each other (which may be as simple as exchanging data) to determine whether the system is operating within safe parameters and/or whether act needs to be taken. 
     The distribution of components and functionality in connection with  FIG. 9   
     Solar panels  102  preferably include a DC/AC inverter to output AC power, such that cables  106  would be at least partially AC power cables. A charge converter and/or batteries (not shown) could also be provided. 
     The various connectors herein are described as single/unitary connectors. However, this need not be the case, and the connectors could have multiple branches, e.g., one or more branches for power transmission, one or more branches for grounding purposes, and/or one or more branches for information transmission. Each branch may itself be made of one or more wires. 
     The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims.