Solar Panel Mounting With Aerodynamic Ballast Trays for Wind Stability
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Solution Overview
Problem
Existing solar panel mounting systems are costly and complex, with a need for simplified structural components that provide sufficient strength to support solar panels, wind ballast trays, and ballast blocks while maintaining stability and electrical conductivity.
Innovation Solution
A tubular component mounting system with curved portions and deflector elements, formed from electrically conductive materials like aluminum or steel, which can be bent into desired shapes to support solar panels at specific angles and include features like channels for ballast weights and security tabs to prevent sliding, and foot elements for surface protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional mounting systems are used, then structural strength is sufficient, but material cost and complexity increase
Solution Approach 1:
The mounting system is divided into separate functional components: support members for structural support, deflector elements for wind management, and ballast trays for weighting. This segmentation allows each component to be optimized independently, reducing overall complexity while maintaining strength.
Solution Approach 2:
The patent extracts the wind deflection function from the structural support function by adding separate deflector elements. This allows the support members to focus on strength while deflectors handle wind forces, reducing the complexity requirement for the support members themselves.
2Quantity of substance
If support members are made thinner to reduce cost, then material cost decreases, but structural strength and stability deteriorate
Solution Approach 1:
Ballast trays with weights are introduced to counteract the reduced structural strength from thinner support members. The ballast provides downward force that stabilizes the mounting system against wind uplift, allowing thinner support members while maintaining overall stability.
Solution Approach 2:
The patent converts the potential harm of thin, flexible support members into a benefit by using aerodynamic deflectors that channel wind flow to create downward pressure on the solar panels, and ballast weights that utilize gravitational force to counteract wind uplift on the lighter structure.
3Object-affected harmful factors
If deflector elements are added to reduce wind impact, then stability against wind improves, but device complexity increases
Solution Approach 1:
The deflector elements are merged with the support member structure, where the support members double as aerodynamic surfaces. This integration reduces the number of separate components needed while still providing wind deflection functionality.
Solution Approach 2:
The support members are designed to serve multiple functions: structural support, aerodynamic deflection, and electrical grounding. This multi-functionality reduces the need for separate dedicated components, thereby reducing overall system complexity despite adding wind protection capabilities.
4Ease of manufacture
If tubular components with bends are used, then ease of manufacture improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies acceptable ranges for bend radii (e.g., 1.5 to 2.5 inches) rather than requiring exact precision. This parameter change allows standard fabrication tolerances to be used, making manufacturing easier while still achieving the required aerodynamic and structural performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system reduces material costs and complexity while providing structural integrity to support solar panels and ballast weights, enhancing stability against winds and ensuring electrical conductivity, with the ability to withstand high wind speeds and maintain panel orientation for optimal energy capture.
Implementation Method 1
the angled support members and deflector elements redirect wind flow to create downward aerodynamic force on the solar panels
Implementation Method 2
The tubular component can include an electrically conductive material configured to provide an electrical path from the one or more solar panel modules to earth ground
Data Source
AI summary
Systems and methods for mounting one or more solar panels are disclosed. A tubular component can be provided. The tubular component can include a first curved portion configured to rise to a first height above and extending along a length of the tubular component. The first curved portion can have a predetermined diameter, a predetermined thickness, and a predetermined bend radius selected to support a first solar panel module attached by a first end at a first attachment point positioned at the first height. The first curved portion can include an elongated leg configured to support a deflector element projecting outwardly at a predetermined angle to the mounting surface. The tubular component also can include a distal end having a second curved portion configured to rise to a second height above and extending along the length of the tubular component. The distal end can have a second attachment point at the second height. The second attachment point can be separated from the first attachment point by a predetermined distance and can be configured to support a second end of a second solar panel module at a predetermined tilt.