Perimeter Cable Support for Low-Load Rooftop Solar Arrays
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Solution Overview
Problem
Traditional solar module installation methods require heavy rack systems that exceed the static load capacity of roofs, causing damage and increasing costs due to the need for multiple anchoring points, labor, and material expenses, while existing cable structures are costly and require additional racks and ballasts.
Innovation Solution
A cable support structure using latitudinal cables anchored on the roof's perimeter, distributing the weight of solar modules without the need for a traditional rack system, combined with an auto-trigger hook for fast and secure attachment, and elastic elements to manage wind loads, reducing material and labor costs and minimizing roof damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional rack system is used to support solar modules, then the solar modules can be securely mounted, but the static load on the roof exceeds its capacity causing damage
Solution Approach 1:
The patent extracts the heavy rack system from the mounting structure and replaces it with a cable-based support system. The cables are anchored to the roof perimeter (walls) rather than requiring multiple heavy anchorages throughout the roof surface, thereby reducing the overall static load while maintaining secure mounting capability.
Solution Approach 2:
The patent transitions from a two-dimensional rack system lying flat on the roof to a three-dimensional cable system that utilizes the vertical dimension by anchoring to the roof perimeter walls. This dimensional change allows weight distribution along the roof perimeter rather than concentrating load on the roof surface.
2Reliability
If multiple anchoring points are created on the roof for the rack system, then the mounting is more secure, but the roof membrane is damaged and requires sealing increasing costs
Solution Approach 1:
The patent removes the need for multiple roof penetrations by anchoring the cable system to the roof perimeter walls instead of creating multiple contact points on the roof membrane. This extraction of the anchoring function to the perimeter eliminates membrane damage at multiple locations.
Solution Approach 2:
Instead of anchoring the support system to the roof surface (traditional approach), the patent inverts the anchoring strategy by securing cables to the roof perimeter walls. This inversion moves the anchoring points from the vulnerable roof membrane to the more robust perimeter structure.
3Weight of stationary object
If a cable net structure is used to support solar modules, then the weight distribution is improved, but the cost increases due to the large number of expensive cables required
Solution Approach 1:
The patent segments the cable system into two functional groups: structural support cables (minimal number) for weight bearing and electrical cables for power transmission. This segmentation allows the use of fewer, larger-diameter structural cables rather than a dense network of smaller cables, reducing the total quantity of cable material required.
Solution Approach 2:
The patent combines structural support and electrical conduction functions into an integrated cable system. The same cables that provide mechanical support also serve as electrical conductors, eliminating the need for separate electrical wiring and reducing the total cable quantity compared to a dedicated structural cable net.
4Stability of the object's composition
If heavy ballasts are added to the rack system, then the mounting becomes more stable, but the overall weight exceeds the roof's static load capacity
Solution Approach 1:
The patent extracts and eliminates the ballast component from the mounting system entirely. Instead of adding heavy counterweights to achieve stability, the cable system achieves stability through proper anchoring to the roof perimeter walls, which provide inherent structural stability without requiring additional weight.
Solution Approach 2:
The patent replaces the ballast counterweight approach with an anchoring-based counterforce system. The cables are anchored to the roof perimeter walls, which provide reaction forces to counterbalance the weight and wind loads of the solar modules, eliminating the need for additional ballast weight.
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
Enables efficient and cost-effective installation of solar modules on roofs with limited static load capacity by distributing weight along the roof perimeter, eliminating the need for heavy racks and anchoring holes, and reducing wind pressure through elastic deformation, thus lowering overall installation costs and preventing roof damage.
Implementation Method 1
While existing wind pressure, the elastic portion will be elastically deformed, which decreases the angle between the panels or solar modules and the direction of wind to decrease the wind pressure acting on the panels or solar modules.
Data Source
AI summary
A cable support structure, used in a solar application or other applications, comprising a cable structure which comprises latitudinal cables extending between two sides of an enclosure of a roof, panels or solar modules being arranged in a row on the latitudinal cables forming an array supported by the cable structure, the cable structure in turn being supported by the sides of the enclosure in such a way that weight of the array and force loads on the array are completely or partially distributed on the sides of the enclosure.