DESC:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION

(See Section 10 and Rule 13)

Title of invention:
HYBRID CHARGE CONTROLLER

APPLICANT:
Prayogik Technologies LLP

An Indian Entity
having address
Room No.8, Rolta Incubation Centre
MANIT Bhopal-462003
India

The following specification describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application claims priority from Indian provisional patent application no. 201621019410, filed on 3rd June, 2016.

TECHNICAL FIELD

The present invention in general relates to a charge controller, and more particularly relates to a hybrid charge controller using a combination of solar power, wind turbines, diesel generator (DG) sets and Combined Cycle Vapor Turbines (CCVT) for charging batteries.

BACKGROUND

Solar power is the conversion of sunlight in form of electricity, either directly using photovoltaics (PV), or indirectly using concentrated solar power. The photovoltaics (PV) are currently used as a source of electricity, through solar energy, for small and medium-sized applications. As the cost of generating electricity via solar energy is comparatively minimal, it has been observed in the recent times that there has substantial increase in the number of grid-connected solar PV systems and utility-scale solar power stations.

In an existing art, battery chargers can charge from AC power source only. The existing systems are available only for low load DC-DC current value applications. Further, there is a need of an attendant to monitor the battery charging and discharging status. Sometimes, the battery may get overcharged or may completely discharge if the attendant is not monitoring, thereby reducing the battery life. There is a need to control and monitor the battery and load to be supplied through battery and charge controller.

Presently, more efficient charge controllers have emerged that provide a better match between solar PV panels and their load. Their goal is to use all the power from the PV panels regardless of the voltage and current at any amount of isolation. Although the newer charge controllers provide improved system efficiencies relative to the older models, they too often suffer from several shortcomings. More particularly, the charge controllers are slow to adapt to changing conditions of the solar PV panels over the course of any given day, including low light conditions in the morning, evening and during cloud cover and also temperature changes. The edges of clouds create particularly issues because they cause a rapid change in lighting which may be followed by a relatively rapid change in temperature. The newer charge controllers do not quickly adapt to changing conditions, have limited efficiency, which results in the need for extra (or larger) PV panels to be used for a given power output and further resulting higher costs.

SUMMARY

This summary is provided to introduce concepts related to a hybrid charge controller and the concepts are further described in the detail description. This summary is not intended to identify essential features of the claimed subject matter nor it is intended to use in determining or limiting the scope of claimed subject matter.

In one implementation, the invention discloses a hybrid charge controller system. The hybrid charge controller system may comprise at least one power generating source, at least one junction box capable of obtaining power from the at least one power generating source and a hybrid charge controller. The hybrid charge controller may further comprise a maximum power point tracker (MPPT), a DC-DC converter, a programmable logic controller (PLC) and a human machine interface (HMI). The system may further comprise one or more chargeable units, wherein the power is transmitted from the at least one power generating source to one or more chargeable units via the hybrid charge controller and the hybrid charge controller controls the power to be transmitted by processing and monitoring the power.

In another implementation, the invention discloses a method of operating a hybrid charge controller. The method may comprise obtaining, via a junction box, the power from at least one power generating source. The method may further comprise conveying, via a connecting cable, the power to the hybrid charge controller. Further, the method may comprise processing, via the hybrid charge controller, the power received from the junction box. The method may further comprise supplying, via the connecting cable, the power to the one or more chargeable units.

BRIEF DESCRIPTION OF DRAWINGS

The detailed description is described with reference to the accompanying Figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.

Figure 1 illustrates a block diagram of the hybrid charge controller system 100, in accordance with an embodiment of the present disclosure.

Figure 2 illustrates a PLC 105 and its components, in accordance with an embodiment of the present disclosure.

Figure 3 (a) illustrates a front view 300-a of an enclosure 300 housing the hybrid charge controller 102, in accordance with an embodiment of the present disclosure.

Figure 3 (b) illustrates a side view 300-b of the enclosure 300 housing the hybrid charge controller 102, in accordance with an embodiment of the present disclosure.

Figure 4 illustrates a hybrid charge controller system 102, in accordance with an embodiment of the present disclosure.

Figure 5 illustrates method 500 of operating the hybrid charge controller 102, in accordance with the embodiment of the present subject matter.

DETAILED DESCRIPTION

Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” 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 various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

In one embodiment, the hybrid charge controller system 100 may interchangeably be referred to as the system 100, may comprise at least one power generating source, at least one junction box capable of obtaining power from the at least one power generating source, a hybrid charge controller and one or more chargeable units. The hybrid charge controller may further comprise a maximum power point tracker (MPPT), a DC-DC converter, a programmable logic controller (PLC) and a human machine interface (HMI). The power from at least one power generating source may be obtained via a junction box. The junction box may convey the power to the hybrid charge controller. The hybrid charge controller may process the power received from the junction box. Further, the power is supplied to one or more chargeable units.

Now referring to figure 1, illustrates a block diagram of the hybrid charge controller system 100, in accordance with an embodiment of the present disclosure.

In one embodiment, the hybrid charge controller system 100 may comprise at least one power generating source. The at least one power generating source may comprise one or more solar panels 101-1, one or more wind turbines 101-2, one or more Diesel Generator (DG) sets 101-3, one or more Combined Cycle Vapor Turbine (CCVT) 101-4, or a combination thereof. The at least one power generating source may be referred to as the power generating source(s) 101 hereinafter. The mounting structure may be used to mount the power generating source 101. The hybrid charge controller system 100 may further comprise at least one junction box 108-1, 108-2, 108-3, 108-4…..108-n may also be referred to as a junction box 108 hereinafter.

In one embodiment, the power generating sources 101 may generate power. For example, the sunlight falling on the solar panels 101-1 may be converted into electricity i.e. into the electrical energy by photovoltaic principle. Further, the junction box 108 may obtain the electrical energy i.e. the power from the power generating sources 101. The power is the function of voltage and current. The required voltage may be obtained by connecting the power generating sources 101 in parallel/series through the junction box 108. The Junction box 108 may further convey the power to a hybrid charge controller 102. The hybrid charge controller 102 may further comprise a Maximum Power Point Tracker (MPPT) 103, DC-DC convertor 104, Programmable Logic Controller (PLC) 105 and Human Machine Interface (HMI) 106. The hybrid charge controller 102 may process the power and further supply power to the one or more chargeable units.

In one embodiment, the one or more chargeable units may be such as but are not limited to loads 107-1, a battery bank 107-2, a battery 107-3 or the like. The one or more chargeable units may collectively be referred to as a chargeable unit(s) 107.

In one embodiment, the MPPT 103 may receive the power generated by the solar panels 101-1 and further the MPPT 103 is capable to optimize the power i.e. the voltage and current as per the requirement of the chargeable units 107. The charging of the chargeable units 107 may be accomplished by the MPPT 103. The MPPT 103 ensures the charging process to be efficient and maximizes the life of the battery. The MPPT 103 may also monitors the state of charge of the chargeable units 107 and controls the charging from solar panels 101-1 in order to protect the chargeable units 107 against over-charging and over-discharging apart from various control functions.

In one embodiment, the DC-DC convertor 104 may provide a constant voltage output irrespective of input voltage variation. The DC-DC convertor 104 may be employed for dynamically charging the battery bank 107-2 or the battery 107-3 or to directly power the load 107-1 at the exact voltage and current that is most appropriate for the battery bank 107-2 or the battery 107-3 or the load 107-1.

In one embodiment, the battery bank 107-2 may be bi-directionally connected to the hybrid charge controller 102 which may further facilitate the bi-directional supply of power between the hybrid charger controller 102 and the battery bank 107-2.

In an exemplary embodiment, the voltage of 48 vdc may be used for the battery bank 107-2 and the required load 107-1 voltage is 24 vdc. There is a need to reduce the 48 vdc voltage to 24 vdc to feed the load 107-1 of 24 vdc. The DC-DC converter 104 does the same function. The input to the DC-DC converter 104 is the battery bank 107-2 voltage and the output is 24 volt required for the load 107-1. The battery voltage will vary from end cell voltage to boost voltage. The DC-DC converter 104 may absorb all the voltage variation at the battery side and provide a constant 24 vdc to the load 107-1.

In one embodiment, the DC-DC converter 104 may use various modules for advanced power processing, control and packaging technologies to provide the performance, flexibility, reliability and cost effectiveness of a mature power component. High frequency zero voltage/zero current switching (ZCS/ZVS) may provide high power density with low noise and high efficiency.

In one embodiment, the PLC 105 may accurately monitor the hybrid charge controller system 100. The PLC 105 may work with independent power supply which may remain unaffected by varying chargeable units 107 and other disturbances in line. The advanced power supply may be used to power the PLC 105. The PLC 105 may provide a constant voltage even with vast variation in the input power supply. The hybrid charge controller system 100 may be designed to ensure 100 % availability of power even in low battery condition as the PLC 105 may control the power to the hybrid charge controller system 100. The PLC 105 may disconnect the load 107-1 when the battery 107-3 or the battery bank 107-2 available becomes critically low. The hybrid charge controller system 100 may be of highly reliable industrial grade and programmable. The PLC 105 may also perform one or more functions. The functions may be such as but are not limited to detecting the reception of power from the at least one of power generating source 101, monitoring the status of the one or more chargeable units 107, monitoring the status of the charging voltage and current, checking interface between interface and PLC-PLC 105 links, processing charging voltage and current or the like.

In one embodiment, the HMI 106 may be the LCD monochrome touch display panel or a display screen. The Hybrid charge controller system 100 may be integrated with HMI 106 making the Hybrid charge controller system 100 easy to operate, control and monitor. The HMI 106 may be capable to display various parameter related to the status of the charging voltage and current; level of the charging voltage and current; status of the one or more chargeable units or the like. Therefore, the identification of the faults and different parameters may be done easily.

Now referring to figure 2, illustrates a PLC 105 and its components, in accordance with an embodiment of the present disclosure. The PLC 105 may comprise various modules. The modules may be a communication module 201, a digital input-output module 202, an analog input-output module 203 and a positioning module 204. The PLC 105 may be tailor made, making it flexible, enabling the PLC 105 to be used for broad range of applications. All the modules are electrically isolated from their environment with optocouplers for maximum reliability.

In one embodiment, the communication module 201 may be configured to check interface between peripherals and PLC-PLC 105 links. The digital input-output module 202 may be configured for a variety of signal levels with relay or transistor switches. The analog input-output module 203 may be configured for processing current/voltage signals and temperature registration with direct connection for thermometers and thermocouples. The positioning module 204 may be configured to provide support for connection of incremental rotary transducers and positioning of servo and stepping motor drives.

In one embodiment, the PLC 105 may have various standard features such as but are not limited to providing indications, providing protections, metering, signalling, communication or the like.

In one embodiment, the PLC 105 may be capable to provide various indications such as but are not limited to array fail indication, the chargeable units 107 voltage high indication, the chargeable units 107 voltage low indication, buzzer on indication, the chargeable units 107 charging low indication, the chargeable units 107 fully charged indication or the like.

In one embodiment, the PLC 105 may provide various type of protection to the hybrid charge controller system 100 such as but are not limited to protection to load voltage regulator against overload and short circuit, 2 pole DC Molded Case Circuit Breaker (MCCB) of suitable rating with shunt trip coil in PV charging path, 2 Pole DC MCCB of suitable rating with shunt trip coil in DG charging path, 2 Pole DC MCCB of suitable rating in load output path, 2 Pole DC MCCB of suitable rating with shunt trip coil in the path of the battery 107-3, protection against the battery 107-3 overcharging & deep discharge, protection against polarity reversal of the battery 107-3, soft-start function, thermal protection, temperature compensated charging for safety and extended life of battery via MPPT 103 or the like.

In one embodiment, the PLC 105 may perform metering such as but are not limited to charge-discharge ammeter, array/ load/ battery voltmeter, load ammeter, load KWh meter, array ammeter or the like; signaling such as but are not limited to the battery 107-3 current 4-20 ma signal, battery 107-3 voltage 4-20 ma signal, load current 4-20 ma signal or the like; and communication such as but are not limited to RJ45, RS 232 or the like.

In one embodiment, the PLC 105 may have various features such as but are not limited to real time clock, hybrid power source management, advanced battery management algorithm, charging modes, temperature compensation, battery tests, current limitation and deep discharge protection, load management, alarm detection or the like.

In one embodiment, the PLC 105 may further enable wireless communication, Simple Network Management Protocol (SNMP), fully programmable for additional logics, color touch screen, additional analog and digital outputs, additional relay drives, additions analog and digital input options for adding different sensors and machines, expandable memory for data logging, USB connectivity for transferring data and battery 107-3 low load management (load shedding) or the like.

Now referring to figure 3(a) and figure 3(b), illustrates a front view 300-a and side view 300-b of an enclosure 300 housing the hybrid charge controller 102, in accordance with an embodiment of the present disclosure.

In one embodiment, the HMI 106 may be fixed to the enclosure 300. One or more indicating lamps 301 may also be affixed to the enclosure 300 which may help in understanding the state of the hybrid charge controller system 100.

In one embodiment, the enclosure 300 of the hybrid charge controller 102 may be made of thick galvanized sheet steel. The enclosure 300 may be manufactured using laser cutting technology giving uniformity and a better finish for the enclosure 300. Base frames may be provided for easy mounting and handling of the enclosure 300. Eye bolts may also be provided for handling the enclosure 300.

In one embodiment, the powder coating or a suitable marine grade paint may be applied to the enclosure 300 in order to protect the enclosure 300 from environmental degradation. The coating may be a powder coating or a suitable marine grade paint. Proper surface preparation may be done to ensure better adhesion of protective coating on panels of the enclosure 300. The enclosure 300 may then achieve corrosion free protection. Gaskets may be provided inside the door panels for better sealing of the enclosure 300. Locks may be provided to prevent tampering of the enclosure 300. Earthing studs may be provided on both sides of the enclosure 300 for safety purpose.

In an embodiment, 14 SWG sheet steel may be used for fabrication of the enclosure 300. The enclosure 300 may further processed with 7 tank powder coating process and/or RAL 7035 as the standard color.

In an exemplary embodiment, the enclosure 300 may be well regulated and protected. The enclosure 300 may comprise a unit that work as constant voltage and constant current source throughout the operation. The unit may have an auto-reset type current limiting circuit provides continuous protection against over-load and output short circuit. The MCCB may be provided in Mains incoming and DC output. The enclosure 300 houses the hybrid charge controller 102 and the hybrid charge controller 102 are well rated to work at maximum operating temperature without malfunctioning. All components used in control cards, control circuits may be of professional/industrial grade, which may ensure long and trouble free service. The above discussed equipment may be housed in the enclosure 300, which may conform to IP42 degree of protection.

Now referring to figure 4, illustrates a hybrid charge controller system 102, in accordance with an embodiment of the present disclosure.

In one embodiment, the hybrid charge controller system 100 may comprise at least one power generating source. The at least one power generating source may comprise one or more solar panels 101-1, one or more wind turbines 101-2, one or more Diesel Generator (DG) sets 101-3, one or more Combined Cycle Vapor Turbine (CCVT) 101-4, or a combination thereof.

In one embodiment, the hybrid charge controller system 100 may further comprise at least one junction box 108.

In one embodiment, the power generating sources 101 may generate power. Further, the junction box 108 may obtain the electrical energy i.e. the power from the power generating sources 101. The power is the function of voltage and current. The required voltage may be obtained by connecting the power generating sources 101 in parallel/series through the junction box 108. The junction box 108 may be connected to the enclosure 300 in which the hybrid charge controller 102 is enclosed. The junction box 108 may further convey the power to a hybrid charge controller 102. The hybrid charge controller 102 may further comprise a Maximum Power Point Tracker (MPPT) 103, DC-DC convertor 104, Programmable Logic Controller (PLC) 105 and Human Machine Interface (HMI) 106. The hybrid charge controller 102 may process the power and further supply power to the one or more chargeable units 107.

In one embodiment, the hybrid charge controller system 100 may comprise one or more hybrid charge controller 102. The hybrid charge controller system 100 may comprise a switch 401. The switch 401 may enable to switch the connection of the junction box 108 from one hybrid charge controller 102 to another hybrid charge controller 102.

In one embodiment, a detail X may represent the circuit connection between the power generating sources 101 and the junction box 108. Further the details Y may represent an array junction and the circuit connection between the power generating sources 101 and the hybrid charge controller.

In one embodiment, the battery 107-3 may also be used for providing power to various loads. The system 100 may prevent battery 107-3 from deep discharge and over charging and thereby improving the life of the battery 107-3. The system 100 may be used for unmanned platforms. The system 100 may be utilized to charge the battery 107-3 and power various critical loads 107-1. The energy stored in battery may be utilized to power DC loads directly or to power AC loads by means of an inverter.

Now referring to figure 5, illustrates method 500 of operating the hybrid charge controller 102, in accordance with the embodiment of the present subject matter.

At step 501, the junction box 108 may obtain power from at least one power generating source 101.

In one embodiment, the hybrid charge controller system 100 may comprise at least one power generating source 101. The at least one power generating source may comprise one or more solar panels 101-1, one or more wind turbines 101-2, one or more DG sets 101-3, one or more CCVT 101-4, or a combination thereof.

In one embodiment, the power generating sources 101 may generate power. Further, the junction box 108 may obtain the electrical energy i.e. the power from the power generating sources 101.

At step 502, the junction box 108 may convey the power to the hybrid charge controller 102 via connecting cables.

At step 503, the hybrid charge controller 102 may further process the power received from the junction box 108.

At step 504, the hybrid charge controller 102, after processing the power, supply the power to the one or more chargeable units 107.

In one embodiment, the one or more chargeable units 107 may be such as but are not limited to loads 107-1, a battery bank 107-2, a battery 107-3 or the like.

In one embodiment, the hybrid charge controller 102 may be utilized for charging or providing power to one or more chargeable units used in multiple applications. The applications may be such as but are not limited to offshore oil & gas unmanned platforms, oil & gas pipeline CP stations, remote oil & gas wells requires DC power, remote mobile towers where grid power is not available, remote railway crossing where grid power is not available, resort and hotels where solar and wind turbine power is used to charge battery bank, remote island, village, street light where grid power is not available, fire and gas detection critical application for plants, mall, residences where grid power may fail, SCADA and remote telemetry unit, instrumentations and navigational aid or the like.

The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

Although implementations for the hybrid charge controller 102 have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as examples of implementations for the hybrid charge controller 102.
,CLAIMS:
WE CLAIM:

1. A hybrid charge controller system, the system 100 comprising:
at least one power generating source 101;
at least one junction box 108 capable of obtaining power from the at least one power generating source 101;
a hybrid charge controller 102, further comprising:
a maximum power point tracker (MPPT) 103;
a DC-DC converter 104;
a programmable logic controller (PLC) 105; and
a human machine interface (HMI) 106;
one or more chargeable units 107;
obtaining, via a junction box 108, the power from at least one power generating source 101;
conveying, via a connecting cable, the power to the hybrid charge controller 102;
processing, via the hybrid charge controller 102, the power received from the junction box 108; and
supplying, via the connecting cable, the power to the one or more chargeable units 108.

2. The system of claim 1, wherein the at least one power generating source 101 comprises at least one of a solar panel 101-1, a wind turbine 101-2, a diesel generator set 101-3, a combined cycle vapor turbine 101-4 or a combination thereof.

3. The system of claim 1, wherein the hybrid charge controller 102 comprises MPPT 103, wherein the MPPT 103 is capable to receive power generated by the solar panel 101-1 and further the MPPT 103 is capable to optimize the voltage and current as per the requirement of the one or more chargeable units 107.

4. The system of claim 1, wherein the hybrid charge controller 102 comprises DC-DC converter 104, wherein the DC-DC converter 104 is capable to provide the constant voltage output irrespective of the input voltage variation.

5. The system of claim 1, wherein the PLC 105 further comprises a communication module 201; a digital input-output module 202; an analog input-output module 203 and positioning module 204, wherein each of the modules are capable to perform one or more functions which further comprises:
detecting the reception of power from the at least one of power generating source 101; monitoring the status of the one or more chargeable units 107; monitoring the status of the charging voltage and current; checking interface between interface and PLC-PLC links; processing charging voltage and current or the like.

6. The system of claim 1, wherein the hybrid charge controller 102 comprises HMI 106, wherein the HMI 106 is a touch sensitive display panel capable to display various parameter related to the status of the charging voltage and current; level of the charging voltage and current; status of the one or more chargeable units 107 or the like.

7. The system of claim 1, wherein the one or more chargeable units 107 comprises at least one of a battery bank 107-2, a load 107-1, a battery 107-3, or the like.

8. The system of claim 1, wherein the battery bank 107-3 is bi-directionally connected to the hybrid charge controller 102 which further facilitates the bi-directional supply of power between the hybrid charger controller 102 and the battery bank 107-3.

9. The system of claim 1, wherein the hybrid charge controller 102 is enclosed in an enclosure 300 which further comprises one or more indicators.

10. A method of operating hybrid charge controller 102, the method comprising:
obtaining, via a junction box 108, the power from at least one power generating source 101;
conveying, via a connecting cable, the power to the hybrid charge controller 102;
processing, via the hybrid charge controller 102, the power received from the junction box 108;
supplying, via the connecting cable, the power to the one or more chargeable units.

Dated this 18th day of May 2017

Priyank Gupta
Agent for the Applicant
IN/PA- 1454