Method of construction for solar energy systems

Abstract

The invention is a method for constructing solar energy mounting apparatuses in which structural elements of the apparatus are cast in molds formed on a substantially horizontal surface. A self curing compound, such as reinforced concrete, is used as the material for the structural elements. After curing for sufficient time to achieve strength necessary to allow for handling, the structural element is hoisted into place in a substantially non-horizontal position. Alternatively, the structural element may be used in the moving portion of a solar energy mounting apparatus that performs a tracking function. The use of reinforced concrete in the structural elements of solar energy mounting apparatuses allows for cost reduction over the prior art in that reinforced concrete is less expensive on a unit strength basis than other typical structural materials, such as steel and aluminum. Additional cost reduction is possible because the mass of the reinforced concrete structural elements offsets ballast material that would otherwise be necessary to increase the mass of the foundation to provide resistance to overturning forces due to wind.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001]None.FEDERALLY SPONSORED RESEARCH [0002]None.SEQUENCE LISTING [0003]None.BACKGROUND—FIELD OF INVENTION[0004]The present invention relates to methods of construction for solar energy systems, specifically low cost methods of construction for mounting apparatuses used in solar energy systemsBACKGROUND—PRIOR ART[0005]There is substantial prior art relating to the design and configuration of mounting apparatuses for solar energy systems. For example, U.S. Pat. No. 4,870,949 (Butler), U.S. Pat. No. 7,252,083 (Hayden), and U.S. Pat. No. 6,722,357 (Shingleton) all show different configurations of solar energy mounting apparatuses.[0006]These mounting apparatuses are generally designed to orient a payload, with respect to the sun. While many mounting apparatuses are designed to actively orient the payload with respect to the sun, others provide only a fixed orientation. For solar energy collection systems in general, the payload can be one of a ...

AI Technical Summary

Problems solved by technology

Practically speaking, mechanical considerations can limit the range of motion such that the tracking apparatus might not be able to address all arbitrary points in the sky.

However, in many applications, such as solar energy collection systems, the range of desired orientations is also limited to a subset of the visible sky.

As such, single axis tracking apparatuses, which are generally not capable of orienting the energy collection device perfectly normal to the solar radiation, are commonly used in solar PV systems.

Further, dual axis designs may not have the dynamic range required to address a large portion of the sky while maintaining the high accuracy required for high concentration PV modules or for telescope applications.

While these materials are sufficient for the application, there are several disadvantages to their use that are difficult to solve.

(a) Metals that are inherently corrosion resistant, such as aluminum or stainless steel are generally expensive.

As such, use of such materials can negatively impact the economics of a particular installation.

(b) While carbon steel is less expensive than aluminum or stainless steel, it subject to corrosion under normal atmospheric conditions.

However, the galvanizing process increases the cost of the raw material significantly.

Furthermore, the galvanizing process is generally considered to be environmentally hazardous, and as such the number of domestic suppliers has been in recent decline.

The optimization of materials tends to lead to mounting apparatus structure designs that are often complex.

The manufacturing processes required to build components for complex systems are generally not suitable for performance in the field.

This can result in increased shipping costs.

As stated previously, higher shipping costs can be a disadvantage of using precast elements, but the optimal solution is typically determined based on project specifics.

However, prior art is limited to use of precast foundation blocks, that were cast in a mold and then moved to the installation location.

Note that there is no prior art for either the use of precast concrete components in the moving part of a tracking mounting system, nor is there any prior art showing the use of tilt-up construction methods, wherein a component is cast in a substantially horizontal orientation and then erected into a non-horizontal orientation.

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