Concentrator PV Module Transport Jig for Housing Deflection Control
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Solution Overview
Problem
Concentrator photovoltaic modules with resin frame bodies suffer from low rigidity, leading to deflection during assembly and transportation, which affects product tolerance and performance.
Innovation Solution
A method involving a transport jig with a support portion that contacts the peripheral edge of a metal bottom plate, fixing it to the frame body, and using a fixing member to secure the housing to the jig, preventing deflection by ensuring the frame and bottom plate are closely adhered and supported.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a resin frame body is used to suppress production cost, then production cost is reduced, but rigidity of the housing decreases leading to deflection during assembly and transportation
Solution Approach 1:
The housing is constructed as a composite structure combining a resin frame body with a metal bottom plate. The metal bottom plate is fixed to the resin frame body, creating a composite housing that leverages the low cost and ease of manufacture of resin while gaining the high rigidity and strength of metal, thereby resolving the contradiction between production cost and rigidity
Solution Approach 2:
The housing is divided into separate components: a resin frame body and a metal bottom plate, which are then assembled together. This segmentation allows each component to be optimized for its specific function (resin for cost-effectiveness, metal for rigidity) while working together as an integrated structure
2Ease of manufacture
If a resin frame body is used to suppress production cost, then production cost is reduced, but deflection during assembly and transportation increases affecting product tolerance
Solution Approach 1:
The composite housing structure with metal bottom plate provides the structural stability needed to maintain product tolerance during assembly and transportation, while the resin frame body keeps production costs low
Solution Approach 2:
The metal bottom plate is pre-fixed to the resin frame body to create a rigid base structure before the photovoltaic modules are assembled onto the housing, ensuring that the housing maintains its shape and tolerance requirements throughout the assembly process
3Ease of manufacture
If the bottom plate is made thin to suppress production cost, then production cost is reduced, but heat dissipation performance deteriorates
Solution Approach 1:
The metal bottom plate in the composite housing structure provides superior heat dissipation performance compared to a thin resin plate, while still maintaining cost-effectiveness. The metal material's high thermal conductivity ensures efficient heat dissipation from the photovoltaic modules
Data Source
AI summary
A method for manufacturing a concentrator photovoltaic module including: power generating elements whereon sunlight is concentrated by condenser lenses; and a housing accommodating the power generating elements. The housing includes a resin frame body, a metal bottom plate closing a bottom-side opening of the frame body and an inner surface wherein power generating elements are disposed. The method includes: a peripheral edge of the inner surface of the bottom plate connected to a bottom end surface of the frame body, fixing the bottom plate to the frame body creating the housing; and fixing the housing to a transport jig for transporting the housing horizontally. The transport jig includes a support portion corresponding to the bottom end surface of the frame body, and supports the housing. The housing is fixed to the transport jig, with the support portion attached to a peripheral edge of an outer surface of the bottom plate.