WO2016113287A1

WO2016113287A1 - Mobile power system

Info

Publication number: WO2016113287A1
Application number: PCT/EP2016/050538
Authority: WO
Inventors: Holger Janke; Norman ABELA; Vincenzo Bruno BELLINI; Gaetan BORGERS
Original assignee: Holger Janke; Norman ABELA; Vincenzo Bruno BELLINI; Gaetan BORGERS
Priority date: 2015-01-13
Filing date: 2016-01-13
Publication date: 2016-07-21
Also published as: LU92633B1

Abstract

The present invention relates to a mobile power system comprising: - a standard ISO container(6) for shipping solar sub-arrays (1) to a desired location, the two vertical walls of largest dimensions forming the side walls (12) of the container (6), - a plurality of solar sub-arrays (1) mounted on the container (6), said solar sub-arrays (1) being sized to fit inside the container (6) and comprising each several modules (2) physically and electrically preassembled in a ready-to-use mode before shipping, - a frame (7) to support the solar sub-arrays (1) on the container (6) and being configured to fit inside the container (6) when the sub-arrays (1) are not mounted, said frame (7) comprising vertical bars (9) detachably mounted along the side walls (12) of the container (6).

Description

MOBILE POWER SYSTEM

Field of the invention

[0001] The present invention relates to a mobile power system for remote areas and/or stand-alone applications.

[0002] More particularly, the present invention relates to a standard shipping container comprising a fast and easy deployable solar array system.

State of the art

[0003] In remote areas or areas affected by natural disasters, the solar energy is particularly appropriate because the sun as fuel resource is available at no cost and requires no delivery costs. However, to use this power source, electric generating systems designed for a fast transport and an easy assembly on site are required.

[0004] To this end, it exists mobile power systems like in the document US

7,230,819 wherein all the components are stored within the interior of a standard freight container and transported to the desired location. Once on the ground, preassembled solar sub-arrays are mounted on the housing of the container. This assembly is quite complex and thereby time consuming, requiring to secure brackets to the housing, to fasten support members to the bottom surface of the solar sub-array, to couple one end of the support member to the brackets and to couple the other end to an adjustable strut assembly, and finally requiring to fix the adjustable strut assembly to the housing of the container. In addition to being complex, the assembly of this mobile power system has the following disadvantages:

it requires important forces to mount each preassembled sub-array on the housing; for large array surfaces, the housing must be anchored to the ground by way of a plurality of tie-down cables in order to avoid undesirable lifting effects under strong winds; the design of the support frame does not allow to position the sub-arrays in a same plane, resulting in shading effects between the different planes of sub-arrays.

[0005] The document US 8,539,724 discloses another mobile power system. The system is housed in two standard military shipping containers. On site, the modules are respectively mounted in a frame on each container and are mounted one at a time. This system also has the disadvantage that it is time consuming and requires important effort to mount each module separately. In addition, like for the mobile power system of the previous document, the design of the support structure with a part protruding at the back of the container does not allow to support large array surfaces without additional foundation because of the lifting effects under the protruding part when exposed to strong winds, such effects being called edge effects.

Aims of the invention

[0006] The present invention aims to provide a complete photovoltaic- based solution easy to transport, to mount and to maintain for users who need to address energy supply in isolated areas and/or for stand-alone applications.

[0007] Specifically, the present invention aims to provide a mobile power system that can be quickly mounted with a minimum effort.

[0008] The present invention also aims to provide a mobile power system able to support a large array surface on site without foundation and without shading effects between the sub-arrays.

[0009] Another aim of the present invention is to develop a mobile power system wherein the housing remains intact without loss of the shipping certificate after use.

[0010] An additional aim of the invention is to provide a fully integrated system not only containing the power generating system but also all the other equipment/station required on site and being supplied with the generated energy.

Summary of the invention

[0011] The present invention relates to a mobile power system comprising: a standard ISO container for shipping solar sub-arrays to a desired location, the two vertical walls of largest dimensions forming the sidewalls of the container, a plurality of solar sub-arrays mounted on the container, said solar sub-arrays being sized to fit inside the container and comprising each several modules physically and electrically preassembled in a ready-to-use mode before shipping,

a frame to support the solar sub-arrays on the container and being configured to fit inside the container when the sub-arrays are not mounted,

said frame comprising vertical bars detachably mounted along the sidewalls of the container.

[0012] According to particular preferred embodiments, the mobile power system further discloses at least one or a suitable combination of the following features: a pair of vertical bars is mounted on each sidewall of the container, each pair having a different length so that the upper ends of the bars form an inclined plane corresponding to the desired solar sub-array exposure;

- the vertical bars are locked in corner fittings of the sidewalls;

the frame further comprises horizontal bars linking the upper ends of the vertical bars of each pair and comprises hollow bars linking the horizontal bars;

the sub-arrays are slidably mounted in the hollow bars;

it comprises wheels mounted at some corners of the sub-arrays;

- the plurality of sub-arrays covers a surface superior to 50 m² and, preferably superior to 60 m², for a 20 feet container, all the surface being deployed in a same plane; the plurality of sub-arrays covers a surface superior to 100 m² and, preferably superior to 120 m², for a 40 feet container, all the surface being deployed in a same plane;

- the frame does not comprise parts protruding out of a plane comprising one of the sidewall so that there are minimal edge effects;

no anchoring system or foundation other than the container itself is required; the solar sub-arrays are mechanically coupled to each other by a hinge assembly so that the solar sub-arrays can be folded inside the container when they are not mounted on the container; it comprises a trolley for moving the folded solar sub-arrays in an inclined position matching with the slope angle of the inclined plane for an easy assembly;

it comprises a winch coupled to the solar sub-arrays for mounting the folded sub- arrays along the hollow bars;

- it is a fully integrated system comprising an equipment or a station to be supplied with the power generated by the solar sub-arrays, said equipment or station being sized to fit inside the container with the plurality of solar sub-arrays and the frame;

the equipment or station is a water pumping station, a telecom station, a desalination station, a multimedia station, a battery charging station, a DC charging station, an AC power source, a DC/AC lighting, a communication device, a refrigeration unit, a heating unit, a chemical treatment and dosing unit or a laboratory.

[0013] The present invention also relates to a method for shipping and assembling a power system, comprising the steps of:

mechanically and electrically coupling a plurality of modules to each other for shipment, said coupled modules forming a solar sub-array;

storing a plurality of said solar sub-arrays and a plurality of bars in a container; shipping the container to a desired location;

mounting bars in a vertical position along vertical walls of the container;

mounting bars in a horizontal position between the bars in vertical position and mounting bars between the bars in horizontal position to form a sliding frame; mounting the solar sub-arrays in the sliding frame.

[0014] According to particular preferred embodiments, the method further discloses at least one or a suitable combination of the following features:

it comprises the step of mechanically coupling to each other the sub-arrays by a hinge assembly in order to transport folded sub-arrays inside the container;

the folded sub-arrays are shipped and moved on a trolley in an inclined position matching with the slope of the sliding frame;

the sub-arrays are unfolded along the sliding frame using a winch.

Short description of the drawin S

[0015] Figure 1 represents a solar sub-array with six physically and electrically preassembled modules. [0016] Figure 2 represents a plurality of sub-arrays folded for shipping.

[0017] Figure 3 represents the hinge mechanism between two folded sub- arrays.

[0018] Figure 4 represents the unfolded sub-arrays.

[0019] Figure 5 illustrates the step of deployment of the folded sub-arrays on the container during mounting.

[0020] Figure 6 represents the folded sub-arrays disposed on an inclined trolley for shipping and mounting.

[0021] Figure 7 represents the sub-arrays stacked on a scissor lift for shipping and mounting.

[0022] Figure 8 represents a partial view of two folded sub-arrays with wheels on some corners.

[0023] Figure 9 represents the support structure mounted on the container.

[0024] Figure 10 represents the solar sub-arrays mounted on the support structure of the container.

[0025] Figures 11 (a) and (b) respectively represent a partial view of the container with the mounted vertical frame and an enlarged view of a vertical bar fixed in a corner fitting of the container.

[0026] Figures 12 and 13 illustrate the different steps of deployment of the folded sub-arrays in the sliding frame. Figure 14 is a detailed view of the sub-arrays sliding in the U profile using a winch.

Legend:

(1) sub-array

(2) module

(3) hinge

(4) trolley

(5) scissor lift

(6) container

(7) support structure, also called frame

(8) wheel (9) vertical frame made up of vertical bars, of the support structure

(10) horizontal frame made up of horizontal bars, of the support structure

(11) sliding frame made up of hollow bars, of the support structure

(12) sidewall of the container

(13) corner fitting

(14) winch

(15) cable

General description of the invention

[0027] The present invention relates to a mobile electric generating system, also called mobile power system, using solar energy as its main resource. It is specifically designed to meet the needs of stand-alone applications, in particular of rural power. The mobile power system according to the invention comprises a standard shipping container, typically a 20 feet (interior dimensions: 2350 mm width, 5896 mm length, 2385 mm height) or a 40 feet (interior dimensions: 2350 mm width, 12035 mm length, 2385 mm height) container, and the power generating devices that include the inverters, the batteries, the solar sub-arrays, and all the components for mounting the solar sub-arrays on the container. In addition, it can comprise other power generating systems such as a wind turbine or a diesel generator.

[0028] According to the invention, all is designed to fit inside the container during transport.

[0029] To this end, the solar sub-arrays are transported folded or stacked inside the container and deployed on site to form the solar array ready for energy production. According to the invention, each sub-array comprises several modules mechanically and electrically coupled to each other during manufacturing before shipping. So, the sub-arrays are directly ready for use on site after unfolding.

[0030] Different deployment mechanisms are described hereafter. All leave the exterior of the shipping container intact to allow shipment and delivery of the system without loss of the certificate for further shipping. All these deployment mechanisms allow an easy assembly with a reduced human intervention to get it up when on site within a few hours. Typically, the assembly is completed and ready for energy production in two hours with two men.

[0031] According to the invention, all the sub-arrays are mounted on the roof of the container in a same plane to avoid shading effects between sub-arrays and thereby loss of power whenever the solar angle exceeds 30 degrees. Preferably, the sub- arrays are disposed side by side.

[0032] Also, the support frame has a specific design that allows to position an array surface superior to 50 m² and, preferably superior to 60 m², for a 20 feet or a 40 feet container, without requiring other foundation than the container itself. For a 40 feet container, the array surface can be doubled compared to a 20 feet container. It means that an array surface superior to 100 m² and, preferably superior to 120 m², can be deployed.

[0033] The container according to the invention is multi-purpose. It comprises all the equipment to generate electricity but can also comprise other equipment such as a fast deployment stand-alone clinic, stand-alone pumping station etc. to be supplied on site with the generated electricity.

[0034] In addition, the container can be coated with a reflection coating to protect the equipment inside the container from the sun. Detailed description of the invention

[0035] Sub-arrays with several modules each are ready cabled and stored inside the container. Each sub-array comprises at least three modules. For example and as shown in figure 1, each sub-array 1 comprises six modules 2 of 250W each. In this configuration, the modules are disposed on two rows. At least five sub-arrays with six modules each are transported to generate about 10KW on a 20 feet container and about 20KW on a 40 feet container. Various other options are available depending on the module type used and the rating. For example, modules rated at 300W or greater can have a sub-array of five modules mounted side by side on a same row.

[0036] The sub-arrays can be transported folded or stacked inside the container. [0037] In a first embodiment shown in figures 2, 3, 4 and 5, the sub-arrays

1 are folded inside the container and unfolded out at arrival to be deployed on a support structure 7 mounted on the container 6. In figure 3, the hinge mechanism 3 between two sub-arrays 1 is displayed. Preferably and as shown in figure 6, the folded sub-arrays are placed on a trolley 4 inside the container according to a given angle, for example 30°, corresponding to the slope of the sliding frame as further explained below.

[0038] In a second embodiment, the sub-arrays are stacked inside the container, preferably, on a scissor lift 5 represented in figure 7.

[0039] In both embodiments, the sub-arrays 1 are slidably mounted in the support structure 7 and to this end provided with wheels 8 at the edges of the sub-arrays in some corners (see figure 8). For the folded sub-arrays, two wheels are disposed on each sub-array in the corners of a same side. For the stacked sub-arrays, they are located at the four corners of each sub-array. In both cases, the wheels are mounted on a horizontal axis.

[0040] The support structure 7 shown in figures 9 and 10 after assembly on the container 6 is shipped in pieces inside the container.

[0041] The support structure comprises several bars forming respectively after assembly the vertical frame 9, the horizontal frame 10 and the sliding frame 11 with a slope optimised for the solar sub-array exposure.

[0042] The vertical frame 9 is made up of bars to be mounted along the vertical sides of the container on the two sidewalls 12, i.e. the walls of largest dimensions. Four vertical bars 9 are provided with brackets that latch into the existing container holes, also called corner fittings 13, as shown in figures 11(a) and (b). Each vertical bar 9 is latched in the upper and the lower corner fitting 13. The advantages of this design is that the profile of the container is used for the vertical fixing and so no penetrations are done in the container that would affect the shipping certificate of the container after disassembly. The vertical bars have two different lengths with bars of a same length being fixed on the same sidewall of the container. According to the invention, the difference of length between the bars of the respective sidewalls is calculated to get the desired slope angle of the sub-array. Optionally, additional vertical bars can be placed in the middle of each sidewall for reinforcing the support structure. These bars are not fixed to the container in order to avoid any penetrations in the container that would result in the loss of the shipping certificate. Those additional vertical bars are fixed to the horizontal frame described below.

[0043] The horizontal frame 10 is made up of bars mounted horizontally between the vertical bars 9 of a same length and fixed using bolts and nuts.

[0044] The sliding frame 11 is made up of bars connecting the horizontal bars and extending beyond one sidewall of the container. The sliding frame is fixed to the horizontal bars with bolts and nuts as well. The bars of the sliding frame form U shaped channels to receive the wheels of the sub-arrays. According to the invention, the open side of the U profile faces the lateral sides of the sub-arrays. Also additional bars can be placed in the middle to support the deployed sub-arrays.

[0045] All bars have a maximum length adapted to fit inside the container.

If a longer supporting structure is required for the sliding frame, additional bars are welded during assembly. Also additional horizontal and vertical frames can be fixed under the sliding frame to further support the sub-arrays when important surfaces are deployed as shown in figure 10.

[0046] Viewed from the side, the support structure has the general shape of a right-angled triangle without protruding parts at the back of the container. In other words, the upper edge of the mounted solar array is essentially in the same plane as the plane formed by the vertical bars of higher length as shown in figure 10 or the right- angled triangle has a side essentially in the same plane as one of the sidewalls 12. This specific design eliminates the lifting effect of strong winds and thereby no anchoring system or foundation other than the container itself is required.

[0047] After assembly of the support structure on the container, the sub- arrays are deployed. For the first embodiment represented in figures 12, 13 and 14, the trolley 4 is pulled out of the container and moves forward towards the lowest part of the sliding frame 11 till the wheels 8 match the U profile. The folded sub-arrays 1 placed on the trolley 4 in a 30° angle can be easily aligned in the plane of the sliding frame. The sub-arrays are unfolded either using a motorized unit or a manual ratchet system as shown in figure 14 representing the mechanical winch 14 on the lateral sides of the sliding frame. On arrival on site, the ratchet system is installed and the end of the cable 15 connected to the first folded frame. Two people are required to unfold the first sub- array onto the U profile and the bolts are fixed. Using the ratchet system, the sub-arrays are unfolded till they are lying completely flat in the sliding frame as shown in figure 10. The fixing bolts are then attached in order to guarantee safe installation of the sub- arrays on the support structure.

[0048] For the second embodiment, the side of the container opens to reveal the sub-arrays stacked on a scissor lift. On site, the sub-arrays are lifted into position at the back of the container using the scissor lift (see figure 7) and the sub- arrays are slid one at a time till the complete array is assembled and facing the sun. The above process can also be carried out manually with personnel loading the sub-arrays into the support structure.

[0049] The mobile power system according to the invention is preferably a fully integrated system including the power generating system and the systems using the collected energy. To this end, the system can comprise a number of subsections mounted inside the container, each having similar or different applications as further described below. For example, in addition to the solar sub-array system, the container can comprise:

• Battery charging station for all type of storage devices including multimedia

devices and mobile phones;

· Desalination station;

• AC power source consisting of socket outlets with one or more configurations and interfaces;

• DC / AC lighting;

• Communication devices such as mobile phone communication (e.g 2G; 3G),

repeater stations (both for voice and data transfer);

• Multimedia station (e.g. audio, video, computing, printing incl. 3D printing,

scanning);

• Outside broadcasting unit;

• Refrigeration and heating for medication, food or living and working space;

· HVAC;

• Chemical treatment and dosing; • Laboratories.

[0050] Also the interior of the container can be transformed after deployment of the solar sub-arrays into a living and working space including climate control. To cite a few, the interior can be transformed into an office space, a retail space, an educational space, a storage space, a control room, a command center, a sanitary/public convenience space, a tourism/information center, security/watchman/border control outposts, etc.

[0051] On site, the exterior of the container can be also used for many applications as billboards, shading space, lighting towers, etc.

Advantages of the invention

[0052] Thanks to the use of a vertical frame fixed along the corners of the container walls , a very large solar array can be supported without foundation/anchoring means other than the contained itself. For this reason, it also requires no construction permit.

[0053] The support frame is fixed to the container only via the four vertical bars latched into the corner fittings. It means that there are no penetrations in the container that would affect the shipping certificate.

[0054] Compared to the support structure of the document US 7,230,819, the arrangement of all the sub-arrays in a same plane prevents shading problems whenever the solar angle exceeds 30 degrees.

[0055] The structure also serves to shade the container beneath it providing it with a cool environment without requiring air conditioning units that consume the energy produced.

[0056] The folded sub-arrays are angled on the trolley to match with the tilt of the sliding frame. Therefore, no vertical handling of the sub-arrays that weight about 1000 kg is required. Also, the stacked sub-arrays are supported on a scissor lift to reduce the human intervention.

[0057] The sub-array deployment is semi-automatic when using a battery operated winch for deploying the sub-arrays. [0058] The open U channels on the sides allow for the wheels of the sub- arrays to automatically align and unfold without stress.

[0059] Solar Power Supplies are typically custom made and require sizing for different loads and regions. The system according to the invention is a standard design with a known energy output and maximum demand capabilities for different regions. It is therefore more of a "drop and go" system like a normal diesel generator, however requiring no fuel other than the solar energy and other renewable energies.

[0060] Its main building block is a standard shipping container, universally recognized and used, and therefore will be easily handled anywhere in the world with standard equipment. It is handling and the logistic can be replicated anywhere.

[0061] The system is stand-alone, requiring no additional fuel other than the sun. Therefore, due to its flexible nature, it can be regarded as a temporary structure that is transported to where it is required and set up within a few hours.

[0062] The container is multi-purpose allowing to generate energy and to provide additional equipment of particular interest for the desired location.

Claims

1. A mobile power system comprising:

a standard ISO container (6) for shipping solar sub-arrays (1) to a desired location, the two vertical walls of largest dimensions forming the sidewalls (12) of the container (6),

a plurality of solar sub-arrays (1) mounted on the container (6), said solar sub-arrays (1) comprising each several modules (2) physically and electrically preassembled in a ready-to-use mode before shipping,

a frame (7) to support the solar sub-arrays (1) on the container (6),

said frame (7) comprising vertical bars (9) mounted along the sidewalls (12) of the container (6).

2. A mobile power system as in claim 1, wherein a pair of vertical bars (9) is mounted on each sidewall (12) of the container (6), each pair having a different length so that the upper ends of the bars (9) form an inclined plane corresponding to the desired solar sub-array exposure.

3. A mobile power system as in claims 1 or 2, wherein each vertical bar (9) is locked in the upper and lower corner fittings (13) of the sidewalls (12).

4. A mobile power system as in any of the previous claims, wherein the frame (7) further comprises horizontal bars (10) linking the upper ends of the vertical bars (9) of each pair and comprises hollow bars (11) linking the horizontal bars (10).

5. A mobile power system as in claim 4, wherein the sub-arrays (1) are slidably mounted in the hollow bars (11).

6. A mobile power system as in any of the previous claims, comprising wheels (8) mounted at some corners of the sub-arrays (1).

7. A mobile power system as in any of the previous claims, wherein the plurality of sub-arrays (1) covers a surface superior to 50 m² and, preferably superior to 60 m², for a 20 feet container, and covers a surface superior to 100 m² and, preferably superior to 120 m², for a 40 feet container, all the surface being deployed in a same plane.

8. A mobile power system as in any of the previous claims, wherein the frame (7) does not comprise parts protruding out of a plane comprising one of the sidewall (12) so that there are minimal edge effects.

9. A mobile power system as in any of the previous claims, wherein the container (6) is the only foundation of the mobile power system.

10. A mobile power system as in any of the previous claims, wherein the solar sub-arrays (1) are mechanically coupled to each other by a hinge assembly (3) so that the solar sub-arrays (1) can be folded inside the container (6) when they are not mounted on the container (6).

11. A mobile power system as in claim 10, comprising a trolley (4) for moving the folded solar sub-arrays (1) in an inclined position matching with the slope angle of the inclined plane for an easy assembly.

12. A mobile power system as in claims 10 or 11, further comprising a winch (14) coupled to the solar sub-arrays (1) for mounting the folded sub-arrays (1) along the hollow bars (11).

13. A mobile power system as in any of the previous claims, being a fully integrated system comprising an equipment or a station to be supplied with the power generated by the solar sub-arrays (1), said equipment or station being sized to fit inside the container (6) with the plurality of solar sub-arrays (1) and the frame (7).

14. A mobile power system as in claim 13, wherein the equipment or station is a water pumping station, a telecom station, a desalination station, a multimedia station, a battery charging station, a DC charging station, an AC power source, a DC/AC lighting, a communication device, a refrigeration unit, a heating unit, a chemical treatment and dosing unit or a laboratory.

15. A method for shipping and assembling a power system, comprising the steps of:

mechanically and electrically coupling a plurality of modules (2) to each other for shipment, said coupled modules (2) forming a solar sub-array (1);

storing a plurality of said solar sub-arrays (1) and a plurality of bars (9,10,11) in a container (6);

shipping the container (6) to a desired location; mounting bars (9) in a vertical position along vertical walls (12) of the container (6), each bar (9) being latched in an upper and a lower corner fittings (13) of the container (6);

mounting bars (10) in a horizontal position between the bars (9) in vertical position and mounting bars between the bars (10) in horizontal position to form a sliding frame (11);

mounting the solar sub-arrays (1) in the sliding frame (11).

16. The method as in claim 15, further comprising the step of mechanically coupling to each other the sub-arrays (1) by a hinge assembly (3) in order to transport folded sub-arrays (1) inside the container (6).

17. The method as in claim 16, wherein the folded sub-arrays (1) are shipped and moved on a trolley (4) in an inclined position matching with the slope of the sliding frame (11).

18. The method as in claims 16 or 17, wherein the sub-arrays (1) are unfolded along the sliding frame (11) using a winch (14).