Ballast Tray Profiles for Wind-Resistant PV Module Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing PV module mounting systems are inefficient, costly, time-consuming, and potentially hazardous, often requiring custom fabrication, penetrating surfaces, and lacking adequate wind resistance and grounding capabilities.
Innovation Solution
A ballast system using weighted first and second ballast trays with distinct side profiles to secure PV modules, providing enhanced wind resistance and grounding without penetrating surfaces, and allowing for quick installation and compatibility with various module types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing mounting systems are used to secure PV modules, then wind resistance is adequate, but installation time is excessive and customization is required
Solution Approach 1:
The mounting system is divided into modular components: ballast trays with standardized configurations that can be independently assembled and adjusted. This segmentation allows workers to quickly assemble modules without custom fabrication while maintaining wind resistance through proper modular arrangement.
Solution Approach 2:
The ballast trays are designed with universal features that allow them to accommodate different PV module types and configurations without requiring custom fabrication. The standardized design enables the same basic component to serve multiple mounting scenarios, reducing installation time while maintaining adequate wind resistance.
2Reliability
If existing mounting systems are used, then PV modules can be secured, but surface penetration occurs causing damage
Solution Approach 1:
The system uses ballast trays filled with weight (ballast material) to create downward force that counteracts upward wind loads on PV modules. This counterweight approach secures modules without penetration, as the weight prevents lifting while distributing loads across the roof surface through the tray structure.
Solution Approach 2:
The ballast tray acts as an intermediary between the PV module and the roof surface. Instead of directly penetrating the roof membrane to secure modules, the tray distributes securing forces across a larger area and uses its weighted structure to prevent module movement, thereby protecting the roof surface while maintaining securing capability.
3Productivity
If traditional mounting systems are used, then installation can be completed, but cost is relatively expensive
Solution Approach 1:
The mounting system uses segmented, modular ballast trays that can be manufactured independently and assembled quickly on-site. This reduces manufacturing complexity and cost compared to custom-fabricated systems, while the modular nature enables rapid installation completion through standardized assembly procedures.
Solution Approach 2:
The ballast trays are designed as simple, inexpensive components that can be easily manufactured and replaced if needed. Their straightforward construction minimizes production costs while their durability ensures they remain functional throughout the PV system's operational life, achieving cost-effective installation completion.
4Reliability
If existing mounting systems are used, then PV modules can be mounted, but excessive space is occupied
Solution Approach 1:
The ballast trays are designed to be adaptable to different PV module configurations and array layouts. Their flexible positioning capability allows optimization of space utilization, enabling modules to be mounted with minimal spacing while maintaining secure attachment, thereby reducing the area occupied by mounting hardware.
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 ballast system efficiently secures PV modules with improved wind resistance, reduces installation time and cost, and ensures compatibility with different module models, while maintaining surface integrity and grounding capabilities.
Implementation Method 1
weighted first and second ballast trays with distinct side profiles to secure PV modules, providing enhanced wind resistance
Implementation Method 2
ballast system using weighted first and second ballast trays with distinct side profiles to secure PV modules
Data Source
AI summary
A ballast system includes a first ballast tray and a second ballast tray. The first ballast tray has a first side profile including a south leg connected to a north leg. The second ballast tray has a second side profile that is different than the first side profile. A length of the north leg of the second side profile is greater than a length of the south leg of the first side profile, and a height of the north leg of the second side profile is substantially equal to a height of the south leg of the first side profile. The north leg of the second side profile includes a curvature so as to partially curve toward the south leg of the second side profile.