Solar Canopy Cold-Rolled Structure for Reduced Wind Load Design
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Solution Overview
Problem
Current solar canopy systems face high costs due to secondary operations required for hot-rolled steel members and are not designed to utilize the advantages of cold-rolled members, as existing designs cannot support the load with feasible cold-rolling processes, leading to increased material and shipping costs.
Innovation Solution
A solar canopy system with a support structure design based on instantaneous time averaging of wind loading across non-parallel solar panels, allowing for the use of cold-rolled components by reducing the actual load applied to the structure, enabling the manufacturing of components using cold-rolling instead of hot-rolling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot-rolled steel members are used to support solar canopy structures, then the structural strength and wind load capacity are improved, but the material cost, fabrication cost, and secondary operation costs increase significantly
Solution Approach 1:
The patent changes the manufacturing parameters of steel members from hot-rolled to cold-formed processes. By optimizing the cold-formed member geometry and manufacturing parameters, the patent achieves sufficient structural strength for solar canopy applications while avoiding the high costs associated with hot-rolled steel fabrication, welding, and secondary operations
Solution Approach 2:
The patent applies local quality optimization by designing cold-formed steel members with specific geometric configurations tailored to the local structural requirements of solar canopy support. The members are engineered with optimized cross-sections and connection details that provide adequate strength at critical locations while minimizing material usage and fabrication complexity
2Ease of manufacture
If cold-rolled steel members are used to reduce fabrication costs, then the material and shipping costs decrease, but the structural members are not large enough to support the required wind loads
Solution Approach 1:
The patent applies segmentation by dividing the solar canopy structure into multiple cold-formed steel members arranged in truss or space frame configurations. By segmenting the structure into interconnected members with optimized geometries, the patent achieves the required overall wind load capacity while using smaller, cost-effective cold-formed components that can be manufactured and assembled more efficiently
Solution Approach 2:
The patent employs composite structural systems by combining multiple cold-formed steel members into integrated truss or space frame assemblies. This composite approach allows the structure to achieve higher load-bearing capacity than individual members could provide alone, while maintaining the cost advantages of cold-formed manufacturing throughout the system
3Strength
If hot-rolled members and custom truss members are used, then the structural capacity to support higher loading is improved, but the number of foundations and support points required increases
Solution Approach 1:
The patent segments the canopy support function across multiple slender cold-formed members arranged in truss or space frame configurations. This segmentation allows the structure to distribute and bear higher loads through composite action of multiple members, reducing the need for numerous heavy foundations while maintaining adequate support capacity
Solution Approach 2:
The patent transitions from two-dimensional planar trusses to three-dimensional space frame structures using cold-formed members. This dimensional change allows for more efficient load distribution through spatial geometry, achieving higher loading capacity with fewer support points and reduced foundation requirements compared to conventional planar configurations
Data Source
AI summary
A solar canopy has a solar panel assembly including a first solar panel coupled to a second solar panel and oriented non-parallel with respect to the second solar panel. A solar panel assembly support structure is coupled to the solar panel assembly. One or more components of the support structure are manufactured by cold rolling. The solar panel assembly has an effective solar-panel-assembly wind loading less than a sum of a first-solar-panel effective wind loading and a second-solar-panel effective wind loading determined individually. An actual load applied by the solar panel assembly to a solar-panel-assembly support structure coupled thereto when the solar panel assembly is subject to a wind loading is less than a design load for the solar panel assembly subject to the wind loading based on a sum of a first-solar-panel net pressure and a second-solar-panel net pressure determined independently.