Photovoltaic module base

Abstract

A photovoltaic module mounting system may include a module clamp including a central portion including two first walls connected at a top of each first wall by a first connection surface. The central portion may have a first cross-sectional height corresponding to a height of each first wall and a first width corresponding to a distance between two first walls. The module clamp may have an end including two second walls connected at the top of each second wall by a second connection surface, where each end has a second cross-sectional height that is shorter than the first cross-sectional height and a second width that is wider than the first width.

Description

Technical Field

[0001] The present disclosure generally relates to a photovoltaic module mount and a method of making the same. Background Art

[0002] A solar panel system may include one or more photovoltaic (PV) modules that convert sunlight into electrical energy. The PV modules may be mounted in rows on a solar tracker that guides the orientation of the PV modules so that the orientation of the PV modules changes throughout the day. For example, a series of piles may be arranged in the ground and may support a torque tube to which the PV modules are connected. The PV modules may be connected to the torque tube using clamps, bolts (e.g., U-bolts), or other connection techniques. As the torque tube rotates under the guidance of the solar tracker, the attached PV modules rotate in a corresponding manner, thereby enabling the PV modules to track the position of the sun throughout the day by changing the orientation of the torque tube.

[0003] The claimed subject matter of the present disclosure is not limited to embodiments that solve any disadvantages or that operate only in environments such as described above. Rather, this background is merely provided to illustrate one exemplary technology area in which some embodiments described in this disclosure may be practiced. Summary of the invention

[0004] One or more embodiments of the present disclosure may include a photovoltaic module mounting system, which may include a module clamp, the module clamp including a central portion, the central portion including two first walls connected at the top of each first wall by a first connecting surface. The central portion may have a first cross-sectional height corresponding to the height of each first wall and a first width corresponding to the distance between the two first walls. The module clamp may have an end portion, the end portion including two second walls connected at the top of each second wall by a second connecting surface, wherein each end portion has a second cross-sectional height shorter than the first cross-sectional height and a second width wider than the first width. The central portion may be connected to each end portion so that the first connecting surface and the second connecting surface are bridged and form a bow tie shape.

[0005] One or more embodiments of the present disclosure may include a photovoltaic module mounting system according to any other embodiment of the present disclosure, wherein each end portion includes one or more slots configured to align with one or more openings of the photovoltaic module.

[0006] One or more embodiments of the present disclosure may include a photovoltaic module mounting system according to any other embodiment of the present disclosure, wherein the module clamp further comprises one or more flanges extending generally horizontally from the one or more first walls.

[0007] One or more embodiments of the present disclosure may include a photovoltaic module mounting system according to any other embodiment of the present disclosure, wherein the module clamp further comprises one or more flanges extending generally horizontally from the one or more end portions.

[0008] One or more embodiments of the present disclosure may include a photovoltaic module mounting system according to any other embodiment of the present disclosure, wherein the module clamp further includes one or more tabs protruding from the connection surface in a direction in which the photovoltaic module engages the module clamp.

[0009] One or more embodiments of the present disclosure may include a photovoltaic module mounting system according to any other embodiment of the present disclosure, wherein the module clamp is made of galvanized steel.

[0010] One or more embodiments of the present disclosure may include a photovoltaic module mounting system, which may include a module clamp, the module clamp including a central portion, the central portion including two first walls connected at the top of each first wall by a first connecting surface. The central portion may include a first cross-sectional height corresponding to the height of each first wall and a first width corresponding to the distance between the two first walls. The module clamp may include one or more ends, the one or more ends including two second walls connected at the top of each second wall by a second connecting surface, wherein each end has a second cross-sectional height shorter than the first cross-sectional height and a second width wider than the first width. The central portion may be connected to each end so that the first connecting surface and the second connecting surface are bridged and form a bow tie shape. The photovoltaic module mounting system may also include a torque tube belt coupled to the module clamp.

[0011] One or more embodiments of the present disclosure may include a photovoltaic module mounting system according to any other embodiment of the present disclosure, wherein the channel includes a cutout portion extending at least partially along the length of the channel. In some embodiments, the cutout portion may be wider in the center portion and narrower at either end.

[0012] One or more embodiments of the present disclosure may include a photovoltaic module mounting system according to any other embodiment of the present disclosure, wherein the module clamp includes a pivot fastener coupling the torque tube strap to the module clamp, the pivot fastener spanning the cutout portion.

[0013] One or more embodiments of the present disclosure may include a photovoltaic module mounting system according to any other embodiment of the present disclosure, wherein the first end and the second end are both higher than the center portion so that the mounting surface forms an arcuate shape from the first end to the center portion and from the center portion to the second end.

[0014] One or more embodiments of the present disclosure may include a method comprising obtaining a metal sheet coil and cutting a generally rectangular patterned sheet having long sides and wide sides from the metal sheet coil. The generally rectangular patterned sheet may include corresponding cutout portions on the two long sides, and the cutout portions may correspond to the contour of at least a portion of the torque tube. The method may also include forming the patterned sheet into a module fixture from the patterned sheet, wherein the module fixture may include a higher height in a central portion adjacent to the cutout portion than at an end of the module fixture, and the module fixture may include a wider width at the end than at the central portion.

[0015] One or more embodiments of the present disclosure may include a method according to any other method of the present disclosure, wherein the metal sheet coil is made of galvanized steel.

[0016] One or more embodiments of the present disclosure may include a method according to any other method of the present disclosure, wherein the method may also include forming one or more grooves in the end of the module fixture or in a portion of the generally rectangular patterned sheet corresponding to the end of the module fixture.

[0017] One or more embodiments of the present disclosure may include a method according to any other method of the present disclosure, wherein the features formed on the module fixture may include one or more protruding tabs or one or more flanges formed along one or more surfaces of the module fixture.

[0018] One or more embodiments of the present disclosure may include a method according to any other method of the present disclosure, wherein forming a module fixture from a patterned sheet may include: positioning the patterned sheet against a contour template block; and applying a force to the patterned sheet so that the patterned sheet presents a shape complementary to the contour template block.

[0019] One or more embodiments of the present disclosure may include a method according to any other method of the present disclosure, wherein cutting a patterned sheet from a roll of metal sheet and forming one or more slots in the patterned sheet may be performed simultaneously.

[0020] One or more embodiments of the present disclosure may include a method according to any other method of the present disclosure, wherein a patterned sheet may be cut from a metal sheet roll and one or more grooves may be formed in the patterned sheet after one or more grooves are formed in the patterned sheet.

[0021] The objects and advantages of the embodiments will be completed and achieved at least by the elements, features and combinations particularly pointed out in the claims.It should be understood that both the above general description and the following detailed description are illustrative and do not limit the invention as claimed. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Exemplary embodiments will be described and explained with additional specificity and detail through the accompanying drawings, in which:

[0023] Figure 1A is an isometric view of an exemplary embodiment of a photovoltaic module mounting system according to at least one embodiment of the present disclosure;

[0024] Figure 1B According to at least one embodiment of the present disclosure Figure 1A A front view of an exemplary photovoltaic module mounting system;

[0025] Figure 1C According to at least one embodiment of the present disclosure Figure 1A A side view of an exemplary photovoltaic module mounting system;

[0026] Figure 2A is an isometric view of a second exemplary embodiment of a photovoltaic module mounting system in accordance with at least one embodiment of the present disclosure;

[0027] Figure 2B According to at least one embodiment of the present disclosure Figure 2A A top view of a second exemplary photovoltaic module mounting system;

[0028] Figure 2C According to at least one embodiment of the present disclosure Figure 2A A side view of a second exemplary photovoltaic module mounting system; and

[0029] Figure 3 shows a flat pattern shape that can be used to form an exemplary photovoltaic module mounting system during manufacturing according to at least one embodiment of the present disclosure;

[0030] Figure 4 is a flow chart of an exemplary method of making a photovoltaic module mounting system in accordance with at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0031] Different solar array sites may include different environmental conditions, such as different wind speeds, rainfall levels, snowfall frequencies, other weather events, or some combination thereof. Depending on the weather events that affect a given solar array site, the pressures and stresses to which photovoltaic (PV) modules at a given solar array site are subjected may be greatly different from the pressures and stresses to which photovoltaic modules located at other solar array sites are subjected. In addition, photovoltaic modules from different manufacturers or suppliers may have different strengths and characteristics, so that even at the same location, pressures and / or stresses that can be withstood by different photovoltaic modules may be observed. Moreover, photovoltaic modules of different sizes may be subjected to different stresses. For example, photovoltaic modules of smaller sizes may exert less stress on the supporting structure than photovoltaic modules of larger sizes. Photovoltaic module mounting assemblies may include different types of structures for handling these different pressure levels. For example, a low-pressure photovoltaic module mounting assembly may include fewer structural features that help to withstand high stress levels imposed on the photovoltaic module or the photovoltaic module mounting assembly itself. In contrast, photovoltaic module mounting assemblies designed for high-pressure environments may include features that improve tolerance to high stresses imposed on the photovoltaic module or the photovoltaic module mounting assembly.

[0032] The present disclosure relates particularly to a photovoltaic module mounting system configured to couple with large photovoltaic modules and / or with smaller photovoltaic modules in higher stress situations (e.g., storm climates, climates with a lot of snow, etc.). In some embodiments, once the photovoltaic module mounting system is coupled to the module rail of the photovoltaic module, the photovoltaic module mounting system may include a higher cross-section toward the middle of the photovoltaic module mounting system and a shorter cross-section at the end of the photovoltaic module mounting system, which corresponds to the difference in stress distribution. Additionally or alternatively, the photovoltaic module mounting system may include features that facilitate attaching the module rail of the photovoltaic module to the photovoltaic module mounting system. For example, the photovoltaic module mounting system may include one or more protruding tabs at the flared end that facilitate spacing of gaps between photovoltaic modules. As another example, the photovoltaic module mounting system may include a lip or flange shape at one or more edges of the flared end that stabilizes an opening in the flared end, the opening being configured to dock with a bolt that couples the photovoltaic module to the photovoltaic module mounting system. The above-described features, along with various other factors, can facilitate the use of photovoltaic module mounting systems in high or medium voltage environments where more robust photovoltaic module mounting features are used to withstand greater pressure loads, but the use of high voltage components may be exotic or too expensive. Additionally or alternatively, these features can facilitate the use of thinner materials in low voltage applications, thereby reducing the cost of materials used to mount photovoltaic modules in such situations.

[0033] The photovoltaic module mounting system can be manufactured at a lower cost than existing photovoltaic module mounting assemblies because the photovoltaic module mounting system according to the present disclosure can be made using less material (or less material) than existing photovoltaic module mounting assemblies. Additionally or alternatively, the photovoltaic module mounting system can be formed using a progressive die stamping process that facilitates the manufacture of photovoltaic module mounting systems with high throughput and high yield. For example, the footprint of the metal component used in manufacturing can include a base rectangular shape, which can significantly reduce the amount of wasted metal material that otherwise may appear in other shapes that provide a higher cross-section toward the middle of the photovoltaic module mounting system.

[0034] Embodiments of the present disclosure are explained with reference to the drawings.

[0035] Figures 1A-1C Various views of an exemplary embodiment of a photovoltaic module mounting system 100 are shown, in accordance with at least one embodiment of the present disclosure, wherein Figure 1A An isometric view of a photovoltaic module mounting system 100 is shown. Figure 1B is a front view of a photovoltaic module mounting system 100 according to at least one embodiment of the present disclosure, and Figure 1C is a side view of a photovoltaic module mounting system 100 according to at least one embodiment of the present disclosure.

[0036] The photovoltaic module mounting system 100 may include a module clamp 110 on which a photovoltaic module (not shown) may be mounted. The module clamp 110 may be coupled to a torque tube strap 120 configured to surround a torque tube (not shown), wherein rotation of the torque tube causes the torque tube strap 120 to rotate accordingly. The rotation of the torque tube strap 120 may cause a corresponding lengthwise movement of the module clamp 110, which in turn may tilt the photovoltaic module mounted on the module clamp 110. In other words, the photovoltaic module mounting system 100 may be configured to control and / or adjust the orientation of the photovoltaic module mounted on the photovoltaic module mounting system 100 based on the rotation of the torque tube to which the photovoltaic module mounting system 100 is coupled, such as for solar tracking or stowing the photovoltaic module during inclement weather conditions.

[0037] In some embodiments, the module clamp 110 may include a bow tie shape, wherein one or more ends 111a and 111b (hereinafter collectively referred to as "ends 111") of the module clamp 110 are wider than a central portion 115 of the module clamp 110. Additionally or alternatively, the ends 111 of the module clamp 110 may be shorter than the central portion 115, such that the central portion 115 has a narrower but taller profile than either end 111. Because the central portion 115 of the module clamp 110 may be subject to greater stress than either end 111 when the photovoltaic module is mounted on the photovoltaic module mounting system 100, the taller cross-section of the central portion 115 may make the central portion 115 more rigid in the vertical direction and able to carry stress from the weight of the photovoltaic module and / or other forces (such as wind or snow) compared to the shorter and wider ends 111.

[0038] In these and other embodiments, either or both of the ends 111 may include one or more slots 114, holes, or other openings extending through the ends 111. The photovoltaic module may include one or more slots corresponding to the slots 114 of the module clamp 110, such that the photovoltaic module may be coupled to the module clamp 110 by aligning the slots, holes, or other openings of the photovoltaic module with the slots 114 and inserting bolts, nuts, screws, any other type of fastener, or some combination thereof into the aligned slots. Although the module clamp 110 is shown as including two slots 114 at each end 111a and 111b, the module clamp 110 may include any number of slots 114. For example, each end 111a and 111b may include three, four, five, or more slots 114 oriented at different angles and spacings to facilitate alignment between the slots 114 and the slots of different photovoltaic modules.

[0039] Additionally or alternatively, either or both of the ends 111 may include one or more tabs 113 protruding from the top surface 112 of the end 111. The photovoltaic modules coupled to the module clamp 110 may abut against the tabs 113 to provide appropriate spacing between adjacent photovoltaic modules. For example, the tabs 113 may provide spacing between two adjacent photovoltaic modules so that they do not contact each other and / or the grooves 114 remain aligned with the holes in the photovoltaic modules.

[0040] In some embodiments, the module clamp 110 may include one or more width-direction flanges 117a and / or one or more length-direction flanges 117b (collectively referred to as "flanges 117") extending horizontally from one or more lateral sides 116 of the module clamp 110. The flanges 117 may include flat and / or curved portions of the lateral sides 116 that extend horizontally from the lateral sides 116 in the width direction 118. The flanges 117 may help distribute stresses experienced by the module clamp 110 and increase the load that the module clamp 110 may carry (e.g., increase the maximum weight of a photovoltaic module that may be mounted on the photovoltaic module mounting system 100). In these and other embodiments, the flanges 117 may or may not extend around the perimeter of the module clamp 110. For example, the width-direction flanges 117a may not be present and extend in the length direction from the end 111 of the module clamp 110. As another example, the lengthwise flange 117b may extend from the end 111 in the lengthwise direction, but the lengthwise flange 117b may not be connected to and is discontinuous with respect to the widthwise flange 117a. In these and other examples, having the flange 117 not extend around the perimeter of the module clamp 110 and / or extend only in the widthwise direction 118 may reduce material stresses borne by the module clamp 110 caused by the weight of the photovoltaic module coupled to the module clamp 110 and / or by external environmental factors such as wind, snow, or other such factors. For example, in some embodiments, the lengthwise flange 117b may start at the end 111a and extend to the bottom surface 119 engaged with the torque tube and may not extend through the portion of the module clamp 110 corresponding to the bottom surface 119 abutting the torque tube, and the lengthwise flange 117b may start again after the portion of the module clamp 110 corresponding to the bottom surface 119 abutting the torque tube and continue to extend to the end 111b. Although illustrated as being horizontal, it will be appreciated that the flanges 117a / b may deviate slightly from horizontal, such as 60°, 70°, 80°, 85°, etc.

[0041] Modifications, additions, or omissions may be made to the module fixture 110 without departing from the scope of the present disclosure. For example, the designation of different elements in the described manner is intended to help explain the concepts described herein and is not limiting. Further, the module fixture 110 may include any number of other elements or may be implemented in other systems or environments other than those described above.

[0042] Figures 2A-2C Different views of a second exemplary embodiment of a photovoltaic module mounting system 200 are shown in accordance with at least one embodiment of the present disclosure. Figure 2A is an isometric view of a second exemplary embodiment of a photovoltaic module mounting system 200 in accordance with at least one embodiment of the present disclosure. Figure 2B is a top view of a second exemplary embodiment of a photovoltaic module mounting system 200 in accordance with at least one embodiment of the present disclosure. Figure 2C is a side view of a second exemplary embodiment of a photovoltaic module mounting system 200 in accordance with at least one embodiment of the present disclosure.

[0043] Photovoltaic module mounting system 200 may include module clamp 210 on which photovoltaic modules (not shown) may be mounted. Module clamp 210 may be coupled to torque tube strap 220, which is configured to surround torque tube 230, wherein rotation of torque tube 230 results in corresponding rotation of torque tube strap 220 and corresponding tilting of module clamp 210 and photovoltaic modules coupled to module clamp 210.

[0044] The mounting surface 212 of the module clamp 210 that interfaces with the photovoltaic module may include a rectangular or substantially rectangular shape including a first end 211a and a second end 211b (hereinafter collectively referred to as "ends 211") and a center portion 215. In some embodiments, the module clamp 210 may include a channel 213 that extends from the first end 211a to the second end 211b, or substantially extends from the first end 211a to the second end 211b. As the channel 213 approaches the center portion 215 of the module clamp 210, the depth of the channel 213 may increase, so that the end 211 may include a shallower height than the center portion 215 where the channel 213 is deepest. The center portion 215 of the module clamp 210 may be more rigid and, therefore, able to withstand greater stress loads than the end portions 211 because the center portion 215 is higher than any of the end portions 211.

[0045] In some embodiments, the module fixture 210 may be shaped such that the end portion 211 is located at a higher level than the center portion 215, and the side profile of the module fixture 210 includes an arcuate shape from the first end portion 211a to the second end portion 211b, such as Figure 2C The arcuate shape of the module clamp 210 can increase the stress loads that the module clamp 210 can handle and provide structural support for the photovoltaic module coupled to the module clamp 210 .

[0046] As mentioned above about Figures 1A-1CAs described above with respect to the slots 114 of the module clamp 110, the end 211 of the module clamp 210 may include one or more slots 214. The slots 214 may be aligned with one or more slots or other fastening features of the photovoltaic module to facilitate coupling the photovoltaic module to the mounting surface 212 of the module clamp 210. In these and other embodiments, coupling the photovoltaic module to the module clamp 210 may allow the bottom surface of the photovoltaic module to meet the end 211 of the module clamp 210 while forming a gap between the bottom surface of the photovoltaic module and the curved portion 216 above the central portion 215 of the module clamp 110.

[0047] In some embodiments, the module clamp 210 may include one or more flanges 217, wherein each flange 217 extends from an edge of the module clamp 210, such as from a widthwise edge at an end 211 of the module clamp 210. Additionally or alternatively, the flange 217 may extend from a lengthwise edge of the module clamp 210. Similar to the flange 117 associated with the module clamp 110 of FIG. 1 , the flange 217 may facilitate distribution of forces experienced by the module clamp 210, which may increase the maximum allowable weight that the photovoltaic module mounting system 200 may carry. In some embodiments, the flange 217b may correspond to a bottom surface 219 that corresponds to an interface between the module clamp 210 and the torque tube.

[0048] In some embodiments, the module fixture 210 may include a cutout portion 218 in the channel 213 and one or more pivot fasteners 222 that span at least the width of the cutout portion 218. The cutout portion 218 may be included in the module fixture 210 to facilitate the manufacture of the module fixture (camp) 210, as described with respect to Figure 3 and 4 The flat pattern sheet 310 and method 400 are described. The pivot fastener 222 can span the width of the cutout portion 218 to provide an axis about which the torque tube band 220 can rotate.

[0049] Modifications, additions, or omissions may be made to the module fixture 210 without departing from the scope of the present disclosure. For example, the designation of the various elements in the manner described is intended to help explain the concepts described herein and is not limiting. Further, the module fixture 210 may include any number of other elements or may be implemented in other systems or environments than those described above. For example, the module fixture 210 may include a plurality of components associated with the module fixture 210. Figures 1A-1C The protrusion 113 adjacent to the end 211a / 21b is similar or equivalent to the protrusion 113.

[0050] Figure 3One or more flat pattern sheets 310 according to at least one embodiment of the present disclosure are shown, which can be used to form a module clamp used in a photovoltaic module mounting system through a die stamping process 300 or other manufacturing process. In some embodiments, the flat pattern sheet 310 can be used to form a module clamp 110 and / or a module clamp 210, as respectively described with respect to Figures 1A-1C and 2A-2C. The flat pattern sheet 310 may include one or more cutout portions 312 such that a modular fixture formed from a given flat pattern sheet 310 includes a gap portion configured to engage with a torque tube. For example, Figure 3 As shown, each cutout portion 312 may include a trapezoidal or semi-hexagonal shape, which may facilitate the engagement of a modular fixture formed from a flat pattern sheet 310 with a torque tube having a circular, square, oval, hexagonal, octagonal, pentagonal, or other cross-sectional shape. In these and other embodiments, the cutout portion 312 may be located at any position to facilitate engagement of the modular fixture with the torque tube. For example, the cutout portion 312 may be located closer to either end of the flat pattern sheet 310.

[0051] The die stamping process 300 may include a roll of sheet material 305, which may be cut into one or more flat pattern sheets 310. Each flat pattern sheet 310 may be input to the die stamping process 300, which may be a progressive die stamping process configured to form one or more features of a modular fixture in a sequential process. In some embodiments, the die stamping process 300 may involve stamping one or more slots 320 into each flat pattern sheet 310 in one or more steps, wherein each step may be performed by one or more sheet metal processing machines. Additionally or alternatively, a channel 314 may be stamped or cut into the flat pattern sheet 310, which may correspond to a groove 320 formed in the flat pattern sheet 310. Figures 2A-2C The cut-away portion 218. In these and other embodiments, the die stamping process 300 can involve bending, folding, cutting, otherwise modifying the flat pattern sheet 310, or some combination thereof, in one or more steps, each of which is performed by one or more sheet metal processing machines.

[0052] An example of a die stamping process 300 may include delivering a roll of sheet material 305 to a first machine that cuts the roll of sheet material 305 to form one or more flat pattern sheets 310. In some embodiments, cutting the roll of sheet material 305 to form a given flat pattern sheet 310 may involve cutting the roll of sheet material 305 a first distance along the length of the roll of sheet material 305 to form a widthwise side 316 of the given flat pattern sheet 310, and cutting the roll of sheet material 305 a second distance along the width of the roll of sheet material 305 to form a lengthwise side 318 of the given flat pattern sheet 310. The first distance that the roll of sheet material 305 is cut along its length may correspond to the size of the given flat pattern sheet 310 along its widthwise side 316, and the second distance may correspond to the size of the given flat pattern sheet 310 along its lengthwise side 318.

[0053] Each flat pattern sheet 310 may be processed by one or more second machines, each second machine being configured to punch out or otherwise form one or more slots 320. Additionally or alternatively, the second machines may each be configured to cut one or more openings through the flat pattern sheet 310, e.g. Figures 2A-2C The cutout portion 218 included in the module fixture 210. The flat pattern sheet 310 including the groove 320 can be processed by one or more third machines, each of which is configured to bend the flat pattern sheet 310 to form a module fixture, such as the module fixture 110 or the module fixture 210. In this example and other examples, the module fixture can be conveyed to one or more fourth machines, each of which is configured to modify the module fixture to form one or more features of the module fixture, such as the flange 117 of the module fixture 110 and / or the flange 217 of the module fixture 210.

[0054] Although an example of an operation sequence for manufacturing a modular fixture is provided, it should be understood that these operations can be performed in a different order. For example, the flat pattern sheet 310 can be folded first, and then after the flat pattern sheet 310 is folded, the features are cut out. As another example, the flat pattern sheet 310 can first cut out the features and then fold. Additionally or alternatively, these operations can be repeated iteratively or occur in any order. For example, a fold can be performed once, followed by cutting out a feature, followed by another fold, followed by cutting out another feature, etc.

[0055] Figure 4 4 is a flow chart of an exemplary method 400 for manufacturing a photovoltaic module mounting system according to at least one embodiment of the present disclosure. The method 400 can be performed by any suitable system, device, or apparatus. For example, the first machine, the second machine, the third machine, the fourth machine, and / or the like can be performed in a die stamping process (e.g., Figure 3Any other device implemented in the die stamping process 300 of the present invention may perform one or more operations associated with the method 400. Although shown in the form of discrete blocks, depending on the specific implementation, the steps and operations associated with one or more blocks of the method 400 may be divided into additional blocks, combined into fewer blocks, or eliminated.

[0056] The method 400 may begin at block 402, where a coil of sheet metal may be obtained. In some embodiments, the coil of sheet metal may be galvanized steel, carbon steel, aluminum steel alloy, or any other type of metal. The coil of sheet metal may be contained in a coil of sheet metal that is continuously fed to a metal cutting device included in a progressive die stamping process. In some embodiments, due to the simplified manufacturing disclosed in the present disclosure, the coil of sheet metal may include pre-treated (e.g., galvanized) material such that post-manufacturing processing may not be required.

[0057] At block 404, a patterned sheet can be cut from the metal sheet roll. The patterned sheet can be cut from the metal sheet roll, for example, by a metal cutting device into which the metal sheet roll is fed, and a rectangular or substantially rectangular patterned sheet can be cut from the metal sheet roll. The patterned sheet can include a substantially rectangular shape with one or more cutouts, for example, about Figure 3 The cutout portion 312 is described to facilitate engagement of a modular fixture formed from a patterned sheet with a corresponding torque tube having a cross-sectional shape corresponding to the cutout shape. In some embodiments, one or more edges of a metal sheet roll can be used as corresponding edges of a patterned sheet to reduce the amount of cutting used to form the patterned sheet. For example, a patterned sheet can be cut from a metal sheet roll such that the length of the patterned sheet is the same or similar to the width of the metal sheet roll, and when the metal sheet roll is conveyed from the widthwise edge of the metal sheet roll into a metal cutting device, the width of the patterned sheet corresponds to a portion of the length of the metal sheet roll. Additionally or alternatively, the patterned sheet can be cut from a metal sheet roll into individual shapes, such as with respect to Figure 3 The flat pattern sheet 310 is shown.

[0058] At block 406, one or more slots may be formed in the patterned sheet. In some embodiments, the slots may be formed as part of a progressive die stamping process applied to the metal sheet roll and the patterned sheet. Thus, as described with respect to block 404, the slots may be formed while the patterned sheet is being formed by cutting the metal sheet roll, or the slots may be formed in a sequential processing step before or after the patterned sheet is formed. Additionally or alternatively, the slots may be formed in the patterned sheet in a given processing step after the patterned sheet is formed as described with respect to block 404, wherein the given processing step simultaneously includes the formation of a modular fixture as described with respect to block 408.

[0059] Additionally or alternatively, forming a slot in the patterned sheet can include forming one or more cut features. For example, a lengthwise slit can be cut in the center of the patterned sheet to create an opening in one or more surfaces of a modular fixture formed from the patterned sheet, such as with respect to Figures 2A-2C The cutout portion 218 of the module fixture 210 is shown.

[0060] At block 408, a module fixture may be formed from a patterned sheet. In some embodiments, forming the module fixture may involve folding, bending, or otherwise changing the shape of the patterned sheet. In these and other embodiments, the shape of the module fixture may be changed by bending one or more portions of the patterned sheet. Additionally or alternatively, the patterned sheet may be pressed against a contour template block so that the patterned sheet is embossed with the overall shape of the contour template block and / or the shape of any prominent features included in the contour template block. For example, the patterned sheet may be placed flush with a rectangular template block having a width shorter than the width of the patterned sheet. The patterned sheet may surround the rectangular template block in response to being pressed against the rectangular template block, which may form a module fixture having a rectangular channel shape.

[0061] At block 410, one or more features may be formed on the module fixture. In some embodiments, the features formed on the module fixture may include additional or alternative bends in one or more portions of the module fixture, such as forming Figures 1A-1C and / or Figures 2A-2C The flange 117 and / or flange 217. Additionally or alternatively, the features formed on the module fixture may include protruding features, such as Figures 1A-1C In these and other embodiments, the features may be formed on the module fixture as part of a progressive die stamping process, where the module fixture formed at block 408 passes through one or more forming / processing stations, where the forming tool at each forming station is configured to form one or more features.

[0062] Without departing from the scope of the present invention, method 400 may be modified, added or omitted. For example, specifying different elements in the described manner is intended to help explain the concepts described herein and is not restrictive. Further, method 400 may include any number of other elements, or may be implemented in other systems or environments other than those described above. Additionally or alternatively, one or more operations may be combined with other operations or performed simultaneously. The operations of method 400 may be performed in any order. For example, in some embodiments, one or more cutting or forming steps 404 and / or 406 may occur before or after one or more forming steps 408 and / or 410. For example, forming steps 408 and / or 410 may be performed, followed by cutting steps 404 and forming steps 406 in any order. Additionally or alternatively, such steps may be performed iteratively, such as forming, cutting, forming, cutting or any other combination of such steps.

[0063] The terms used in this disclosure and especially in the following claims (eg, the bodies of the following claims) are generally intended to be “open terms” (eg, the term “including” should be interpreted as “including, but not limited to”).

[0064] Additionally, if a specific number of an introduced claim recitation is intended, such intent will be explicitly stated in the claim, and in the absence of such a statement, no such intent exists. For example, to facilitate understanding, the following appended claims may include the use of the introductory phrases "at least" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to mean that a claim recitation introduced by the indefinite article "a" or "an" limits any specific claim containing such introduced claim recitation to embodiments containing only one such recitation, even if the same claim includes the introductory phrases "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" are interpreted as "at least one" or "one or more"); the same applies to the use of definite articles to introduce claim recitations.

[0065] Furthermore, even if a specific number of an introduced claim recitation is explicitly stated, one skilled in the art will recognize that such a statement should be interpreted to mean at least the stated number (e.g., a simple statement of "two recitations," without other modifications, means at least two recitations, or two or more recitations). Furthermore, where a convention similar to "at least one of A, B, and C, etc." or "one or more of A, B, and C, etc." is used, generally such a construction is intended to include A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together, etc.

[0066] In addition, any disjunctive word or phrase preceding two or more alternative terms, whether in the specification, claims or drawings, should be understood to contemplate the possibility of including one, either or both of these terms. For example, the phrase "A or B" should be understood to include the possibility of "A" or "B" or "A and B".

[0067] All examples and conditional language described in this disclosure are intended to be used for teaching purposes to help readers understand the present disclosure and the concepts contributed by the inventors to promote the prior art, and should be interpreted as not being limited to the specifically cited examples and conditions. Although the embodiments of the present disclosure have been described in detail, various changes, substitutions and modifications may be made thereto without departing from the spirit and scope of the present disclosure.

Claims

1. A method comprising: Obtaining a roll of sheet metal; cutting a generally rectangular patterned sheet having long sides and wide sides from the metal sheet roll; The generally rectangular patterned sheet includes respective cutout portions on two of the long sides, the cutout portions corresponding to a contour of at least a portion of a torque tube; and The patterned sheet is formed into a module jig from the patterned sheet, the module jig including a height higher in a central portion adjacent to the cutout portion than at ends of the module jig, and the module jig including a width wider at the ends than at the central portion.

2. The method according to claim 1, wherein: The sheet metal coil is made of galvanized steel. 3 . The method of claim 1 , further comprising forming one or more grooves in an end portion of the module fixture or in a portion of the generally rectangular patterned sheet corresponding to the end portion of the module fixture.

4. The method according to claim 1, wherein: Features formed on the module fixture include one or more protruding tabs or one or more flanges formed along one or more surfaces of the module fixture.

5. The method according to claim 1, wherein: Forming the module fixture from the patterned sheet includes: positioning the patterned sheet against a contour template block; and A force is applied to the patterned sheet so that the patterned sheet assumes a shape complementary to the contour template block.

6. The method according to claim 1, wherein: The operations of cutting the patterned sheet from the metal sheet roll and forming one or more grooves in the patterned sheet are performed simultaneously.

7. The method according to claim 1, characterized in that After forming one or more grooves in the patterned sheet, the patterned sheet is cut from the roll of metal sheet.

8. A photovoltaic module mounting system comprising: A modular fixture comprising: a central portion including two first walls connected at a top of each first wall by a first connecting surface, the central portion having a first cross-sectional height corresponding to the height of each first wall and a first width corresponding to the distance between two first walls; and one or more end portions, the one or more end portions comprising two second walls connected at a top of each second wall by a second connecting surface, wherein each of the end portions has a second cross-sectional height shorter than the first cross-sectional height and a second width wider than the first width, wherein the central portion is connected to each of the end portions such that the first connection surface and the second connection surface are bridged and form a bow tie shape; and A torque tube strap is coupled to the module clamp.

9. The photovoltaic module mounting system according to claim 8, wherein: Each of the end portions includes one or more grooves configured to align with one or more openings of a photovoltaic module.

10. The photovoltaic module mounting system according to claim 8, wherein: The module fixture also includes one or more flanges extending generally horizontally from one or more of the first walls.

11. The photovoltaic module mounting system according to claim 8, wherein: The module fixture also includes one or more flanges extending generally horizontally from one or more of the ends.

12. The photovoltaic module mounting system according to claim 8, wherein: The module clamp further includes one or more tabs protruding from the connection surface in a direction in which a photovoltaic module engages with the module clamp.

13. The photovoltaic module mounting system according to claim 8, wherein: The module clamps are made of galvanized steel.

14. A photovoltaic module mounting system, comprising: A modular fixture comprising: a central portion including two first walls and a mounting surface connected to a horizontal plane perpendicular to the first walls, the central portion having a first cross-sectional height corresponding to the height of each of the first walls and a first width corresponding to the width of the mounting surface; a first end and a second end, wherein the first end and the second end each have a second cross-sectional height shorter than the first cross-sectional height and a second width wider than the first width; and a channel extending from the first end to the second end, including a cutout portion extending at least partially along the length of the channel; and A torque tube strap is coupled to the module clamp.

15. The photovoltaic module mounting system according to claim 14, wherein: Each of the first end and the second end includes one or more grooves configured to align with one or more openings of a photovoltaic module.

16. The photovoltaic module mounting system according to claim 14, wherein: The module fixture also includes one or more flanges extending generally horizontally from one or more of the first walls.

17. The photovoltaic module mounting system of claim 14, wherein: The module clamp also includes one or more flanges extending from at least one of the first end and the second end.

18. The photovoltaic module mounting system of claim 14, wherein: The cutout portion is wider near the center portion than near the first end portion.

19. The photovoltaic module mounting system of claim 18, wherein: The module clamp includes a pivot fastener coupling the torque tube strap to the module clamp, the pivot fastener spanning the cutout portion.

20. The photovoltaic module mounting system of claim 14, wherein: The first end and the second end are both higher than the central portion, so that the mounting surface forms an arcuate shape from the first end to the central portion and from the central portion to the second end.

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