A lightweight aluminum alloy support structure for photovoltaic EPC (Engineering, Procurement, and Construction) projects

Abstract

This application relates to the field of photovoltaic (PV) support technology, and in particular to a lightweight aluminum alloy support structure for PV EPC (Engineering, Procurement, and Construction) projects. The structure includes a support frame, connectors, and adjustment components. The support frame uses an I-shaped aluminum alloy profile with internal reinforcing ribs and weight-reducing holes, and its surface is coated with an anti-corrosion coating. The connectors enable quick installation via fixing blocks and locking bolts. The adjustment components include adjustment rods and positioning clamps, allowing for precise adjustment of the PV module angle. This application, through optimized structural design and material usage, reduces weight while improving the support's load-bearing capacity, wind resistance, and installation efficiency. Furthermore, it enhances intelligence and stability through temperature sensors and damping materials, meeting the requirements of efficient construction and long-term durability in PV EPC projects.

Description

Technical Field

[0001] This utility model belongs to the field of photovoltaic power generation support technology, specifically a lightweight aluminum alloy support structure for photovoltaic EPC (Engineering, Procurement, and Construction) projects. Background Technology

[0002] A photovoltaic (PV) power generation system is a device that uses solar energy to convert light energy into electrical energy through photovoltaic modules. PV support structures are a crucial component of PV power generation systems, primarily used to support and secure the PV modules, ensuring their stable operation in outdoor environments. Currently, PV support structures mainly use steel or traditional aluminum alloy structures. While steel supports offer high strength, they are heavy, inconvenient to install, and susceptible to corrosion, affecting their lifespan. Traditional aluminum alloy supports, although lighter, have limitations in load-bearing capacity and wind resistance. To meet the demands of PV EPC projects for lightweight and high-strength support structures, the industry urgently needs a new type of aluminum alloy support structure to optimize material usage, reduce overall weight, and simultaneously improve structural stability and installation efficiency. However, existing support designs often require a trade-off between strength and durability when achieving lightweighting, posing challenges for practical applications. Utility Model Content

[0003] To address the shortcomings of existing technologies, this invention provides a lightweight aluminum alloy support structure for photovoltaic (PV) EPC projects, thus resolving the issues of insufficient strength, poor wind resistance, and low installation efficiency inherent in traditional PV support systems during the weight reduction process. By optimizing material usage and structural design, this invention significantly improves the load-bearing capacity and stability of the support structure while reducing overall weight, meeting the demands of PV EPC projects for efficient construction and long-term durability.

[0004] The technical solution adopted by this utility model to solve its technical problem is a lightweight aluminum alloy support structure for photovoltaic EPC (Engineering, Procurement, and Construction) photovoltaic system, including a support frame, connectors, and adjustment components. The support frame is composed of multiple aluminum alloy profiles with an "I"-shaped cross-section and reinforcing ribs evenly distributed along the length of the profile and fixedly connected to its inner wall. The connectors include a fixing block and locking bolts. A slot matching the end of the profile is provided in the center of the fixing block, and the inner wall of the slot has anti-slip teeth. The end of the profile is inserted into the slot and fixed by the locking bolts. The adjustment components include an adjustment rod and a positioning clamp. One end of the adjustment rod is hinged to the fixing block, and the other end is threaded to the positioning clamp, which is used to fix the photovoltaic module.

[0005] On the other hand, mounting holes are provided at both ends of the profile supporting the frame. Metal bushings are embedded in the mounting holes, with the outer wall of the metal bushings having an interference fit with the inner wall of the profile. The inner wall of the metal bushings is threaded for engagement with the locking bolts of the connecting parts. In the "I"-shaped structure of the profile, the thickness of the upper and lower flanges is greater than that of the web, and the surfaces of the upper and lower flanges are coated with an anti-corrosion coating. Weight-reducing holes are provided in the middle of the web, and these holes are evenly distributed along the length of the profile. The weight-reducing holes are elliptical in shape to reduce material usage while maintaining structural strength.

[0006] On the other hand, the fixing block of the connector is equipped with an elastic washer inside. The elastic washer is located at the bottom of the slot and is fixedly connected to the inner wall of the slot. A through hole is opened in the middle of the elastic washer. The diameter of the through hole is smaller than the opening size of the slot, which is used to provide pre-tightening force when the profile is inserted. The fixing block is symmetrically provided with mounting ears on both sides. The mounting ears are provided with bolt holes. Anti-loosening washers are installed in the bolt holes to prevent the locking bolts from loosening during use.

[0007] On the other hand, the adjusting rod of the adjusting component has scale markings in the middle, which are evenly distributed along the axis of the adjusting rod to precisely control the installation angle of the photovoltaic module. One end of the adjusting rod is connected to the fixing block via a ball joint, and the ball joint has a lubricating coating to reduce frictional resistance and improve adjustment flexibility. The other end of the adjusting rod is connected to the positioning clamp via a thread, and the inside of the positioning clamp has a rubber pad with anti-slip protrusions to enhance the contact stability with the photovoltaic module.

[0008] On the other hand, locking handles are provided on both sides of the positioning clamp. These locking handles are connected to the positioning clamp via screws. One end of the screw is fixedly connected to the locking handle, and the other end passes through the positioning clamp and is threadedly connected to the adjusting rod. Rotating the locking handles causes the screw to rotate, thus clamping or releasing the photovoltaic module. A guide groove is provided in the middle of the positioning clamp, and a guide block is slidably installed within the guide groove. The guide block contacts the edge of the photovoltaic module and is used to position the photovoltaic module during installation.

[0009] On the other hand, the profiles supporting the frame form a grid structure through connectors. Reinforcing plates are installed at the nodes of the grid structure and are fixedly connected to the profiles by welding. Drainage holes are provided in the center of the reinforcing plates, extending along the thickness of the reinforcing plates to drain rainwater and prevent water accumulation from corroding the profiles. An anodized layer is applied to the surface of the reinforcing plates to improve their corrosion resistance.

[0010] On the other hand, anchor bolts are installed at the bottom of the support frame. These anchor bolts are fixed to the profile with nuts. The lower part of the anchor bolt has a tapered tip, which is used to insert into the ground and improve the overturning resistance of the support. A leveling nut is installed at the top of the anchor bolt. The leveling nut contacts the bottom of the profile and is used to adjust the overall levelness of the support.

[0011] On the other hand, the surface of the supporting frame profile is coated with a reflective coating, which is evenly distributed along the length of the profile to reflect sunlight and reduce the surface temperature of the support. The reflective coating surface is also provided with a microporous structure, which is evenly distributed along the coating surface to improve the heat dissipation performance of the coating.

[0012] On the other hand, a temperature sensor is installed inside the positioning clamp of the adjustment component. The temperature sensor is connected to an external monitoring system via wires to monitor the operating temperature of the photovoltaic module in real time. A protective cover is installed on the surface of the temperature sensor, which is fixedly connected to the positioning clamp by a buckle. The inner wall of the protective cover is provided with a heat insulation layer to prevent external heat from affecting the measurement accuracy of the temperature sensor.

[0013] On the other hand, the inner cavity of the supporting frame profile is filled with damping material, which is evenly distributed along the length of the profile to absorb vibration energy and improve the wind resistance of the support. An adhesive layer is provided on the surface of the damping material, and this adhesive layer is fixedly connected to the inner wall of the profile to prevent the damping material from falling off during use.

[0014] This invention achieves a lightweight design for photovoltaic support structures through the aforementioned technical solutions, while significantly improving the load-bearing capacity and wind resistance. The "I"-shaped structure and reinforcing rib design of the profiles effectively enhance the overall strength of the support structure, while the application of weight-reducing holes and anti-corrosion coatings further optimizes material usage and durability. The design of connectors and adjustment components simplifies the installation process and improves construction efficiency, while the application of temperature sensors and damping materials enhances the intelligence and stability of the support structure. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention, showing the overall layout of the lightweight aluminum alloy bracket, including a support frame, connectors, and adjustment components.

[0016] Figure 2 This utility model Figure 1 A partial structural diagram.

[0017] Figure 3 This utility model Figure 2 Enlarged view of point A.

[0018] Figure 4 This utility model Figure 2 Enlarged view of point B.

[0019] Figure 5 This utility model Figure 2 Enlarged view of point C.

[0020] The attached figures are labeled as follows:

[0021] 1. Support frame; 2. Profile; 3. Reinforcing rib; 4. Weight reduction hole; 5. Connector; 6. Fixing block; 7. Slot; 8. Locking bolt; 9. Adjustment assembly; 10. Adjustment rod; 11. Positioning clamp; 12. Reinforcing plate; 13. Anchor bolt. Detailed Implementation

[0022] This utility model provides a lightweight aluminum alloy support structure for photovoltaic EPC (Engineering, Procurement, and Construction) projects, the specific implementation of which is described in conjunction with the attached figure. Figure 1 To be continued Figure 5 Please provide a detailed explanation. For example... Figure 1 As shown, the support structure mainly includes a support frame 1, connectors 5, and adjustment components 9. The precise design of each component achieves a balance between lightweight and high strength. The support frame 1 is composed of multiple aluminum alloy profiles 2, with the cross-section of the profiles 2 being I-shaped. Figure 2 As shown, the thickness of its upper and lower flanges is greater than that of the web to enhance bending resistance. Reinforcing ribs 3 are provided within the profile 2's inner cavity, evenly distributed along the length of the profile 2 and fixedly connected to its inner wall, further improving overall strength. Multiple elliptical weight-reducing holes 4 are formed in the middle of the web, evenly distributed along the length of the profile 2, significantly reducing material usage while maintaining structural strength.

[0023] Connector 5 includes a fixing block 6 and a locking bolt 8, such as Figure 3 As shown, the fixing block 6 has a slot 7 in the middle that matches the end of the profile 2. The inner wall of the slot 7 is provided with anti-slip teeth to increase friction and prevent loosening. After the end of the profile 2 is inserted into the slot 7, it is fixed by the locking bolt 8. An elastic washer is provided inside the fixing block 6. The elastic washer is located at the bottom of the slot 7 and is fixedly connected to the inner wall of the slot 7. The elastic washer has a through hole in the middle. The diameter of the through hole is smaller than the opening size of the slot 7, which is used to provide pre-tightening force when the profile 2 is inserted. The fixing block 6 has mounting ears symmetrically arranged on both sides. The mounting ears have bolt holes. Anti-loosening washers are provided in the bolt holes to prevent the locking bolt 8 from loosening during use.

[0024] Adjustment assembly 9 includes adjustment rod 10 and positioning clamp 11, such as Figure 4As shown, one end of the adjusting rod 10 is connected to the fixed block 6 via a ball joint. A lubricating coating is provided inside the ball joint to reduce frictional resistance and improve adjustment flexibility. The other end of the adjusting rod 10 is threadedly connected to the positioning clamp 11. A rubber pad is provided on the inner side of the positioning clamp 11, and anti-slip protrusions are provided on the surface of the rubber pad to enhance contact stability with the photovoltaic module. A scale mark is provided in the middle of the adjusting rod 10, evenly distributed along the axis of the adjusting rod 10, for precise control of the installation angle of the photovoltaic module. Locking handles are provided on both sides of the positioning clamp 11. The locking handles are connected to the positioning clamp 11 via screws. One end of the screw is fixedly connected to the locking handle, and the other end passes through the positioning clamp 11 and is threadedly connected to the adjusting rod 10. When the locking handles are rotated, they drive the screw to rotate, causing the positioning clamp 11 to clamp or release the photovoltaic module. A guide groove is provided in the middle of the positioning clamp 11, and a guide block is slidably installed in the guide groove. The guide block contacts the edge of the photovoltaic module for positioning the photovoltaic module during installation.

[0025] The profile 2 of the supporting frame 1 has mounting holes at both ends, and metal bushings are embedded in the mounting holes. The outer wall of the metal bushing is interference-fitted with the inner wall of the profile 2, and the inner wall of the metal bushing is threaded for engagement with the locking bolts 8 of the connector 5. The profiles 2 form a mesh structure through the connectors 5, such as... Figure 5 As shown, reinforcing plates 12 are installed at the nodes of the grid structure, and the reinforcing plates 12 are fixedly connected to the profile 2 by welding. A drainage hole is provided in the middle of the reinforcing plate 12, extending along the thickness direction of the reinforcing plate 12, to drain rainwater and prevent water accumulation from corroding the profile 2. An anodized layer is provided on the surface of the reinforcing plate 12 to improve its corrosion resistance.

[0026] Anchor bolts 13 are installed at the bottom of the support frame 1. Anchor bolts 13 are fixedly connected to the profile 2 by nuts. The lower part of the anchor bolt 13 has a tapered tip, which is used to insert into the ground and improve the support's anti-overturning ability. A leveling nut is installed at the top of the anchor bolt 13, which contacts the bottom of the profile 2 and is used to adjust the overall levelness of the support. A reflective coating is applied to the surface of the profile 2, evenly distributed along its length, to reflect sunlight and reduce the surface temperature of the support. The reflective coating surface has a microporous structure, evenly distributed along the coating surface, to improve the coating's heat dissipation performance.

[0027] A temperature sensor is installed inside the positioning clamp 11 of the adjustment component 9. The temperature sensor is connected to an external monitoring system via wires to monitor the operating temperature of the photovoltaic module in real time. A protective cover is installed on the surface of the temperature sensor, and the protective cover is fixedly connected to the positioning clamp 11 by a buckle. The inner wall of the protective cover is provided with a heat insulation layer to prevent external heat from affecting the measurement accuracy of the temperature sensor. The inner cavity of the profile 2 is filled with damping material, which is evenly distributed along the length of the profile 2 to absorb vibration energy and improve the wind resistance of the support. An adhesive layer is installed on the surface of the damping material, and the adhesive layer is fixedly connected to the inner wall of the profile 2 to prevent the damping material from falling off during use.

[0028] The implementation process of this utility model is as follows: First, multiple profiles 2 are cut to the required length according to design requirements, and mounting holes and metal bushings are machined at both ends of the profiles 2. Next, the profiles 2 are assembled into a grid structure using connectors 5, and reinforcing plates 12 are welded to the nodes of the grid structure to improve overall stability. After assembly, anchor bolts 13 are inserted into the ground, and the level of the bracket is adjusted using leveling nuts. Then, the adjusting component 9 is installed, with one end of the adjusting rod 10 connected to the fixing block 6, and the other end connected to the positioning clamp 11 via threads. The photovoltaic module is fixed by the positioning clamp 11, and the locking handle is used to clamp or loosen the photovoltaic module. During installation, the angle of the photovoltaic module is precisely adjusted using the scale markings on the adjusting rod 10. After installation, a temperature sensor monitors the operating temperature of the photovoltaic module in real time and transmits the data to an external monitoring system. Through the above steps, this utility model achieves a lightweight design for the photovoltaic bracket while possessing high load-bearing capacity and wind resistance, meeting the requirements of photovoltaic EPC projects for efficient construction and long-term durability.

[0029] To enable those skilled in the art to fully understand and implement this utility model, the specific implementation principle of this utility model is further explained below in conjunction with a specific application scenario.

[0030] First, when installing the support frame 1, multiple aluminum alloy profiles 2 need to be cut to the specified length according to the design requirements, and mounting holes and metal bushings need to be machined at both ends of the profiles 2. The outer wall of the metal bushing and the inner wall of the profile 2 are interference-fitted to ensure that they will not loosen during use. At the same time, the threads on the inner wall of the metal bushing can be tightly fitted with the locking bolts 8 of the connector 5, thereby improving the stability of the overall structure. Subsequently, the multiple profiles 2 are assembled into a grid structure using the connector 5, such as... Figure 5 As shown, reinforcing plates 12 are welded at the nodes of the mesh structure. The design of the reinforcing plates 12 not only enhances the load-bearing capacity at the nodes, but also allows rainwater to drain through drainage holes in the middle, preventing water accumulation and corrosion of the profile 2. The anodized layer on the surface of the reinforcing plates 12 further improves corrosion resistance and extends the service life of the bracket.

[0031] Next, after the grid structure is assembled, anchor bolts 13 are inserted into the ground to secure the bracket. The tapered tip design of the lower part of the anchor bolt 13 allows it to be firmly inserted into the ground, thereby improving the bracket's resistance to overturning. The leveling nut on the upper part of the anchor bolt 13 is used to adjust the overall levelness of the bracket, ensuring that the photovoltaic modules maintain the optimal angle after installation to maximize power generation efficiency. In addition, the reflective coating on the surface of the profile 2 effectively reflects sunlight, reducing the surface temperature of the bracket, while the microporous structure of the coating surface improves heat dissipation performance, preventing material aging due to high temperatures.

[0032] Subsequently, when installing the adjustment assembly 9, one end of the adjustment rod 10 is first connected to the fixing block 6 via a ball joint, and the other end is connected to the positioning clamp 11 via a thread. The scale markings in the middle of the adjustment rod 10 can precisely control the installation angle of the photovoltaic module, ensuring that it meets the design requirements. The rubber pad on the inside of the positioning clamp 11 enhances the contact stability with the photovoltaic module through anti-slip protrusions on its surface, while the guide block in the guide groove can accurately position the photovoltaic module during installation. The locking handle is connected to the positioning clamp 11 via a screw. When the locking handle is turned, the screw rotates, causing the positioning clamp 11 to clamp or release the photovoltaic module, thereby simplifying the installation and disassembly process.

[0033] In actual operation, the operating temperature of photovoltaic modules is one of the important factors affecting power generation efficiency. Therefore, a temperature sensor installed inside the positioning clamp 11 can monitor the operating temperature of the photovoltaic modules in real time and transmit the data to an external monitoring system. The protective cover on the surface of the temperature sensor isolates external heat interference through a heat insulation layer, ensuring measurement accuracy. Furthermore, the damping material filling the inner cavity of profile 2 can absorb vibration energy, thereby improving the wind resistance of the support structure. The adhesive layer on the surface of the damping material is fixedly connected to the inner wall of profile 2 to prevent it from falling off during long-term use.

[0034] Through the above steps, this utility model achieves a lightweight design for photovoltaic brackets while significantly improving load-bearing capacity and wind resistance. The "I"-shaped structure and reinforcing ribs 3 of profile 2 effectively improve overall strength, while the weight-reducing holes 4 in the middle of the web reduce material usage while maintaining structural strength. The anti-slip serrations on the inner wall of the slots 7 of the connector 5 and the pre-tightening force provided by the elastic gaskets ensure the stability of the connection between profiles 2. The flexibility and precision of the adjustment components 9 further optimize installation efficiency, meeting the needs of photovoltaic EPC projects for efficient construction and long-term durability.

[0035] The above description is merely a preferred embodiment of this utility model and is not intended to limit this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A lightweight aluminum alloy support structure for a photovoltaic package, characterized by, It includes a support frame (1), connectors (5), and adjustment components (9); The support frame (1) is composed of multiple aluminum alloy profiles (2). The profile (2) has an "I" shaped cross section and is equipped with reinforcing ribs (3) in the inner cavity. The reinforcing ribs (3) are evenly distributed along the length of the profile (2) and are fixedly connected to its inner wall. The connector (5) includes a fixing block (6) and a locking bolt (8). The fixing block (6) has a slot (7) in the middle that matches the end of the profile (2). The inner wall of the slot (7) is provided with anti-slip teeth. After the end of the profile (2) is inserted into the slot (7), it is fixed by the locking bolt (8). The adjustment assembly (9) includes an adjustment rod (10) and a positioning clamp (11). One end of the adjustment rod (10) is hinged to the fixed block (6), and the other end is threaded to the positioning clamp (11).

2. A lightweight aluminum alloy support structure for a PV turnkey package according to claim 1, characterized in that: The profile (2) has mounting holes at both ends, and a metal bushing is embedded in the mounting hole. The outer wall of the metal bushing is interference-fitted with the inner wall of the profile (2). The inner wall of the metal bushing is threaded for use with the locking bolt (8) of the connector (5).

3. A lightweight aluminum alloy support structure for a PV turnkey package according to claim 1, characterized in that: In the "I" shaped structure of the profile (2), the upper and lower flanges are coated with anti-corrosion coating, and a weight reduction hole (4) is opened in the middle of the web. The weight reduction hole (4) is evenly distributed along the length of the profile (2), and the weight reduction hole (4) is elliptical in shape.

4. A lightweight aluminum alloy support structure for a PV turnkey package according to claim 1, characterized in that: An elastic gasket is provided inside the fixing block (6). The elastic gasket is located at the bottom of the slot (7) and is fixedly connected to the inner wall of the slot (7). A through hole is opened in the middle of the elastic gasket, and the diameter of the through hole is smaller than the opening size of the slot (7).

5. A lightweight aluminum alloy support structure for a PV turnkey package according to claim 1, characterized in that: The adjusting rod (10) has a scale mark in the middle, and the scale mark is evenly distributed along the axis of the adjusting rod (10). One end of the adjusting rod (10) is connected to the fixed block (6) through a ball joint, and a lubricating coating is provided inside the ball joint.

6. A lightweight aluminum alloy support structure for photovoltaic EPC (Engineering, Procurement, and Construction) as described in claim 1, characterized in that: A rubber pad is provided on the inner side of the positioning clamp (11), and anti-slip protrusions are provided on the surface of the rubber pad. Locking handles are provided on both sides of the positioning clamp (11). The locking handles are connected to the positioning clamp (11) through a screw. One end of the screw is fixedly connected to the locking handle, and the other end passes through the positioning clamp (11) and is threadedly connected to the adjusting rod (10).

7. A lightweight aluminum alloy support structure for photovoltaic EPC (Engineering, Procurement, and Construction) as described in claim 1, characterized in that: The profiles (2) of the supporting frame (1) are connected by connectors (5) to form a grid structure. Reinforcing plates (12) are provided at the nodes of the grid structure. The reinforcing plates (12) are fixedly connected to the profiles (2) by welding. Drainage holes are provided in the middle of the reinforcing plates (12) and the drainage holes penetrate along the thickness direction of the reinforcing plates (12).

8. A lightweight aluminum alloy support structure for photovoltaic EPC (Engineering, Procurement, and Construction) as described in claim 1, characterized in that: Anchor bolts (13) are provided at the bottom of the support frame (1). The anchor bolts (13) are fixedly connected to the profile (2) by nuts. The lower part of the anchor bolts (13) is provided with a tapered tip. The upper part of the anchor bolts (13) is provided with a horizontal adjustment nut. The horizontal adjustment nut is in contact with the bottom of the profile (2).

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