Deployable PV Assembly Stiffening for Compact Solar Transport
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ground mount photovoltaic assemblies for large-scale solar energy collection face challenges in shipping and installation due to their large size and complex assembly requirements, leading to high shipping costs and environmental impact, as well as susceptibility to wind forces without adequate structural integrity.
Innovation Solution
A compact PV assembly design featuring a perimeter frame with a stiffening device that can be transitioned between a shipping state and a deployed state, allowing for pre-assembled shipping and enhanced structural integrity, with a shipping density of at least 100 kWp per container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If PV assemblies are delivered in a pre-assembled state, then installation time is reduced, but shipping footprint increases and shipping costs increase
Solution Approach 1:
The PV assembly is divided into modular components: a base frame with PV laminates and a separate stiffening device. The stiffening device can be folded or detached during shipping to reduce volume, then assembled at the installation site to provide structural support. This segmentation allows compact shipping while enabling complete assembly for reduced installation time.
Solution Approach 2:
The stiffening device is designed to nest within or attach to the base frame in a compact configuration during shipping. The stiffening members can be folded flat against the frame or stored in dedicated compartments, allowing the entire assembly to fit within standard shipping containers without requiring excessive space, thus reducing shipping footprint while maintaining pre-assembled benefits.
2Volume of moving object
If PV assemblies are delivered in an unassembled state, then shipping footprint is reduced, but installation complexity increases and installation time increases
Solution Approach 1:
The PV laminates are pre-assembled to the base frame in a controlled manufacturing environment before shipping. This preliminary assembly of the core components reduces on-site installation complexity to primarily attaching the stiffening device, while still allowing compact shipping configuration. The pre-assembly ensures proper alignment and connection of critical components.
Solution Approach 2:
The stiffening device is designed with self-aligning features and simplified connection mechanisms that enable easy attachment to the base frame at the installation site. The design incorporates features such as pre-drilled holes, matching interfaces, and intuitive assembly sequences that reduce the need for complex tools or specialized skills, thereby reducing installation complexity while maintaining compact shipping.
3Strength
If PV assemblies use robust stiffening components for wind resistance, then structural integrity is improved, but device complexity increases and shipping footprint increases
Solution Approach 1:
The stiffening device is designed to be dynamic rather than static, allowing it to be in a compact, low-profile configuration during shipping and then deployed to a full structural configuration at the installation site. This dynamic transformation enables the structure to provide maximum wind resistance when needed while minimizing shipping footprint and assembly complexity through a straightforward deployment process.
Solution Approach 2:
The stiffening members are designed as thin, flexible elements that can be folded or rolled during shipping but provide rigid structural support when deployed. These thin-walled structures or flat panels can be easily stored in compact form and then assembled to create the necessary structural integrity for wind resistance, reducing both shipping footprint and assembly complexity compared to traditional bulky stiffening components.
4Strength
If PV assemblies use robust stiffening components for wind resistance, then structural integrity is improved, but shipping costs increase
Solution Approach 1:
By segmenting the stiffening device into separate, foldable components that can be compacted during shipping, the overall shipping volume is reduced. This allows more efficient container loading and reduced number of transport vehicles required, thereby reducing shipping costs while maintaining the structural integrity benefits of robust stiffening components when deployed.
Solution Approach 2:
The stiffening device nests within the base frame or attaches in a compact configuration during shipping, maximizing space utilization in transport containers. This nesting capability reduces the number of shipments required and optimizes container loading efficiency, leading to reduced shipping costs while ensuring the stiffening components are available to provide necessary structural integrity at the installation site.
Data Source
AI summary
A PV assembly including framework, PV laminate(s), and a stiffening device. The framework includes a perimeter frame at least 10 feet in length and at least 5 feet in width. The PV laminate(s) are assembled to the perimeter frame to define a receiving zone having a depth of not more than 8 inches. The stiffening device is associated with the framework and is configured to provide a first state and a second state. In the first state, an entirety of the stiffening device is maintained within the receiving zone. In the second state, at least a portion of the stiffening device projects from the receiving zone. The stiffening device enhances a stiffness of the PV assembly in a plane of the perimeter frame, and can include rods defining truss structures.