Solar Panel Truss Mounting for Low-Hardware PV Installation
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Solution Overview
Problem
The solar PV 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
1Ease of manufacture
If traditional mounting systems are used for large-scale solar installations, then structural support is provided, but installation costs and complexity remain high
Solution Approach 1:
The mounting system is divided into modular components including truss assemblies, support members, and interchangeable connectors that can be independently manufactured and assembled. This segmentation enables parallel manufacturing processes and simplifies installation procedures while maintaining structural integrity across large-scale solar installations
Solution Approach 2:
The truss assembly design incorporates universal mounting interfaces and standardized connection points that can accommodate various panel types and configurations. The system uses multi-functional components such as adjustable support members and versatile connectors that serve multiple purposes, reducing the total number of different parts needed and simplifying the overall system
2Strength
If more hardware and materials are used to increase structural integrity, then mounting stability improves, but BoS costs increase
Solution Approach 1:
The truss assemblies are pre-engineered with optimized member configurations and connection geometries that maximize structural efficiency. Critical connection points are pre-positioned and pre-drilled, allowing for precise assembly with minimal field adjustments. This preliminary design optimization ensures that material is placed only where structurally necessary, reducing overall material consumption while maintaining required strength
Solution Approach 2:
The mounting system utilizes composite construction approaches combining different materials with complementary properties. Aluminum extrusions provide corrosion resistance and structural framework, while steel fasteners and connection hardware provide high-strength joining capability. This composite material strategy optimizes the strength-to-weight ratio and reduces the total quantity of material needed compared to using a single heavy-duty material throughout
3Adaptability or versatility
If custom mounting solutions are designed for specific panel configurations, then adaptability improves, but manufacturing and installation time increase
Solution Approach 1:
The mounting system incorporates adjustable and reconfigurable elements including telescopic support members, rotating connectors, and repositionable clamps that can adapt to different panel sizes and orientations. These dynamic components allow the same basic truss structure to accommodate various solar panel configurations without requiring custom-designed mounting solutions for each scenario, maintaining fast assembly speeds while providing configuration flexibility
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.