WO2019058165A1 - Solar module mounting assembly - Google Patents

Solar module mounting assembly Download PDF

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Publication number
WO2019058165A1
WO2019058165A1 PCT/IB2018/001050 IB2018001050W WO2019058165A1 WO 2019058165 A1 WO2019058165 A1 WO 2019058165A1 IB 2018001050 W IB2018001050 W IB 2018001050W WO 2019058165 A1 WO2019058165 A1 WO 2019058165A1
Authority
WO
WIPO (PCT)
Prior art keywords
rail
solar
bottom support
torque tube
tracker
Prior art date
Application number
PCT/IB2018/001050
Other languages
French (fr)
Inventor
Etienne Menard
Original Assignee
Helioslite
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 Helioslite filed Critical Helioslite
Publication of WO2019058165A1 publication Critical patent/WO2019058165A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S30/00—Arrangements for moving or orienting solar heat collector modules
    • F24S30/40—Arrangements for moving or orienting solar heat collector modules for rotary movement
    • F24S30/42—Arrangements for moving or orienting solar heat collector modules for rotary movement with only one rotation axis
    • F24S30/425—Horizontal axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S30/00—Arrangements for moving or orienting solar heat collector modules
    • F24S30/40—Arrangements for moving or orienting solar heat collector modules for rotary movement
    • F24S30/42—Arrangements for moving or orienting solar heat collector modules for rotary movement with only one rotation axis
    • F24S30/428—Arrangements for moving or orienting solar heat collector modules for rotary movement with only one rotation axis with inclined axis
    • 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
    • H02S20/10—Supporting structures directly fixed to the ground
    • 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
    • H02S20/30—Supporting structures being movable or adjustable, e.g. for angle adjustment
    • H02S20/32—Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar 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
    • Y02E10/40—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

  • This invention is in the general field of solar power generation.
  • one particularly important, although nonexclusive, application of the invention is in the field of photovoltaic solar tracker systems capable of tracking the sun during the course of the day to maximize the energy output of photovoltaic modules.
  • Photovoltaic solar tracker systems provide means for rotating an array of photovoltaic solar modules around one or multiple axis in order to orient these solar modules toward the sun.
  • Single axis, 1.5 axis or dual axis solar tracker systems typically comprise a main torque tube and one or multiple module mounting support assemblies for supporting an array of photovoltaic solar modules above the tracker main torque tube.
  • Module mounting support assemblies may comprise one or multiple mechanical parts such as rails, clamp assemblies and or mounting brackets assemblies for attaching the array of photovoltaic solar modules to the tracker main torque tube.
  • the module mounting support assemblies represent critical " mechanical parts of these tracker systems as these assemblies provide mechanical support to the solar modules and need to withstand very high loads when the solar modules are exposed to high wind pressure forces.
  • These mounting support assemblies also need to be quick and simple to assemble in the field in order to minimize the time required for the installation of tracker systems. In order to reduce manufacturing costs, these assemblies need to be optimally designed in order to be compatible with cost effective high volume manufacturing processes and to reduce to a minimum material usage.
  • the patent application US2016/0190976 presents an exemplary design of a mounting bracket assembly which may be used for mounting an array of solar modules onto the main torque tube of a single axis tracker.
  • the mounting bracket assembly presented in this patent application is only suitable for mounting a single row of solar modules onto the tracker torque tube. Scaling up the dimensions of the mounting bracket assembly presented in this patent application in order to support multiple rows of solar modules would be very unpractical from a manufacturing standpoint as the main part of this mounting bracket assembly is extruded along a direction which is parallel to the longitudinal axis of the tracker main torque tube.
  • the module support rails are elongated elements which need to have a very high mechanical stiffness in order to withstand extreme bending loads when the array of solar modules are exposed to high wind speed pressure forces.
  • Such design is thus sub-optimal by design from a material usage as elongated mechanical beams have weak resistance to bending forces applied perpendicularly to their principal longitudinal axis.
  • the present invention mainly proposes a solar module mounting assembly to be mounted on a torque tube of a photovoltaic solar tracker, which minimizes material usage, simplifies field assembly, reduces shipping volume and comprising a pair of rails which can be easily fabricated using cost effective high volume manufacturing processes.
  • the solar module mounting assembly of the invention mainly includes the following elements:
  • an elongated top rail arranged to support one or multiple rows of solar modules, a one piece elongated bottom support rail which is bent into a concave shape,
  • a set of fasteners or self-locking features for mechanically coupling the top rail and the bottom support rail to said tracker torque tube.
  • the concave shape is a V shape or a U shape with angled legs .
  • this part forms a double triangle or quasi triangle mechanical structure which provides a very material efficient shape for supporting the top rail and transferring mechanical loads to the tracker torque tube along the 2 angled longitudinal axis of the bottom support rail.
  • the top and bottom rails each having a shape elongated along respective longitudinal axis, have and/or are obtained from a non-variable sectional shape profile across said respective longitudinal axis.
  • material may be removed in some. areas of these two rails using standard pre or post processing operations such as punching, cutting or rapid machining operations.
  • the bottom support rail comprises one or multiple areas presenting a flat external surface.
  • the bottom support rail may be manufactured and shipped as a straight rail having a multi rectangular cross sectional shape.
  • the bottom support rail can be easily manually bent into a final V or U with angled legs shape, when the bottom support rail is mounted in the field during the assembly of the tracker system.
  • the top and bottom support rails comprise protruding features which are designed to self-lock into some mating holes or slots defined in specific areas of a tracker main torque tube, thus eliminating the need for using extra fasteners to mechanically attach these two rail elements to the tracker main torque tube.
  • the invention further proposes a support structure comprising a plurality of solar module mounting assemblies as described above, and a torque tube comprising one or two rigidifying beams transversely disposed and fixed between the top and bottom rails of said solar module mounting assemblies .
  • the invention also proposes a process to assemble on site such support structure comprising the following steps:
  • Figure 1A shows a 2D side view diagram of a solar module mounting assembly according to one embodiment of the invention arranged for supporting two rows of solar modules (partially represented) .
  • Figure IB shows an exploded 3D view diagram of the solar module mounting assembly of figure 1A.
  • Figure 2 shows a 3D view diagram of a linear array of solar module mounting assemblies according to an embodiment of the invention, supporting a two rows array of solar modules onto the main torque tube of a solar tracker.
  • FIGS 3A and 3B show two figures in side view of a photovoltaic solar tracker unit comprising a support structure of an array of photovoltaic modules, said structure comprising solar module mounting assemblies according to an embodiment of the invention.
  • the invention essentially provides a solar module mounting assembly which minimizes material usage, simplifies field assembly, minimizes shipping volume and comprises a pair of elongated rail elements which can be easily fabricated using cost effective high volume manufacturing processes.
  • FIG 1A shows a 2D side view diagram of a solar module mounting assembly according to the herein most described embodiment of the invention, comprising a top 30 and bottom support rail 40 structure which are operably connected to the main torque tube 20 of a solar tracker system and supports one or multiple rows of solar modules 10 as it will be more precisely described hereafter in reference to figures 3A and 3B.
  • the main torque tube 20 of the solar tracker may comprise a single torsion beam or a pair of beams 20A & 20B as illustrated in this figure.
  • Figure IB shows an exploded 3D view diagram of the solar module mounting assembly of figure 1A which comprises a top rail 30 and a bottom rail 40 which is bent into a U with angled legs and/or V shape, thus forming a mechanically robust structure with two triangles.
  • the angle value of the legs of the U with regard to the bottom branch is for example comprised between 170° and 100°, and advantageously between 160° and 120°, for instance 150°.
  • the top ends 40A and 40B of the bottom support rail 40 are mechanically coupled to the top rail using a pair of mechanical fasteners 50A & 50B such as bolts or rivets.
  • the top rail 30 comprises multiple openings 31 to be used for attaching the solar modules with standard clamps or other type of mechanical fasteners.
  • Such multiple openings 31 may also be designed to match the external shape of the main torque tube 20 in order to facilitate alignment in the field.
  • Figure 2 shows a 3D view diagram of a linear array of solar module mounting assemblies according to the herewith most described embodiment of the invention, supporting a two rows array of solar modules 10 onto the torque tube 20 of a solar tracker .
  • the top rail 30 comprises protruding features 32 which are designed to self- lock (in a manner known per se) into some mating holes or slots 21 defined in specific areas of the tracker main torque tube 20, thus eliminating the need for using extra fasteners for mechanically coupling the top rail 30 to the tracker main torque tube 20.
  • the self-locking comprises a pair of protruding fingers 32 substantially rectangular with a gripping spigot and extending in the plan of an external face of the top rail 30 and arranged to be engaged in corresponding mating slots 21 of complementary shape and capable to retain the spigot in a blocking position when the top rail 30 is assembled onto the tracker main torque tube 20.
  • the bottom support rail 40 may comprise protruding features 42 which are designed to self-lock into some mating holes or slots 22 defined in specific areas of the tracker main torque tube 20, here again eliminating the need for using extra fasteners for mechanically attaching the top rail to the tracker main torque tube.
  • protruding features 42 of the bottom support rail 40 is designed to engage into mating holes or slots defined in specific areas of the tracker main torque tube 20 when the bottom support is bent into its final V shape during the assembly of the tracker system.
  • Other holes 43 may be also used to mechanically couple the bottom support rail 40 to the tracker main torque tube with standard mechanical fasteners such as bolts, rivets or screws.
  • a linear array of mating holes or slots 22 may be defined along the longitudinal axis of the tracker main torque tube 20 to permit the assembly of various models of solar modules having different width dimensions.
  • fasteners may also be used to obtain a continuous electrical grounding path between these elements.
  • Figure 3A shows a tracking photovoltaic solar system comprising at least a one tracker unit relying on a "Rocking” and “Rolling” kinetic to maintain an array of photovoltaic modules aligned to the sun during the course of the day.
  • the tracking system is here systematically described assuming that the system is installed at a site located in the Northern hemisphere, however this tracking system may also be installed on sites located in the Southern hemisphere after performing a rotation of 180 degrees.
  • the tracker unit includes a module support structure 100 comprising an array of module support elements or solar mounting assemblies 105, according to the invention, (schematically represented on the figure), supporting an array of photovoltaic modules 101 (of a known type) , a primary longitudinal support or torque tube 104 for supporting said array of module support elements 105, and primary rotating means for rotating said torque tube 104 around a primary rolling rotation axis or first rotational axis 106 having a variable inclination angle a.
  • a module support structure 100 comprising an array of module support elements or solar mounting assemblies 105, according to the invention, (schematically represented on the figure), supporting an array of photovoltaic modules 101 (of a known type) , a primary longitudinal support or torque tube 104 for supporting said array of module support elements 105, and primary rotating means for rotating said torque tube 104 around a primary rolling rotation axis or first rotational axis 106 having a variable inclination angle a.
  • pole structure 200 comprising a first pair of pivot points (102 & 103) on its upper side, wherein said pair of first pivot points 102 & 103 defines the primary "Rolling" rotation axis 106 of said torque tube, and on its lower end a second pair of pivot points 203E & 203W defining a secondary "Rocking" rotation axis or second rotational axis 204 for rotating the pole structure 200 and the operably connected torque tube 104 and said module array support structure (100) , wherein said secondary rotation axis 204 is orthogonal to said primary rotation axis, and
  • the foundations are here and for example a block of concrete fixed, anchored or disposed on the ground.
  • the tracker also comprises a steering mechanism 300 for rotating the module support structure 100.
  • the steering mechanism is actioned by a motor, for instance an electronic motor known per se, which is controlled by a computer (not represented) adequately programmed in a way easily undertaken by the man skilled in the art.
  • the steering mechanism 300 is mechanically coupling the rotation of said primary axis 106 to said secondary axis 204 of said photovoltaic solar tracker. It comprises upper 303 and lower 301 steering arm structures.
  • the upper steering arm structure 303 comprises an upper arm element 303A, for instance a metallic tube, having a pivot point 304 at its upper-end operably connected to the torque tube 104 having a pivoting axis 305 orthogonal to said primary rotation axis 106.
  • the upper steering arm element 303A further comprises a spherical joint 302 at its lower end operably connected to said lower steering arm structure 301, wherein said lower steering arm structure 301 comprises a pair of steering arm elements 301N and 301S connected to a pair of pivot points 306N & 306S at their lower end operably connected to the foundation 500 of said tracker having a pivoting axis 307 orthogonal to said secondary axis 204 of said pole structure 200.
  • said tracker also comprises a drive assembly 400, comprising a driver 401 for instance an electronic motor controlling a pole, operably connected on one side to a mounting structure 402 (i.e. a support having two legs disposed triangularly and connected to the foundations) fixed onto the tracker foundation 500 and on the other side to said lower steering arm elements 301 of said steering mechanism 300, providing a mean for inducing a "Rocking" and “Rolling” motion to said photovoltaic module support structure 100.
  • a driver 401 for instance an electronic motor controlling a pole
  • a mounting structure 402 i.e. a support having two legs disposed triangularly and connected to the foundations
  • the pole structure 200 of the tracker unit may comprise two pairs of mechanical beam elements 201E & 201W and 202E & 202W each having upper and lower ends, with the upper ends of 201W & 202E elements connected together to the first pivot point 102 of the torque tube 104, with the upper ends of 201E & 202W elements connected together to the second pivot point 103 of the torque tube 104, with the lower ends of 201E & 202E elements connected together to the first pivot point 203E of the pole structure 200, and with the lower ends of 201W & 202W elements connected together to the second pivot point 203W of the pole structure 200.
  • the pole structure 200 comprises two pairs of beam elements (metallic tubes for instance) providing a mechanically robust and lightweight mechanical structure and an efficient means for transferring to the foundation 500 the dead weight of the upper structure and the forces resulting from wind loads on the surface of the array of the photovoltaic modules 101.
  • the lower steering arm 301 of the steering mechanism 300 may alternatively comprise a pair of beam elements 301N & 301S having upper and lower ends, with the upper ends of both beam elements 301N & 301S operably connected to the upper steering arm 303 with a spherical joint 302, and with the lower ends of the beam elements 301N & 301S connected to the foundation 500 with a pair of pivot points 305N and 305S.
  • the shape of the pair of beam elements 301N & 301S is triangle which renders it a mechanically robust and lightweight mechanical structure, which provides an efficient mean for transferring the actuation force of the drive system 400 to the upper steering arm 303 of the steering mechanism 300.
  • the driver 401 of the drive system 400 system is here formed by an axe or tube actioned by an hydraulic or electronic jack pushing or pulling from a fixed point on a center bar fixed on the two beam elements, for instance on their middle part.
  • the installation on site of the solar module mounting assembly comprises the following steps: i) attaching the top rail of said solar module mounting assembly onto the tracker main torque tube using fasteners or self-locking features, ii) positioning the center section of the bottom support rail of said solar module mounting assembly into contact with the bottom surface of the tracker main torque tube, iii) bending upward said bottom support rail into a V or U shape with angled legs to engage the protruding features of said bottom support rail into mating holes or slots defined into specific areas of the tracker main torque tube, iv) attaching the top ends of the bent bottom support rail with said top rail using fasteners.
  • the rail is for instance in a form of a flat junction at such relevant emplacement 41, without rigidifying sides as on the rest of the rail or beam, having for example a U shape, such as represented on figure IB
  • the extremities 41B for fixation on the top rail or beam may also be arranged to be bent to match the external surface of said elongated top rail.
  • the section of the flat junction is arranged to allow bending while not weakening the solidity of fixation of the V shape rail on the torque tube while allowing a good transmission of the strengths from the solar module weight and wind pressure, as it can be calculated by the man skilled in the art according to the meteorological local parameters and the tracker specificities.
  • the invention has been described with reference to various specific and preferred embodiments and techniques.

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Abstract

The invention concerns a solar module mounting assembly to be mounted on a torque tube of a photovoltaic solar tracker including : an elongated top rail arranged to support one or multiple rows of solar modules, a one piece elongated bottom support rail which is bent into a concave shape, a pair of fasteners for mechanically coupling the top ends of the bottom support rail to the top rail, and a set of fasteners or self-locking features for mechanically coupling the top rail and the bottom support rail to said tracker torque tube. It also concerns a support structure comprising a plurality of such solar module mounting assemblies, and a process to assemble on site such support structure.

Description

SOLAR MODULE MOUNTING ASSEMBLY
FIELD OF THE INVENTION
This invention is in the general field of solar power generation.
More specifically, one particularly important, although nonexclusive, application of the invention is in the field of photovoltaic solar tracker systems capable of tracking the sun during the course of the day to maximize the energy output of photovoltaic modules.
PRIOR ART DISCUSSION
Photovoltaic solar tracker systems provide means for rotating an array of photovoltaic solar modules around one or multiple axis in order to orient these solar modules toward the sun. Single axis, 1.5 axis or dual axis solar tracker systems typically comprise a main torque tube and one or multiple module mounting support assemblies for supporting an array of photovoltaic solar modules above the tracker main torque tube. Module mounting support assemblies may comprise one or multiple mechanical parts such as rails, clamp assemblies and or mounting brackets assemblies for attaching the array of photovoltaic solar modules to the tracker main torque tube. The module mounting support assemblies represent critical" mechanical parts of these tracker systems as these assemblies provide mechanical support to the solar modules and need to withstand very high loads when the solar modules are exposed to high wind pressure forces. These mounting support assemblies also need to be quick and simple to assemble in the field in order to minimize the time required for the installation of tracker systems. In order to reduce manufacturing costs, these assemblies need to be optimally designed in order to be compatible with cost effective high volume manufacturing processes and to reduce to a minimum material usage.
The patent application US2016/0190976 presents an exemplary design of a mounting bracket assembly which may be used for mounting an array of solar modules onto the main torque tube of a single axis tracker. However, the mounting bracket assembly presented in this patent application is only suitable for mounting a single row of solar modules onto the tracker torque tube. Scaling up the dimensions of the mounting bracket assembly presented in this patent application in order to support multiple rows of solar modules would be very unpractical from a manufacturing standpoint as the main part of this mounting bracket assembly is extruded along a direction which is parallel to the longitudinal axis of the tracker main torque tube.
When multiple rows of solar modules are mounted onto a tracker main torque tube, more standard support rails are typically used for supporting multiple rows of solar modules which may be arranged in portrait or landscape orientation. The patent application US2016/0190976 presents different variants of simple clamp assemblies which may be used for mechanically coupling to a tracker torque tube standard rails which are suitable for supporting multiple rows of solar modules. In this configuration, the module support rails are elongated elements which need to have a very high mechanical stiffness in order to withstand extreme bending loads when the array of solar modules are exposed to high wind speed pressure forces. Such design is thus sub-optimal by design from a material usage as elongated mechanical beams have weak resistance to bending forces applied perpendicularly to their principal longitudinal axis.
In fact, the prior art fails to propose an easy to manufacture product sufficiently cost effective to authorize installation in remote places and/or at a reasonable price.
It is therefore an object of the present invention to further reduce manufacturing, shipping and installation costs of solar module mounting assemblies, via an exemplary mechanical design which addresses many of the limitations of prior-art designs.
To this end the present invention mainly proposes a solar module mounting assembly to be mounted on a torque tube of a photovoltaic solar tracker, which minimizes material usage, simplifies field assembly, reduces shipping volume and comprising a pair of rails which can be easily fabricated using cost effective high volume manufacturing processes.
According to theses aims the solar module mounting assembly of the invention mainly includes the following elements:
an elongated top rail arranged to support one or multiple rows of solar modules, a one piece elongated bottom support rail which is bent into a concave shape,
a pair of fasteners for mechanically coupling the top ends of the bottom support rail to the top rail, and
a set of fasteners or self-locking features for mechanically coupling the top rail and the bottom support rail to said tracker torque tube.
Advantageously the concave shape is a V shape or a U shape with angled legs .
When the bottom support rail is bent into such V shape or equivalent, this part forms a double triangle or quasi triangle mechanical structure which provides a very material efficient shape for supporting the top rail and transferring mechanical loads to the tracker torque tube along the 2 angled longitudinal axis of the bottom support rail.
In an advantageous embodiment, the top and bottom rails, each having a shape elongated along respective longitudinal axis, have and/or are obtained from a non-variable sectional shape profile across said respective longitudinal axis.
This renders these parts compatible with high volume steel roll forming or extrusion manufacturing processes. Accordingly material may be removed in some. areas of these two rails using standard pre or post processing operations such as punching, cutting or rapid machining operations.
In yet another advantageous embodiment of 'the invention, the bottom support rail comprises one or multiple areas presenting a flat external surface. In this embodiment of the invention the bottom support rail may be manufactured and shipped as a straight rail having a multi rectangular cross sectional shape.
By multi rectangular cross section, one should understand transverse rectangular section of different sizes (on specific lengths) along the axis of the rail. With flats placed in appropriate locations, the bottom support rail can be easily manually bent into a final V or U with angled legs shape, when the bottom support rail is mounted in the field during the assembly of the tracker system.
In yet another advantageous embodiment of the invention, the top and bottom support rails comprise protruding features which are designed to self-lock into some mating holes or slots defined in specific areas of a tracker main torque tube, thus eliminating the need for using extra fasteners to mechanically attach these two rail elements to the tracker main torque tube.
Advantageously the invention further proposes a support structure comprising a plurality of solar module mounting assemblies as described above, and a torque tube comprising one or two rigidifying beams transversely disposed and fixed between the top and bottom rails of said solar module mounting assemblies .
The invention also proposes a process to assemble on site such support structure comprising the following steps:
i) attaching the top rail of said solar module mounting assemblies onto the tracker torque tube using fasteners or self-locking features, ii) positioning the center section of the bottom support rail of said solar module mounting assemblies into contact with the bottom surface of said tracker torque tube, iii) bending upward said bottom support rail into a V or U shape with angled legs to engage protruding features of said bottom support rail into mating holes or slots defined into specific areas of the tracker torque tube, iv) attaching the top ends of the bent bottom support rail with said top rail using a pair of fasteners.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the present invention will become apparent upon review of the following summarized and detailed descriptions taken into conjunction with the accompanying drawings in which:
Figure 1A shows a 2D side view diagram of a solar module mounting assembly according to one embodiment of the invention arranged for supporting two rows of solar modules (partially represented) .
Figure IB shows an exploded 3D view diagram of the solar module mounting assembly of figure 1A.
Figure 2 shows a 3D view diagram of a linear array of solar module mounting assemblies according to an embodiment of the invention, supporting a two rows array of solar modules onto the main torque tube of a solar tracker.
Figures 3A and 3B show two figures in side view of a photovoltaic solar tracker unit comprising a support structure of an array of photovoltaic modules, said structure comprising solar module mounting assemblies according to an embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION
The invention essentially provides a solar module mounting assembly which minimizes material usage, simplifies field assembly, minimizes shipping volume and comprises a pair of elongated rail elements which can be easily fabricated using cost effective high volume manufacturing processes.
Figure 1A shows a 2D side view diagram of a solar module mounting assembly according to the herein most described embodiment of the invention, comprising a top 30 and bottom support rail 40 structure which are operably connected to the main torque tube 20 of a solar tracker system and supports one or multiple rows of solar modules 10 as it will be more precisely described hereafter in reference to figures 3A and 3B.
The main torque tube 20 of the solar tracker may comprise a single torsion beam or a pair of beams 20A & 20B as illustrated in this figure.
Figure IB shows an exploded 3D view diagram of the solar module mounting assembly of figure 1A which comprises a top rail 30 and a bottom rail 40 which is bent into a U with angled legs and/or V shape, thus forming a mechanically robust structure with two triangles.
The angle value of the legs of the U with regard to the bottom branch is for example comprised between 170° and 100°, and advantageously between 160° and 120°, for instance 150°. The top ends 40A and 40B of the bottom support rail 40 are mechanically coupled to the top rail using a pair of mechanical fasteners 50A & 50B such as bolts or rivets.
In a preferred embodiment of the invention, the top rail 30 comprises multiple openings 31 to be used for attaching the solar modules with standard clamps or other type of mechanical fasteners. Such multiple openings 31 may also be designed to match the external shape of the main torque tube 20 in order to facilitate alignment in the field.
Figure 2 shows a 3D view diagram of a linear array of solar module mounting assemblies according to the herewith most described embodiment of the invention, supporting a two rows array of solar modules 10 onto the torque tube 20 of a solar tracker .
In a preferred embodiment of the invention, the top rail 30 comprises protruding features 32 which are designed to self- lock (in a manner known per se) into some mating holes or slots 21 defined in specific areas of the tracker main torque tube 20, thus eliminating the need for using extra fasteners for mechanically coupling the top rail 30 to the tracker main torque tube 20. More particularly the self-locking comprises a pair of protruding fingers 32 substantially rectangular with a gripping spigot and extending in the plan of an external face of the top rail 30 and arranged to be engaged in corresponding mating slots 21 of complementary shape and capable to retain the spigot in a blocking position when the top rail 30 is assembled onto the tracker main torque tube 20.
In yet another preferred embodiment of the invention, the bottom support rail 40 may comprise protruding features 42 which are designed to self-lock into some mating holes or slots 22 defined in specific areas of the tracker main torque tube 20, here again eliminating the need for using extra fasteners for mechanically attaching the top rail to the tracker main torque tube.
Accordingly the protruding features 42 of the bottom support rail 40 is designed to engage into mating holes or slots defined in specific areas of the tracker main torque tube 20 when the bottom support is bent into its final V shape during the assembly of the tracker system. Other holes 43 may be also used to mechanically couple the bottom support rail 40 to the tracker main torque tube with standard mechanical fasteners such as bolts, rivets or screws.
In yet another preferred embodiment of the invention, a linear array of mating holes or slots 22 may be defined along the longitudinal axis of the tracker main torque tube 20 to permit the assembly of various models of solar modules having different width dimensions.
These fasteners may also be used to obtain a continuous electrical grounding path between these elements.
It will now be described more particularly but not limitatively a tracking photovoltaic solar system using a plurality of solar mounting assemblies of the invention in reference to figures 3A and 3B.
Figure 3A shows a tracking photovoltaic solar system comprising at least a one tracker unit relying on a "Rocking" and "Rolling" kinetic to maintain an array of photovoltaic modules aligned to the sun during the course of the day.
In order to simplify the description, the tracking system is here systematically described assuming that the system is installed at a site located in the Northern hemisphere, however this tracking system may also be installed on sites located in the Southern hemisphere after performing a rotation of 180 degrees.
The tracker unit includes a module support structure 100 comprising an array of module support elements or solar mounting assemblies 105, according to the invention, (schematically represented on the figure), supporting an array of photovoltaic modules 101 (of a known type) , a primary longitudinal support or torque tube 104 for supporting said array of module support elements 105, and primary rotating means for rotating said torque tube 104 around a primary rolling rotation axis or first rotational axis 106 having a variable inclination angle a.
It further comprises a pole structure 200 comprising a first pair of pivot points (102 & 103) on its upper side, wherein said pair of first pivot points 102 & 103 defines the primary "Rolling" rotation axis 106 of said torque tube, and on its lower end a second pair of pivot points 203E & 203W defining a secondary "Rocking" rotation axis or second rotational axis 204 for rotating the pole structure 200 and the operably connected torque tube 104 and said module array support structure (100) , wherein said secondary rotation axis 204 is orthogonal to said primary rotation axis, and
wherein said second pair of pivot points 203E & 203W on the lower end of said pole structure 100 are fixed to the foundations 500 of the tracker unit. The foundations are here and for example a block of concrete fixed, anchored or disposed on the ground.
The tracker also comprises a steering mechanism 300 for rotating the module support structure 100.
The steering mechanism is actioned by a motor, for instance an electronic motor known per se, which is controlled by a computer (not represented) adequately programmed in a way easily undertaken by the man skilled in the art.
The steering mechanism 300 is mechanically coupling the rotation of said primary axis 106 to said secondary axis 204 of said photovoltaic solar tracker. It comprises upper 303 and lower 301 steering arm structures. The upper steering arm structure 303 comprises an upper arm element 303A, for instance a metallic tube, having a pivot point 304 at its upper-end operably connected to the torque tube 104 having a pivoting axis 305 orthogonal to said primary rotation axis 106.
The upper steering arm element 303A further comprises a spherical joint 302 at its lower end operably connected to said lower steering arm structure 301, wherein said lower steering arm structure 301 comprises a pair of steering arm elements 301N and 301S connected to a pair of pivot points 306N & 306S at their lower end operably connected to the foundation 500 of said tracker having a pivoting axis 307 orthogonal to said secondary axis 204 of said pole structure 200.
According to this non-limitative type of tracker, said tracker also comprises a drive assembly 400, comprising a driver 401 for instance an electronic motor controlling a pole, operably connected on one side to a mounting structure 402 (i.e. a support having two legs disposed triangularly and connected to the foundations) fixed onto the tracker foundation 500 and on the other side to said lower steering arm elements 301 of said steering mechanism 300, providing a mean for inducing a "Rocking" and "Rolling" motion to said photovoltaic module support structure 100.
In an embodiment of the tracker, the pole structure 200 of the tracker unit may comprise two pairs of mechanical beam elements 201E & 201W and 202E & 202W each having upper and lower ends, with the upper ends of 201W & 202E elements connected together to the first pivot point 102 of the torque tube 104, with the upper ends of 201E & 202W elements connected together to the second pivot point 103 of the torque tube 104, with the lower ends of 201E & 202E elements connected together to the first pivot point 203E of the pole structure 200, and with the lower ends of 201W & 202W elements connected together to the second pivot point 203W of the pole structure 200.
In this embodiment the pole structure 200 comprises two pairs of beam elements (metallic tubes for instance) providing a mechanically robust and lightweight mechanical structure and an efficient means for transferring to the foundation 500 the dead weight of the upper structure and the forces resulting from wind loads on the surface of the array of the photovoltaic modules 101.
But in other embodiment of the invention, the lower steering arm 301 of the steering mechanism 300 may alternatively comprise a pair of beam elements 301N & 301S having upper and lower ends, with the upper ends of both beam elements 301N & 301S operably connected to the upper steering arm 303 with a spherical joint 302, and with the lower ends of the beam elements 301N & 301S connected to the foundation 500 with a pair of pivot points 305N and 305S.
In this specific embodiment, the shape of the pair of beam elements 301N & 301S is triangle which renders it a mechanically robust and lightweight mechanical structure, which provides an efficient mean for transferring the actuation force of the drive system 400 to the upper steering arm 303 of the steering mechanism 300.
The driver 401 of the drive system 400 system is here formed by an axe or tube actioned by an hydraulic or electronic jack pushing or pulling from a fixed point on a center bar fixed on the two beam elements, for instance on their middle part.
Note that in case of multiple tracker units they may be driven by a common driver.
It will now be described the installation on site of assemblies, according to one embodiment of the invention, and their implementation on the structure and on the tracker here above described as a matter of example.
The procedure for installing on site the solar mounting assembly is described for the preferred embodiment of the invention which relies on. bottom support rails which are manufactured and shipped to the site as straight beams. For this specific embodiment of the invention, the installation on site of the solar module mounting assembly comprises the following steps: i) attaching the top rail of said solar module mounting assembly onto the tracker main torque tube using fasteners or self-locking features, ii) positioning the center section of the bottom support rail of said solar module mounting assembly into contact with the bottom surface of the tracker main torque tube, iii) bending upward said bottom support rail into a V or U shape with angled legs to engage the protruding features of said bottom support rail into mating holes or slots defined into specific areas of the tracker main torque tube, iv) attaching the top ends of the bent bottom support rail with said top rail using fasteners.
Due to the bottom support rail capability to be bent easily manually or with an apparatus known per se, on site, at the relevant emplacement 41 of bending, such adjustability allows a mounting authorizing small difference in the dimension and/or angulation, in order to fix correctly the rails together.
For authorizing such bending the rail is for instance in a form of a flat junction at such relevant emplacement 41, without rigidifying sides as on the rest of the rail or beam, having for example a U shape, such as represented on figure IB The extremities 41B for fixation on the top rail or beam may also be arranged to be bent to match the external surface of said elongated top rail. The section of the flat junction is arranged to allow bending while not weakening the solidity of fixation of the V shape rail on the torque tube while allowing a good transmission of the strengths from the solar module weight and wind pressure, as it can be calculated by the man skilled in the art according to the meteorological local parameters and the tracker specificities. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that variations and modifications may be made while remaining within the spirit and the scope of the invention. This invention is not to be limited b the embodiments disclosed, including any shown in the drawings or exemplified in the specification,, which are given by way of example or illustration and not of limitation. The scope of the invention shall only be limited by the claims.

Claims

1. A solar module mounting assembly to be mounted on a torque tube of a photovoltaic solar tracker including:
an elongated top rail arranged to support one or multiple rows of solar modules,
a one piece elongated bottom support rail which is bent into a concave shape,
a pair of fasteners for mechanically coupling the top ends of the bottom support rail to the top rail, and
a set of fasteners or self-locking features for mechanically coupling the top rail and the bottom support rail to said tracker torque tube.
2. The solar mounting assembly according to claim 1 wherein the concave shape is a V shape or a U shape with angled legs .
3. The solar mounting assembly according to claim 1 wherein the top and bottom rails, each having a shape elongated along respective longitudinal axis, have a non- variable sectional shape profile across said respective longitudinal axis.
4. The solar system assembly according to claim 1 wherein the bottom support rail comprises one or multiple areas presenting a flat external surface.
5. The solar system assembly according to claim 4 wherein the bottom support rail is a straight rail having a multi rectangular cross sectional shape so that it can be easily manually bent into a final V or U with angled legs shape, when the bottom support rail is mounted.
6. The solar system assembly according to claim 1 wherein the top and bottom support rails comprise protruding features which are designed to self-lock into some mating holes or slots defined in specific areas of said tracker torque tube.
7. A support structure comprising a plurality of solar module mounting assemblies according to claim 1, and a torque tube comprising one or two rigidifying beams transversely disposed and fixed between the top and bottom rails of said solar module mounting assemblies.
8. A Process to assemble on site a support structure comprising a plurality of solar mounting assemblies according to claim 1 comprising the following steps: i) attaching the top rail of said solar module mounting assemblies onto the tracker torque tube using fasteners or self-locking features, ii) positioning the center section of the bottom support rail of said solar module mounting assemblies into contact with the bottom surface of said tracker torque tube, iii) bending upward said bottom support rail into a V or U shape with angled legs to engage protruding features of said bottom support rail into mating holes or slots defined into specific areas of the tracker torque tube, iv) attaching the top ends of the bent bottom support rail with said top rail using a pair of fasteners.
PCT/IB2018/001050 2017-09-19 2018-09-14 Solar module mounting assembly WO2019058165A1 (en)

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US62/560,315 2017-09-19

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CN111396813A (en) * 2020-04-20 2020-07-10 永康市美汇灯具有限公司 Multi-functional gardens solar energy L ED lamp
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