Abstract: Photovoltaic modules are constructed having separate positive and negative junction boxes positioned at the corners of each photovoltaic module. A photovoltaic array assembled from these photovoltaic modules can be aligned such that the positive and negative junction boxes connect in an arrangement that minimizes the amount of wire needed to install the photovoltaic array. The arrangement of photovoltaic modules connecting the positive and negative junction boxes on adjacent photovoltaic modules leads to successive rows of photovoltaic modules in the photovoltaic array are oriented in opposing directions.

Abstract: A three-directional photovoltaic module connector. The module connector includes first serial connection portion on each side for connecting two adjacent photovoltaic modules together in a serial, end-to-end connection. The module connector also includes a first parallel connection portion for connecting the two serially connected pairs of adjacent photovoltaic modules together in parallel, that is, side-to-side. The module connector further includes a vertical connection portion for attaching a mounting foot to elevate the photovoltaic module connector above a support surface such as a roof.

Abstract: This disclosure relates to the design of pile cap assemblies configured to rotatably couple the torque tube of a photovoltaic solar tracker to multiple support piles that elevate the torque tube above the ground. The pile cap assemblies define low friction bearings that allow the torque tube to rotate smoothly within the low friction bearings. The pile cap assemblies also include numerous mounting hole configurations that allow for adjustment of a position of the pile cap assemblies with respect to the support piles. This allows for any small variation in positioning of the support piles to be accommodated.

Abstract: Methods and apparatus for controlling an energy-generation device may be provided. Sockets of the device may be configured to electrically couple to respective energy-generation modules. In some examples, the device may include a connector, memory, and a processor configured to execute instructions for managing the electrical configuration of the sockets.

Abstract: Systems and methods for transferring solar cells while maintaining a controlled micro-environment are provided. In particular, such systems provide automated loading and unloading of solar cells by use of a conveyor and elevator within a tank receptacle sealingly connected with a solar cell carrying pods and a flow tube of solar cell components in a solar cell fabrication process. The tank receptacle can include one or more ports for sealingly and operably coupling with a cover of a solar cell carrying pod, each port having an elevator for withdrawing a removable base of the pod along with a solar cell carrying cassette into the tank and a conveyor to facilitate loading and/or unloading of solar cells with the cassette by coordinated movement of the elevator and conveyor. Such systems can further include a robotic arm having a gripper and nozzle to maintain a micro-environment within the pod during transport.

Abstract: Methods for controlling an energy storage device to reduce peak power demand at a site are provided. In one embodiment, load data corresponding to a load in a utility grid-connecting energy generation (EG) system is received. The load data may be sampled at a first predetermined interval, and the EG system may include an energy storage device. A load threshold level is received, and a discharge control signal is generated. The discharge control signal may be generated when the measured load is at or above the load threshold level. The control signal may be applied to the measured load for a second predetermined interval that is longer than the first predetermined interval.

Abstract: Systems and methods for assembling and wiring photovoltaic arrays are provided. The wiring systems can include retractable wires included in photovoltaic modules that may be extended during installation of photovoltaic modules in the array to connect to wires of adjacent photovoltaic modules, which can retract into a tightened position under the array as the installation is completed. The wires may be made retractable by wire retraction mechanisms mounted to a frame of the photovoltaic module, which maintain a desired tension on the wires of the photovoltaic module. The wire retraction mechanism may include springs that urge components connected to the wire to rotate a particular direction so as to maintain tension on the wire. The wiring systems may also have wire guides to keep the wires accessible for installation and adjustment.

Abstract: One embodiment of the present invention provides an apparatus for attaching conductive tabs to photovoltaic structures. The apparatus includes a cassette configured to store a plurality of conductive tabs and a pick-and-place apparatus configured to obtain a conductive tab from the cassette and place the conductive tab at an edge of a photovoltaic structure. The pick-and-place apparatus further includes a tab holder configured to pick up and release the conductive tab and a substantially horizontal track coupled to the tab holder. The tab holder is further configured to move back and forth along the track.

Abstract: An attachment point apparatus and system for photovoltaic arrays is disclosed. One embodiment provides a rail system for receiving a PV module, including a first rail, a second rail, a substantially rectilinear double male connector adapted for coupling an end of the first rail to an end of the second rail, and a connector adapted to attach a PV module to the first rail. Another embodiment provides a PV module including a PV laminate, a frame integral with and supporting the PV laminate, and a spanner bar adapted to solely span a width of the PV module, orthogonally connect at various locations along the frame, and attach to a support structure. A further embodiment provides a coupling device for a PV module comprising a first coupling portion adapted to rotatably engage a PV module, and a second coupling portion adapted to rotatably engage a rail.

Abstract: A method for constructing a photovoltaic (PV) substrate. A moving frame can be lowered towards a stack of back sheets and a back sheet of the stack of back sheets may be secured to the moving frame. The back sheet can be transferred from the moving frame to a vacuum table. An adhesive can be dispensed to the back sheet using an adhesive dispenser. At least one string may be placed onto the adhesive applied to the back sheet. The vacuum table can be rotated, and the back sheet can be released from the vacuum table onto a glass sheet.

Abstract: A power conditioning unit for delivering power from a power source to a mains utility supply, the power conditioning unit comprising a plurality of input terminals for connecting to the power source, a plurality of output terminals for connecting to the mains utility supply, a voltage increasing converter connected to the input terminals, a voltage reducing converter connected to the voltage increasing converter and a dc-to-ac converter connected to the voltage reducing converter and to the output terminals.

Abstract: A two-piece rooftop photovoltaic mounting system. A fixed base portion is attached directly to a roof surface via a lag bolt or other mechanical fastener. A movable portion is attached to and pivots about the base portion providing freedom of movement radially and axially with respect to the base portion. A photovoltaic module coupler is attached to the movable portion to support at least two photovoltaic modules at a location dictated by positioning of the movable portion. A locking nut locks the movable portion to the base portion at the desired location. A sheet of sealant material under the base portion helps prevent ingress of water into the roof surface via the lag bolt.

Abstract: A photovoltaic (PV) mounting hardware support system having a base portion. A foot has an elongated body adapted to connect to at least one PV module frame mounting component. A latch is located between the foot and the base portion and comprising first and second flexible flanges adapted to extend into fixed connection with the top portion of base portion. A plunger having first and second extensions, the plunger is located between the latch and the base portion and moveable from a first position to a second position. In the first position of the plunger, the first and second flexible flanges of the latch are not in fixed connection with the base portion. In the second position of the plunger, the first and second extensions of the plunger respectively apply forces to the first and second flexible flanges such that the first and second flexible flanges are placed into fixed connection with the base portion.

Abstract: One embodiment can provide an electrode grid of a photovoltaic structure. The electrode grid can include a plurality of finger lines and a busbar coupled to the finger lines. The busbar can include one or more stress-release structures, thereby reducing stress caused by thermal expansion mismatch between the busbar and underlying layers of the photovoltaic structure.

Abstract: Photovoltaic mounting systems and coupling assemblies for mounting photovoltaic modules are provided. The mounting systems may include short extruded base members that are mounted onto the supporting surface at approximate locations on the supporting surface, and coupling assemblies that may slide along the length of the base members during installation and be locked at particular positions on the length of the base members. The coupling assemblies may be coupled to connectors that in turn couple to two photovoltaic modules. In operation, the installer may first determine approximate locations on which to mount the base members and mount all required base members, and then, place the coupling assemblies at desired locations, lock the coupling assemblies at the desired locations, position the photovoltaic modules in the connectors of the coupling assemblies, and move to the next set of coupling assemblies.

Abstract: A cleaving apparatus for cleaving a photovoltaic structure into multiple strips is described. The apparatus can include a supporting post and a cleaving platform for cleaving the photovoltaic structure. The cleaving platform can be coupled to the supporting post via a translation stage and can include multiple platform segments that are configured to move relative to each other during cleaving. Each of the multiple platform segments can include a wafer-holding surface for holding at least a portion of the photovoltaic structure.

Abstract: Systems and methods are described for transferring wafers between processing steps in the fabrication of solar cells. The wafers may be processed using a cluster tool including a load-lock, a plurality of processing modules, and a central robot to transfer wafers between the plurality of modules. Each module may include a pedestal including wafer recesses to support the wafers, and puck recesses for supporting ferromagnetic pucks below the wafers. The central robot includes electromagnets for attracting the ferromagnetic pucks toward the electro magnets in order to clamp the wafers between the ferromagnetic pucks and the electromagnets.

Abstract: A photovoltaic (PV) module framing and coupling system enables the attachment of PV modules to a roof or other mounting surface without requiring the use of separate structural support members which attach directly to and span between multiple PV modules in a formed PV array. The apparatus provides a parallel coupling for securely interlocking the outside surfaces of parallel frame members together in a side to side arrangement to form an array with improved structural load distribution. The coupling may attach to a slot in the frame at substantially any position along the length of the frame thereby enabling the interconnection of adjacent PV modules along both an x and y axis. The apparatus may further provide a rotating portion and locking portion, mounting brackets for direct connection to a mounting surface, grounding teeth, and a twist-lock engagement means for interlocking and aligning PV modules in the array.