U.S. patent application number 14/055978 was filed with the patent office on 2014-06-26 for solar module array pre-assembly method and apparatus.
This patent application is currently assigned to CHEVRON U.S.A. INC.. The applicant listed for this patent is David Sterling Potter. Invention is credited to David Sterling Potter.
Application Number | 20140175251 14/055978 |
Document ID | / |
Family ID | 44971698 |
Filed Date | 2014-06-26 |
United States Patent
Application |
20140175251 |
Kind Code |
A1 |
Potter; David Sterling |
June 26, 2014 |
SOLAR MODULE ARRAY PRE-ASSEMBLY METHOD AND APPARATUS
Abstract
An apparatus is provided 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 supporting a plurality of solar panels; a track member
disposed proximate a bottom portion of the support member attached
to or integral with the support or base members for vertically
aligning and 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, each having a free and attached ends, the
attached ends pivotally attached proximate to opposing ends of the
base or support members and each arm members having a longitudinal
axis oriented substantially perpendicular to the longitudinal axis
of the base and support members and extending outward from the base
member and support members.
Inventors: |
Potter; David Sterling;
(Danville, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Potter; David Sterling |
Danville |
CA |
US |
|
|
Assignee: |
CHEVRON U.S.A. INC.
San Ramon
CA
|
Family ID: |
44971698 |
Appl. No.: |
14/055978 |
Filed: |
October 17, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13112314 |
May 20, 2011 |
8584338 |
|
|
14055978 |
|
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|
61347523 |
May 24, 2010 |
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Current U.S.
Class: |
248/544 ;
211/41.1 |
Current CPC
Class: |
Y02E 10/47 20130101;
B65G 49/068 20130101; F16B 2/10 20130101; F16M 11/2085 20130101;
H02S 30/10 20141201; Y10T 29/49826 20150115; H01L 31/048 20130101;
H01L 31/02 20130101; Y02E 10/50 20130101; B65G 49/063 20130101;
B65G 49/067 20130101; F16M 11/42 20130101; F24S 25/63 20180501;
F24S 25/10 20180501 |
Class at
Publication: |
248/544 ;
211/41.1 |
International
Class: |
F24J 2/52 20060101
F24J002/52; H01L 31/048 20060101 H01L031/048 |
Claims
1. An apparatus for pre-assembly of an electrically connected array
of solar panels for a solar canopy comprising: (a) a support member
for aligning side-by-side a plurality of solar panels with a bottom
portion of the solar panels exposed; and (b) an arm member attached
at one longitudinal end portion proximate to the side portion of
the support member and configured and adapted for removably
attaching at least two solar panel support channels.
2. An apparatus for pre-assembly of an electrically connected array
of solar panels for a solar canopy comprising: (a) a base member
horizontally disposed for supporting other elements; (b) a support
member having attached along one side portion of the support member
to the base member and an opposing side portion disposed away from
the base member for aligning side-by-side a plurality of solar
panels with a bottom portion of the solar panels exposed; and (c)
an arm member attached at one longitudinal end portion proximate to
the side portion of the support member attached to the base member
and configured and adapted for removably attaching at least two
solar panel support channels.
3. An apparatus for pre-assembly of an electrically connected array
of solar panels for a solar canopy comprising: (a) a substantially
planar base member for resting on a horizontal surface, (b) a
substantially planar support member for horizontally aligning
side-by-side and horizontally supporting a plurality of solar
panels when a photo-voltaic cell side of the solar panels rests
against the support member, wherein a bottom portion of the support
member is integral with the base member or fixed attached to the
base member, and the support member extends upward from the planar
base member; (c) 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 (d) at
least two arm members, each having a free end and an attached end,
the attached ends pivotally attached proximate to opposing ends of
the base member or support member and each arm members having a
longitudinal axis oriented substantially perpendicular to the
longitudinal axis of the base member and support member and
extending outward from the base member and support member, and
configured to pivot in a vertical plane from a position
substantially parallel to the ground upward to a position
substantially parallel to parallel to the plane of the support
member, wherein upon pivoting in one direction the free end moves
closer towards the support member and pivoting in the other
direction the free end moves away from the support member, the arm
members being configured and adapted for removably attaching at
least two solar panel support channels.
4. The apparatus of claim 3, further comprising a clamp member
attached to each of the arm members for removably attaching a solar
panel support channel.
5. The apparatus of claim 3, further comprising a shaft member
rotatable attached to a side portion of the base member and
perpendicularly to attached ends of each of the arm members.
6. The apparatus of claim 4, further comprising a motor attached to
the shaft member for rotating the shaft member, thereby actuating
pivoting of each of the arm members.
7. The apparatus of claim 3, wherein the support member has a
height of at least half of the longitudinal axis of a solar panel
it is configured to support.
8. The apparatus of claim 3, wherein the support member is inclined
from vertical sufficiently for supporting the solar panels.
9. The apparatus of claim 8, wherein the support member is inclined
from about 3 degrees to about 25 degrees from vertical.
10. The apparatus of claim 3, wherein the support member comprises
a lattice framework.
11. The apparatus of claim 3, wherein the arm members are further
configured and adapted for removably attaching at least two solar
panel support channels at multiple positions and spacing along the
longitudinal axis of arm members so as to be suitable for use with
a plurality of solar panel sizes.
12. The apparatus of claim 3, further comprising an alignment beam
having a free end and a fixed end where the fixed end is movably
attached perpendicularly to an arm member and is configured and
adapted for aligning and preventing lateral movement of a solar
panel support channels, wherein the alignment beam is adjustable
along the longitudinal axis of the arm member to suit various solar
panel sizes.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. application Ser.
No. 13/112,314 filed on May 20, 2011 and U.S. Provisional
Application 61/347,523 filed on May 24, 2010, the contents of which
are incorporated by reference in its entirety.
COPYRIGHT NOTICE AND AUTHORIZATION
[0002] This patent document contains material which is subject to
copyright protection.
[0003] .RTM.Copyright 2010-2013. Chevron Energy Solutions Company,
a division of Chevron U.S.A. Inc. All rights reserved.
[0004] With respect to this material which is subject to copyright
protection. The owner, Chevron Energy Solutions Company has no
objection to the facsimile reproduction by any one of the patent
disclosure, as it appears in the Patent and Trademark Office patent
files or records of any country, but otherwise reserves all rights
whatsoever.
FIELD OF THE INVENTION
[0005] This invention relates an apparatus and method for
pre-assembly of certain components of a solar canopy.
BACKGROUND OF THE INVENTION
[0006] Solar energy is a clean, renewal energy source.
Photo-electro voltaic cell technology is increasing rapidly and
makes installation of solar collector panels housing the
photo-electro voltaic cells more and more economically feasible.
Beyond the photo-electro voltaic cell technology itself are the
problems of placement and support of the solar collector panels.
Large numbers of solar collector panels must be assembled in series
to achieve useful power production. In remote areas these may be
placed on the ground without interfering with land use. In more
developed areas, it is desirable to place the solar collector
panels such that the land may also be used for other purposes,
e.g., for parking lots, school/office hallways, playgrounds, or
sports fields. To achieve this requires an elevated structure to
support the solar collector panels.
[0007] In prior known systems, installation costs amount to around
25% of the overall cost of a solar parking shade installation.
These installation cost includes the cost to place modules on a
rack, wire the modules together and to a combiner box, bolt the
modules in place, and place the support structure on a parking
shade structure. These costs often amount to almost the actual
panel cost themselves due to the lack of ability to achieve
assembly efficiency as well as the need in governmental markets to
use union labor.
[0008] An additional deficiency in known methods/systems for solar
canopy installation is that the size of solar modules used is
limited to the size module a contractor can physically carry. The
installation process is also cumbersome and dangerous due to work
on nonstandard sites and at an elevated height.
[0009] It is desirable to have a method and system which overcomes
the deficiencies of known systems. The instant invention provides
such a solution.
SUMMARY OF THE INVENTION
[0010] The invention in one embodiment includes an apparatus for
pre-assembly of an electrically connected array of solar panels for
a solar canopy comprising:
[0011] (a) a support member for aligning side-by-side a plurality
of solar panels with a bottom portion of the solar panels exposed;
and
[0012] (b) an arm member attached at one longitudinal end portion
proximate to the side portion of the support member and configured
and adapted for removably attaching at least two solar panel
support channels.
[0013] The invention in another embodiment includes an apparatus
for pre-assembly of an electrically connected array of solar panels
for a solar canopy comprising:
[0014] (a) a base member horizontally disposed for supporting other
elements;
[0015] (b) a support member having attached along one side portion
of the support member to the base member and an opposing side
portion disposed away from the base member for aligning
side-by-side a plurality of solar panels with a bottom portion of
the solar panels exposed; and
[0016] (c) an arm member attached at one longitudinal end portion
proximate to the side portion of the support member attached to the
base member and configured and adapted for removably attaching at
least two solar panel support channels.
[0017] The invention in another embodiment includes an apparatus
for pre-assembly of an electrically connected array of solar panels
for a solar canopy comprising:
[0018] (a) a substantially planar base member for resting on a
horizontal surface,
[0019] (b) a substantially planar support member for horizontally
aligning side-by-side and horizontally supporting a plurality of
solar panels when a photo-voltaic cell side of the solar panels
rests against the support member, wherein a bottom portion of the
support member is integral with the base member or fixed attached
to the base member, and the support member extends upward from the
planar base member;
[0020] (c) 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
[0021] (d) at least two arm members, each having a free end and an
attached end, the attached ends pivotally attached proximate to
opposing ends of the base member or support member and each arm
members having a longitudinal axis oriented substantially
perpendicular to the longitudinal axis of the base member and
support member and extending outward from the base member and
support member, and configured to pivot in a vertical plane from a
position substantially parallel to the ground upward to a position
substantially parallel to parallel to the plane of the support
member, wherein upon pivoting in one direction the free end moves
closer towards the support member and pivoting in the other
direction the free end moves away from the support member, the arm
members being configured and adapted for removably attaching at
least two solar panel support channels.
[0022] In another embodiment the invention includes a method for
pre-assembly of an electrically connected array of solar panels for
a solar canopy, the method comprising:
[0023] The invention in another embodiment includes a method for
pre-assembly of an electrically connected array of solar panels for
a solar canopy, the method comprising:
[0024] (a) aligning a plurality of solar panels side-by-side in an
electrically connected array of solar panels pre-assembly
apparatus, the pre-assembly apparatus comprising:
[0025] a base member for resting on a horizontal surface;
[0026] a support member for horizontally aligning side-by-side and
horizontally supporting a plurality of solar panels when a
photo-voltaic cell side of the solar panels rests against the
support member, wherein a bottom portion of the support member is
integral with the base member or fixed attached to the base member,
and the support member extends upward from the base member;
[0027] 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
[0028] at least two arm members, each having a free end and an
attached end, the attached ends pivotally attached proximate to
opposing ends of the base member or support member and each arm
members having a longitudinal axis oriented substantially
perpendicular to the longitudinal axis of the base member and
support member and extending outward from the base member and
support member, and configured to pivot in a vertical plane from a
position substantially parallel to the ground upward to a position
substantially parallel to parallel to the plane of the support
member, wherein upon pivoting in one direction the free end moves
closer towards the support member and pivoting in the other
direction the free end moves away from the support member, the arm
members being configured and adapted for removably attaching at
least two solar panel support channels;
[0029] wherein a bottom portion of the plurality of solar panels is
supported by the track member and a front portion is supported by
the support member, facing inward towards the base member;
[0030] (b) removably attaching at least two solar panel support
channels to the arm members of the solar panel array pre-assembly
apparatus, wherein the longitudinal axis of the solar panel support
channels is parallel to the longitudinal axis of the base member
and positioned to contact a bottom portion of all of the plurality
of solar panels, near opposite longitudinal ends of each of the
plurality of solar panels when the arm members are rotated about
the longitudinal axis of the base member where attached;
[0031] (c) manipulating the position of the arm members of the
electrically connected array of solar panels pre-assembly apparatus
relative to position of the support member of the electrically
connected array of pre-assembly apparatus such that the solar panel
support channels contacts a bottom portion of all of the plurality
of solar panels, near opposite longitudinal ends of each of the
plurality of solar panels, thereby aligning the solar panel support
channels for attachment to bottom of the plurality of solar
panels;
[0032] (d) fixedly attaching a top portion of the solar panel
support channels to a bottom portion of each of the plurality of
solar panels; and
[0033] (e) reversing the manipulation in step (c) of the position
of the arm members of the solar panel array pre-assembly apparatus
relative to position of the support member of the pre-assembly
apparatus, such that the plurality of solar panels and attached
solar panel support channels lay parallel with the ground surface
and are ready to be loaded on a truck for transportation to the job
site.
[0034] These and other features and advantages of the present
invention will be made more apparent through a consideration of the
following detailed description of preferred embodiments of the
invention. In the course of this description, frequent reference
will be made to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a perspective view of one embodiment of the
present invention.
[0036] FIG. 2 is a top view of one embodiment of the present
invention.
[0037] FIG. 3 is a side view in one embodiment of the present
invention.
[0038] FIG. 4 is an opposite side view in one embodiment of the
present invention.
[0039] FIG. 5 is a front view of one embodiment of the present
invention.
[0040] FIG. 6 is a back view of one embodiment of the present
invention.
[0041] FIG. 7 is a perspective view of one embodiment of the
present invention with emphasis on depicting the arm members for
supporting Zee-channels or C-channels.
[0042] FIG. 8 is a perspective view of one embodiment of the
present invention depicting one Zee-channel attached to the arm
members.
[0043] FIG. 9 is a perspective view of one embodiment of the
present invention depicting two Zee-channels attached to the arm
members.
[0044] FIG. 10 is an alternate perspective view of one embodiment
of the present invention depicting two Zee-channels attached to the
arm members.
[0045] FIG. 11 is a perspective view of one embodiment of the
present invention depicting two Zee-channels attached to the arm
members and one solar panel resting in the track member.
[0046] FIG. 12 is a perspective view of one embodiment of the
present invention depicting two Zee-channels attached to the arm
members and one solar panel resting in the opposite end of the
track member.
[0047] FIG. 13 is a perspective view of one embodiment of the
present invention depicting two Zee-channels attached to the arm
members and a plurality of solar panel resting in the track
member.
[0048] FIG. 14 is a perspective view of one embodiment of the
present invention depicting two Zee-channels attached to the arm
members and a plurality of solar panel resting in the track member,
and the arm members partially folded/rotated upward towards the
Zee-channels/support member.
[0049] FIG. 15 is a perspective view of one embodiment of the
present invention depicting two Zee-channels attached to the arm
members and a plurality of solar panel resting in the track member,
and the arm members fully folded/rotated upward towards the
Zee-channels/support member, so as to place the Zee-channels in
position to be attached to the plurality of solar panels.
[0050] FIG. 16 is a perspective view of one embodiment of the
present invention depicting two Zee-channels attached to the arm
members and a plurality of solar panel resting in the track member,
and the arm members fully folded/rotated upward towards the two
Zee-channels/support member, with the Zee-channels attached to the
plurality of solar panels, and a pallet structure in position to
receive the two Zee-channels attached to the plurality of solar
panels.
[0051] FIG. 17 is a perspective view of one embodiment of the
present invention depicting the two Zee-channels attached to the
plurality of solar panels and supported by the pallet
structure.
[0052] FIG. 18 is a perspective view of one embodiment of the
present invention depicting the two Zee-channels attached to the
plurality of solar panels, released from the arm members, supported
by the pallet structure, and in position to be picked up by a fork
lift.
[0053] FIG. 19 is a perspective view of one embodiment of the
present invention depicting the two Zee-channels attached to the
plurality of solar panels, released from the arm members, supported
by the pallet structure, and being removed by a fork lift for
loading on a truck to take to the job site.
[0054] FIG. 20 is a perspective view of one embodiment of the
pallet structure of the present invention.
[0055] FIG. 21 is a top view of one embodiment of the pallet
structure of the present invention.
[0056] FIG. 22 is a side view of one embodiment of the pallet
structure of the present invention.
[0057] FIG. 23 is an end view of one embodiment of the pallet
structure of the present invention.
[0058] FIG. 24 is a perspective view of one embodiment of multiple
stacked pallet structures of the present invention with completed
Zee-channels attached to a plurality of solar panels loaded on each
pallet structure.
[0059] FIG. 25 is a perspective view of one embodiment of the clamp
structure of the present invention.
[0060] FIG. 26 is an alternate perspective view of one embodiment
of the clamp structure of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0061] Other embodiments of the present invention and its
individual components will become readily apparent to those skilled
in the art from the foregoing detailed description. As will be
realized, the invention is capable of other and different
embodiments, and its several details are capable of modifications
in various obvious respects, all without departing from the spirit
and the scope of the present invention. Accordingly, the drawings
and detailed description are to be regarded as illustrative in
nature and not as restrictive. It is therefore not intended that
the invention be limited except as indicated by the appended
claims.
[0062] As used in this specification and claims, the "solar panel
support channels" comprise "Z"-shaped sheet metal, also referred to
as "Zee-channels" or "Z-channels", "C"-shaped sheet metal, also
referred to as "Cee-channels" or "c-channels", or standard beams,
bars, and other suitable support members.
[0063] FIG. 1 is a perspective view of one embodiment of the
present invention. The invention includes an apparatus 100 for
pre-assembly of an electrically connected array of solar panels for
a solar canopy. Base member 110 (having longitudinal and lateral
side portions) is for resting on any solid stable horizontal
surface capable of supporting the weight of the apparatus, workers,
and solar panels to be assembled. In one embodiment the base member
110 is substantially planar. Optionally, wheels 190 are attached at
the bottom of base member 110 to allow repositioning of the
apparatus 100. In another embodiment (not shown) there is no base
member 110 and instead support member 120 is self-supporting or
supported, e.g., by attachment to a wall, floor or other fixture,
or by placement of "post" legs at the bottom of the support member
into "post" holes in the floor. In another embodiment the support
member 120 is self supporting due to its shape, e.g., box-shaped or
triangle shaped.
[0064] A support member 120 is fixedly or removably attached to
base member 110 and is for horizontally aligning side-by-side and
horizontally supporting a plurality of solar panels when a
photo-voltaic cell side of the solar panels rests against the
support member 120. In one embodiment the support member 120 is
substantially planar. A bottom portion of support member 120 is
integral with the base member or fixed attached to the base member
110, and the support member 120 extends upward from the base member
110. The support member 120 is inclined from vertical sufficiently
for supporting the solar panels. In one embodiment the support
member 120 is inclined from about 3 degrees to about 25 degrees
from vertical. Optionally, support member 120 is comprised of a
lattice framework. A solid form is another option, e.g. molded
plastic or forged metal.
[0065] A track member 140 is disposed proximate a bottom portion of
the support member 120 and is attached to or integral with the
support member 120 or base member 110 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 140. At least two arm members 130, each having a free end
and an attached end, the attached ends pivotally attached proximate
to opposing ends of the base member 110 or support member 120. In
this embodiment one end of arm members 130 is attached to pivot bar
150 (also referred to as shaft member) and the opposing ends of
pivot bar 150 are attached to brackets on opposing ends of base
member 110. Each arm members 130 having a longitudinal axis
oriented substantially perpendicular to the longitudinal axis of
the base member 110 and pivot bar 150 and extend outward from the
base member 110. The arm members 130 are configured to pivot in a
vertical plane from a position substantially parallel to the ground
upward to a position substantially parallel to parallel to the
plane of the support member 120.
[0066] Upon pivoting in one direction the free end of the arm
members 130 moves closer towards the support member 120 and
pivoting in the other direction the free end of the arm members 130
moves away from the support member 120. The arm members 130 are
configured and adapted for removably attaching at least two solar
panel support channels (see FIGS. 13 and 14). Also, the arm members
130 in one embodiment are configured and adapted for removably
attaching at least two solar panel support channels 810 (see FIG.
8) at multiple positions and spacing along the longitudinal axis of
arm members 130 so as to be suitable for use with a plurality of
solar panel sizes. In one embodiment arms 130 are movable and may
be adjusted along pivot bar 150 for different size solar panel
arrays. Also, in another embodiment arm members 130 may be folded
towards and against pivot bar 150 to allow for more easy
transportation of the apparatus 100.
[0067] Optionally, one or more alignment beams 160 are attached to
one of the arm members 130. Alignment beams 160 have a free end and
a fixed end where the fixed end is movably attached perpendicularly
to an arm member 130 at one end of assembly 100 and extending away
from other arm members 130, i.e., in longitudinal alignment with
the base member 110. Alignment beams 160 are configured and adapted
for aligning and preventing lateral movement of a solar panel
support channels (see FIGS. 9 and 10), wherein the alignment beam
is adjustable along the length of the arm member to suit various
solar panel sizes. In another embodiment alignment beams 160 may be
folded towards and against arm members 130 to allow for more easy
transportation of the apparatus 100.
[0068] Optionally, a tool rail 170 is attached via tool rail
support arms 175 to a top portion of support member 120 and is
parallel to it. It is configured to receive a movable tool caddy
180 which can be slide along the tool rail 170 by a technician and
has a hook, strap or other device for holding a tool such as an
electric drill or riveter. The tool rail 170 and tool caddy 180
reduces the lifting and moving work of the technician of heavy
tools.
[0069] FIG. 2 is a top view of one embodiment of the present
invention 200. An additional optional element more clearly shown in
this figure is brace members 210 which attach to arm members 130
and pivot bar 150 where the two are joined.
[0070] FIG. 3 is a side view in one embodiment of the present
invention 300. More clearly shown in this figure is the track in
tool rail 170 in which tool caddy 180 may slide. Also this side
view more clearly shows one end of pivot bar 150 where it is
rotatably attached to base member 110. More than one tool caddy 180
may be slid on tool rail 170, e.g., one for each technician working
on the assembly.
[0071] FIG. 4 is an opposite side view in one embodiment of the
present invention 400.
[0072] FIG. 5 is a front view of one embodiment of the present
invention 500. This view more clearly shows a plurality of optional
wheels 190 attached at the bottom of base member 110 to allow easy
relocation of the apparatus 500.
[0073] FIG. 6 is a back view of one embodiment of the present
invention 600.
[0074] FIG. 7 is a perspective view of one embodiment of the
present invention 700 with emphasis on depicting the arm members
130 for supporting Zee-channels or C-channels. Also this figure
more clearly shows a base member protrusion 710 and "C" bracket 720
for securing each end of pivot bar 150. Also this figure depicts
clamp member 730 attached to arm members 130 for removably
attaching, e.g., a Zee-channel (shown in FIG. 8). For each
Zee-channel used in the assembly of a solar module array there are
at least two corresponding clamp members 730, i.e., one for
attaching the Zee-channel to each of the preferably at least two
arm members 130. Any known clamping structure may be used, e.g.,
screw-down clamp, magnetic clamp, bar and clasp clamp, bar and lock
clamp, to hold the Zee-channel during assembly and to release the
solar module array at the Zee-channel after assembly is
completed.
[0075] The clamp members 730 are preferably attached to respective
arm members 130 at equal distances from the pivot bar 150 so as to
allow attaching the Zee-channels parallel to the longitudinal
access of the base member 110. Where optional alignment beams 160
are attached to arm members 130, the clamp members are positioned
so that when a Zee-channel is attached via a clamp member 730 one
end of the Zee-channel rests along the alignment beam 160 and abuts
its end portion, thus easily positioning the Zee-channel for
attachment to the bottom of solar panels (see FIGS. 13 and 14).
[0076] FIG. 8 is a perspective view of one embodiment of the
present invention 800 depicting one Zee-channel 810 attached via
clamp members 730 to the arm members 130. One end of the
Zee-channel 810 rests along the alignment beam 160 and abuts its
end portion.
[0077] FIG. 9 is a perspective view of one embodiment of the
present invention 900 depicting two Zee-channels 810 attached to
the arm members 130, both having one end resting along an alignment
beam 160 and abutting an end portion of the alignment beam.
[0078] FIG. 10 is an alternate perspective view of one embodiment
of the present invention 1000 depicting two Zee-channels 810
attached to the arm members 130, both having one end resting along
an alignment beam 160 and abutting an end portion of the alignment
beam.
[0079] FIG. 11 is a perspective view of one embodiment of the
present invention 1100 depicting two Zee-channels 810 attached to
the arm members and one solar panel 1110 resting in the track
member 140. The solar panel 1110 has a bottom portion supported by
resting in track member 140 and upper portion supported by leaning
against support member 120.
[0080] FIG. 12 is a perspective view of one embodiment of the
present invention 1200 depicting two Zee-channels attached to the
arm members 130 and one solar panel 1110 resting in the opposite
end of the track member 140 from that shown in FIG. 11. This
depicts one optional method of use of the apparatus 1200 where one
end of the track member 140 and support member 120 is the "feed"
end for feeding a plurality of solar panels onto the apparatus.
This mode would be convenient where the supply of solar panels 1110
is stacked on that side of the apparatus. Then each solar panel is
slide to the opposite end of the track member 140 and support
member 120 and this is repeated until a sufficient number of solar
panels have been placed on the apparatus. Alternately, solar panels
1110 could be feed from both ends of the track member 140 and
support member 120, either alternately or simultaneously depending
on available number of technicians and placement of solar panel
stock.
[0081] FIG. 13 is a perspective view of one embodiment of the
present invention 1300 depicting two Zee-channels 810 attached to
the arm members 130 and a plurality of solar panels 1110 resting in
the track member 140 and against support member 120. The plurality
of solar panels is now positioned for attachment of the
Zee-channels 810.
[0082] FIG. 14 is a perspective view of one embodiment of the
present invention 1400 depicting two Zee-channels 810 attached to
the arm members 130 and a plurality of solar panels 1110 resting in
the track member 140 and against support member 120, and the arm
members 130 partially folded/rotated upward towards the support
member 120.
[0083] FIG. 15 is a perspective view of one embodiment of the
present invention 1500 depicting two Zee-channels 810 attached to
the arm members 130 and a plurality of solar panels 1110 resting in
the track member 140 and against support member 120, and the arm
members 130 fully folded/rotated upward towards the support member
120 and bottom of solar panels 1110 and in contact with the bottom
of solar panels 1110 and therefore positioned for attachment to the
solar panels 1110 so as to place the Zee-channels 810 in position
to be attached to the plurality of solar panels 1110. The
positioning of the tool rail 170 is above the height of arm members
130 when fully folded so as not to interfere with their
folding.
[0084] FIG. 16 is a perspective view of one embodiment of the
present invention 1600 depicting two Zee-channels 810 attached to
the arm members 130 and a plurality of solar panels 1110 resting in
the track member 140, and the arm members 130 fully folded/rotated
upward towards the two support member 120, with the Zee-channels
810 now attached to the plurality of solar panels 1110, and a
pallet structure 1610 in position to receive the newly assembled
solar module array 1710 (consisting of two Zee-channels 810
attached to the plurality of solar panels 1110). Optionally, the
pallet structure 1610 is properly positioned to receive the solar
module array 1710 by abutting one side of pallet structure 1610
against pivot bar 150.
[0085] FIG. 17 is a perspective view of one embodiment of the
present invention 1700 depicting the solar module array 1710
supported by the pallet structure. Once the solar module array 1710
is assembled by attaching the Zee-channels 810 to the plurality of
solar panels 1110, the solar module array 1710 is lowered by
reversing the rotation of the arm members 130 until substantially
horizontal, touching the floor or the solar module array 1710 is
resting on the pallet structure 1610. Raising and lowering the arm
structures is optionally achieved manually, or via known
mechanical, pneumatic, or other mechanisms such as gears, winches,
electric so motors. When the arm members 130 are being rotated up
they only bear their own weight and the weight of the Zee channels
810. When the arm members 130 are being lowered they bear the
additional weight of the completed solar module array 1710 which is
much heavier and so care must be taken for safe lowering of this
weight.
[0086] FIG. 18 is a perspective view of one embodiment of the
present invention 1800 depicting the solar module array 1710,
released via clamp member 730 from the arm members 130, supported
by the pallet structure 1610, and in position to be picked up by a
fork lift 1810.
[0087] FIG. 19 is a perspective view of one embodiment of the
present invention 1900 depicting the solar module array 1710,
released via clamp member 730 from the arm members 130, supported
by the pallet structure 1610, and being removed by a fork lift 1810
for loading on a truck to take to the job site.
[0088] FIG. 20 is a perspective view of one embodiment of the
pallet structure/assembly 2000 of the present invention. The pallet
assembly 2000 is configured and adapted for supporting the solar
module array 1710, which in one embodiment is electrically
connected array of a plurality of solar panels 1110 fixedly
attached to Zee-channels 810 during storage and transport. The
pallet assembly 2000 comprises a deck 2010 (comprised of beam
members 2060 and 2050 joined); a plurality of feet 2020 extending
downward from the deck a sufficient depth to allow for stacking of
multiple pallet assemblies 2000 with one solar module array 1710
loaded on each pallet assembly 2000, i.e., at least the thickness
of one solar module array 1710 plus any additional depth needed for
stacking; a plate (not shown) attached to an edge portion of the
deck 2010, for aligning the pallet assembly 2000 with the apparatus
100 (see e.g., FIG. 1) for building an electrically connected array
of a plurality of solar panels, i.e., solar module array 1710; and
at least one alignment bracket 2040 for aligning and preventing
lateral movement of at least two solar panel support channels 810,
e.g., Zee Channels, attached to the bottom of the electrically
connected array of a plurality of solar panels 1110.
[0089] Other configurations of deck 2010 and feet 2020 could
include, e.g., a single integral molded plastic form, a solid deck
or molded deck 2010 attached to feet 2020, a box-type structure
with a bottom recess to provide space for stacking, or detachable
legs that, e.g., are temporarily attached to a portion of a solar
module array 1710.
[0090] FIG. 21 is a top view of one embodiment of the pallet
assembly 2000 of the present invention. FIG. 22 is a side view of
one embodiment of the pallet assembly 2000 of the present
invention. FIG. 23 is an end view of one embodiment of the pallet
assembly of the present invention.
[0091] FIG. 24 is a perspective view of one embodiment of multiple
stacked pallet assemblies 2000 of the present invention with
completed solar module arrays 1710 loaded on each pallet structure.
The upper portion and lower portions of feet 2020, shown at the 4
corners of the pallet assemblies in this embodiment, are configured
and adapted for stacking by any known methods, e.g., having a
recess on the upper portion and a matching protrusion on the lower
portion of each foot 2020 so the feet align and stack securely when
one pallet assembly is stacked on top of another pallet assembly.
Alternative embodiments might include a locking latch member, snap
latches, or other known connecting mechanisms. Since with stacking
of pallet assemblies, the load is higher on the lower pallet
assemblies, the weight capacity of each pallet assembly must be
weight on the bottom pallet assembly when stacked with the maximum
contemplated number of pallet assemblies. In addition, appropriate
safety margins should be used, e.g., to allow for additional
dynamic load when transporting the stacked pallet assemblies.
[0092] FIG. 25 is a perspective view of one embodiment of the clamp
structure 730 of the present invention 2500. A base bracket 2525 is
optionally used to fixedly or movably attach clamp structure 730 to
arm member 130. Pressure pin member 2560 contacts an edge portion
of Zee-channel 810 and "pins" the Zee-channel to arm member
130.
[0093] FIG. 26 is an enlarged alternate perspective view of one
embodiment of the clamp structure 730 of the present invention.
Clamp base 2535 is fixedly attached to base bracket 2525. A
pneumatic, hydraulic, electric, or manually powered ram 2520 is
actuated to cause piston 2530 to move forward or backward in ram
2520. The movement of piston 2530 in rotatable coupling with hinge
2540 moves pin bracket 2550 open or closed, i.e., up or down,
thereby causing pressure pin member 2560 to pin or release the
Zee-channel 810. Various other clamp mechanisms and clamp actuating
mechanisms may be used and are within the scope of the
invention.
[0094] Other embodiments of the present invention and its
individual components will become readily apparent to those skilled
in the art from the foregoing detailed description. As will be
realized, the invention is capable of other and different
embodiments, and its several details are capable of modifications
in various obvious respects, all without departing from the spirit
and the scope of the present invention. Accordingly, the drawings
and detailed description are to be regarded as illustrative in
nature and not as restrictive. It is therefore not intended that
the invention be limited except as indicated by the appended
claims.
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