Pre-assembly based installation for a single axis solar tracker
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Solution Overview
Problem
Conventional solar panel mounting structures for single axis solar trackers require on-site assembly and electrical connection at elevated heights, necessitating the use of fall protection and increasing installation time, particularly for 2-Up Portrait trackers.
Innovation Solution
A method involving the assembly of a solar panel assembly with parallel beams, purlins, and a semicircular ring, which is then transported and rotated into place using a pin connection to a post, allowing for ground-level assembly and reducing the need for fall protection by minimizing on-site connections to three key points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solar panel mounting structure is fully assembled at operating position piece-by-piece, then structural stability is ensured, but installation time increases and fall protection is required
Solution Approach 1:
The mounting structure is pre-assembled into modular sections at ground level before transport to the installation site. This preliminary assembly action eliminates the need for time-consuming piece-by-piece assembly at height, while the pre-assembled modules maintain structural stability when installed
Solution Approach 2:
The mounting structure is divided into separate modular sections that can be assembled independently at ground level. These segments are then transported and connected at the installation site, reducing installation time while maintaining overall structural integrity through standardized connection interfaces
2Reliability
If mechanical assembly and electrical connection are performed at elevated height, then proper installation is achieved, but fall protection equipment is required increasing complexity
Solution Approach 1:
All mechanical assembly operations are performed preliminarily at ground level where fall protection is not required. The pre-assembled modules are then lifted into position and connected, separating the complex assembly tasks from elevated work zones and eliminating fall protection requirements
Solution Approach 2:
The installation process is segmented into ground-level assembly operations and elevated connection operations. By completing the complex mechanical assembly at ground level and transporting complete modules, the need for fall protection during assembly is eliminated, while only simple connection operations remain at elevation
3Reliability
If complete assembly is performed on-site, then structural integrity is maintained, but installation productivity decreases
Solution Approach 1:
The mounting structure sections are assembled in advance at ground level in a controlled environment, allowing for higher productivity through efficient assembly operations. The pre-assembled sections maintain structural integrity and are quickly installed at the site, significantly improving overall installation productivity
Solution Approach 2:
The structure is segmented into modular sections that can be assembled independently and in parallel, increasing productivity. The standardized interfaces ensure structural integrity when sections are connected, while the modular approach enables faster installation compared to complete on-site assembly
Data Source
AI summary
A method of installing a solar panel assembly that includes a first beam, a second beam and a third beam where the first and second beams are parallelly spaced and perpendicular to the third beam, and further includes a plurality of purlins, a semicircular ring fastened to the third beam, and a plurality of photovoltaic panels between adjacent ones of the plurality of purlins to form the solar panel assembly, the method comprising lifting the solar panel assembly and rotatably attaching it to a post by inserting a pin into a first bore in a flange extending from the third beam and into a second bore in the post, where the first and second bores are coaxial such that the solar panel assembly has a range of rotational motion about the pin, and fastening proximate and distal ends of the first and second beams to distal and proximate ends of adjacent solar panel assemblies.