WO2010044830A2 - Système de montage de champ de panneaux photovoltaïques - Google Patents

Système de montage de champ de panneaux photovoltaïques Download PDF

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Publication number
WO2010044830A2
WO2010044830A2 PCT/US2009/005523 US2009005523W WO2010044830A2 WO 2010044830 A2 WO2010044830 A2 WO 2010044830A2 US 2009005523 W US2009005523 W US 2009005523W WO 2010044830 A2 WO2010044830 A2 WO 2010044830A2
Authority
WO
WIPO (PCT)
Prior art keywords
spar
solar panel
metal
tilt
channel
Prior art date
Application number
PCT/US2009/005523
Other languages
English (en)
Other versions
WO2010044830A3 (fr
Inventor
Robert H.J. Miros
Margaret Birmingham
Original Assignee
Sunlink, Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sunlink, Corporation filed Critical Sunlink, Corporation
Publication of WO2010044830A2 publication Critical patent/WO2010044830A2/fr
Publication of WO2010044830A3 publication Critical patent/WO2010044830A3/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • H02S20/24—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures specially adapted for flat roofs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/10—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
    • F24S25/16—Arrangement of interconnected standing structures; Standing structures having separate supporting portions for adjacent modules
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
    • F24S25/632—Side connectors; Base connectors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
    • F24S25/634—Clamps; Clips
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/70—Arrangement of stationary mountings or supports for solar heat collector modules with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surface; with means for compensating mounting tolerances
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S2025/6002—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by using hooks
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S2025/6003—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by clamping
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S2025/80—Special profiles
    • F24S2025/801—Special profiles having hollow parts with closed cross-section
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S40/00—Safety or protection arrangements of solar heat collectors; Preventing malfunction of solar heat collectors
    • F24S40/80—Accommodating differential expansion of solar collector elements
    • F24S40/85—Arrangements for protecting solar collectors against adverse weather conditions
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/20—Solar thermal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/40—Solar thermal energy, e.g. solar towers
    • Y02E10/47—Mountings or tracking
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present invention relates generally to a system for mounting and installing photovoltaic solar panels, and more particularly, to a photovoltaic solar panel mounting support system providing enhanced features.
  • PV panels photovoltaic solar panels
  • These PV panel systems are being installed in sites of high energy usage, such as on commercial building rooftops, in industrial open areas, and in proximity to substations tied to the electric grid.
  • These commercial energy systems, or power plants vary in size but can cover many thousands of square feet on a building rooftop and many acres of land when installed on the ground.
  • Roof mounted systems are particularly attractive in that business owners can elect to offset the energy consumption of their facilities through the use of existing space on the tops of their buildings.
  • the solar panels are mounted in a "tilted" configuration in order to maximize the effective capture of solar radiation, i.e. the solar panels are aligned with the solar angle of incidence.
  • the effects of various loads on the mounting surface, such as a roof must be understood.
  • the loads include standing loads and variable loads, also commonly called dead loads and live loads, respectively.
  • Standing loads are the result of the combined weight of the solar panels and the mounting system. These standing loads are predictable and are therefore easier to accommodate for during the installation of the solar panels and the mounting system.
  • Variable loads on the tilted solar panels are mainly caused by environmental conditions, such as wind, rain, snow, hail, etc. Other potential environmental hazards include seismic events, temperature extremes, debris and mold. In order to be able to reliably predict and accommodate variable loads, these environmental problems have to be understood and resolved.
  • the most common and problematic forces are wind- related forces (including hurricanes and tornados), namely lift and drag forces generated by the wind conditions.
  • a variety of mounting systems have been commercially available for mounting solar panels, which have attempted to address and mitigate the wind-induced forces.
  • Non-tilted solar arrays can be divided into three general categories: non-tilted solar arrays; enclosed tilted solar arrays; and tilted solar panels with wind deflectors attached to every row.
  • U.S. Patent Nos. 5,746,839 (Dinwoodie) and 6,570,084 (Dinwoodie) are examples of implementations involving non-tilted solar panels. While non-tilted solar panels do present a lower profile with respect to wind forces, they are less efficient at converting solar energy to electrical energy when installed at locations with higher latitudes.
  • Another disadvantage of a non-tilted system is the accumulation of dirt, dust, debris and snow on top of the solar panels, which can further reduce the conversion efficiency of the panels.
  • U.S. Publication No. 2004/0128923 discloses an example of an enclosed tilted solar panel system. While such a design offers advantages such as improved rigidity, less debris accumulation, and better protection of electrical components, an enclosed solar panel system increase the cost and weight of the system, is likely to increase wind-induced drag forces and also significantly reduces beneficial cooling from natural airflow. The additional heat introduced into the panels by the mounting system results in lower energy output from the photovoltaic panels. As shown in U.S. Patent Nos. 6,063,996 (Takada), 6,809,251 (Dinwoodie) and
  • deflectors are installed on the north-facing back of every panel in order to reduce the wind-induced uplift forces, when installed in the northern hemisphere. Disadvantages of such systems include significantly increased cost and weight of the installed system. These systems also increase the required labor time for installation in that more parts must be assembled in order to complete the array. In addition, reduced cooling of the solar panels can also significantly reduce the solar conversion efficiency of the system.
  • the present invention is a solar array mounting system having unique installation and grounding features, and which is adaptable for mounting solar panels having mounting holes located in different locations.
  • the solar array mounting system includes tilt brackets and longitudinal links forming columns.
  • a tilt bracket includes a tilt arm for supporting an upper spar of one row, and a pivot block for supporting a lower spar of a next row.
  • the spars may be made from aluminum or from steel, wherein the steel spars include an exposed metal channel to provide a common electrical equipment ground.
  • Panel clamps are used to clamp the solar panel frames to the spars, allowing for variations in mounting hole locations.
  • a spar for supporting one or more solar panels comprises a metal body forming a hollow rectangular frame and an extended section aligned with one side of the frame, a top channel in the rectangular frame, a bottom channel in the rectangular frame, and a coating covering the external surfaces of the metal body, except at least a portion of the bottom channel is uncoated metal to form an equipment ground connection surface.
  • the spar may be pre-galvanized before a paint or powder coating is applied to the spar.
  • the spar can also be formed from extruded aluminum
  • a solar panel mounting clamp comprises a top section having a stud to engage a mounting hole of a solar panel, and a threaded hole, a middle section aligned parallel to and below the top section, and having an opening aligned with the threaded hole in the top section, a hinged joint connecting the top and middle sections, a bottom section extending from the middle section at a right angle at a point between the stud and the threaded hole, and having an angled end formed to attach to a spar channel, and a bolt mounted through the opening in the middle section and into the threaded hole.
  • the panel clamp may be formed from a unitary piece of metal.
  • a solar panel clamp comprises a pawl having a stud to engage a mounting hole on a solar panel, a wire bail to attach to a spar channel, and a hasp connected to the pawl and wire bail, the hasp including a front opening.
  • a pivot block according to an embodiment of the present invention comprises a metal body, a mounting hole through the metal body, an alignment groove located on a bottom of the body; a tilt-up stop groove located at a rear of the body along a curved bottom edge of the body from the alignment groove, a top groove, and a front spar engagement channel and lip.
  • a solar panel array system comprises at least one solar panel having a metal frame, an upper spar and a lower spar, each spar comprising a metal body forming a hollow rectangular frame and an extended section aligned with one side of the frame, a top channel in the rectangular frame, a bottom channel in the rectangular frame, and a coating covering the external surfaces of the metal body, except at least a portion of the bottom channel is uncoated metal to form an equipment ground connection surface, at least one solar panel clamp connecting the upper spar to the at least one solar panel frame, wherein the at least one solar panel clamp comprises a stud to engage a mounting hole of a solar panel frame, and a spar engagement member to engage the uncoated metal on the bottom spar channel, at least one solar panel clamp connecting the lower spar to the at least one solar panel frame, wherein the at least one solar panel clamp comprises, a stud to engage a mounting hole of a solar panel frame, and a spar engagement member to engage the uncoated metal on the bottom spar channel, at least two metal tilt brackets, a
  • the system may further comprise a clamp block attached to each solar panel to clamp the solar panel to an upper spar and a wind deflector mounted to the upper spar.
  • a solar panel array system may comprise at least two solar panel module assemblies, each assembly comprising at least two solar panels having a metal frame, an upper spar and a lower spar, each spar comprising a metal body forming a hollow rectangular frame and an extended section aligned with one side of the frame, a top channel in the rectangular frame, a bottom channel in the rectangular frame; and a coating covering the external surfaces of the metal body, except at least a portion of the bottom channel is uncoated metal to form an equipment ground connection surface, at least one solar panel clamp connecting each solar panel frame to the upper spar, wherein the at least one solar panel clamp comprises a stud to engage a mounting hole of a solar panel frame, and a spar engagement member to engage the uncoated metal on the bottom spar channel, at least one solar panel clamp connecting each solar panel frame to the lower spar, wherein the at least one solar panel clamp comprises a stud to engage a mounting hole of a solar panel frame, and a spar engagement member to engage the uncoated metal on the bottom spar channel, at least two front
  • the system may further comprise a clamp block attached to each solar panel to clamp the solar panel to an upper spar, and a wind deflector mounted to the upper spar. If required to insure a solid metal -to-metal connection between the components the panel clamp, tilt leg and pivot block may include sharp metal protrusions (i.e. teeth) to positively engage the uncoated spar channel and/or panel frame.
  • FIG. IA is a side view of a solar panel mounting system according to the present invention
  • FIG. IB is a perspective view of the solar panel mounting system of FIG. IA;
  • FIG. 1C is a top view of the solar panel mounting system of FIG. IA;
  • FIG. 2 A is a side view of one embodiment of a spar according to the present invention
  • FIG. 2B is a side view of a second embodiment of a spar according to the present invention
  • FIG. 2C is a top perspective view of the spar of FIG. 2 A;
  • FIG. 2D is bottom perspective view of the spar of FIG. 2 A;
  • FIG. 3 A is a side view of first panel clamp embodiment according to the present invention.
  • FIG. 3B is a perspective view of the panel clamp of FIG. 3 A clamped to a solar panel;
  • FIG. 3C is a side view showing the panel clamp of FIG. 3 A attached to a solar panel and spar;
  • FIG. 4A is a side view of a second panel clamp embodiment according to the present invention.
  • FIG. 4B is a perspective view of the panel clamp of FIG. 4 A clamped to a solar panel;
  • FIG. 4C is a side view of the panel clamp of FIG. 4A attached to a solar panel and spar;
  • FIG. 5 A is a perspective view of a pivot block according to an embodiment of the present invention.
  • FIG. 5B is a side view of the pivot block of FIG. 5 A;
  • FIG. 5C is cross-sectional view of the pivot block of FIG. 5B;
  • FIG. 6A is a side view of a tilt leg according to an embodiment of the present invention.
  • FIG. 6B is a perspective view of the tilt leg of FIG. 6A;
  • FIG. 7 is a perspective view of a tilt bracket according to the present invention.
  • FIG. 8 A is perspective view of a wind deflector according to the present invention.
  • FIG. 8B is a side view of the wind deflector of FIG. 8 A;
  • FIG. 9A is a side view of top section of a panel clamp block according to an embodiment of the present invention.
  • FIG. 9B is a side view of a bottom section of a panel clamp block according to an embodiment of the present invention.
  • FIG. 9C is a side view of the top and bottom sections of the panel clamp attached to a solar panel and a spar;
  • FIG. 1OA is a perspective view of a lateral link according to an embodiment of the present invention.
  • FIG. 1OB is a side view of the lateral link of FIG. 1OA installed between spars according to an embodiment of the invention
  • FIG. 1OC is an enlarged view of lateral link of FIG. 1OB;
  • FIG. 11 is an enlarged side view of the solar panel mounting system;
  • FIG. 12 shows the panel assembly in the raised position, pivoting on the tilt brackets via the pivot blocks
  • FIG. 13 is an enlarged view of a tilt bracket showing the pivot block in position to receive a panel module.
  • FIGs. IA - 1C illustrate the basic components of the solar array mounting system according to the present invention.
  • the fundamental design and operation of the basic architecture is described in detail in U.S. Application Serial No. 11/176,036, entitled SOLAR ARRAY INTEGRATION SYSTEM AND METHODS
  • a system may comprise a panel module 12 having one or more photovoltaic solar panels.
  • three or four panels are used to form the panel module 12.
  • the panels are attached together with an upper support bar 26 and a lower support bar 24 (the support bars are referred to as "spars" herein).
  • Two tilt brackets 14, 16 are connected by a longitudinal link 22.
  • two other tilt brackets 18, 20 are connected via another longitudinal link (not shown).
  • the front tilt brackets 14, 18 include a pivot block 28, which attaches to the lower spar 24, and which allows the panel module 12 to be raised and lowered.
  • the upper spar 26 is connected to a tilt leg 30, which connects to the rear tilt bracket 16.
  • a symmetrically attached tilt leg not shown in the figures is attached to tilt bracket 20 in the same fashion.
  • the length of the tilt leg 30 determines the tilt angle of the panel module.
  • the tilt leg 30 and the hidden tilt leg, and tilt brackets 14, 16, 18 and 20 are sized to provide a tilt angle of 5°, 10°, 15° or 20°. The larger the angle, the greater the potential shading from row to row, so the rows are typically spaced farther apart.
  • the tilt brackets, tilt legs, and/or longitudinal links are longer than for lower tilt angles.
  • tilt brackets are connected together with longitudinal links to form a column of tilt brackets and links.
  • Parallel columns of tilt brackets and links form the support structure for multiple rows of panel modules.
  • wind deflectors 32, 34 are added to deflect wind from the underside of the array.
  • These wind deflectors have openings 130A, 130B, 130C, 130D to allow for installation of the deflectors over the existing structure of the tilt legs 30 and the tilt brackets 16, 20.
  • these tilt brackets may be shortened to allow service and emergency personnel a wider access way around the perimeter of the array.
  • FIGs. 2A - 2D illustrate the construction of the spars in greater detail.
  • the spars are roll formed from 1/16" steel.
  • the spars can be made from extruded aluminum.
  • the length of a spar is determined by the number of solar panels used in an installation for the module assembly, but is typically between 12 - 24 feet.
  • a spar 40 has a generally rectangular hollow body (illustrated as a generally square cross-section), with a top channel 44 and a bottom channel 46.
  • the metal is folded back on itself to form an extended section 42.
  • the extended section 42 abuts the edges of the solar panel frames.
  • the front edge 48 of the bottom channel is angled at less than 90° from vertical to facilitate the engagement of a clamp (described below).
  • a perspective view of this embodiment is shown in FIG. 2C.
  • FIG. 2B A second embodiment of a spar is shown in FIG. 2B. It has a similar- construction as the spar of FIG. 2 A, except that its front edge 58 of its bottom channel 56 angles away from the front edge of the spar 50. This edge 58 facilitates the engagement of a second clamp embodiment (described below).
  • One prior solution is to cover (i.e. with adhesive tape) fixed spots on the steel during the coating process. Once the coating has been applied, the covering can be removed leaving an exposed metal surface. The metal surface can then be used as a connection point with other components, or a grounding strap could be affixed via the exposed spot. The problem with this approach is that the grounding connection must occur at the exact predesigned location. This greatly reduces the flexibility of the system during installation.
  • each spar includes an uncoated bottom groove 46 to provide a common ground connection for the various components of the system, and allows the spar to be manufactured from steel, if desired, without sacrificing corrosion resistance of the spars.
  • the spars are made from steel and are first "pre- galvanized" to deposit a thin layer of zinc on the spar. This thin layer will provide fair corrosion resistance, but at a much lower cost than fully galvanizing the spars through a hot dipping process.
  • An adhesive strip is then placed on the bottom of the bottom channel 46, 56.
  • the spar can then be either painted or powder coated to provide additional corrosion protection.
  • the adhesive strip is then removed to expose a metal strip along the bottom channel of the spar.
  • the adhesive strip for example, only a center section where panels are most likely to be clamped to the spar could be covered, thereby coating some portion of the ends of the channel.
  • the enhancements of the present disclosure may be necessary, for example the coating and/or exposed metal channels, etc.
  • solar panels typically comprise an aluminum frame, which has mounting holes on the back side. Bolts are typically placed through the holes into a support member, and fastened with a threaded nut. This is a very labor intensive process. In addition, the mounting holes would have to be perfectly aligned with corresponding mounting holes on the spars.
  • the present system utilizes a panel mounting clamp to attach the solar panel frames to the spars.
  • a first embodiment of a suitable clamp is shown in FIGs. 3A - 3C.
  • the clamp generally comprises a top section 63, a middle section 65, and a bottom section 67.
  • the clamp is preferably formed from a unitary piece of metal.
  • the top section 63 of the clamp includes a stud 62, such as commercially available PEM® studs from Perm Engineering and Manufacturing, Corp.
  • the stud 62 engages the standard mounting hole on a solar panel frame, as shown in FIGs. 3B and 3C.
  • the top section 63 also includes a threaded hole 64 to receive a tightening bolt 70.
  • the metal is folded back on itself at a hinged joint 66.
  • the hinged joint 66 may be formed by, for example, removing alternate metal sections at the curved joint to form a hinge, as shown in FIG. 3B.
  • the middle section 65 is aligned generally parallel to and under the top section 63. It has an opening aligned with the threaded hole 64 to allow a tightening bolt 70 to pass through.
  • the middle section 65 is angled at a right angle away from the top section 63.
  • the bottom section 67 is approximately the length of the front side of a spar 40.
  • the end 68 of the bottom section is angled to engage the angled front edge 48 of the spar 40. To install, the angled end 68 is placed under the spar 40.
  • the stud 62 is then placed into a mounting hole on the solar panel frame.
  • the bolt 70 is tightened to clamp the panel 12 and spar 40 together.
  • FIGs. 4A - 4C A second embodiment of a panel clamp is illustrated in FIGs. 4A - 4C.
  • the panel clamp 70 comprises a pawl 71, a wire bail 76, which are connected with a hasp (buckle) 74.
  • the pawl includes a stud 72, such as a PEM® stud available from Perm Engineering and Manufacturing, Corp.
  • the wire bail 76 is formed with a hooked end to engage the tapered edge of the bottom channel of the second spar embodiment 50.
  • the hasp 74 can be designed to allow for hand operation.
  • the hasp can be formed with an opening 78, to allow a special tool or a screwdriver, etc. to be used to apply the requisite force on the hasp 74 to close and open the clamp 70, as the closing force may be higher than would be appropriate for an installation technician installing multiple clamps.
  • Additional "sharp" engagement features may be added to either the first or second panel clamp embodiments to insure a solid metal-to-metal connection to the bottom spar channel.
  • serrated teeth or similar features could be added to the clamp end 68 or wire bail 76.
  • similar sharp features could be added to the panel clamp where it engages the aluminum frame at the mounting hole.
  • either clamp embodiment allows different types of panels, having mounting holes in different locations, to be used with the same spar design. Since the spars include a continuous upper channel, the clamps can be positioned along the channel, regardless of the location of the mounting holes on the panels (i.e. the mounting studs can extend downward into the channel at any point along the channel). This allows for a versatile support system for panels from different manufacturers. In addition, since each clamp contacts the uncoated metal strip on the bottom of the spar (or the aluminum spar), the clamp forms a ground connection between the spar and each panel frame.
  • the solar panels, spars, panel clamps and pivot blocks For many installations, it is convenient to pre-assemble the solar panels, spars, panel clamps and pivot blocks. For example, these components may be assembled at a convenient location on the ground and then the entire assembly is lifted onto a roof. On the roof, the tilt brackets, longitudinal links, and tilt legs are pre-installed in parallel columns. Therefore, when the panel assembly is lowered into position, it is important to align the pivot blocks into their respective tilt brackets.
  • a pivot block 80 comprises a metal body and has a center mounting hole 84 for attaching the pivot block 80 to a tilt bracket. This also provides a "pivot" point for raising and lowering the panel assembly, if required.
  • a rear section 87 of the pivot block 80 is generally curved. On one end of this curved section 87, at the bottom of the pivot block 80, is an alignment groove 83. This alignment groove aligns with a pre-installed bolt or pin on the tilt bracket. When the panel assembly with the pivot block 80 is lowered into the tilt brackets, the pivot block can slide along the bolt or pin until the alignment groove is positively engaged. As a result, an installer can easily install a mounting bolt through the mounting hole 84, since the pivot block will be properly aligned with holes in the tilt bracket.
  • the curved section 87 also includes a tilt-up stop groove 82 located at a rear of the body.
  • the tilt-up stop groove will abut against the bolt or pin normally aligned with the alignment groove 83 whenever the panel assembly is raised (pivoting at the mounting hole 84).
  • a top groove 81 on the top of the block 80 can be used to lock the entire assembly in the raised position (i.e. by placing a pin or bolt through a corresponding hole in the tilt bracket).
  • the front of the pivot block 80 attaches to a lower spar. Specifically, a lip 88 engages the bottom channel of a lower spar, and an engagement channel conforms to the shape of the spar.
  • the top of the pivot block lip 88 may have a sharp protrusion that directly engages the metal in the bottom of the spar channel 46, thus forming a continuous ground path through the material.
  • a notch 86 is configured in the front face of the body 80 to hold a threaded nut and tension spring combination. This allows the spar to be bolted to the pivot block 80 by placing a bolt through the spar. With a threaded nut held in place this can be accomplished with one hand, thereby simplifying the installation process.
  • a tilt leg is shown in detail in FIGs. 6A and 6B.
  • a tilt leg 90 comprises a generally rectangular hollow metal frame. It is simply bolted to a tilt bracket on one end. The end that engages the spar includes a channel 91 to conform to the bottom shape of the spar, and a front edge 92.
  • the front edge 92 of top of the tilt leg 90 is designed to insure a solid metal-to-metal connection between the tilt leg 90 and the exposed metal channel on the spar.
  • the front edge 92 may have a sharp protrusion that directly engages the metal in the bottom of the spar channel, thus forming a continuous ground path through the material.
  • the tilt leg 90 is bolted to the spar via top hole 93. Since the front edge 92 engages the bottom channel of the spar, this reduces any "twisting" by the tilt leg 90.
  • a tilt bracket 100 according to one embodiment of the present invention is illustrated in detail in FIG. 7.
  • the tilt bracket 100 is formed from single metal sheet, and includes two symmetric sides HOA, HOB. Each side includes tabs 111, 112 for installing the tilt bracket 100 onto a support plate (not shown).
  • One end of the tilt bracket 100 supports a tilt leg, which is bolted through holes 10IA 5 IOlB. The other end is configured to mount a pivot block.
  • a pivot block is mounted to the tilt bracket 100 via hole 102 and a corresponding hole (not shown) on side HOA.
  • An alignment pin or bolt is inserted intojioles 104A, 104B.
  • a locking pin or bolt is inserted into hole 103 (and it corresponding hole on HOA) to lock the pivot block into a raised position, when desired.
  • the top of the opening between the two sides HOA, HOB includes two tabs 105, 106.
  • the tabs 105, 106 flare out to provide a guide for the pivot block during installation, and helps spread the sides HOA, HOB as the pivot block is inserted.
  • FIGs. 8A and 8B A wind defector is shown in FIGs. 8A and 8B.
  • Wind deflectors are generally installed on the last, northern most row of a solar array installation. The wind deflectors deflect the wind from the underside of the array, thereby reducing wind uplift forces.
  • the wind deflector 120 is configured as a single sheet of metal, which attaches to an upper spar, and to the last row of tilt brackets in an array.
  • the wind deflector includes two openings 121, 122 to allow tilt legs to be attached to the spars and tilt brackets. If the solar panel frames and spars are not attached at the top edge, the panel may have a tendency to "roll away" from the spar.
  • FIGs. 9A - 9D A clamp block assembly is illustrated in FIGs. 9A - 9D.
  • a top section 130 is configured and angled to conform to overlap the top of the solar panel 12 and the extended section of the spar 40. It includes a threaded hole (or affixed threaded nut) 131.
  • a lower section 132 clips on to the spar 40. Specifically, a notched bottom surface 133 of the lower section 132 is configured to engage the top channel of the spar 40. The lower section includes an angled clip 134 to engage the bottom channel of the spar 40.
  • a bolt 135 feeds through the lower section 132 and into the threaded hole or nut 131. As the bolt 135 is tightened, the top section 130 and the lower section 132 are drawn together, thereby tightening the solar panel 12 against the spar 40.
  • one clamp block assembly is attached between adjacent panels in a module.
  • the solar panel mounting system provides an interconnection between rows of panel modules via the tilt brackets and longitudinal links. It is also desirable to connect the panel modules together along each row by connecting the spars together.
  • the above-described solar panel mounting system is well suited for flat surface installations, such as flat commercial roofs. However, flat commercial roofs can actually be quite uneven. In fact, the ends of the spars will often not be aligned.
  • the present mounting system includes a lateral link 140, as shown in FIGs. 1OA - 1OB.
  • the lateral link 140 is formed as a generally U- shaped channel 141, with mounting holes on each end.
  • the lateral link 140 includes a set of elongated mounting holes on at least one end.
  • the holes on the outermost edge 143 may be elongated vertically, and the interior set 142 may be elongated horizontally.
  • the U- shaped channel 141 is inserted over the outside of two adjacent spars, and is then bolted to each spar.
  • the spars can be connected laterally, forming an interconnection between the panel modules both laterally and longitudinally.
  • FIG. 11 An enlarged side view of the system according to the present invention is shown in FIG. 11.
  • the top view is an enlarged version of FIG. 1 A showing the elements in greater detail.
  • the bottom view illustrates the connection between three rows of tilt brackets (two solar panel rows). Note that for tilt brackets in the middle of the array, one end connects to a tilt leg and an upper spar of one row, and the other end of the tilt bracket connects to a lower spar (via a pivot block) to a next row of solar panels.
  • FIG. 12 illustrates the advantage of using the pivot blocks - the panel assembly can be raised up as a unit, as necessary, to perform system or roof maintenance.
  • FIG. 13 is an enlarged view of a tilt bracket showing a pivot block mounted in position to receive a spar on the edge of a solar panel module.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Thermal Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Combustion & Propulsion (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Photovoltaic Devices (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)

Abstract

La présente invention concerne un système de montage de champ de panneaux photovoltaïques comprenant des éléments uniques d’installation et de mise à la terre, et qui est adaptable pour le montage de panneaux solaires comprenant des trous de montage situés à des emplacements différents. Le système de montage de champ de panneaux photovoltaïques comporte des supports d’inclinaison et des liaisons longitudinales formant des colonnes. Un support d’inclinaison comporte un bras d’inclinaison pour assurer le support d’un montant supérieur d’une rangée, ou un bloc de pivotement pour assurer le support d’un chevron de la rangée suivante. Les montants peuvent être réalisés à partir d’aluminium extrudé ou à partir d’acier, les montants d’acier comprenant un passage métallique exposé pour assurer une mise à la terre commune de matériel électrique. Des colliers de serrage de panneaux sont utilisés pour claveter les châssis des panneaux solaires aux montants, permettant ainsi des variations dans les emplacements des trous de montage.
PCT/US2009/005523 2008-10-13 2009-10-08 Système de montage de champ de panneaux photovoltaïques WO2010044830A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12/250,433 2008-10-13
US12/250,433 US20100089390A1 (en) 2008-10-13 2008-10-13 Solar array mounting system

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WO2010044830A2 true WO2010044830A2 (fr) 2010-04-22
WO2010044830A3 WO2010044830A3 (fr) 2010-07-01

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