Solar Array Pre-Assembly for Ground-Level Canopy Installation
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Solution Overview
Problem
Existing solar canopy installation methods are inefficient and costly due to high installation costs, limited module size, and hazardous conditions, particularly in developed areas where solar panels need to be elevated for multiple land uses.
Innovation Solution
A pre-assembly apparatus for solar panels includes a support member, arm members, and a track member that allow for the alignment and attachment of solar panels in an electrically connected array, enabling efficient assembly and transportation, with features like pivotable arm members and removable solar panel support channels to facilitate easier handling and reduced labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If solar panels are installed using traditional methods at elevated heights, then the solar panels can be placed over developed areas for multiple land uses, but the installation becomes hazardous and costly
Solution Approach 1:
The solar panels are pre-assembled into complete arrays on the ground at ground level before being transported to the installation site. This preliminary assembly action eliminates the need for workers to handle individual panels at elevated heights, thereby reducing installation hazards while still enabling installation over developed areas for multiple land uses
2Productivity
If solar panels are pre-assembled into arrays, then assembly efficiency improves and installation costs reduce, but the device complexity increases
Solution Approach 1:
The pre-assembly apparatus is designed with segmented, modular components including separate support members, arm members with grippers, and track members that can independently perform alignment and attachment functions. This segmentation allows each component to be simple in its individual function while collectively achieving complex pre-assembly operations, thereby improving assembly efficiency without excessively increasing overall device complexity
Solution Approach 2:
The arm members are designed with universal grippers that can accommodate different panel sizes and configurations. The support members and track members work together in a multi-functional system that can handle various array configurations. This universality allows a single apparatus design to improve assembly efficiency across multiple applications without requiring overly complex specialized components for each scenario
3Ease of operation
If traditional installation methods are used, then the installation process is straightforward, but the module size is limited by what a contractor can physically carry
Solution Approach 1:
By performing the assembly action in advance at ground level, the system eliminates the physical carrying limitation. Large modules that would be impossible to manually carry to elevated positions are instead assembled into complete arrays on the ground using the pre-assembly apparatus, then transported as complete units. This preliminary assembly action allows module sizes to exceed traditional carrying limits while maintaining operational simplicity through ground-level work
4Adaptability or versatility
If work is performed at elevated heights, then solar panels can be installed over developed areas, but the installation process becomes cumbersome and dangerous
Solution Approach 1:
The system performs all complex assembly actions at ground level before transportation. Complete solar arrays are pre-assembled, aligned, and secured on the ground using the apparatus, then transported to elevated installation locations as complete units. This preliminary action transfers all difficult operations from elevated heights to ground level, maintaining installation location flexibility while dramatically improving ease of operation
Solution Approach 2:
The pre-assembly apparatus acts as an intermediary system between ground-level assembly and elevated installation. It enables complete arrays to be assembled at ground level and then transported to elevated positions, serving as a mediator that decouples the assembly process from the installation location, thereby maintaining flexibility while improving operational ease
Data Source
AI summary
The present invention is directed to an apparatus for pre-assembly of an electrically connected array of solar panels for a solar canopy including a substantially planar base member for resting on a horizontal surface; a substantially planar support member; a track member disposed proximate a bottom portion of the support member attached to or integral with the support member or base member for vertically aligning side-by-side and vertically supporting a plurality of solar panels when a side edge portion of the solar panels rests on the track member; and at least two arm members, each having a free end and an attached end, the attached ends pivotally attached proximate to opposing ends of the base member or support member, the arm members being configured and adapted for removably attaching at least two solar panel support channels.