Solar Array Pallet Assembly for Pre-Assembled Transport Alignment
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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 pallet assembly system for pre-assembling and transporting solar panels, featuring a deck with feet, cross beams, and alignment beams to securely support and align solar panels, allowing for efficient storage, transport, and assembly, reducing installation complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solar panels are installed individually on-site, then installation flexibility is maintained, but installation costs increase and assembly efficiency decreases
Solution Approach 1:
The patent applies preliminary action by pre-assembling solar panels with support channels and electrical connections on a pallet before transport to the installation site. This pre-assembly includes attaching multiple solar panels to aluminum support channels, wiring them in series, and securing them to a pallet platform, thereby reducing on-site assembly time and labor costs while maintaining installation flexibility
Solution Approach 2:
The patent segments the solar installation system into modular units that can be independently assembled on pallets. Each module consists of solar panels mounted on support channels with pre-made electrical connections, allowing multiple modules to be transported separately and quickly assembled at the installation site, improving both efficiency and flexibility
2Quantity of substance
If larger solar panel arrays are used, then power production increases, but transport and handling become more difficult
Solution Approach 1:
The patent transitions from horizontal ground mounting to vertical wall mounting by designing support channels with vertical orientation capability. This dimensional change allows solar panels to be arranged in vertical arrays on pallets, increasing power production capacity per transport unit while maintaining manageable size and weight for handling and transport
Solution Approach 2:
The patent creates universal support channels that can accommodate different solar panel sizes and configurations. The aluminum support channels are designed with standardized dimensions and mounting features that work with various panel types, allowing flexible assembly of different array sizes on the same pallet platform, thus increasing capacity without compromising transportability
3Adaptability or versatility
If workers install panels at elevated heights, then land use efficiency improves, but safety risks increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling complete solar modules on ground-level pallets before transport. All electrical connections, mechanical attachments, and panel alignments are completed on the ground, eliminating the need for workers to perform assembly tasks at elevated heights and thereby reducing safety risks while maintaining the ability to install on vertical surfaces
Solution Approach 2:
The patent introduces the pallet assembly system as an intermediary that transfers pre-assembled solar modules from ground level to elevated installation positions. The pallet serves as a stable platform that can be safely positioned at height, and the pre-assembled modules can be secured to the pallet on the ground before being lifted, reducing worker exposure to hazardous elevated conditions
Data Source
AI summary
The invention is a pallet assembly for supporting an electrically connected array of a plurality of solar panels during storage and transport, the pallet manufacture including: a deck; a plurality of feet extending downward from the deck; a plate attached to an edge portion of the deck, for aligning the pallet assembly with an apparatus for building an electrically connected array of a plurality of solar panels; and at least one alignment bracket for aligning and preventing lateral movement of at least two solar panel support channels attached to the bottom of the electrically connected array of a plurality of solar panels.