Solar Panel Truss Mounting With Modular Pre-Assembly
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Solution Overview
Problem
The solar panel industry faces high balance of system (BoS) costs, which account for over 40% of total installed costs, necessitating a reduction in material, manufacturing, labor, and equipment usage to achieve grid parity, and current mounting systems lack efficiency and structural integrity for large-scale solar power installations.
Innovation Solution
A solar panel truss mounting system comprising a base, truss assembly, and connectors, with support members and dual-torque connectors, providing structural support and efficient installation methods, including a modular design and adaptable base for easy adjustment and reduced hardware usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mounting systems are used for large-scale solar installations, then structural support can be provided, but installation costs are high and structural integrity is insufficient
Solution Approach 1:
The mounting system is divided into modular truss assemblies that can be independently manufactured, transported, and assembled. Each truss assembly functions as a self-contained structural unit with integrated support members, rails, and connectors, eliminating the need for complex on-site fabrication while maintaining overall structural integrity through standardized connection interfaces.
Solution Approach 2:
The truss assembly utilizes composite construction combining aluminum extrusions for the truss framework with steel support members and fasteners. This composite approach optimizes the structural properties by leveraging the corrosion resistance and weight advantages of aluminum while incorporating the high strength-to-weight ratio of steel components where maximum load-bearing capacity is required.
2Productivity
If conventional mounting systems are used, then solar panels can be mounted, but labor costs and installation time are excessive
Solution Approach 1:
The truss assemblies are pre-fabricated in a controlled manufacturing environment with all structural components, rails, and connectors precisely positioned and pre-assembled. This preliminary action eliminates time-consuming on-site measurements, cutting, and assembly operations, allowing installers to simply transport and connect pre-built modules to the mounting location.
Solution Approach 2:
The mounting system incorporates adjustable and adaptable components that can be quickly configured for different panel sizes and installation geometries. The dynamic adaptability of the truss design allows installers to modify the structure without requiring complex tools or specialized skills, significantly reducing installation time while maintaining ease of operation.
3Reliability
If standard mounting hardware is used, then solar panels can be secured, but material costs and hardware usage are high
Solution Approach 1:
The truss assembly integrates multiple mounting functions into unified structural components. The truss framework simultaneously provides structural support, serves as the mounting platform for rails, and incorporates integrated connection points for panels. This merging of functions eliminates the need for separate support structures, mounting brackets, and fastening systems, reducing total hardware quantity while maintaining mounting reliability.
Solution Approach 2:
The standardized truss assembly design serves multiple purposes: it provides structural support for the entire array, acts as a transportable module, offers adjustable mounting configurations for various panel types, and includes integrated corrosion protection. This multi-functionality reduces the need for specialized hardware for each function, decreasing overall material consumption while ensuring reliable mounting performance.
4Ease of operation
If traditional installation methods are used, then solar arrays can be assembled, but worker safety risks increase and labor needs are high
Solution Approach 1:
By pre-assembling complete truss modules in a controlled factory environment, the system eliminates time-consuming and potentially hazardous on-site activities such as working at heights with heavy materials, performing precise measurements and calculations, and assembling complex structural connections in adverse weather conditions. Installers only need to perform simple connection tasks at ground level, significantly improving worker safety.
Solution Approach 2:
Dividing the solar mounting system into modular, pre-fabricated truss assemblies reduces the amount of material handling and assembly work required on-site. Each module is designed to be transported and installed as a complete unit, minimizing the time workers spend exposed to safety risks while maintaining the ability to assemble large-scale arrays through systematic module deployment.
Data Source
AI summary
An exemplary embodiment of the present invention provides a solar panel truss mounting system comprising a base and a truss assembly coupled to the base. The truss assembly comprises a first panel rail mount, second panel rail mount parallel to the first panel rail mount, base rail mount parallel to the first and second panel rail mounts, and a plurality of support members. A first portion of the plurality of support members extends between the first and second panel rail mounts. A second portion of the plurality of support members extends between the first panel rail mount and the base rail mount. A third portion of the plurality of support members extends between the second panel rail mount and the base rail mount. The system can further comprise a plurality of connectors for coupling a plurality of photovoltaic solar panels to the truss assembly.