U.S. patent application number 15/343043 was filed with the patent office on 2017-02-23 for rail systems and methods for installation and operation of photovoltaic arrays.
The applicant listed for this patent is Alion Energy, Inc.. Invention is credited to Wolfgang Oels, Anders Swahn.
Application Number | 20170054407 15/343043 |
Document ID | / |
Family ID | 44861879 |
Filed Date | 2017-02-23 |
United States Patent
Application |
20170054407 |
Kind Code |
A1 |
Swahn; Anders ; et
al. |
February 23, 2017 |
RAIL SYSTEMS AND METHODS FOR INSTALLATION AND OPERATION OF
PHOTOVOLTAIC ARRAYS
Abstract
Rail system and method for a photovoltaic array. The system
includes at least one modular rail in a first direction. The
modular rail includes a first vehicle support surface along the
first direction and a first mounting surface along the first
direction. The first vehicle support surface is configured to
support at least a first vehicle moving in the first direction, and
the first mounting surface is configured to support one or more
photovoltaic modules mounted on the first mounting surface.
Inventors: |
Swahn; Anders; (Tiburon,
CA) ; Oels; Wolfgang; (Dortmund, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Alion Energy, Inc. |
Richmond |
CA |
US |
|
|
Family ID: |
44861879 |
Appl. No.: |
15/343043 |
Filed: |
November 3, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14050237 |
Oct 9, 2013 |
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15343043 |
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13091960 |
Apr 21, 2011 |
9462734 |
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14050237 |
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61328575 |
Apr 27, 2010 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B08B 1/008 20130101;
B21C 23/00 20130101; F24S 25/11 20180501; F24S 2080/012 20180501;
H05K 13/00 20130101; H02S 20/10 20141201; H02S 20/00 20130101; H02S
40/32 20141201; H02S 40/34 20141201; Y02E 10/47 20130101; F24S
2025/014 20180501; H02S 40/10 20141201; B25J 5/007 20130101; H05K
13/0015 20130101; H02S 50/00 20130101; Y02E 10/50 20130101; F24S
25/16 20180501; Y10T 29/49002 20150115; H02S 40/36 20141201 |
International
Class: |
H02S 40/10 20060101
H02S040/10; B21C 23/00 20060101 B21C023/00; H02S 40/32 20060101
H02S040/32; B08B 1/00 20060101 B08B001/00; H05K 13/00 20060101
H05K013/00; H02S 50/00 20060101 H02S050/00 |
Claims
1.-40. (canceled)
41. A system comprising: a first photovoltaic module array
extending in a first lateral direction; a second photovoltaic
module array extending in the first lateral direction; a rail
comprising first and second vehicle support surfaces each extending
in a second lateral direction that is perpendicular to the first
lateral direction; a transportation vehicle supported by the first
and second vehicle support surfaces; and a photovoltaic module
cleaning vehicle, the photovoltaic module cleaning vehicle being
operable along the first photovoltaic module array in the first
lateral direction so as to remove dirt or dust on the first
photovoltaic module array, the photovoltaic module cleaning vehicle
being movable by the transportation vehicle along the second
lateral direction from the first photovoltaic module array to the
second photovoltaic module array, and the photovoltaic module
cleaning vehicle, after being moved by the transportation vehicle,
being operable along the second photovoltaic module array in the
first lateral direction so as to remove dirt or dust on the second
photovoltaic module array.
42. The system of claim 41, further comprising: a first elongated
rail comprising first and second photovoltaic module support
surfaces each extending along the first lateral direction, the
first photovoltaic module array being supported by the first and
second photovoltaic module support surfaces; and a second elongated
rail comprising third and fourth photovoltaic module support
surfaces each extending along the first lateral direction, the
second photovoltaic module array being supported by the third and
fourth photovoltaic module support surfaces.
43. The system of claim 41, wherein the first and second
photovoltaic module arrays each are vertically tilted relative to
an installation surface.
44. The system of claim 41, the rail including a void between the
first and second vehicle support surfaces.
45. The system of claim 41, further comprising: a positional
indicator disposed along the first photovoltaic module array; and a
sensor disposed on the photovoltaic module cleaning vehicle and
configured to detect the positional indicator.
46. The system of claim 41, further comprising: a positional
indicator disposed along the rail; and a sensor disposed on the
transportation vehicle and configured to detect the positional
indicator.
47. The system of claim 41, wherein the photovoltaic module
cleaning vehicle comprises one or more wheels, continuous tracks,
or caterpillar treads that move the photovoltaic module cleaning
vehicle along the first photovoltaic module array and along the
second photovoltaic module array.
48. The system of claim 41, wherein the photovoltaic module
cleaning vehicle comprises one or more wheels, continuous tracks,
or caterpillar treads that move the photovoltaic module cleaning
vehicle along the first photovoltaic module array and along the
second photovoltaic module array.
49. The system of claim 41, wherein the transportation vehicle
comprises one or more wheels, continuous tracks, or caterpillar
treads that move the transportation along the first and second
vehicle support surfaces.
50. The system of claim 41, wherein the photovoltaic module
cleaning vehicle operates periodically.
51. The system of claim 41, wherein the photovoltaic module
cleaning vehicle and the transportation vehicle are configured to
communicate with one another.
52. A method comprising: providing a first photovoltaic module
array extending in a first lateral direction; providing a second
photovoltaic module array extending in the first lateral direction;
providing a rail comprising first and second vehicle support
surfaces each extending in a second lateral direction that is
perpendicular to the first lateral direction; operating a
photovoltaic module cleaning vehicle along the first photovoltaic
module array in the first lateral direction so as to remove dirt or
dust on the first photovoltaic module array; moving the
photovoltaic module cleaning vehicle by the transportation vehicle
along the second lateral direction from the first photovoltaic
module array to the second photovoltaic module array; and after
moving the photovoltaic module cleaning vehicle by the
transportation vehicle, operating the photovoltaic module cleaning
vehicle along the second photovoltaic module array in the first
lateral direction so as to remove dirt or dust on the second
photovoltaic module array.
53. The method of claim 52, further comprising: supporting the
first photovoltaic module array with first and second photovoltaic
module support surfaces of a first elongated rail, the first and
second photovoltaic module support surfaces each extending along
the first lateral direction; and supporting the second photovoltaic
module array with third and fourth photovoltaic module support
surfaces of a second elongated rail, the third and fourth
photovoltaic module support surfaces each extending along the first
lateral direction.
54. The method of claim 52, wherein the first and second
photovoltaic module arrays each are vertically tilted relative to
an installation surface.
55. The method of claim 52, the rail including a void between the
first and second vehicle support surfaces.
56. The method of claim 52, further comprising: disposing a
positional indicator along the first photovoltaic module array; and
detecting the positional indicator with a sensor disposed on the
photovoltaic module cleaning vehicle.
57. The method of claim 52, further comprising: disposing a
positional indicator along the rail; and detecting the positional
indicator with a sensor disposed on the transportation vehicle.
58. The method of claim 52, wherein the photovoltaic module
cleaning vehicle comprises one or more wheels, continuous tracks,
or caterpillar treads that move the photovoltaic module cleaning
vehicle along the first photovoltaic module array and along the
second photovoltaic module array.
59. The method of claim 52, wherein the photovoltaic module
cleaning vehicle comprises one or more wheels, continuous tracks,
or caterpillar treads that move the photovoltaic module cleaning
vehicle along the first photovoltaic module array and along the
second photovoltaic module array.
60. The method of claim 52, wherein the transportation vehicle
comprises one or more wheels, continuous tracks, or caterpillar
treads that move the transportation along the first and second
vehicle support surfaces.
61. The method of claim 52, wherein the photovoltaic module
cleaning vehicle operates periodically.
62. The method of claim 52, wherein the photovoltaic module
cleaning vehicle and the transportation vehicle communicate with
one another.
Description
1. CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional No.
61/328,575, filed Apr. 27, 2010, commonly assigned and incorporated
by reference herein for all purposes.
[0002] Additionally, this application is related to U.S. patent
application Ser. No. 13/043,286, commonly assigned, incorporated by
reference herein for all purposes.
2. BACKGROUND OF THE INVENTION
[0003] The present invention is directed to utility arrays. More
particularly, the invention provides systems and methods for
installation and operation of photovoltaic arrays. Merely by way of
example, the invention has been applied to solar farms. But it
would be recognized that the invention has a much broader range of
applicability.
[0004] Photovoltaics convert sunlight into electricity, providing a
desirable source of clean energy. FIG. 1 is a simplified diagram of
a conventional photovoltaic array. The photovoltaic array 100
includes strings 1, 2, 3, 4, . . . n, where n is a positive integer
larger than or equal to 1. Each string includes photovoltaic (PV)
modules (e.g., solar panels) that are connected in series. The
photovoltaic array 100 is connected to a central inverter 110,
which provides an alternating current (AC) connection to a power
grid 120. FIG. 2 is a simplified diagram of a conventional
photovoltaic module. The photovoltaic (PV) module 210 includes a
junction box 220 on the backside of the PV module 210.
[0005] The installation of photovoltaic arrays often presents
logistical challenges. Not only does the site for the photovoltaic
array need to be properly prepared, but large quantities of
materials also need to be transported to and within the site. For
example, the site for the photovoltaic array may have existing
vegetation that would interfere with the installation and operation
of the photovoltaic array. This vegetation usually has to be
cleared. The site may also have uneven terrain that usually
requires extensive grading and earth moving. Once the site is
prepared, it is then often necessary to build an extensive
infrastructure on which the strings of PV modules 210 are to be
affixed. The PV modules 210 are then moved into position, affixed
to the structure, and interconnected so that power can be delivered
to the power grid 120. Each of these operations can be
time-consuming and expensive.
[0006] Once the photovoltaic array is in operation, additional
infrastructure often is used to support, maintain, evaluate, and
repair the array. In order to support the operation of the
photovoltaic array, equipment and materials routinely need to be
transported from one end of the array to another. For example, the
test equipment is transported to a PV module that is under
evaluation. In another example, the cleaning equipment is
transported to remove debris and dirt from the PV module. In yet
another example, an additional module is transported as replacement
for the defective module. Depending upon the terrain, soils, and
weather, simply getting equipment and materials from one end of the
array to another often poses significant challenges, especially if
the ground is muddy. As with the installation, these operational
needs can also be time-consuming and expensive.
[0007] Hence, it is highly desirable to improve techniques for
installation and operation of photovoltaic arrays.
3. BRIEF SUMMARY OF THE INVENTION
[0008] The present invention is directed to utility arrays. More
particularly, the invention provides systems and methods for
installation and operation of photovoltaic arrays. Merely by way of
example, the invention has been applied to solar farms. But it
would be recognized that the invention has a much broader range of
applicability.
[0009] According to one embodiment, a rail system for a
photovoltaic array includes at least one modular rail in a first
direction. The modular rail includes a first vehicle support
surface along the first direction and a first mounting surface
along the first direction. The first vehicle support surface is
configured to support at least a first vehicle moving in the first
direction, and the first mounting surface is configured to support
one or more photovoltaic modules mounted on the first mounting
surface.
[0010] For example, the modular rail further includes a plenum
along the first direction, the plenum being configured to hold one
or more cables. In another example, the modular rail further
includes a cover for the plenum. In yet another example, the
modular rail further includes one or more notches at one or more
intervals respectively along the modular rail, and the one or more
notches are substantially perpendicular to the first direction. In
yet another example, the modular rail further includes a base
surface opposite to the first mounting surface, and the first
mounting surface is tilted relative to the base surface. In yet
another example, the modular rail further includes a base surface
opposite to the first mounting surface. The base surface forms one
or more channels at one or more intervals along the modular rail,
and the one or more channels are substantially perpendicular to the
first direction. In yet another example, the modular rail further
includes a second mounting surface along the first direction, and
the second mounting surface is substantially coplanar with the
first mounting surface. In yet another example, the modular rail
further includes one or more indicia at one or more intervals
respectively along the modular rail, and the one or more indicia
are configured to identify one or more locations in the rail
system.
[0011] In yet another example, the rail system further includes a
first photovoltaic module affixed to the first mounting surface
with at least one or more mechanical connectors. In yet another
example, the rail system further includes a first photovoltaic
module affixed to the first mounting surface with at least one or
more adhesive materials. In yet another example, the first
photovoltaic module is affixed to the first mounting surface using
at least a flexible spacer with at least the one or more adhesive
materials. In yet another example, the rail system further includes
a second photovoltaic module coupled to the first photovoltaic
module through at least an interconnector. In yet another example,
the interconnector is selected from a group consisting of a rigid
in-line slide-on interconnector, a flexible slide-in
interconnector, a flexible ribbon interconnector, and an in-line
slide-in edge interconnector.
[0012] In yet another example, the rail system further includes the
first vehicle configured to perform one or more first tasks. In yet
another example, each of the one or more first tasks is associated
with at least installation, operation, logistics, or servicing of a
photovoltaic array. In yet another example, the first vehicle is
further configured to perform the one or more first tasks
automatically. In yet another example, the first vehicle includes
at least a power supply selected from a group consisting of a
battery, a photovoltaic module, and a combustion engine. In yet
another example, the first vehicle includes at least a sensor
configured to determine a location of the first vehicle. In yet
another example, the modular rail includes one or more indicia at
one or more intervals respectively along the modular rail, the one
or more indicia are configured to identify one or more locations in
the rail system, and the sensor is further configured to determine
the location using the one or more indicia. In yet another example,
the first vehicle includes at least a communication system to
communicate with a second vehicle, the second vehicle being
configured to perform one or more second tasks. In yet another
example, the second vehicle is further configured to transport the
first vehicle.
[0013] In yet another example, the rail system further includes at
least one index rail in a second direction. The index rail includes
a second vehicle support surface along the second direction, and
the second vehicle support surface is configured to support at
least a second vehicle moving in the second direction. In yet
another example, the second vehicle support surface is further
configured to support at least the first vehicle moving in the
second direction. In yet another example, the index rail further
includes a plenum along the second direction, the plenum being
configured to hold one or more cables. In yet another example, the
index rail further includes a cover for the plenum. In yet another
example, the index rail further includes one or more notches at one
or more intervals respectively along the index rail, and the one or
more notches are substantially perpendicular to the second
direction. In yet another example, the index rail further includes
a base surface forming one or more channels at one or more
intervals along the index rail, and the one or more channels being
substantially perpendicular to the second direction. In yet another
example, the first direction and the second direction are
substantially perpendicular.
[0014] According to another embodiment, a method for making a
photovoltaic rail includes grading an installation site, and
extruding at least one photovoltaic rail associated with a
substantially uniform profile along its length. The process for
extruding at least one photovoltaic rail includes making at least a
vehicle support surface along the photovoltaic rail.
[0015] For example, the method further includes placing a
reinforcing mesh on the installation site before the process for
extruding at least one photovoltaic rail is performed. In another
example, the process for extruding at least one photovoltaic rail
further includes making at least a mounting surface along the
photovoltaic rail. In yet another example, the process for
extruding at least one photovoltaic rail further includes making at
least a plenum along the photovoltaic rail. In yet another example,
the method further includes covering the plenum of the photovoltaic
rail. In yet another example, the method further includes making
one or more notches at one or more intervals respectively along the
photovoltaic rail, and the one or more notches are substantially
perpendicular to the modular rail. In yet another example, the
photovoltaic rail is a modular rail or an index rail.
[0016] According to yet another embodiment, a method for installing
a photovoltaic array includes forming at least one modular rail in
a first direction. The modular rail includes a first vehicle
support surface along the first direction and a mounting surface
along the first direction. Additionally, the method includes
affixing at least a first photovoltaic module and a second
photovoltaic module to the mounting surface, and interconnecting
the first photovoltaic module to the second photovoltaic module.
The process for affixing at least a first photovoltaic module and a
second photovoltaic module to the mounting surface includes moving
a first vehicle along the first vehicle support surface, and the
first vehicle includes at least one robotic arm. Additionally, the
process for affixing at least a first photovoltaic module and a
second photovoltaic module to the mounting surface includes
affixing the first photovoltaic module and the second photovoltaic
module to the mounting surface by at least the robotic arm. For
example, the method further includes forming at least one index
rail in a second direction, and the index rail includes a second
vehicle support surface along the index rail. In another example,
the method further includes loading a first vehicle onto a second
vehicle, and moving the second vehicle carrying the first vehicle.
In yet another example, the process for affixing at least a first
photovoltaic module and a second photovoltaic module to the
mounting surface is performed with at least one or more adhesive
materials. In yet another example, the process for affixing at
least a first photovoltaic module and a second photovoltaic module
to the mounting surface is performed with at least one or more
mechanical connectors.
[0017] The present invention provides advantages over conventional
technology. Certain embodiments of the present invention provide a
photovoltaic array based on at least one or more modular rails that
enable partial or full automation of many installation and
operational tasks. Some embodiments of the present invention can
reduce time and cost of installation and operation of a
photovoltaic array. For example, the maintenance and operation cost
of the photovoltaic array is significantly reduced. In another
example, the servicing of the photovoltaic array (e.g.,
diagnostics, cleaning, and/or snow removal) is significantly
improved. Certain embodiments of the present invention provide one
or more vehicles that can move along one or more modular rails
and/or one or more index rails to navigate throughout the
photovoltaic array and perform various tasks. Some embodiments of
the present invention provide a photovoltaic array that does not
need panel-to-panel cable strain relief. Certain embodiments of the
present invention provide an installation method and system that
eliminates expensive junction boxes and standardized cable
interconnects of conventional PV modules. Some embodiments of the
present invention can improve wind tolerance of a photovoltaic
array.
[0018] Depending upon the embodiment, one or more of these benefits
may be achieved. These benefits and various additional objects,
features, and advantages of the present invention can be fully
appreciated with reference to the detailed description and
accompanying drawings that follow.
4. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a simplified diagram of a conventional
photovoltaic array.
[0020] FIG. 2 is a simplified diagram of a conventional
photovoltaic module.
[0021] FIG. 3 is a simplified diagram showing a system for
installation and operation of a photovoltaic array according to one
embodiment of the present invention.
[0022] FIG. 4 is a simplified diagram showing the modular rail for
installation and operation of the photovoltaic array according to
one embodiment of the present invention.
[0023] FIG. 5 is a simplified diagram showing the modular rail that
supports one or more PV modules according to one embodiment of the
present invention.
[0024] FIG. 6 is a simplified diagram showing placement of one or
more cables in one or more plenums of the modular rail according to
one embodiment of the present invention.
[0025] FIG. 7 is a simplified diagram showing the modular rail for
installation and operation of the photovoltaic array according to
another embodiment of the present invention.
[0026] FIG. 8 is a simplified diagram showing the modular rail that
supports the one or more PV modules according to another embodiment
of the present invention.
[0027] FIG. 9 is a simplified diagram showing the index rail for
installation and operation of the photovoltaic array according to
one embodiment of the present invention.
[0028] FIG. 10 is a simplified diagram showing placement of one or
more cables in one or more plenums of the index rail according to
one embodiment of the present invention.
[0029] FIG. 11 is a simplified diagram showing a method for
constructing the photovoltaic array according to one embodiment of
the present invention.
[0030] FIG. 12 is a simplified diagram showing a PV-module
interconnection apparatus used for installation and operation of
the photovoltaic array according to an embodiment of the present
invention.
[0031] FIG. 13 is a simplified diagram showing a PV module
interconnection apparatus used for installation and operation of
the photovoltaic array according to another embodiment of the
present invention.
[0032] FIG. 14 is a simplified diagram showing a PV module
interconnection apparatus used for installation and operation of
the photovoltaic array according to yet another embodiment of the
present invention.
[0033] FIGS. 15 and 16 are simplified diagrams showing a PV module
interconnection apparatus used for installation and operation of
the photovoltaic array according to yet another embodiment of the
present invention.
[0034] FIG. 17 is a simplified diagram of a vehicle for performing
one or more tasks in the photovoltaic array according to one
embodiment of the present invention.
[0035] FIG. 18 is a simplified diagram of a vehicle for performing
one or more tasks in the photovoltaic array according to another
embodiment of the present invention.
5. DETAILED DESCRIPTION OF THE INVENTION
[0036] The present invention is directed to utility arrays. More
particularly, the invention provides systems and methods for
installation and operation of photovoltaic arrays. Merely by way of
example, the invention has been applied to solar farms. But it
would be recognized that the invention has a much broader range of
applicability.
[0037] FIG. 3 is a simplified diagram showing a system for
installation and operation of a photovoltaic array according to one
embodiment of the present invention. This diagram is merely an
example, which should not unduly limit the scope of the claims. One
of ordinary skill in the art would recognize many variations,
alternatives, and modifications. In FIG. 3, the photovoltaic array
300 is organized around one or more modular rails 310 (e.g.
photovoltaic (PV) rails) oriented in a first direction. For
example, the photovoltaic array 300 includes one or more
photovoltaic modules. In another example, these modular rails 310
are arranged in a general east-west orientation. In yet another
example, each modular rail 310 provides infrastructure for one or
more module strings 320 (e.g. photovoltaic (PV) module strings) of
one or more PV modules.
[0038] According to one embodiment, the modular rails 310 are
crossed by one or more index rails 330 that are substantially
perpendicular to the modular rails 310. For example, the index
rails 330 are arranged in a second direction (e.g., a general
north-south orientation). In another example, each of the modular
rails 310 has a substantially uniform profile along its length. In
yet another example, each of the index rails 330 has a
substantially uniform profile along its length.
[0039] According to another embodiment, the photovoltaic array 300
includes one or more cables 340 (e.g. DC cables) that run in
parallel along or perpendicularly to the modular rails 310 and/or
the index rails 330. For example, the one or more cables 340 are
connected to a central inverter 350, which is coupled to the power
grid. In another example, each of the PV module strings 320 employs
a string inverter, and/or each of the PV modules within the same
string employs a micro-inverter. According to yet another example,
the string inverter or the micro-inverter is used to convert the
power generated at each string or module to AC power locally,
without the need of the central inverter 350.
[0040] In one embodiment, one or more vehicles 360 (e.g.
installation rail cars) are used to travel along the modular rails
310 and/or the index rails 330. For example, the one or more
vehicles 360 are used to aid in the installation of the
photovoltaic array 300. In another example, the one or more
vehicles 360 are used to provide logistics and maintenance support
for the photovoltaic array 300. In yet another example, the one or
more vehicles 360 are used for transporting materials. In another
embodiment, one or more vehicles 370 (e.g. index rail cars) are
used for transporting vehicles and/or materials along the index
rails 330.
[0041] FIG. 4 is a simplified diagram showing the modular rail 310
for installation and operation of the photovoltaic array according
to one embodiment of the present invention. This diagram is merely
an example, which should not unduly limit the scope of the claims.
One of ordinary skill in the art would recognize many variations,
alternatives, and modifications.
[0042] As shown in FIG. 4, the modular rail 310 includes one or
more mounting surfaces 410. For example, the one or more mounting
surfaces 410 serve as the mechanical substrate for the mounting of
one or more PV modules and/or one or more PV module strings. In
another example, the mounting surfaces 410 are substantially
coplanar.
[0043] FIG. 5 is a simplified diagram showing the modular rail 310
that supports one or more PV modules according to one embodiment of
the present invention. This diagram is merely an example, which
should not unduly limit the scope of the claims. One of ordinary
skill in the art would recognize many variations, alternatives, and
modifications.
[0044] In one embodiment, a PV module 510 is affixed to the one or
more mounting surfaces 410 by using at least one or more mechanical
connectors. In another embodiment, a PV module 510 is affixed
directly to the one or more mounting surfaces 410 by using one or
more adhesive materials. For example, the one or more adhesive
materials include a glue. In another example, the one or more
adhesive materials include tape, paste, T5200, Silicone, epoxy,
and/or Polyurethane foam. In yet another example, the PV module 510
is not affixed directly to the one or more mounting surfaces 410,
but is affixed along with one or more flexible spacers using the
one or more adhesive materials. In yet another embodiment, the one
or more mounting surfaces 410 of the modular rail 310 are
implemented with a tilt angle. For example, the tilt angle varies
depending upon the geographic location (e.g. latitude or
orientation) of the photovoltaic array so that the affixed PV
module 510 is oriented for optimal energy capture from the light
source (e.g., the Sun).
[0045] The use of the one or more mounting surfaces 410 provides
certain advantages over conventional technology for the mounting of
PV modules and PV module strings. In one embodiment, the PV modules
510 are fixed along their entire length to the one or more mounting
surfaces 410 using glue or other adhesive materials. In another
embodiment, the PV modules 510 do not have to be as strong as
required by certain conventional technology. For example, the
adhesive mounting along the one or more surfaces 410 provides a
shorter span between the contact points of the PV modules 510 and
the one or more mounting surfaces 410; therefore, the PV modules
510 are exposed to less mechanical stress due to wind loads than
the PV modules mounted using conventional edge-mounted brackets. In
another example, the PV modules 510 can be made of thinner material
than the conventional edge-mounted PV modules; therefore, the PV
modules 510 can be manufactured and transported at lower cost due
to their lighter weight.
[0046] In yet another embodiment, the PV modules 510 benefit from
the "heat sink" effect due to the proximity of the PV modules 510
to the modular rails 310. For example, the PV modules 510 can stay
slightly cooler than conventional modules and can operate more
efficiently (e.g., due to the negative temperature coefficient). In
yet another embodiment, the use of flexible spacers can provide the
PV modules 510 with additional air cooling that can significantly
reduce negative effects caused by the "heat sink" effect of the
modular rails 310.
[0047] Returning to FIG. 4, in another embodiment, the modular rail
310 also includes one or more plenums 420 for the placement of one
or more cables. FIG. 6 is a simplified diagram showing placement of
one or more cables in one or more plenums of the modular rail 310
according to one embodiment of the present invention. This diagram
is merely an example, which should not unduly limit the scope of
the claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications.
[0048] In one embodiment, a cable 610 is placed in a first cable
plenum 620 and/or another cable 630 is placed in a second cable
plenum 640. For example, the one or more cables 340 include the
cable 610 and/or the cable 630. In another example, additional
plenums can be provided for additional cables. In another
embodiment, the central mounting surface 650 is eliminated to form
a single plenum in which the cable 610 and/or the cable 630 are
placed together. For example, the elimination of the central
mounting surface 650 results in reduced material costs for the
modular rail 310 as well as a reduction in its overall weight. In
yet another embodiment, the cable plenum 620 and/or the cable
plenum 640 also has a cover that provides both mechanical and
weather protection for the one or more cables.
[0049] In yet another embodiment, the modular rail 310 is scribed,
slotted, and/or notched at one or more intervals along its length
to provide one or more plenums for the placement of one or more
cables (e.g., the one or more cables 340) that are perpendicular to
the modular rail 310 and/or for the drainage of water from the
modular rail 310. For example, the one or more notches are
substantially perpendicular to the modular rail 310. In yet another
embodiment, the cable 610 and/or the cable 630 does not need to be
placed in the plenum 620 and/or the plenum 640, but could instead
be placed separately from the modular rails 310, for example, in
underground trenches. In yet another embodiments, the plenum 620
and/or the plenum 640 provides space to accommodate the junction
box of a PV module.
[0050] According to some embodiments, the cable 610 and/or the
cable 630 serve to interconnect the various PV modules or PV module
strings. For example, the cables are used to send the DC power
generated by the PV modules or PV module strings to a central
inverter 350 for conversion to AC power and transmission to the
power grid. According to certain embodiments, the cables are
factory pre-made with connectors that allow for easy field
interconnections between the PV module strings and the central
inverter 350.
[0051] Returning again to FIG. 4, in one embodiment, the modular
rail 310 also includes one or more vehicle support surfaces 430
(e.g., tracks, rails or road beds). In one embodiment, the one or
more vehicle support surfaces 430 allow a vehicle to move along the
modular rail 310. For example, the vehicle is used to install PV
modules and/or provide logistics, operational, and/or maintenance
support for the photovoltaic array. In another example, the modular
rail 310 includes various positional indicators that are installed
at intervals along its length. For example, the positional
indicators include, but not limited to, magnetic wires, RFID
modules, and/or visual indicators that denote the location of the
particular modular rail segment within the larger photovoltaic
array. In another example, a vehicle that operates along the
modular rail includes sensors for detecting these positional
indicators so that the vehicle can detect its location within the
photovoltaic array.
[0052] As shown in FIG. 4, the modular rail 310 is optimized to
reduce the amount of material needed per unit length. For example,
the thickness of a bottom portion 440 of the modular rail 310 is
optimized to reduce amount of material needed for a given surface
roughness of a particular site. In one example, the modular rail
310 is constructed from concrete. In yet another example, the
modulation rail 310 is constructed on site (e.g., being extruded in
place using a slip-form extrusion machine).
[0053] As discussed above and further emphasized here, FIG. 4 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. For example, the
bottom portion 440 of the modular rail 310 has a bottom surface
that forms one or more channels at one or more intervals along the
length of the modular rail 310. In one embodiment, the one or more
channels are perpendicular to the modular rail 310. In another
embodiment, the one or more channels allow water to flow under the
modular rail 310.
[0054] FIG. 7 is a simplified diagram showing the modular rail 310
for installation and operation of the photovoltaic array according
to another embodiment of the present invention. FIG. 8 is a
simplified diagram showing the modular rail 310 that supports the
one or more PV modules according to another embodiment of the
present invention. These diagrams are merely examples, which should
not unduly limit the scope of the claims. One of ordinary skill in
the art would recognize many variations, alternatives, and
modifications.
[0055] As shown in FIGS. 7 and 8, the modular rail 310 includes
only a single mounting surface 710 for the PV module 510 or the PV
module string according to one embodiment. In another embodiment,
the modular rail 310 also includes a void 720, which, for example,
reduces the amount of material needed per unit length and/or
reduces the overall weight and cost of the modular rail 310.
[0056] FIG. 9 is a simplified diagram showing the index rail 330
for installation and operation of the photovoltaic array according
to one embodiment of the present invention. Additionally, FIG. 10
is a simplified diagram showing placement of one or more cables in
one or more plenums of the index rail 330 according to one
embodiment of the present invention. These diagrams are merely
examples, which should not unduly limit the scope of the claims.
One of ordinary skill in the art would recognize many variations,
alternatives, and modifications.
[0057] In one embodiment, the index rail 330 includes one or more
plenums 910. For example, two adjacent plenums 910 are separated by
a divider 920. In another example, the one or more plenums 910 are
used for the placement of one or more cables 1010. In yet another
example, the one or more cables 340 include the one or more cables
1010. In another embodiment, the index rail 330 is used to support
movement between modular rails. In yet another embodiment, the
divider 920 of the index rail 330 is eliminated so that one or more
cables 1010 are placed in the same plenum of the index rail 330. In
yet another embodiment, the one or more cables 1010 are
interconnected with the cable 610 and/or the cable 630 in order to,
for example, collect the generated power at the central inverter
350 for transmission to the power grid.
[0058] According to one embodiment, the one or more cable plenums
910 also have one or more covers that provide both mechanical and
weather protection for the one or more cables. According to another
embodiment, the index rail 330 is scribed, slotted, or notched at
one or more intervals along its length to provide one or more
plenums for the placement of one or more cables (e.g., the one or
more cables 340) that are perpendicular to the index rail 330
and/or for the drainage of water from the index rail 330. For
example, the one or more notches are substantially perpendicular to
the index rail 330. According to yet another embodiment, the one or
more cables 1010 do not need to be placed in the one or more
plenums 910, but could instead be placed separately from the index
rail 330, for example, in underground trenches.
[0059] As shown in FIG. 9, in one embodiment, the index rail 330
also includes one or more vehicle support surfaces 930 (e.g.,
tracks, rails or road beds). In one embodiment, the one or more
vehicle support surfaces 930 allow a vehicle to move along the
index rail 330. For example, the vehicle is used to install PV
modules and/or provide logistics, operational, and/or maintenance
support for the photovoltaic array. In another example, the index
rail 330 includes various positional indicators that are installed
at intervals along its length. For example, the positional
indicators include, but not limited to, magnetic wires, RFID
modules, and/or visual indicators that denote the location of the
particular index rail segment within the larger photovoltaic array.
In another example, a vehicle that operates along the index rail
includes sensors for detecting these positional indicators so that
the vehicle can detect its location within the photovoltaic
array.
[0060] In another embodiment, the index rail 330 is optimized to
reduce the amount of material needed per unit length. For example,
the thickness of a bottom portion 940 of the index rail 330 is
optimized to reduce amount of material needed for a given surface
roughness of a particular site. In one example, the index rail 330
is constructed from concrete. In yet another example, the index
rail 330 is constructed on site (e.g., being extruded in place
using a slip-form extrusion machine).
[0061] As discussed above and further emphasized here, FIG. 9 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. For example, the
bottom portion 940 of the index rail 330 has a bottom surface that
forms one or more channels at one or more intervals along the
length of the index rail 330. In one embodiment, the one or more
channels are perpendicular to the index rail 330. In another
embodiment, the one or more channels allow water to flow under the
index rail 330.
[0062] FIG. 11 is a simplified diagram showing a method for
constructing the photovoltaic array 300 according to one embodiment
of the present invention. This diagram is merely an example, which
should not unduly limit the scope of the claims. One of ordinary
skill in the art would recognize many variations, alternatives, and
modifications. The method 2100 includes a process 2110 for building
the one or more index rails 330, a process 2120 for building the
one or more modular rails 310, a process 2130 for placing the one
or more cables 340, a process 2140 for mounting the one or more PV
modules along the one or more modular rails 310, a process 2150 for
connecting the one or more PV modules, a process 2160 for
installing the one or more inverters, a process 2170 for connecting
the one or more inverters to the one or more PV modules, and a
process 2180 for coupling the one or more inverters to the power
grid.
[0063] According to certain embodiments, the process 2110 for
building the one or more index rails 330 and/or the process 2120
for building the one or more modular rails 310 can be performed
with various methods. For example, the installation site is graded,
to the extent necessary, where each of the one or more index rails
330 and/or the one or more modular rails 310 are to be placed. In
another example, one or more "carpets" of reinforcing mesh are
rolled out where each rail is to be placed. These "carpets" are
made of concrete iron rebar mesh and/or of other non-metal
reinforcing meshes of materials such as polymers and/or glass
fibers. Afterwards, a specialized machine (e.g. a slip-form
extrusion machine) lays a continuous profile of concrete that makes
up each rail according to one embodiment.
[0064] As a specific example, the slip-form extrusion machine is
used to create a customized profile. In one embodiment, the uneven
surface of the ground where each rail is cast is naturally filled
with concrete in between the reinforcing mesh to provide a stable
rail track. In another embodiment, at one or more intervals along
the length of each rail, the concrete rail is scribed, slotted,
and/or notched (e.g., before or after the concrete has cured) to
ensure separation of the rail for thermal expansion and contraction
to prevent cracking of the rail. In yet another embodiment, the
scribes, slots, and/or notches also serve as water drainage points
along each rail to keep each cable plenum dry as well as to provide
access points for the cable that connect to the ends of the PV
module strings.
[0065] Referring to the process 2110, the one or more index rails
330 are placed substantially parallel to each other in a first
direction according to one embodiment. For example, this first
direction is approximately north-south in orientation. In another
example, once the one or more index rails 330 are in place, they
provide a convenient mechanism for the transportation of materials
and other equipment across the installation site by use of the
vehicle support surfaces 930 of the index rails. In other
embodiments, the array of rails allows for movement around the
array while avoiding the problems of ground water and mud.
[0066] Referring to the process 2120, the one or more modular rails
310 are placed substantially perpendicular to the one or more index
rails 330 according to another embodiment. For example, the one or
more modular rails 310 are placed in an approximately east-west
orientation.
[0067] As shown in FIG. 11, at the process 2130, the one or more
cables 340 are placed. For example, once the one or more index
rails 330 and/or the one or more modular rails 310 are in place,
the one or more cables 340 are placed using one or more of the
various plenums and scribes, slots, and/or notches. In another
example, the one or more cables 340 route the DC power generated by
the PV modules to the central inverter 350 for conversion.
[0068] At the process 2140, the one or more PV modules (e.g., the
PV module 510) are mounted along the one or more modular rails 310.
For example, the process 2140 is performed by at least the one or
more robotic arms 1640. In another example, the installation
process for the PV modules includes multiple operations that can be
performed in various orders. In one embodiment, these multiple
operations include affixing a PV module (e.g., a solar panel) to
the one or more mounting surfaces of a modular rail 310 using at
least one or more mechanical connectors and/or one or more adhesive
materials. For example, the one or more adhesive materials include
glue, tape, paste, T5200, Silicone, epoxies, and/or Polyurethane
foam. In another embodiment, one or more PV modules are installed
end-to-end along the modular rail 310 to form a PV module string
320.
[0069] At the process 2150, the one or more PV modules are
connected. For example, the one or more PV modules (e.g., the PV
module 510) are connected using one or more types of
interconnectors (e.g., a rigid in-line slide-on interconnector, a
flexible slide-in interconnector, a flexible ribbon interconnector,
and/or an in-line slide-in edge interconnector). In another
example, the one or more PV modules (e.g., the PV module 510) are
connected using one or more types of conventional interconnectors.
In one embodiment, one or more interconnectors are used to provide
electrical connections between the PV modules. In another
embodiment, the one or more interconnectors can provide additional
structural stability between the PV modules. In yet another
embodiment, the one or more interconnectors can eliminate the
conventional junction boxes. In yet another embodiment, the one or
more interconnectors also reduce or eliminate the need for the
extensive cabling often found in a conventional photovoltaic array.
In yet another embodiment, the one or more interconnectors are used
to connect individual PV modules into PV module strings. In yet a
further embodiment, the one or more interconnectors are used to
provide flexible interconnections between the PV modules in order
to reduce the stresses caused by heating and cooling of the PV
modules.
[0070] As shown in FIG. 11, at the processes 2160, 2170, and 2180,
the one or more inverters are installed, connected to the one or
more PV modules, and coupled to the power grid according to certain
embodiments.
[0071] FIG. 12 is a simplified diagram showing a PV-module
interconnection apparatus used for installation and operation of
the photovoltaic array 300 according to an embodiment of the
present invention. This diagram is merely an example, which should
not unduly limit the scope of the claims. One of ordinary skill in
the art would recognize many variations, alternatives, and
modifications. As shown in FIG. 12, a PV module 1110 is connected
to another PV module 1120 using a rigid in-line slide-on
interconnector 1130. As an example, the rigid in-line slide-on
interconnector 1130 includes a connector surface that mates with
the flat contact areas of at least two PV modules 1110 and 1120. In
another example, the rigid in-line slide-on interconnector 1130 is
in contact with the front glass and/or the back glass of at least
two PV modules 1110 and 1120 and is folded over the edge of the
front glass and/or the back glass of the PV modules 1110 and
1120.
[0072] FIG. 13 is a simplified diagram showing a PV module
interconnection apparatus used for installation and operation of
the photovoltaic array 300 according to another embodiment of the
present invention. This diagram is merely an example, which should
not unduly limit the scope of the claims. One of ordinary skill in
the art would recognize many variations, alternatives, and
modifications. As shown in FIG. 13, a PV module 1210 is connected
to another PV module 1220 using a flexible slide-on interconnector
1230. As an example, the flexible slide-on interconnector 1230
includes two separate connector surfaces, which mate with the flat
contact areas of the PV modules 1210 and 1220 respectively. In
another example, the flexible slide-on interconnector 1230 is in
contact with the front glass and/or the back glass of at least two
PV modules 1210 and 1220 and is folded over the edge of the front
glass and/or the back glass of the PV modules 1210 and 1220.
[0073] FIG. 14 is a simplified diagram showing a PV module
interconnection apparatus used for installation and operation of
the photovoltaic array 300 according to yet another embodiment of
the present invention. This diagram is merely an example, which
should not unduly limit the scope of the claims. One of ordinary
skill in the art would recognize many variations, alternatives, and
modifications. As shown in FIG. 14, a PV module 1310 is connected
to another PV module using a flexible ribbon interconnector 1320.
As an example, the flexible ribbon interconnector 1320 is
integrated with at least two PV modules. In one embodiment, the
flexible ribbon interconnector 1320 is partially inserted between
the front glass and the back glass of the PV module 1310 and
between the front glass and the back glass of another PV module. In
another embodiment, the flexible ribbon interconnector 1320 allows
factory preassembly (including pre-interconnection) of PV modules.
After the preassembly, the PV modules can be folded on top of each
other for storage and/or transportation according to some
embodiments.
[0074] FIGS. 15 and 16 are simplified diagrams showing a PV module
interconnection apparatus used for installation and operation of
the photovoltaic array 300 according to yet another embodiment of
the present invention. These diagrams are merely examples, which
should not unduly limit the scope of the claims. One of ordinary
skill in the art would recognize many variations, alternatives, and
modifications.
[0075] In one embodiment, a PV module 1410 is connected to another
PV module 1420 using an in-line slide-in edge interconnector 1450.
As an example, the in-line slide-in edge interconnector 1450 is
mounted under two PV modules 1410 and 1420. In one embodiment, the
in-line slide-in edge interconnector 1450 allows for automatic
installation. In another embodiment, the in-line slide-in edge
interconnector 1450 can improve environmental and mechanical
protection. In another embodiment, the in-line slide-in edge
interconnector 1450 includes a male connector 1440 and a female
connector 1430. For example, the male connector 1440 and the female
connector 1430 are mounted under two different PV modules 1420 and
1410, respectively. In another example, the pin on the male
connector 1440 can slide in and out of the mating socket on the
corresponding female connector 1430. In yet another example, the
in-line slide-in edge interconnector 1450 allows for movement
(e.g., due to thermal expansion) to take place between the PV
modules 1410 and 1420. In yet another embodiment, in-line slide-in
edge interconnectors 1450 are pre-mounted onto multiple PV modules
so that the multiple PV modules can be installed as a group to
become a PV module string 320. In yet another embodiment, the
in-line slide-in edge interconnectors 1450 are mounted onto
multiple PV modules during installation of the PV modules.
[0076] FIG. 17 is a simplified diagram of a vehicle for performing
one or more tasks in the photovoltaic array 300 according to one
embodiment of the present invention. This diagram is merely an
example, which should not unduly limit the scope of the claims. One
of ordinary skill in the art would recognize many variations,
alternatives, and modifications. A vehicle 1600 includes one or
more wheels 1610, one or more power supplies 1620, one or more
cargo areas 1630, one or more robotic arms 1640, one or more tools
1650, one or more devices 1660 for sensing, controlling, and/or
communicating, one or more adhesive dispensing apparatuses 1670,
and one or more apparatuses 1680 for concrete surface
preparation.
[0077] For example, the vehicle 1600 can be operated along the one
or more modular rails 310 and/or the one or more index rails 330.
In another example, the vehicle 1600 is used as the vehicle 360
and/or the vehicle 370. In yet another example, the vehicle 1600
can perform one or more automated tasks and can have one or more
features depending upon the particular embodiments.
[0078] In one embodiment, the vehicle 1600 can use one or more
vehicle support surfaces (e.g., the one or more vehicle support
surfaces 430 and/or the one or more vehicle support surfaces 930).
For example, the vehicle 1600 includes the one or more wheels 1610
that roll around on the one or more vehicle support surfaces. In
another example, other forms of locomotion can be used, for example
continuous tracks and/or caterpillar treads may be used. In another
embodiment, the vehicle 1600 can use various forms of propulsion
for locomotion. For example, one or more electrical motors are used
to drive one or more of the wheels and/or caterpillar treads. In
another example, hydraulics can be used to drive one or more of the
wheels and/or caterpillar treads. In yet another example, an
internal combustion engine can be used to drive one or more of the
wheels and/or caterpillar treads.
[0079] In another embodiment, the vehicle 1600 can access one or
more power sources to run its various systems. For example, the
vehicle 1600 uses one or more batteries as the one or more power
supplies 1620. In another example, the vehicle 1600 uses an
internal combustion generator for generating power and/or
recharging the one or more batteries. In yet another example, the
vehicle 1600 uses one or more PV modules for generating power
and/or recharging the one or more batteries. In yet another
example, the vehicle 1600 is capable of recharging the one or more
batteries using one or more dedicated charging stations located at
one or more locations within the photovoltaic array 300. In yet
another example, the vehicle 1600 uses other alternative fuel
sources and generators.
[0080] In yet another embodiment, the vehicle 1600 includes the one
or more cargo areas 1630 for transporting materials and supplies
throughout the photovoltaic array 300. For example, the one or more
cargo areas 1630 can be used to transport one or more PV modules to
their points of installation. In another example, the one or more
cargo areas 1630 can be used to transport one or more replacement
PV modules to one or more desired locations and then carry away one
or more replaced PV modules. In yet another example, the one or
more cargo areas 1630 can be used to transport one or more cables,
adhesive materials, connectors, and/or other supplies needed during
the installation and operation of the photovoltaic array 300.
[0081] As shown in FIG. 17, the vehicle 1600 includes the one or
more robotic arms 1640 and/or the one or more tools 1650 according
to one embodiment. For example, each of the one or more robotic
arms 1640 is equipped with a universal gripping attachment. In
another example, each of the one or more robotic arms 1640 is
equipped with one or more specialized tools 1650. In one
embodiment, the one or more specialized tools 1650 includes a
special glass-panel lifting tool for lifting and/or manipulating
one or more glass PV modules. In another embodiment, the one or
more specialized tools 1650 can be used to apply the one or more
adhesive materials. In yet another embodiment, the one or more
specialized tools 1650 can be used to place cables, install the one
or more interconnectors (e.g., the interconnector 1130, the
interconnector 1230, the interconnector 1320, and/or the
interconnector 1450) between the PV modules, transport materials
and supplies throughout the photovoltaic array 300, load and unload
supplies, and/or any of many other tasks needed during installation
and operation of the photovoltaic array 300.
[0082] According to certain embodiments, the vehicle 1600 includes
the one or more devices 1660 for sensing, controlling, and/or
communicating. For example, the one or more devices 1660 are used
at least for sensing. In one embodiment, the vehicle 1600 is
equipped with one or more sensors used to determine its location
within the photovoltaic array 300. For example, the one or more
sensors include a sensor for global positioning system (GPS), a
mechanical sensor, a wheel sensor, an optical sensor, an RFID
sensor, and/or a magnetic sensor. In another example, the wheel
sensor is used to keep track of the location of the vehicle 1600
along the modular rail 310 and/or the index rail 330. In yet
another example, the optical sensor recognizes the edges of already
installed PV modules. In yet another example, the optical sensor is
used to recognize one or more fixed locations along the modular
rail 310 and/or the index rail 330. In yet another example, the
RFID sensor recognizes one or more fixed locations along the
modular rail 310 and/or the index rail 330 and/or recognizes one or
more selected PV modules. In yet another example, the magnetic
sensor recognizes one or more magnetic wires that are embedded into
or affixed to the modular rail 310 and/or the index rail 330.
[0083] In another example, the one or more devices 1660 are used at
least for controlling. In one embodiment, the vehicle 1600 includes
a computer system for coordinating one or more tasks that the
vehicle 1600 performs. In another embodiment, the vehicle 1600 is
in communication with a central or distributed computer system that
coordinates one or more tasks of one or more vehicles 1600 that
operate within the photovoltaic array 300.
[0084] In yet another example, the one or more devices 1660 is used
at least for communicating. In one embodiment, the vehicle 1600
communicates with one or more other vehicles within the
photovoltaic array 300 to jointly coordinate performance of the one
or more tasks. In another embodiment, the vehicle 1600 includes a
wireless communications interface (e.g., a WiFi interface, a
Bluetooth interface, and/or an RFID interface). For example, the
wireless communications interface allows the vehicle 1600 to
communicate with the external world via a wireless transceiver that
is coupled to the Internet.
[0085] According to some embodiments, the vehicle 1600 includes the
one or more adhesive dispensing apparatuses 1670, which are, for
example, used to dispense and/or apply one or more adhesive
materials (e.g., during the process 2140). According to certain
embodiments, the vehicle 1600 includes the one or more apparatuses
1680 that are used to prepare (e.g., cleaning) concrete surfaces
(e.g., the one or more mounting surfaces 410 and/or 710) during,
for example, the process 2140.
[0086] As discussed above and further emphasized here, FIG. 17 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In one embodiment, one
or more components (e.g., the one or more adhesive dispensing
apparatuses 1670) are removed from the vehicle 1600. In another
embodiment, the vehicle 1600 is used as an installation vehicle, a
supply vehicle, and/or a maintenance vehicle. For example, the
vehicle 1600 (e.g., the vehicle 360) moves along both the one or
more modular rails 310 and the one or more index rails 330.
[0087] FIG. 18 is a simplified diagram of a vehicle for performing
one or more tasks in the photovoltaic array 300 according to
another embodiment of the present invention. This diagram is merely
an example, which should not unduly limit the scope of the claims.
One of ordinary skill in the art would recognize many variations,
alternatives, and modifications. A vehicle 1700 includes one or
more wheels 1730, one or more power supplies 1740, one or more
devices 1750 for sensing, controlling, and/or communicating, one or
more parking areas 1710, and/or one or more ramps 1720.
[0088] For example, the one or more wheels 1730, the one or more
power supplies 1740, and the one or more devices 1750 are the same
as the one or more wheels 1610, the one or more power supplies
1620, and the one or more devices 1660, respectively. In another
example, the vehicle 1700 can be operated along the one or more
modular rails 310 and/or the one or more index rails 330. In yet
another example, the vehicle 1700 is used as the vehicle 370 that
carries one or more vehicles 360. In yet another example, the
vehicle 1700 can perform one or more automated tasks and can have
one or more features depending upon the particular embodiments
(e.g., transporting construction material along the one or more
index rails 330).
[0089] In one embodiment, the one or more parking areas 1710 and
the one or more ramps 1720 serve to transport one or more vehicles
(e.g., the vehicle 360 and/or the vehicle 1600) between different
modular rails 310. For example, the vehicle 1700 is automated and
pre-programmed to move to a selected modular rail 310 through a
wireless communications interface (e.g., a WiFi interface, a
Bluetooth interface, and/or an RFID interface). In another example,
the vehicle 1700 can also communicate with the one or more other
vehicles (e.g., the vehicle 360 and/or the vehicle 1600) so that
the vehicle 1700 can send commands to and/or receive commands from
the one or more other vehicles as to which modular rail 310 the
vehicle 1700 should move to.
[0090] As shown in FIGS. 17 and 18, depending upon the embodiments,
one or more vehicles can be used to automate one or more tasks for
the installation and operation of the photovoltaic array 300. For
example, a general-purpose vehicle (e.g., the vehicle 1600) can be
used to perform all the tasks, without any assistance from the
vehicle 1700. In another example, a specialized vehicle (e.g., the
vehicle 1600 and/or the vehicle 1700) can be used to perform one or
more specialized tasks.
[0091] In one embodiment, a vehicle (e.g., the vehicle 1600 and/or
the vehicle 1700) is used to partially or fully automate one or
more installation tasks of the photovoltaic array 300. For example,
the vehicle can transport the one or more PV modules to one or more
locations within the photovoltaic array 300 where the PV modules
are to be installed. In another example, the vehicle can apply the
one or more adhesive materials and/or the one or more flexible
spacers, which are used to affix the one or more PV modules to the
one or more mounting surfaces of the one or more modular rails 330
(e.g., the one or more mounting surfaces 410 and/or the one or more
mounting surfaces 710). In yet another example, the vehicle can
assemble and/or install the one or more interconnectors (e.g., the
interconnector 1130, the interconnector 1230, the interconnector
1320, and/or the interconnector 1450) between the PV modules. In
yet other examples, the vehicle can place and interconnect the one
or more cables 340 throughout the photovoltaic array 300.
[0092] In another embodiment, a vehicle (e.g., the vehicle 1600
and/or the vehicle 1700) is used to partially or fully automate one
or more operational tasks of the photovoltaic array 300, including
without limitation one or more maintenance, diagnostics, material
supply, and/or repair functions for the photovoltaic array 300. For
example, the one or more maintenance functions include vegetation
control, snow removal, cleaning, mounting integrity assessment,
and/or mobile illumination (e.g., for assessing performance of one
or more selected photovoltaic modules). In another example, the
vehicle includes one or more robotic arms (e.g., the one or more
robotic arms 1640) and/or one or more tools (e.g., the one or more
tools 1650) to perform one or more tasks. In yet another example,
the one or more tasks include cleaning of one or more PV modules to
remove dirt and dust on the front glass, replacing one or more
defective PV modules, and/or replacing one or more damaged or
deteriorated interconnectors. In yet another example, the one or
more tasks include communicating with one or more PV modules via a
wireless communications interface (e.g., a WiFi interface, a
Bluetooth interface, and/or an RFID interface) to determine the
self-diagnostic status of the one or more PV modules, and/or
lighting up individual panels of the PV modules at night and
performing diagnostic tests as to their status and general health.
In yet another example, the one or more tasks include asset
tracking and/or removing ground vegetation that interferes with the
PV modules (e.g., with a lawnmower-style accessory and/or with a
chemical spray system).
[0093] According to some embodiments, the photovoltaic array 300
can bring benefits to certain conventional PV modules 210 that are
not designed specifically for the photovoltaic array 300 if, for
example, the junction boxes 220 on the conventional PV modules 210
do not interfere with the PV-module surfaces that are to be mounted
onto one or more mounting surfaces, (e.g., the one or more mounting
surfaces 410 and/or the mounting surface 710). In one embodiment,
if the junction boxes 220 on the conventional PV modules 210 are
accessible after the PV modules 210 are affixed to the one or more
modular rails 310, automatic mounting and/or interconnection of the
PV modules 210 by one or more vehicles (e.g., the one or more
vehicles 1600 and/or the one or more vehicles 1700) can be
performed. In another embodiment, placing of the one or more cables
340 in one or more plenums (e.g., the one or more plenums 420, the
one or more plenums 620, and/or the one or more plenums 640) can be
performed for the photovoltaic array 300 with certain conventional
PV modules 210. In yet another embodiment, the periodic cleaning,
vegetation control, and testing of certain conventional PV modules
210 can be performed by one or more vehicles (e.g., the one or more
vehicles 1600 and/or the one or more vehicles 1700) for the
photovoltaic array 300. In yet another embodiment, the testing and
asset tracking of certain conventional PV modules 210 can be
performed by one or more vehicles (e.g., the one or more vehicles
1600 and/or the one or more vehicles 1700), if, for example, one or
more built-in smart RFID sensors are added to the conventional PV
modules 210.
[0094] According to another embodiment, a rail system for a
photovoltaic array includes at least one modular rail in a first
direction. The modular rail includes a first vehicle support
surface along the first direction and a first mounting surface
along the first direction. The first vehicle support surface is
configured to support at least a first vehicle moving in the first
direction, and the first mounting surface is configured to support
one or more photovoltaic modules mounted on the first mounting
surface. For example, the system is implemented according to at
least FIG. 3, FIG. 4, and/or FIG. 7.
[0095] In another example, the modular rail further includes a
plenum along the first direction, the plenum being configured to
hold one or more cables. In yet another example, the modular rail
further includes a cover for the plenum. In yet another example,
the modular rail further includes one or more notches at one or
more intervals respectively along the modular rail, and the one or
more notches are substantially perpendicular to the first
direction. In yet another example, the modular rail further
includes a base surface opposite to the first mounting surface, and
the first mounting surface is tilted relative to the base surface.
In yet another example, the modular rail further includes a base
surface opposite to the first mounting surface. The base surface
forms one or more channels at one or more intervals along the
modular rail, and the one or more channels are substantially
perpendicular to the first direction. In yet another example, the
modular rail further includes a second mounting surface along the
first direction, and the second mounting surface is substantially
coplanar with the first mounting surface. In yet another example,
the modular rail further includes one or more indicia at one or
more intervals respectively along the modular rail, and the one or
more indicia are configured to identify one or more locations in
the rail system.
[0096] In yet another example, the rail system further includes a
first photovoltaic module affixed to the first mounting surface
with at least one or more mechanical connectors. In yet another
example, the rail system further includes a first photovoltaic
module affixed to the first mounting surface with at least one or
more adhesive materials. In yet another example, the first
photovoltaic module is affixed to the first mounting surface using
at least a flexible spacer with at least the one or more adhesive
materials. In yet another example, the rail system further includes
a second photovoltaic module coupled to the first photovoltaic
module through at least an interconnector. In yet another example,
the interconnector is selected from a group consisting of a rigid
in-line slide-on interconnector, a flexible slide-in
interconnector, a flexible ribbon interconnector, and an in-line
slide-in edge interconnector.
[0097] In yet another example, the rail system further includes the
first vehicle configured to perform one or more first tasks. In yet
another example, each of the one or more first tasks is associated
with at least installation, operation, logistics, or servicing of a
photovoltaic array. In yet another example, the first vehicle is
further configured to perform the one or more first tasks
automatically. In yet another example, the first vehicle includes
at least a power supply selected from a group consisting of a
battery, a photovoltaic module, and a combustion engine. In yet
another example, the first vehicle includes at least a sensor
configured to determine a location of the first vehicle. In yet
another example, the modular rail includes one or more indicia at
one or more intervals respectively along the modular rail, the one
or more indicia are configured to identify one or more locations in
the rail system, and the sensor is further configured to determine
the location using the one or more indicia. In yet another example,
the first vehicle includes at least a communication system to
communicate with a second vehicle, the second vehicle being
configured to perform one or more second tasks. In yet another
example, the second vehicle is further configured to transport the
first vehicle.
[0098] In yet another example, the rail system further includes at
least one index rail in a second direction. The index rail includes
a second vehicle support surface along the second direction, and
the second vehicle support surface is configured to support at
least a second vehicle moving in the second direction. In yet
another example, the second vehicle support surface is further
configured to support at least the first vehicle moving in the
second direction. In yet another example, the index rail further
includes a plenum along the second direction, the plenum being
configured to hold one or more cables. In yet another example, the
index rail further includes a cover for the plenum. In yet another
example, the index rail further includes one or more notches at one
or more intervals respectively along the index rail, and the one or
more notches are substantially perpendicular to the second
direction. In yet another example, the index rail further includes
a base surface forming one or more channels at one or more
intervals along the index rail, and the one or more channels being
substantially perpendicular to the second direction. In yet another
example, the first direction and the second direction are
substantially perpendicular.
[0099] According to yet another embodiment, a method for making a
photovoltaic rail includes grading an installation site, and
extruding at least one photovoltaic rail associated with a
substantially uniform profile along its length. The process for
extruding at least one photovoltaic rail includes making at least a
vehicle support surface along the photovoltaic rail. For example,
the method is implemented according to at least FIG. 4, FIG. 7,
and/or FIG. 9.
[0100] In another example, the method further includes placing a
reinforcing mesh on the installation site before the process for
extruding at least one photovoltaic rail is performed. In yet
another example, the process for extruding at least one
photovoltaic rail further includes making at least a mounting
surface along the photovoltaic rail. In yet another example, the
process for extruding at least one photovoltaic rail further
includes making at least a plenum along the photovoltaic rail. In
yet another example, the method further includes covering the
plenum of the photovoltaic rail. In yet another example, the method
further includes making one or more notches at one or more
intervals respectively along the photovoltaic rail, and the one or
more notches are substantially perpendicular to the modular rail.
In yet another example, the photovoltaic rail is a modular rail or
an index rail.
[0101] According to yet another embodiment, a method for installing
a photovoltaic array includes forming at least one modular rail in
a first direction. The modular rail includes a first vehicle
support surface along the first direction and a mounting surface
along the first direction. Additionally, the method includes
affixing at least a first photovoltaic module and a second
photovoltaic module to the mounting surface, and interconnecting
the first photovoltaic module to the second photovoltaic module.
The process for affixing at least a first photovoltaic module and a
second photovoltaic module to the mounting surface includes moving
a first vehicle along the first vehicle support surface, and the
first vehicle includes at least one robotic arm. Additionally, the
process for affixing at least a first photovoltaic module and a
second photovoltaic module to the mounting surface includes
affixing the first photovoltaic module and the second photovoltaic
module to the mounting surface by at least the robotic arm. For
example, the method is implemented according to at least FIG. 3,
FIG. 5, FIG. 8, and/or FIG. 11. In another example, the method
further includes forming at least one index rail in a second
direction, and the index rail includes a second vehicle support
surface along the index rail. In yet another example, the method
further includes loading a first vehicle onto a second vehicle, and
moving the second vehicle carrying the first vehicle. In yet
another example, the process for affixing at least a first
photovoltaic module and a second photovoltaic module to the
mounting surface is performed with at least one or more adhesive
materials. In yet another example, the process for affixing at
least a first photovoltaic module and a second photovoltaic module
to the mounting surface is performed with at least one or more
mechanical connectors.
[0102] The present invention provides advantages over conventional
technology. Certain embodiments of the present invention provide a
photovoltaic array based on at least one or more modular rails that
enable partial or full automation of many installation and
operational tasks. Some embodiments of the present invention can
reduce time and cost of installation and operation of a
photovoltaic array. For example, the maintenance and operation cost
of the photovoltaic array is significantly reduced. In another
example, the servicing of the photovoltaic array (e.g.,
diagnostics, cleaning, and/or snow removal) is significantly
improved. Certain embodiments of the present invention provide one
or more vehicles that can move along one or more modular rails
and/or one or more index rails to navigate throughout the
photovoltaic array and perform various tasks. Some embodiments of
the present invention provide a photovoltaic array that does not
need panel-to-panel cable strain relief. Certain embodiments of the
present invention provide an installation method and system that
eliminates expensive junction boxes and standardized cable
interconnects of conventional PV modules. Some embodiments of the
present invention can improve wind tolerance of a photovoltaic
array.
[0103] Although specific embodiments of the present invention have
been described, it will be understood by those of skill in the art
that there are other embodiments that are equivalent to the
described embodiments. For example, various embodiments and/or
examples of the present invention can be combined. Accordingly, it
is to be understood that the invention is not to be limited by the
specific illustrated embodiments, but only by the scope of the
appended claims.
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