Method for mounting a plurality of photovoltaic modules on at least one substrate, and module assembly

Abstract

The invention relates to a method for mounting a plurality of photovoltaic modules on at least one substrate. The invention likewise relates to a module assembly comprising: a plurality of photovoltaic modules (10) and at least one module carrier (14, 36), wherein the at least one module carrier (14, 36) comprises at least one mounting profile (38), wherein the mounting profile (38) has a first connecting portion (44) for connecting the mounting profile (38) to the plurality of photovoltaic modules (10), and wherein the mounting profile (38) has a second connecting portion (46) for connecting the mounting profile (38) to at least one substructure (26) fastened to a substrate.

Description

[0001] Method for mounting a plurality of photovoltaic modules on at least one substrate and module assembly

[0002] The invention relates to a method for mounting a plurality of photovoltaic modules on at least one substrate. The invention also relates to a module assembly comprising a plurality of photovoltaic modules and at least one module carrier.

[0003] The importance of photovoltaic modules for the transition from fossil fuels to renewable energies is well known to experts. However, this transition from fossil fuels to renewable energies, particularly the use of solar energy, presents several challenges. One such challenge is reducing the cost of installing photovoltaic modules.

[0004] For example, large solar parks comprise several thousand photovoltaic modules spread across an area of ​​several hectares and at least partially interconnected electrically to feed the generated energy into a power grid. A large number of technically qualified personnel are required to reliably install this quantity of photovoltaic modules.

[0005] This results in high personnel costs on the one hand, and on the other hand it is often difficult to find enough trained personnel who can provide the work required for the installation of photovoltaic modules.

[0006] Based on this, the task was therefore set to specify a method for assembling a plurality of photovoltaic modules as well as a module assembly which enables the assembly of a plurality of photovoltaic modules in a cost-effective and resource-saving manner.

[0007] According to a first aspect, the aforementioned problem is solved by a method for mounting a plurality of photovoltaic modules on at least one substrate, comprising the following steps: providing a plurality of photovoltaic modules and a plurality of module carriers; wherein each module carrier comprises at least one mounting profile; pre-assembling the plurality of photovoltaic modules and the plurality of module carriers into a plurality of module assemblies; wherein each module assembly comprises a plurality of photovoltaic modules and at least one module carrier; and wherein the plurality of photovoltaic modules are connected to one another by means of the at least one module carrier, in particular by means of the at least one mounting profile of the at least one module carrier; storage, in particular stacked storage, of the plurality of module assemblies on at least one transport unit;wherein the mounting profiles of the majority of module carriers are designed such that the majority of module assemblies can be stacked at least partially on top of and / or next to each other; and transport of the majority of module assemblies, in particular by means of the at least one transport unit, to at least one assembly position; assembly of the majority of module assemblies on at least one substructure fixed to a substrate.

[0008] This enables a process which advantageously allows the assembly of a plurality of photovoltaic modules, whereby these can first be pre-assembled into module assemblies as automatically as possible with the help of at least one mounting profile of a module carrier, and the mounting profiles of the module carriers are designed in such a way that stacking is possible at least partially on top of and / or next to each other.

[0009] Subsequently, the majority of the modular assemblies stored on the at least one transport unit can be moved to an assembly position, whereby the majority of modular assemblies can be mounted at the assembly position on at least one substructure fixed to a substrate.

[0010] For example, the substructure attached to a substrate can consist of at least one longitudinal beam, preferably at least two longitudinal beams, which are each attached to the substrate by means of a plurality of foundation posts.

[0011] Pre-assembling the majority of photovoltaic modules and module carriers into multiple module assemblies, particularly at a central pre-assembly location, optimizes logistical processes and workflows during module assembly. For example, it eliminates the need for costly, separate transport of individual modules to the final assembly position. It also reduces the number of workers required to travel long distances to connect the photovoltaic modules to the module carriers at the final assembly location and then attach them to the substructure.

[0012] For example, the majority of photovoltaic modules and the majority of module carriers can be assembled into a majority of module assemblies in a so-called "field factory", so that advantageous manufacturing conditions for pre-assembly can be provided centrally at one location.

[0013] Preferably, three photovoltaic modules are connected to form a module assembly by means of module carriers, wherein, in particular, at least two mounting profiles are used for a module assembly. For example, a module carrier thus comprises two mounting profiles. However, it is also conceivable that a module carrier comprises only one mounting profile, and in this case, two module carriers are used for the pre-assembly of three photovoltaic modules into a module assembly. A preferred embodiment is characterized in that the pre-assembly further comprises: at least partially automated pre-assembly of the majority of photovoltaic modules and the majority of module carriers into a majority of module assemblies by means of at least one handling robot. For example, such pre-assembly can be carried out on a substantially automated production line. For example, at least one handling robot and at least one roller conveyor are used for this purpose.By mapping out pre-assembly at a central location, it is possible to provide an infrastructure that works quickly and has a high degree of automation.

[0014] Preferably, the majority of photovoltaic modules and / or the majority of module carriers have an indexing system, wherein the position of the majority of photovoltaic modules and / or the majority of module carriers is detected by means of at least one sensor. The indexing can be implemented, for example, by a geometric feature and / or by a color marking. The indexing system advantageously enables at least partially automated pre-assembly, since the position of the majority of photovoltaic modules and / or the majority of module carriers can be reliably detected. The at least one sensor can be, for example, at least one camera, at least one scanner, at least one laser sensor, at least one motion sensor, and / or at least one RFID sensor.When providing at least one RFID sensor, it is preferred that the majority of photovoltaic modules and / or the majority of module carriers have at least one RF1D transponder for indexing. For example, it may also be preferred if a barcode is provided for indexing. Mechanical sensor means may also be provided. These mechanical sensor means may, for example, be sensor means that deform mechanically and can thus detect indexing. For example, the mechanical sensor means may be probes that generate a corresponding signal upon contact with a surface.

[0015] For example, the loading of a pre-assembly station by means of at least one manipulation robot is essentially automated, whereby in particular the majority of module carriers and / or the majority of photovoltaic modules are automatically fed to the pre-assembly station by means of the manipulation robot.

[0016] Preferably, the at least one manipulation robot connects the majority of module carriers and / or the majority of photovoltaic modules of the pre-assembly station by means of at least one connecting means, in particular by means of at least one clamp.

[0017] For example, the majority of module carriers can be fed manually to the pre-assembly station, while the majority of photovoltaic modules can be fed automatically to the pre-assembly station and connected using the majority of module carriers, preferably automatically.

[0018] Another preferred embodiment is characterized in that the pre-assembly further comprises: connecting the plurality of photovoltaic modules and the plurality of module carriers to form a plurality of module assemblies by means of a positive-locking, force-locking and / or friction-locking connection, in particular by means of a plurality of fasteners. This enables a reliable connection of the components of a module assembly. For example, the plurality of photovoltaic modules and / or the plurality of module carriers can be manufactured by means of a screw connection, a rivet connection, a clamp connection, clinching and / or adhesive bonding.

[0019] For example, the connection of multiple photovoltaic modules and module carriers to form multiple module assemblies can be achieved through mechanical forming of the multiple photovoltaic modules and / or the multiple module carriers. This advantageously eliminates the need for additional connecting elements.

[0020] For example, a connection of the majority of photovoltaic modules and the majority of module carriers to form a majority of module assemblies can be made possible by means of a snap-fit ​​function.

[0021] Another preferred embodiment is characterized in that the pre-assembly further comprises: automated feeding of the majority of fasteners, in particular by means of a pre-assembled magazine. This enables further automation of the pre-assembly. For example, the majority of fasteners can also be placed loosely as bulk material into a sorting and feeding system, where they are subsequently fed, in particular automatically.

[0022] Another preferred embodiment is characterized in that the pre-assembly further comprises: recording the majority of photovoltaic modules and / or the majority of module carriers; and comparing the recorded majority of photovoltaic modules and / or the recorded majority of module carriers with reference values ​​stored in a database. This enables, for example, quality control of the majority of photovoltaic modules and / or the majority of module carriers.

[0023] For example, an error signal can optionally be output if the measured dimensions of the majority of photovoltaic modules and / or the measured dimensions of the majority of module carriers are outside the reference values ​​stored in the database. This allows an operator of the pre-assembly station to check whether the respective photovoltaic modules and / or module carriers need to be replaced or whether they are suitable for pre-assembly and / or final assembly. According to a preferred embodiment, the majority of photovoltaic modules and / or the majority of module carriers are measured, for example, by means of a measuring device, in particular a camera. Specifically, after measuring the majority of photovoltaic modules and / or the majority of module carriers, features of the respective photovoltaic module and / or the respective module carrier are first identified.

[0024] For example, the identified characteristics may be features that allow conclusions to be drawn about the quality of the respective photovoltaic module and / or the respective module carrier. This allows a kind of incoming goods inspection to be carried out during pre-assembly.

[0025] For example, the identified characteristics could be an identification identifier such as a barcode, serial number, or RFID transponder, to name just a few examples. After capturing such an identification identifier, a digital twin of the respective photovoltaic module and / or module carrier can preferably be created and analyzed using the manufacturing data to determine the precise position at which the module assembly, comprising the respective photovoltaic module and / or module carrier, is installed. Therefore, if it is subsequently discovered that certain batches were defective, this allows for easy identification of the respective module assemblies, enabling them to be replaced in a cost-effective manner.

[0026] Another preferred embodiment is characterized in that the pre-assembly further comprises: inserting and / or placing the majority of photovoltaic modules into at least one mounting profile, in particular into at least two mounting profiles; wherein the majority of photovoltaic modules are preferably fixed in a form-fitting manner after insertion and / or placement. This enables a connection between the majority of photovoltaic modules and the at least one mounting profile to be facilitated in a technically advantageous manner.

[0027] It is preferred that the majority of photovoltaic modules are fixed in a form-fit manner, preferably by rotating at least one mounting profile around an axis in the insertion direction of the at least one mounting profile. This allows, for example, a solution to be provided that requires few or no additional fasteners, resulting in reduced costs and simpler installation.

[0028] According to a further preferred embodiment, the pre-assembly further comprises: inserting and / or placing the majority of photovoltaic modules into at least one mounting profile, in particular into at least two mounting profiles. Preferably, the majority of photovoltaic modules are positively connected by snapping them into a locking lip, preferably a locking lip integrated into the at least one mounting profile, and in particular an integrally formed locking lip. Preferably, the majority of photovoltaic modules are positively connected by partial mechanical deformation into a lip, preferably a lip integrated into the at least one mounting profile, and preferably an integrally formed lip.

[0029] According to a further preferred embodiment, the pre-assembly further comprises: inserting and / or placing the majority of photovoltaic modules into at least one mounting profile, in particular into at least two mounting profiles, wherein the majority of photovoltaic modules are preferably connected by means of at least one connecting element, in particular by means of at least one clamping means, with which at least one mounting profile, in particular with two mounting profiles, is connected.

[0030] Another preferred embodiment is characterized in that the plurality of module assemblies are mounted on the at least one substructure by means of at least one installation vehicle, wherein the at least one installation vehicle preferably recognizes the plurality of module assemblies on the at least one transport unit in a substantially automated manner; wherein at least one manipulator of the at least one installation vehicle preferably removes the plurality of module assemblies from the at least one transport unit in a substantially automated manner. This further enables a substantially automated arrangement of the plurality of module assemblies on the at least one substructure. "Mounted on the substructure" in this context does not necessarily mean that all assembly steps have already been completed.For example, simply placing the majority of module units onto the at least one substructure can also constitute the assembly of the majority of module units. Preferably, the majority of module assemblies are removed from the at least one manipulator near their final assembly position and, with a removal step, mounted on the substructure at the respective final assembly position.

[0031] A preferred embodiment is characterized in that the at least one manipulator removes the plurality of module assemblies from the at least one transport unit, in particular by means of at least one vacuum suction element, by means of a positive-locking and force-locking mechanical connection, and / or by means of magnetic force. This allows the plurality of module assemblies to be reliably removed from the at least one transport unit and preferably placed on the at least one substructure. Preferably, the plurality of module assemblies are not only removed by means of the manipulator, but also preferably (pre-)assembled on the at least one substructure by means of the manipulator.

[0032] A preferred embodiment is characterized in that the at least one installation vehicle detects the at least one assembly position and / or the at least substructure, wherein the at least one manipulator transports at least one module assembly to the assembly position, wherein the at least one installation vehicle is preferably coupled to the at least one manipulator, in particular electronically or mechanically coupled, and wherein the at least one manipulator places the at least one module assembly in the assembly position on the substructure or mounts it on the substructure.

[0033] For example, the distance between the module assembly to be laid down and the previously mounted module assembly can be checked and adjusted using at least one sensor. To lay down the module assembly, its fixation to the manipulator can be released, and then, due to gravity, the module assembly engages the substructure, particularly the longitudinal beams of the substructure, by means of a second connecting section, in particular a hook-shaped second connecting section of the mounting profile of the module assembly, or a hook-shaped holding element connected to the second connecting section. This secures the position of the module assembly against slippage and also against lifting loads. The laying process of the respective module assembly by the installation vehicle can then be completed.Similarly, the attachment of at least one module carrier to the majority of photovoltaic modules can also be automated. For example, a completely manual installation process is also possible.

[0034] Another preferred embodiment is characterized in that the majority of module assemblies are attached manually and / or automatically to the at least one substructure by means of force-fit, material-fit, and / or friction-fit connections. For example, the majority of module assemblies can be attached manually and / or automatically using self-drilling screws, metric screws with nuts, clamps, blind rivets, self-piercing rivets, clinching, flow-drilling screws, and / or locking ring bolts, to name a few non-limiting embodiments. Another preferred embodiment is characterized in that the at least one installation vehicle places the module assemblies at a mounting position on the substructure, and the module assemblies are subsequently transported at least partially from the mounting position to the final assembly position by means of the substructure.Since the substructure for mounting the module assemblies on a substrate is already in place, it can also be advantageously used to transport the module assemblies to the final assembly position. This simplifies the assembly process from an assembly perspective, as all module assemblies of a substructure can be mounted at the same location. For example, the module assemblies and / or the substructure are designed to allow the module assemblies to be moved along the substructure. Alternatively, an additional transport rack can be provided to move the module assemblies along the substructure to the final assembly position.

[0035] Another preferred embodiment is characterized in that the at least one transport unit transports the majority of the module assemblies along an elongated extension of the at least one substructure, with the module assemblies being placed and / or mounted at their final assembly position on the substructure. This allows for a structurally simple design of the module assemblies and / or the substructure, which can make them less prone to errors. Furthermore, the placement step of the respective module assembly can be carried out essentially simultaneously with the final assembly step, i.e., the fastening of the module assembly to the substructure, which can be advantageous from an assembly engineering perspective.

[0036] According to a second aspect, the aforementioned task is solved by a

[0037] Module assembly comprising: a plurality of photovoltaic modules and at least one module support, wherein the at least one module support comprises at least one mounting profile, wherein the mounting profile has a first connection section for connecting the mounting profile to the plurality of photovoltaic modules, and wherein the mounting profile has a second connection section for connecting the mounting profile to at least one substructure fixed to a substrate, wherein the second connection section is designed such that it is at least partially stackable on the surface of a plurality of photovoltaic modules, in particular on the surface of a plurality of photovoltaic modules of a further module assembly.At least partially stackable storage of the individual module assemblies enables pre-assembly of the module assemblies at a central location and subsequent stacking of the module assemblies onto a transport unit, so that the pre-assembled assemblies can then be moved to an assembly position. Pre-assembling the majority of photovoltaic modules and module carriers into a majority of module assemblies, particularly at a central pre-assembly location, makes it possible to further optimize the logistical processes and workflows during the assembly of the photovoltaic modules.

[0038] An embodiment of the second connecting section such that it can be stacked on the surface of a plurality of photovoltaic modules of a further module assembly means in particular that the claimed module assembly can be stacked or stored at least partially on and / or next to a further module assembly.

[0039] A stacking of the plurality of module assemblies at least partially on top of and / or next to each other preferably comprises both the arrangement of the plurality of photovoltaic modules essentially on top of each other and the arrangement of the plurality of photovoltaic modules next to each other, wherein these are inclined at least at a certain angle, for example by at least 5°, so that the second connecting section can rest on the surface of an adjacent module assembly.

[0040] Another preferred embodiment is characterized in that the first connecting section has at least one recess for connecting the module carrier to the plurality of photovoltaic modules. This enables a connection between the at least one module carrier and the plurality of photovoltaic modules that is advantageous from an assembly perspective.

[0041] Preferably, the module assembly further comprises at least one connecting element, wherein the at least one connecting element can be arranged in the at least one recess of the first connection section. The at least one connecting element advantageously enables a connection, in particular a clampable connection, between each photovoltaic module and the at least one module support or the at least one mounting profile.

[0042] A preferred embodiment is characterized in that the at least one connecting element is designed as at least one clamping element. Preferably, the at least one clamping element is designed essentially as a U-profile comprising at least two legs, each of which has at least one recess. This enables a reliable connection between the majority of photovoltaic modules and the at least one module carrier or the at least one mounting profile. Preferably, the at least one recess is formed on the end faces of the two legs. The inner side surfaces of the recess preferably have a ribbed texture, which improves the clamping effect of the at least one clamping element.

[0043] For example, at least one mounting profile has at least one projection and / or at least one recess in which at least one connecting element, in particular at least one clamping element, can be arranged. Equipotential bonding and / or a locking function can also be enabled by means of at least one projection.

[0044] Clamping function, such as that which at least one connecting element enables.

[0045] Another preferred embodiment is characterized in that the at least one mounting profile, in particular the second connecting section of the at least one mounting profile, has at least one retaining element, in particular at least one hook-shaped retaining element, and is in particular connected to a retaining element, wherein the at least one module assembly can be secured to at least one substructure by means of the at least one retaining element. In particular, the at least one module assembly can be secured in its position by means of the at least one retaining element after being placed on the substructure, and lateral guidance can be enabled. For example, final assembly of the module assemblies on the substructure can then be carried out manually or automatically.

[0046] A preferred embodiment is characterized in that the first connecting section and / or the second connecting section extends at least partially along a plane of extension, wherein the plane of extension in the assembled state of the module assembly essentially corresponds to the plane in which the majority of photovoltaic modules essentially extend. This provides the first connecting section with an area that serves as a mounting surface for the individual photovoltaic modules. With regard to the second connecting section, an area can be provided which, due to its direction of extension, enables a mounting surface for stacking the majority of photovoltaic modules on top of or next to each other.

[0047] A preferred embodiment is characterized in that the first connecting section and / or the second connecting section extends at least partially orthogonally to a plane of extension, wherein the plane of extension in the assembled state of the module assembly essentially corresponds to the plane in which the majority of photovoltaic modules essentially extend. A substantially orthogonal extension of the first connecting section and / or the second connecting section provides a stop surface that enables the fixing of at least one mounting profile to the respective module support or to each other.

[0048] A preferred embodiment is characterized in that the mounting profile has a third connecting section, wherein the third connecting section connects the first connecting section and the second connecting section, and wherein the third connecting section extends at least partially obliquely to a plane of extension, the plane of extension in the assembled state of the module assembly essentially corresponding to the plane in which the majority of photovoltaic modules essentially extend. By providing at least one third connecting section, a spacer between the first connecting section and the second connecting section can be advantageously provided in a structurally advantageous manner.

[0049] For example, at least one mounting profile for realizing the first connection section, the second connection section and / or the third connection section may have an essentially S-shaped cross-sectional profile, an essentially E-shaped cross-sectional profile or an essentially W-shaped cross-sectional profile.

[0050] Another preferred embodiment is characterized in that the second connecting section comprises at least one through-hole, wherein the second connecting section can be connected, by means of the at least one through-hole, to at least one substructure mounted on a substrate and / or to at least one further module assembly. This enables reliable final assembly of the at least one module assembly onto at least one substructure. Another preferred embodiment is characterized in that the plurality of photovoltaic modules each have two spaced-apart mounting profiles on their underside, wherein the module assembly comprises at least two module carriers, and wherein a first connecting section of a mounting profile of a module carrier can be connected to a mounting profile of the plurality of photovoltaic modules.This enables reliable mounting of the majority of photovoltaic modules with at least one module carrier.

[0051] According to a third aspect, the aforementioned task is solved by at least one module carrier, wherein the at least one module carrier comprises at least one of the aforementioned mounting profiles.

[0052] According to a fourth aspect, the aforementioned task is solved by at least one system comprising a plurality of the aforementioned modular assemblies.

[0053] Further advantageous exemplary embodiments of the invention can be found in the following detailed description of some exemplary embodiments of the present invention, particularly in conjunction with the figures. However, the figures accompanying the application are intended only for illustrative purposes and not to define the scope of protection of the invention. The accompanying drawings are not necessarily to scale and are intended only to reflect the general concept of the invention by way of example. In particular, features included in the figures should by no means be considered a necessary component of the present invention. The sequence of the individual steps in the illustrated process summaries does not necessarily represent the actual (chronological) sequence of the steps and is merely exemplary.Nevertheless, the steps can occur / be carried out in exactly the sequence shown in the process overviews. Furthermore, they can be, but do not have to be, carried out in response to one another. This shows:

[0054] Fig. aa shows a first embodiment of a method for mounting a plurality of photovoltaic modules on at least one substrate in a schematic representation;

[0055] Fig. 1b shows a second embodiment of a method for mounting a plurality of photovoltaic modules on at least one substrate in a schematic representation;

[0056] Fig. 2 shows a third embodiment of a method for mounting a plurality of photovoltaic modules on at least one substrate in a schematic representation;

[0057] Fig. 3 shows a perspective view of an embodiment of a plurality of modular assemblies on a substructure;

[0058] Fig. 4 shows a detail of a sectional view along the section line IV shown in Fig. 3;

[0059] Fig. 5 shows a perspective view of an embodiment of a plurality of modular assemblies on a frame of a transport unit;

[0060] Fig. 6 shows a sectional view along the section line VI shown in Fig. 5;

[0061] Fig. 7a shows a perspective view of the underside of a modular assembly in a schematic view;

[0062] Fig. 7b is a detailed view of detail VII b shown in Fig. 7a; Fig. 7c is a sectional view along the section line VII c shown in Fig. 7a;

[0063] Fig. 8a shows a sectional view of a first embodiment of a mounting profile;

[0064] Fig. 8b shows a sectional view of a second embodiment of a mounting profile;

[0065] Fig. 8c shows a sectional view of a third embodiment of a mounting profile;

[0066] Fig. 8d shows a sectional view of a fourth embodiment of a mounting profile; and

[0067] Fig. 8e shows a sectional view of a fifth embodiment of a mounting profile.

[0068] Fig. 1 a shows a first embodiment of a method for mounting a plurality of photovoltaic modules 10 on at least one substrate in a schematic representation.

[0069] In a first step 1, the individual photovoltaic modules 10 are delivered, for example, by truck 11. These are initially still packaged. Subsequently, the delivered photovoltaic modules 10 are unloaded, for example, by a forklift 12, and can be stored in a subsequent optional step 2.

[0070] Subsequently, the delivered photovoltaic modules 10 are pre-assembled in a so-called "field factory" 13 in step 3. For this purpose, in addition to the majority of photovoltaic modules 10, a majority of module carriers 14 are fed into the field factory 13, so that the majority of photovoltaic modules 10 and the majority of module carriers 14 can be pre-assembled in the field factory 13. The pre-assembly in the field factory 13 can be carried out, for example, by means of a manipulation robot 16 and additionally, at least partially, manually by workers 18. In the field factory 13, the majority of photovoltaic modules 10 and the majority of module carriers 14 are pre-assembled into module assemblies 20. A module assembly 20 is shown, in which the last photovoltaic module 10 is currently being mounted.

[0071] Subsequently, a plurality of pre-assembled module assemblies 20 are transported by means of a transport unit 22 to a pre-assembly position 24. At the pre-assembly position 24, the plurality of module assemblies 20 are mounted on a substructure 26 in step 4a.

[0072] The substructure 26 essentially comprises two longitudinally extending longitudinal beams 28. The majority of the module assemblies 20 are removed from the transport unit 22 by means of a manipulator 30 of a laying vehicle 32 and transported to a (final) assembly position 33. It can be seen that the laying vehicle 32 moves laterally outside the two longitudinal beams 28 for this purpose. The manipulator 30 then places the respective module assembly 20 onto the substructure 26 in the final assembly position 33.

[0073] The method shown in Fig. 1b essentially corresponds to the method shown in Fig. 1a for mounting a plurality of photovoltaic modules, except that in step 4b the installation vehicle 32 does not move laterally outside the two longitudinal beams 28, but rather inside the two longitudinal beams 28. Otherwise, the two methods shown are essentially identical.

[0074] Fig. 2 shows a third embodiment of a method for mounting a plurality of photovoltaic modules 10 on at least one substrate in a schematic representation. The mounting of the plurality of module assemblies 20 on the at least one substructure 26 differs from the embodiments in Figs. 1a and 1b by step 4c. The module assemblies 20 are first placed at a pre-assembly position 24 on an end face 34 of the substructure 26. This can be done, for example, using a manipulator or manually by workers 18. Subsequently, the module assemblies 20 are transported from the pre-assembly position 24, at least partially, by means of the substructure 26 to the respective final assembly position 33.

[0075] Fig. 3 shows a perspective view of an embodiment of a plurality of module assemblies 20 mounted on a substructure 26. Each plurality of module assemblies 20 comprises three photovoltaic modules 10. The plurality of module assemblies 20 are mounted on longitudinal beams 28 of a substructure 26 by means of module carriers 36, each comprising two mounting profiles 38. The longitudinal beams 28 are fastened to a substrate (not shown) by means of a plurality of posts 40.

[0076] Fig. 4 shows a detail of a sectional view along the section line 1V-1V shown in Fig. 3. The structure of a module assembly 20 can be seen from this view. A mounting profile 38 of a module carrier 36 is arranged on the longitudinal side of each module assembly 20. The mounting profile 38 comprises a first connecting section 44 for connecting the mounting profile 38 to the mounting profiles 52 of the photovoltaic modules 10, a second connecting section 46 for connecting the mounting profile 38 to the substructure 26, and a third connecting section 48 for connecting the first connecting section 44 to the second connecting section 46.

[0077] The first connecting section 44 of the mounting profile 38 is attached to a profile 52 of a photovoltaic module 10 by means of a connecting element 50 in the form of a clamp. Furthermore, the second connecting section 46 of the mounting profile 38 has a through-hole to which a hook-shaped retaining element 56 is connected by means of a connecting element 54, wherein one module assembly 20 can be secured to the substructure 26 by means of the at least one retaining element 56.

[0078] Fig. 5 shows a perspective view of an embodiment of a plurality of modular assemblies 20 on a frame 58, which can be arranged, for example, on a transport unit 22.

[0079] Fig. 6 shows a sectional view along section line VI shown in Fig. 5. It can be seen that the second connecting section 46 and the retaining means 56 are designed such that they rest on a surface 60 or a side surface 62 of an adjacent module assembly 20, in particular on a surface 60 or a side surface 62 of adjacent photovoltaic modules 10, so that the individual module assemblies 20 can be stacked on top of or next to each other.

[0080] Fig. 7a shows a perspective view of a bottom surface 64 of a module assembly 20. As previously described, the module assembly 20 comprises three photovoltaic modules 10 and two mounting profiles 38, the mounting profiles 38 extending along the outer longitudinal sides 66 of the module assembly 20 in the longitudinal direction of the module assembly 20. Preferably, the longitudinal sides 66 and the transverse sides 67 of the module assembly 20 define a plane of extension of the module assembly 20.

[0081] As shown in Fig. 7b, the mounting profiles 38 have recesses 68 for receiving the fasteners 50. The fastener 50 has a U-shaped profile with two legs 69, each leg 69 having a recess 72 on one end face 71. The inner side surfaces of the recess 72 also have a ribbed texture 74, which improves the clamping effect of the at least one clamping element / fastener 50. Figs. 8a to 8e show sectional views of further embodiments of a mounting profile 38. For example, the mounting profiles 38 have a substantially E-shaped cross-sectional profile (Fig. 8c), which is a mirror image of a conventional E. In addition, the cross-sectional profile shown in Fig. 8c has a projection 70 for attaching a fastener 50 or for equipotential bonding.Regarding the detailed design of the further embodiments shown in Figs. 8a to 8e, reference is made to the figures.

[0082] The exemplary embodiments / exemplary embodiments of the present invention described in this specification are to be understood as disclosed in all combinations with one another. In particular, the description of a feature encompassed by an embodiment—unless explicitly stated otherwise—is not to be understood as meaning that the feature is indispensable or essential for the function of the exemplary embodiment. The sequence of the process steps described in this specification is not mandatory; alternative sequences of process steps are conceivable.All disclosures in this specification are to be understood with regard to all categories of device, method, and computer program, such that, for example, the description of a method step also discloses a corresponding device that includes means for carrying out and / or controlling the method step, and a corresponding device that is configured to control and / or carry out the method step.

[0083] Terms used in the claims, such as "comprise," "have," "include," "contain," and the like, do not exclude further elements or steps. The phrase "at least partially" covers both "partially" and "completely." The phrase "and / or" should be understood to mean that both the alternative and the combination are disclosed; thus, "A and / or B" means "(A) or (B) or (A and BJ)." A plurality of units, persons, or the like, in the context of this specification, means multiple units, persons, or the like. The use of the indefinite article does not preclude a plurality. A single device can perform the functions of several units or devices mentioned in the claims. Reference numerals specified in the claims are not to be considered as limitations on the means and steps employed.

[0084] Reference symbol list

[0085] 1 First step of the assembly process

[0086] 2 Second, optional step of the assembly process

[0087] 3 Third step of the assembly process

[0088] 4 Fourth step of the assembly process

[0089] 10 photovoltaic modules

[0090] 11 trucks

[0091] 12 forklifts

[0092] 13 Field Factory

[0093] 14 module carriers

[0094] 16 manipulation robots

[0095] 18 workers

[0096] 20 modular assembly

[0097] 22 transport units

[0098] 24 Pre-assembly position

[0099] 26 Substructure

[0100] 28 longitudinal beams

[0101] 30 Manipulator

[0102] 32 laying vehicle

[0103] 33 Final assembly position

[0104] 34 Front side of the substructure

[0105] 36 module carriers

[0106] 38 Mounting profile

[0107] 40 posts

[0108] 44 first connecting section

[0109] 46 second connecting section

[0110] 48 third connecting section

[0111] 50 fasteners

[0112] 52 Profile of a photovoltaic module

[0113] 54 connecting element 56 holding means

[0114] 58 Frame of a transport unit

[0115] 60 Surface area of ​​a modular assembly

[0116] 62 Side surface of a modular assembly 64 Underside of a modular assembly

[0117] 66 Long side of a modular assembly

[0118] 67 Cross side of a modular assembly

[0119] 68 Recess of a mounting profile

[0120] 69 Legs of the connecting element 70 Display of a mounting profile

[0121] 71 End face of the fastener

[0122] 72 Recess of the connecting element

[0123] 74. Grooving of the connecting element

Claims

Patent claims 1. Method for mounting a plurality of photovoltaic modules on at least one substrate comprising the following steps: Providing a plurality of photovoltaic modules and a plurality of module carriers; wherein each module carrier comprises at least one mounting profile; Pre-assembly of a plurality of photovoltaic modules and a plurality of module carriers into a plurality of module assemblies; wherein each module assembly comprises a plurality of photovoltaic modules and at least one module carrier; and wherein the plurality of photovoltaic modules are connected to one another by means of the at least one module carrier, in particular by means of the at least one mounting profile of the at least one module carrier; Storage, in particular stacked storage, of the majority of module assemblies on at least one transport unit; wherein the mounting profiles of the majority of module carriers are designed in such a way that the majority of module assemblies can be stacked at least partially on top of and / or next to each other; and Transport of the majority of modular assemblies, in particular by means of at least one transport unit, to at least one assembly position; assembly of the majority of modular assemblies on at least one substructure fixed to a substrate.

2. The method according to claim 1, wherein the pre-assembly further comprises: at least partially automated pre-assembly of the plurality of photovoltaic modules and the plurality of module carriers into a plurality of module assemblies by means of at least one manipulation robot; wherein Preferably, the majority of photovoltaic modules and / or the majority of module carriers have an indexing system, wherein the position of the majority of photovoltaic modules and / or the majority of module carriers is detected by means of an indexing system using at least one sensor; preferably, automated loading of a pre-assembly station by means of at least one manipulation robot; wherein, in particular, the majority of module carriers and / or the majority of photovoltaic modules are automatically fed to the pre-assembly station by means of the manipulation robot.

3. Method according to claim 1 or 2, wherein the pre-assembly further comprises: connecting the plurality of photovoltaic modules and the plurality of module carriers to form a plurality of module assemblies by means of a positive-locking, force-locking and / or friction-locking connection, in particular by means of a plurality of connecting means; and / or automated feeding of the plurality of connecting means, in particular by means of a pre-assembled magazine.

4. Method according to any one of claims 1 to 3, wherein the pre-assembly further comprises: Capturing the majority of photovoltaic modules and / or the majority of module carriers; and Comparing the recorded majority of photovoltaic modules and / or the recorded majority of module carriers with reference values ​​stored in a database; and optionally outputting an error signal if the recorded dimensions of the majority of photovoltaic modules and / or the recorded dimensions of the majority of module carriers are outside the reference values ​​stored in the database.

5. Method according to any one of claims 1 to 4, wherein the pre-assembly further comprises: Inserting and / or placing the majority of photovoltaic modules into at least one mounting profile, in particular into at least two mounting profiles; wherein the majority of photovoltaic modules are preferably fixed in a form-fitting manner after insertion and / or placement; and / or wherein the majority of photovoltaic modules are preferably fixed in a form-fitting manner by rotating the at least one mounting profile about an axis in the insertion direction of the at least one mounting profile.

6. A method according to any one of claims 1 to 5, wherein the plurality of module assemblies are mounted on the at least one substructure by means of at least one installation vehicle, wherein the at least one installation vehicle preferably recognizes the plurality of module assemblies on the at least one transport unit in a substantially automated manner; wherein at least one manipulator of the at least one installation vehicle preferably removes the plurality of module assemblies from the at least one transport unit in a substantially automated manner, and / or wherein the at least one manipulator removes the plurality of module assemblies from the at least one transport unit in particular by means of at least one vacuum suction element, by means of a form-fit and force-fit mechanical connection and / or by means of magnetic force.

7. Method according to any one of claims 1 to 6, wherein the at least one laying vehicle detects the at least one assembly position and / or the at least substructure, wherein the at least one manipulator transports at least one module assembly to the assembly position, wherein the at least one laying vehicle is preferably coupled to the at least one manipulator, in particular electronically or mechanically coupled, and wherein the at least one manipulator places the at least one module assembly in the assembly position on the substructure.

8. Method according to one of claims 1 to 7, wherein the plurality of module assemblies are manually and / or automatically attached to the at least one substructure by means of force-locking, material-locking and / or friction-locking.

9. Method according to any one of claims 1 to 8, wherein the module assemblies are each placed at a mounting position on the substructure, wherein the module assemblies are subsequently transported from the mounting position to the final assembly position at least partially by means of the substructure.

10. Method according to any one of claims 1 to 9, wherein the at least one transport unit transports the majority of the module assemblies along an elongated extension of the at least one substructure, wherein the module assemblies are placed on the substructure at their final assembly position.

11. Module assembly comprising: a plurality of photovoltaic modules (10) and at least one module carrier (14, 36), wherein the at least one module carrier (14, 36) comprises at least one mounting profile (38), wherein the mounting profile (38) has a first connecting section (44) for connecting the mounting profile (38) to the plurality of photovoltaic modules (10), and wherein the mounting profile (38) has a second connecting section (46) for connecting the mounting profile (38) to at least one substructure (26) attached to a substrate, characterized in that the second connecting section (46) is designed such that it can be stacked on the surface of a plurality of photovoltaic modules (10), in particular on the surface of a plurality of photovoltaic modules (10) of a further module assembly (20).

12. Module assembly according to claim 11, wherein the first connecting section (44) has at least one recess (68, 70) for connecting the module carrier (14, 36) to the plurality of photovoltaic modules (10), wherein the module assembly (20) further comprises at least one connecting means (50) and wherein the at least one connecting means (50) can be arranged in the at least one recess (68, 70) of the first connecting section (44).

13. Modular assembly according to claim 12, wherein the at least one connecting means (50) is designed as at least one clamping means, wherein the at least one clamping means (50) is essentially designed as a U-profile comprising at least two legs (69), wherein the at least two legs (69) each have at least one recess (72).

14. Modular assembly according to one of claims 11 to 13, wherein the at least one mounting profile (38) has at least one retaining means (56), in particular at least one hook-shaped retaining means (56), wherein the at least one modular assembly (20) can be secured to at least one substructure (26) by means of the at least one retaining means (56).

15. Module assembly according to one of claims 12 to 14, wherein the first connecting section (44) and / or the second connecting section (46) extends at least partially along a plane of extension, and / or wherein the first connecting section (44) and / or the second connecting section (46) extends at least partially orthogonally to a plane of extension, and / or wherein the mounting profile (38) has a third connecting section (48), wherein the third connecting section (48) connects the first connecting section (44) and the second connecting section (46) to each other, wherein the third connecting section (48) preferably extends at least partially obliquely to a plane of extension, wherein the plane of extension in the assembled state of the module assembly (20) essentially corresponds to the plane in which the plurality of photovoltaic modules (10) and / or the module assembly (20) essentially extend.

16. Module assembly according to one of claims 11 to 15, wherein the second connecting section (46) comprises at least one through-hole, wherein the second connecting section (46) can be connected by means of the at least one through-hole to at least one substructure (26) mounted on a substrate and / or to at least one further module assembly (20), and / or wherein the plurality of photovoltaic modules (10) each have two spaced-apart mounting profiles (52) on their underside (64), wherein the module assembly (20) comprises at least two module carriers (14, 36), and wherein a first connecting section (44) of a mounting profile (38) of a module carrier (14, 36) can be connected to a fastening profile (52) of the plurality of photovoltaic modules (10).

Images