Solar module array pre-assembly method and apparatus
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Solution Overview
Problem
Existing solar canopy installation methods are inefficient and costly due to the lack of assembly efficiency, high labor costs, and limitations in the size of solar modules that can be physically handled, leading to cumbersome and dangerous installation processes, especially in elevated and non-standard sites.
Innovation Solution
A pre-assembly apparatus and method for aligning and supporting solar panels, featuring a support member, arm members, and a track member that allow for the efficient alignment and attachment of solar panels, enabling their electrical connection and easy transportation, which reduces installation costs and enhances safety by allowing for pre-assembly on the ground before site installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If solar panels are assembled and installed directly at elevated sites using traditional methods, then installation can be completed on-site, but the process becomes cumbersome and dangerous due to work at elevated heights and limited module size handling
Solution Approach 1:
The patent applies preliminary action by pre-assembling solar panels into complete arrays on the ground before transportation. The support structure, panels, and wiring are all assembled in advance at ground level, eliminating the need for dangerous elevated work during installation. The pre-assembled array is then transported as a single unit to the final elevated location and installed efficiently.
2Productivity
If solar modules are made larger to reduce the number of panels needed, then fewer panels must be handled, but the modules exceed the physical carrying capacity of contractors
Solution Approach 1:
The patent merges multiple individual solar panels and their support structures into a single integrated pre-assembled array. By combining panels, mounting hardware, and electrical connections into one unified structure that can be handled as a single unit, the system enables installation of larger effective capacity without exceeding contractor carrying limits.
3Reliability
If traditional installation methods are used with union labor requirements, then labor standards are met, but installation costs amount to around 25% of the overall project cost
Solution Approach 1:
The patent reduces installation costs by performing assembly operations in advance at ground level where efficient labor practices can be used. The pre-assembly process completes complex tasks including panel mounting, wiring, and structural attachment before transportation, minimizing the need for expensive union labor at the final installation site while maintaining quality standards.
Data Source
AI summary
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 for horizontally aligning side-by-side and horizontally supporting a plurality of solar panels and a support member extending upward from the base 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 pivotally attached proximate to opposing ends of the base member or support member.