MECHANICAL PHOTOVOLTAIC MODULE CARTRIDGE AND METHOD OF CONSTRUCTION
A photovoltaic panel cartridge for mounting a plurality of photovoltaic panels and method of its construction are described. The photovoltaic panel cartridge is formed from a unitary frame with internal beams and struts for stability. The photovoltaic panels are inserted into channels within the frame, struts, and/or the internal beams in order to be mounted to the photovoltaic panel cartridge and secured to mounting regions on a different one of the frame, struts, and/or internal beams. The photovoltaic panel cartridge is configured to be stacked upon similarly configured photovoltaic panel cartridges for ease in transport and to reduce damage to the photovoltaic panels during transport. The photovoltaic panel cartridge may be slidably mounted to rails of a support structure.
This application is a continuation-in-part of U.S. patent application Ser. No. 12/957,808, filed Dec. 1, 2010, which in turn is a continuation-in-part of U.S. patent application Ser. No. 12/846,621, filed Jul. 29, 2010, Ser. No. 12/846,644, filed Jul. 29, 2010, and Ser. No. 12/846,686, filed Jul. 29, 2010, the disclosures of each of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTIONEmbodiments of the invention relate to the field of photovoltaic (PV) power generation systems, and more particularly to a system for simplifying installation of photovoltaic panels, also known as PV modules, in large-scale arrays.
BACKGROUND OF THE INVENTIONPhotovoltaic power generation systems are currently constructed by installing a foundation system (typically a series of posts or footings), a module structural support frame (typically brackets, tables or rails, and clips), and then mounting individual photovoltaic panels to the support frame. The photovoltaic panels are then grouped electrically together into PV strings, which are fed to an electric harness. The harness conveys electric power generated by the photovoltaic panels to an aggregation point and onward to electrical inverters.
Prior art commercial scale PV systems such as this must be installed by moving equipment, materials, and labor along array rows to mount photovoltaic panels on the support frames one-at-a-time. This is a time-consuming process, which becomes increasingly inefficient with larger scale systems.
With innovations in PV cell efficiency quickly making PV-generated energy more cost-effective, demand for large-scale PV systems installations is growing. Such systems may have a row length of half a mile or more. Accordingly, a simplified system for photovoltaic panel installation is needed.
In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and which illustrate specific embodiments of the invention. These embodiments are described in sufficient detail to enable those of ordinary skill in the art to make and use them. It is also understood that structural, logical, or procedural changes may be made to the specific embodiments disclosed herein.
Described herein is a method for mounting and sliding a multiplicity of mountable photovoltaic panels along a rail system using a photovoltaic panel cartridge. For utility scale ground mounted photovoltaic systems or commercial or residential rooftop systems, the use of a rail system to slide cartridges each containing one or more photovoltaic panels into place provides several benefits. By moving all work to one or more locations along each row, e.g., at the head, the system maximizes the use of preassembled components, minimizes material movement logistics, and reduces both on-site field labor and equipment movement over the site. One embodiment of the system is constructed by installing a support structure comprising a plurality of spaced parallel rails, which may be ground or structure supported, designed to receive and allow sliding movement of a pre-assembled cartridge that supports either a single photovoltaic panel or a plurality of photovoltaic panels as a unit. The support structure could also comprise a photovoltaic tracking system which would allow the rails to be rotated.
A first embodiment of a cartridge 100 is depicted in
As shown in more detail in
Clips and grooves are not the only way photovoltaic panels can be mounted in recesses of the cartridge 100; glue, Velcro™, or other known engagement means can be used. In another embodiment for securing the photovoltaic panels to the recesses, resilient engagement members can be used to hold the panels in place.
In general, solar-generated electricity is harvested and transmitted through a pre-wired common bus or cable system integral to the cartridge 100. Some examples of a common bus system that may be employed are described in more detail in co-pending application Ser. No. 12/846,671, the disclosure of which is incorporated by reference herein. One embodiment of pre-wiring a cartridge 100 for connection to a common bus system 280 is schematically shown in
As shown in
As shown in
As can be seen in
As mentioned above, row length in large-scale PV systems can be half a mile or more. In order to easily slide cartridges along such a long path, as shown in
The truck 760 comprises a plurality of paired spaced rollers 764a-b mounted on a corresponding axle 762. The truck 760 only takes up a small portion of space inside the attachment structure 760a, so that a rail 740, which may have a T or other cross-sectional shape, can extend far enough in the attachment structures 730a-b to stabilize the cartridge 700. Once a cartridge 700 is slid into position on the rails 740, it can be secured to the rails 740 by extending a set screw 752 (in channel 750) or other fastener to engage a groove 742 in the rail 740. Advantageously, the set screw 752 also functions as an electrical ground, if made of conductive material, grounding a conductive cartridge 700, to a conductive rail 740.
Although, as shown in
Cartridge 1000 is also equipped with a common bus system 1080. Wiring 1012 for the common bus system 1080 is run through the spaced elongated members 1010a-d.
Although the rails depicted in
A plurality of cartridges may be stacked together and shipped to an installation site. For this reason, the cartridges, e.g., 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, 2200, and 2300 are generally designed to lie flat or fit together vertically and are configured to protect the photovoltaic panels in transit, and the trucks, e.g., 760, 960 are designed to be completely contained flush or preferably entirely within the attachment structures. In addition, as noted above, the photovoltaic panels are preferably recessed in the cartridges 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, and 2300. Optionally, as is shown in
As is shown in
A wheel assembly 1541 formed of a wheel 1542 and axle 1543 can be provided which allows the cartridge 1500 to slide easily along the cartridge mounting rails 1540a of
In another embodiment, shown in
Next, as shown in
As shown in
In one embodiment, shown in
Once the frame 1505 is assembled, as shown in
Once the cartridges of the various embodiments discussed above (e.g. 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, 2200, and 2300) have been transported to the installation site and are prepared for installation on the corresponding support structure, the cartridges 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, 2200, and 2300 may be installed in one of several manners. These installation methods, described below, may be used with cartridges 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, 2200, and 2300 of any of the embodiments discussed above but are described in detail in the following exemplary embodiments.
As discussed above, the cartridges 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, 2200, and 2300 may be installed by manually placing the cartridges 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, 2200, and 2300 one after another onto the rails (e.g. 640a,b), (for example, by lowering the cartridge 100 onto the rails 640a,b or aligning attachment structures (e.g. 130a,b, 1130a,b, 1522a,b,c,d) on the cartridges to the rails) and advancing them by having an operator slide them on the rails 640a,b into a desired position. This placing and sliding can be done at the head end of a row or at spaced positions along a row. Head-end installation reduces equipment and labor movement. Both the rails 640a,b and the cartridges 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, 2200, and 2300 are designed so that cartridges can quickly be placed onto rails and slid into a final position.
The cartridges (e.g. 2200, 2200b) may be deployed manually as shown in
Similar to
It should be noted that the support structure 2300 is shown as being designed to run along a horizontal surface of a roof, as opposed to perpendicular to it (i.e. in a vertical direction). Although the support structures (e.g., 2400) described herein could be adapted to vertical mounting, horizontal mounting is preferred because it permits cartridges to be slid into a desired position without requiring a locking mechanism to prevent the cartridges from falling back down the structure. It should also be understood that various combinations of trucks or no trucks, and different types of rails can be used with any of the cartridges (e.g., 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, 2200, and 2300) described herein.
Since, as noted above, manual installation of cartridges can become difficult as the row length increases, a more automated cartridge mounting and delivery system may be used. One such delivery system is described in more detail in co-pending application Ser. No. 12/846,644, which is incorporated by reference herein.
As seen in
In another embodiment, shown in
In another embodiment, the cartridge rails may be configured without the T-shape at an installation location along the cartridge mounting rails 1540b as is shown in
As shown in a second embodiment in
In a third embodiment, shown in
Deployment of cartridges at spaced positions along a row or at the end of each row reduces equipment and labor movement. Both rails and cartridges are designed so the cartridges can quickly be placed onto the rails and slid along the rows and moved into a final position. In this manner, each cartridge mounts one or more photovoltaic panels (e.g., one, four or eight, as shown in the Figs.) at once to a set of rails, thereby simplifying installation time and cost. A field installation 2000 is shown in
It should also be noted that the cartridges (e.g., 100, 600, 700, 800, 900, 1000, 1100, 1400, 1500, 2200, and 2300) can be prewired to facilitate photovoltaic panel interconnection and the cartridges themselves can plug into one another to further reduce installation labor. It should also be noted that any other system components, such as wire harnesses, DC/DC converters, and the like could also be slid in from the ends of the rows, to further increase installation efficiency.
While embodiments have been described in detail, it should be readily understood that the invention is not limited to the disclosed embodiments. Rather the embodiments can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described. Although certain features have been described with some embodiments of the cartridge, such features can be employed in other disclosed embodiments of the cartridge as well. Accordingly, the invention is not limited by the foregoing embodiments, but is only limited by the scope of the appended claims.
Claims
1. A cartridge for mounting a plurality of photovoltaic panels thereon comprising:
- a frame;
- at least a first strut transversely mounted to a first side of the frame and a second side of the frame, opposite the first side, wherein a first mounting channel is provided on one of the frame and the first strut, and a first mounting region is provided on the other of the frame and the first strut.
2. The cartridge according to claim 1, further comprising a central beam transversely mounted to the first side of the frame and the second side of the frame,
- wherein the central beam is mounted such that the first strut is provided between the central beam and a third side of the frame,
- wherein a second mounting channel is provided on one of the central beam and the first strut, and a second mounting region is provided on the other of the central beam and first strut.
3. The cartridge according to claim 2, further comprising a second strut transversely mounted to the first side of the frame and the second side of the frame, wherein the second strut is mounted such that the second strut is provided between the central beam and a fourth side of the frame,
- wherein a third mounting channel is provided on one of the central beam and the second strut and a third mounting region is provided on the other of the central beam and the second strut, and
- wherein a fourth mounting channel is provided on one of the frame and the second strut and a fourth mounting region is provided on the other of the frame and the second strut.
4. The cartridge according to claim 1, wherein the frame is formed from one continuous frame blank.
5. The cartridge according to claim 1, wherein the frame comprises:
- a first side;
- a second side, opposite the first side, wherein the first side and the second side are of equal lengths;
- a third side;
- a fourth side opposite the third side, wherein the third side and fourth side are of equal lengths.
6. The cartridge according to claim 5, wherein the first side, second side, third side, and fourth side are of equal lengths.
7. The cartridge according to claim 1, wherein the frame comprises a longitudinal extent and a reinforced area, wherein the reinforced area is provided along the longitudinal extent.
8. The cartridge according to claim 1, wherein the first strut comprises a longitudinal extent and a reinforced area, wherein the reinforced area is provided along the longitudinal extent.
9. The cartridge according to claim 2, wherein the central beam comprises a longitudinal extent and a reinforced area, wherein the reinforced area is provided along the longitudinal extent.
10. The cartridge according to claim 2, wherein a top surface of at least one of the frame, first strut, and central beam comprise a reinforced area.
11. The cartridge according to claim 3, wherein the first strut and the second strut are configured to attach to corresponding cartridge mounting rails associated with a support structure.
12. The cartridge according to claim 11, wherein the frame has first and second notches corresponding to a first location and a second location where the first strut is mounted to the frame and third and fourth notches corresponding to a third location and a fourth location where the second strut is mounted to the frame, wherein the notches are configured to allow the frame to move over the cartridge mounting rails.
13. The cartridge according to claim 1, further comprising a first photovoltaic panel mounted to the cartridge, wherein a first longitudinal side of the first photovoltaic panel is inserted into the mounting channel and a second longitudinal side of the first photovoltaic panel, opposite the first longitudinal side, rests in the mounting region.
14. The cartridge according to claim 3, further comprising:
- a first photovoltaic panel mounted to the cartridge, wherein a first longitudinal side of the first photovoltaic panel is inserted into the mounting channel and a second longitudinal side of the first photovoltaic panel, opposite the first longitudinal side, rests in the mounting region;
- a second photovoltaic panel mounted to the cartridge, wherein a third longitudinal side of the second photovoltaic panel is inserted into the second mounting channel and a fourth longitudinal side of the second photovoltaic panel, opposite the third longitudinal side, rests in the second mounting region;
- a third photovoltaic panel mounted to the cartridge, wherein a fifth longitudinal side of the third photovoltaic panel is inserted into the third mounting channel and a sixth longitudinal side of the third photovoltaic panel, opposite the fifth longitudinal side, rests in the third mounting region; and
- a fourth photovoltaic panel mounted to the cartridge, wherein a seventh longitudinal side of the fourth photovoltaic panel is inserted into the fourth mounting channel and a eighth longitudinal side of the fourth photovoltaic panel, opposite the seventh longitudinal side, rests in the fourth mounting region.
15. The cartridge according to claim 3, further comprising eight photovoltaic panels mounted therein.
16. The cartridge according to claim 15, wherein:
- a first longitudinal side of the first photovoltaic panel and a first longitudinal side of the second photovoltaic panel are inserted into the first mounting channel and a second longitudinal side of the first photovoltaic panel and a second longitudinal side of the second photovoltaic panel opposite their respective first longitudinal sides are secured in the first mounting region;
- a first longitudinal side of the third photovoltaic panel and a first longitudinal side of the fourth photovoltaic panel are inserted into the second mounting channel and a second longitudinal side of the third photovoltaic panel and a second longitudinal side of the fourth photovoltaic panel opposite their respective first longitudinal sides are secured in the second mounting region;
- a first longitudinal side of the fifth photovoltaic panel and a first longitudinal side of the sixth photovoltaic panel are inserted into the third mounting channel and a second longitudinal side of the fifth photovoltaic panel and a second longitudinal side of the sixth photovoltaic panel opposite their respective first longitudinal sides are secured in the third mounting region; and
- a first longitudinal side of the seventh photovoltaic panel and a first longitudinal side of the eighth photovoltaic panel are inserted into the fourth mounting channel and a second longitudinal side of the seventh photovoltaic panel and a second longitudinal side of the eighth photovoltaic panel opposite their respective first longitudinal sides are secured in the fourth mounting region.
17. The cartridge according to claim 3, wherein:
- the first mounting region and the fourth mounting region are provided on the frame;
- the first mounting channel and the second mounting channel are provided on the first strut;
- the second mounting region and the third mounting region are provided on the central beam; and
- the third mounting channel and the fourth mounting channel are provided on the second strut.
18. The cartridge according to claim 3, wherein:
- the first mounting channel and the fourth mounting channel are provided on the frame;
- the first mounting region and the second mounting region are provided on the first strut;
- the second mounting channel and the third mounting channel are provided on the central beam; and
- the third mounting region and the fourth mounting region are provided on the second strut.
19. The cartridge according to claim 11, wherein each strut is configured to move along its corresponding cartridge mounting rail.
20. The cartridge according to claim 19, wherein each strut comprises a plurality of wheel assemblies configured to allow the cartridge to move along the cartridge mounting rails.
21. The cartridge according to claim 13, further comprising at least one bracket for securing the first photovoltaic panel to the cartridge, wherein the at least one bracket is fastened adjacent the mounting region.
22. The cartridge according to claim 21, wherein the at least one bracket is fastened adjacent the mounting region using at least one of screws, bolts, rivets, and welds.
23. The cartridge according to claim 1, wherein the frame is provided a nesting channel, wherein the nesting channel is configured to allow a frame of a second cartridge to seat within the nesting channel to allow the cartridge to be stackable.
24. The cartridge according to claim 3, wherein the central beam and struts are fastened to the frame by at least one of screws, bolts, rivets, and welds.
25. The cartridge according to claim 1, wherein the first strut comprises a first opposed arm and a second opposed arm, wherein the first opposed arm is configured to face a first side of a mounting rail and the second opposed arm is configured to face a second side of the mounting rail opposite the first side.
26. The cartridge according to claim 1, wherein the first strut comprises a pair of opposed arms that are configured to wrap around a T-shaped cartridge mounting rail.
27. The cartridge according to claim 25, wherein the first strut is provided the mounting channel, and further wherein an angled portion of the first opposed arm defines a first side of the first mounting channel and is configured to allow a photovoltaic panel to be inserted into the first mounting channel at an angle.
28. The cartridge according to claim 1, wherein the first strut is provided the first mounting channel and a second mounting channel, wherein the first mounting channel is configured to receive the first side of the photovoltaic panel and the second mounting channel is configured to receive a first side of a second photovoltaic panel.
29. The cartridge according to claim 1, wherein the frame comprises a first height and the first strut comprises a second height less than the first height.
30. A method of constructing a cartridge for mounting a plurality of photovoltaic panels comprising:
- providing a rectangular frame comprising: a first side; a second side, opposite the first side, wherein the first side and the second side are of equal lengths; a third side; a fourth side opposite the third side, wherein the third side and fourth side are of equal lengths;
- transversely attaching at least a first strut to the frame, wherein the first strut is mounted to the first side of the frame and the second side of the frame;
- providing a first mounting channel on one of the third side of the frame and the first strut;
- providing a first mounting region on the other of the third side of the frame and the first strut, wherein a photovoltaic panel is mountable to the cartridge by inserting a first longitudinal side of the photovoltaic panel into the first mounting channel and securing a second longitudinal side of the photovoltaic panel to the first mounting region.
31. The method of claim 30, further comprising:
- providing a frame blank; and
- bending the frame blank to form the rectangular frame.
32. The method of claim 30, further comprising transversely attaching a second strut to the first side and the second side of the frame.
33. The method of claim 32, further comprising transversely attaching a central beam to the frame, wherein the central beam is positioned between the first and second struts
34. The method according to claim 30, further comprising inserting a photovoltaic panel into the first mounting channel.
35. The method according to claim 34, wherein the photovoltaic panel is inserted into the first mounting channel at an angle of between approximately 30° and approximately 60°.
36. The method according to claim 34, further comprising seating the photovoltaic panel into the first mounting region.
37. The method according to claim 33, further comprising inserting a first side of a photovoltaic panel into a second mounting channel provided on one of the central beam and the first strut.
38. The method according to claim 37, further comprising seating a second side of the photovoltaic panel opposite the first side into a second mounting region provided on the other of the central beam and the first strut.
39. The method according to claim 36, further comprising fastening at least one bracket adjacent to the first mounting region in order to secure the photovoltaic panel to the cartridge.
40. The method according to claim 30, wherein the first strut is attached to the frame by at least one of screws, bolts, rivets, and welds.
41. The method according to claim 33, wherein the central beam is attached to the frame by at least one of screws, bolts, rivets, and welds.
42. The method according to claim 30, further comprising notching the frame blank to allow the cartridge to travel along at least one cartridge mounting rail.
43. The method according to claim 42, wherein the first strut is attached in alignment with the notches.
44. The method according to claim 31, further comprising forming bend notches in the frame blank to allow the frame blank to be bent to form the frame.
45. The method according to claim 44, further comprising welding a first end of the frame blank to a second end of the frame blank to form the rectangular frame.
46. A method of installing a cartridge for mounting photovoltaic panels onto a support structure comprising:
- providing a cartridge comprising: a frame comprising: a first side; a second side, opposite the first side, wherein the first side and the second side are of equal lengths; a third side; a fourth side opposite the third side, wherein the third side and fourth side are of equal lengths. a first strut and second strut transversely mounted to the first side and the second side of the frame; wherein a photovoltaic panel is mountable to the cartridge by inserting a first side of the photovoltaic panel into a first mounting channel provided on one of the first strut and the frame and securing a second side of the photovoltaic panel to a first mounting region provided on the other of the frame and the first strut;
- affixing said first strut to a first cartridge mounting rail;
- affixing said second strut to a second cartridge mounting rail;
- sliding said cartridge to a mounting location along said cartridge mounting rails.
47. The method according to claim 46, wherein said affixing step is accomplished by lowering said cartridge onto said cartridge mounting rail in a vertical direction.
48. The method according to claim 46, wherein said affixing step is accomplished by sliding said cartridge onto said cartridge mounting rail in a horizontal direction.
49. The method according to claim 46, further comprising inserting a fastener through said first strut and into said first cartridge mounting rail to secure the cartridge at the mounting location.
50. The method according to claim 46, wherein said cartridge mounting rails have a T-shaped cross section.
51. The method according to claim 46, wherein said cartridge mounting rails have a rectangular cross section.
52. The method according to claim 50, wherein the struts comprise opposed arms that are configured to wrap around the top of the T-shaped cartridge mounting rails.
53. The method according to claim 50, wherein the struts comprise opposed arms that define a generally U-shaped cross section.
54. The method according to claim 50, wherein the struts comprise a plurality of wheel assemblies that permit the cartridge to roll along the cartridge mounting rails.
55. A system for transporting a plurality of cartridges for mounting photovoltaic panels comprising:
- a first cartridge comprising: a first frame comprising: a first side; a second side, opposite the first side, wherein the first side and the second side are of equal lengths; a third side; a fourth side opposite the third side, wherein the third side and fourth side are of equal lengths; a nesting channel formed along the first, second, third, and fourth sides of the frame; a first strut transversely mounted to the first side and the second side of the frame; wherein a first mounting channel is provided on one of the first strut and the first frame, and a first mounting region is provided on the other of the first frame and the first strut; and
- a second cartridge comprising: a second frame comprising: a fifth side; a sixth side, opposite the fifth side, wherein the fifth side and the sixth side are of equal lengths; a seventh side; a eighth side opposite the seventh side, wherein the seventh side and eighth side are of equal lengths. a second strut transversely mounted to the fifth side and the sixth side of the frame; wherein a second mounting channel is provided on one of the second strut and the second frame, and a second mounting region is provided on the other of the second frame and the second strut; wherein the second frame is configured to seat onto the nesting channel of the first frame to facilitate stacking of the first and second cartridges.
56. The system of claim 55, wherein the fifth, sixth, seventh, and eighth sides of the second frame comprise longitudinal extents with a reinforced area provided along the longitudinal extents of each of the sides.
57. The system of claim 56, wherein the reinforced area is provided along a bottom portion of the fifth, sixth, seventh, and eighth sides of the second frame and is configured to seat onto the nesting channel of the first frame.
Type: Application
Filed: Mar 21, 2012
Publication Date: Sep 20, 2012
Inventors: John Perkins (Pittstown, NJ), William Piekarski (Clinton, NJ), Adam Dumm (Easton, PA), Michael Monaco (Stanhope, NJ)
Application Number: 13/426,274
International Classification: E04B 1/19 (20060101);