U.S. patent application number 16/226224 was filed with the patent office on 2019-04-25 for systems and methods for dual tilt, ballasted photovoltaic module racking.
The applicant listed for this patent is Alion Energy, Inc.. Invention is credited to Jesse Atkinson, Sean Bailey, Luis Francisco Castro Hernandez, Karl Johnson, Mark Kingsley, Brett West.
Application Number | 20190123681 16/226224 |
Document ID | / |
Family ID | 62244174 |
Filed Date | 2019-04-25 |
View All Diagrams
United States Patent
Application |
20190123681 |
Kind Code |
A1 |
Kingsley; Mark ; et
al. |
April 25, 2019 |
SYSTEMS AND METHODS FOR DUAL TILT, BALLASTED PHOTOVOLTAIC MODULE
RACKING
Abstract
Systems and methods for dual tilt, ballasted photovoltaic module
racking are provided herein. Under one aspect, a system for
supporting first and second photovoltaic modules can include first
and second elongated stiffeners respectively configured to be
coupled to and support the first and second photovoltaic modules.
The system also can include first and second feet respectively
configured to be coupled to first and second grooves respectively
provided within first and second ballasts. The system also can
include a first stiffener hinge rotatably coupling the first and
second stiffeners to one another, a first foot hinge rotatably
coupling the first foot to the first stiffener, and a second foot
hinge rotatably coupling the second foot to the second stiffener.
At least one of the first stiffener hinge and the first and second
foot hinges can include a respective mechanical stop inhibiting
rotation of that hinge beyond a respective predetermined angle.
Inventors: |
Kingsley; Mark; (Hollis,
NH) ; Atkinson; Jesse; (San Francisco, CA) ;
Bailey; Sean; (Emeryville, CA) ; Johnson; Karl;
(Berkeley, CA) ; West; Brett; (Martinez, CA)
; Castro Hernandez; Luis Francisco; (Richmond,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Alion Energy, Inc. |
Richmond |
CA |
US |
|
|
Family ID: |
62244174 |
Appl. No.: |
16/226224 |
Filed: |
December 19, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15728416 |
Oct 9, 2017 |
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16226224 |
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62406322 |
Oct 10, 2016 |
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62406874 |
Oct 11, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02S 20/10 20141201;
H02S 30/10 20141201; F24S 25/617 20180501; F24S 2030/16 20180501;
F24S 25/13 20180501; H02S 30/20 20141201; H02S 20/24 20141201; H01L
31/00 20130101; H02S 40/10 20141201 |
International
Class: |
H02S 30/10 20060101
H02S030/10; H02S 20/10 20060101 H02S020/10; H02S 30/20 20060101
H02S030/20; H02S 20/24 20060101 H02S020/24; H02S 40/10 20060101
H02S040/10 |
Claims
1. A system for supporting first and second photovoltaic modules
comprising: first and second elongated stiffeners respectively
configured to be coupled to and support the first and second
photovoltaic modules; first and second feet respectively configured
to be coupled to first and second grooves respectively provided
within first and second ballasts; a first stiffener hinge rotatably
coupling the first and second stiffeners to one another; a first
foot hinge rotatably coupling the first foot to the first
stiffener; and a second foot hinge rotatably coupling the second
foot to the second stiffener, wherein at least one of the first
stiffener hinge and the first and second foot hinges comprises a
respective mechanical stop inhibiting rotation of that hinge beyond
a respective predetermined angle.
2. The system of claim 1, wherein the first and second foot hinges
each comprises a respective mechanical stop inhibiting rotation of
that hinge beyond the respective predetermined angle.
3. The system of claim 1, wherein the first and second ballasts
each comprises an elongated piece of concrete having at least two
grooves provided therein.
4. The system of claim 1, wherein the first stiffener is configured
to be coupled along an edge of the first photovoltaic module, and
wherein the second stiffener is configured to be coupled along an
edge of the second photovoltaic module.
5. The system of claim 1, further comprising: third and fourth
elongated stiffeners respectively configured to be coupled to and
support the first and second photovoltaic modules; third and fourth
feet respectively configured to be coupled to the first and second
grooves; a second stiffener hinge rotatably coupling the third and
fourth stiffeners to one another; a third foot hinge rotatably
coupling the third foot to the third stiffener; and a fourth foot
hinge rotatably coupling the fourth foot to the fourth
stiffener.
6. The system of claim 5, wherein: the first and third stiffeners
are parallel to one another and configured to be coupled to an
underside of the first photovoltaic module; and the second and
fourth stiffeners are parallel to one another and configured to be
coupled to an underside of the second photovoltaic module.
7. The system of claim 1, wherein: the first stiffener further is
configured to be coupled to and support a third photovoltaic
module; and the second stiffener further is configured to be
coupled to and support a fourth photovoltaic module.
8. The system of claim 1, wherein, when the first and second feet
respectively are coupled to the first and second grooves, the first
and second stiffeners are at an angle of approximately 180 degrees
to one another.
9. The system of claim 8, wherein the first and second feet are
different lengths than one another.
10. The system of claim 1, wherein, when the first and second feet
respectively are coupled to the first and second grooves, the first
and second stiffeners are at an angle of approximately 120-160
degrees to one another.
11. The system of claim 1, wherein the first and second feet are
the same lengths as one another.
12. A method for supporting first and second photovoltaic module
comprising: providing first and second elongated stiffeners
respectively configured to be coupled to the first and second
photovoltaic modules so as respectively to support the first and
second photovoltaic modules; and respectively coupling first and
second feet to first and second grooves respectively provided
within first and second ballasts; wherein the first and second
stiffeners are rotatably coupled to one another with a first
stiffener hinge; wherein the first foot and the first stiffener are
rotatably coupled to one another with a first foot hinge; and
wherein the second foot and the second stiffener are rotatably
coupled to one another with a second foot hinge, wherein at least
one of the first stiffener hinge and the first and second foot
hinges comprises a respective mechanical stop inhibiting rotation
of that hinge beyond a respective predetermined angle.
13. The method of claim 12, wherein the first and second foot
hinges each comprises a respective mechanical stop inhibiting
rotation of that hinge beyond the respective predetermined
angle.
14. The method of claim 12, wherein the first and second ballasts
each comprises an elongated piece of concrete having at least two
grooves provided therein.
15. The method of claim 12, wherein the first stiffener is
configured to be coupled along an edge of the first photovoltaic
module, and wherein the second stiffener is configured to be
coupled along an edge of the second photovoltaic module.
16. The method of claim 12, wherein third and fourth elongated
stiffeners are configured to be coupled to the first and second
photovoltaic modules so as respectively to support the first and
second photovoltaic modules, the method further comprising
respectively coupling third and fourth feet to the first and second
grooves; wherein the third and fourth stiffeners are rotatably
coupled to one another with a second stiffener hinge; wherein the
third foot is rotatably coupled to the third stiffener with a third
foot hinge; and wherein the fourth foot is rotatably coupled to the
fourth stiffener with a fourth foot hinge.
17. The method of claim 16, wherein: the first and third stiffeners
are parallel to one another and configured to be coupled to an
underside of the first photovoltaic module; and the second and
fourth stiffeners are parallel to one another and configured to be
coupled to an underside of the second photovoltaic module.
18. The method of claim 12, wherein the first stiffener further is
configured to be coupled to a third photovoltaic module so as to
support the third photovoltaic module; and wherein the second
stiffener further is configured to be coupled to a fourth
photovoltaic module so as to support the fourth photovoltaic
module.
19. The method of claim 12, wherein, when the first and second feet
respectively are coupled to the first and second grooves, the first
and second stiffeners are at an angle of approximately 180 degrees
to one another.
20. The method of claim 19, wherein the first and second feet are
different lengths than one another.
21. The method of claim 12, wherein, when the first and second feet
respectively are coupled to the first and second grooves, the first
and second stiffeners are at an angle of approximately 120-160
degrees to one another.
22. The method of claim 12, wherein the first and second feet are
the same lengths as one another.
23. The method of claim 12, further comprising: receiving a crate
storing the first and second feet folded parallel to the first and
second photovoltaic modules by respective rotation of the first and
second foot hinges and the first and second stiffeners folded
parallel to one another by rotation of the first stiffener hinge;
removing the first and second photovoltaic modules coupled to the
folded first and second stiffeners coupled to the folded first and
second feet from the received crate; respectively unfolding the
first and second feet by rotating the first and second foot hinges;
unfolding the first and second stiffeners by rotating the first
stiffener hinge; inserting the unfolded first foot into the first
groove; and inserting the unfolded second foot into the second
groove.
24. The method of claim 23, further comprising: adhering the first
foot into the first groove; and adhering the second foot into the
second groove.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of and claims the benefit
of U.S. application Ser. No. 15/728,416, filed Oct. 9, 2017 and
entitled "Systems and Methods for Dual Tilt, Ballasted Photovoltaic
Module Racking", the contents of which are hereby fully
incorporated by reference.
FIELD
[0002] This invention pertains to solar photovoltaic power
plants.
BACKGROUND
[0003] A key component of a solar photovoltaic (PV) power plant is
a mechanical support structure, which can be referred to as
racking, that holds the PV modules of the power plant. Large
numbers of mechanical support structures can be used for large
solar plants.
SUMMARY
[0004] Systems and methods for dual tilt, ballasted photovoltaic
module racking are provided herein.
[0005] Under one aspect, a system is provided for supporting first
and second photovoltaic modules. The system can include first and
second elongated stiffeners respectively configured to be coupled
to and support the first and second photovoltaic modules. The
system also can include first and second feet respectively
configured to be coupled to first and second grooves respectively
provided within first and second ballasts. The system also can
include a first stiffener hinge rotatably coupling the first and
second stiffeners to one another, a first foot hinge rotatably
coupling the first foot to the first stiffener, and a second foot
hinge rotatably coupling the second foot to the second stiffener.
At least one of the first stiffener hinge and the first and second
foot hinges can include a respective mechanical stop inhibiting
rotation of that hinge beyond a respective predetermined angle.
[0006] In some configurations, the first and second foot hinges
optionally each includes a respective mechanical stop inhibiting
rotation of that hinge beyond the respective predetermined angle.
In some configurations, the first and second ballasts optionally
each includes an elongated piece of concrete having at least two
grooves provided therein. In some configurations, the first
stiffener optionally is configured to be coupled along an edge of
the first photovoltaic module, and the second stiffener optionally
is configured to be coupled along an edge of the second
photovoltaic module.
[0007] In some configurations, the system optionally further can
include third and fourth elongated stiffeners respectively
configured to be coupled to and support the first and second
photovoltaic modules, and third and fourth feet respectively
configured to be coupled to the first and second grooves. The
system optionally further can include a second stiffener hinge
rotatably coupling the third and fourth stiffeners to one another,
a third foot hinge rotatably coupling the third foot to the third
stiffener, and a fourth foot hinge rotatably coupling the fourth
foot to the fourth stiffener. Optionally, the first and third
stiffeners are parallel to one another and configured to be coupled
to an underside of the first photovoltaic module; and optionally
the second and fourth stiffeners are parallel to one another and
configured to be coupled to an underside of the second photovoltaic
module.
[0008] In some configurations, the first stiffener optionally
further is configured to be coupled to and support a third
photovoltaic module; and the second stiffener optionally further is
configured to be coupled to and support a fourth photovoltaic
module.
[0009] In some configurations, when the first and second feet
respectively are coupled to the first and second grooves, the first
and second stiffeners optionally are at an angle of approximately
180 degrees to one another. As a further option, the first and
second feet can be different lengths than one another. In some
configurations, when the first and second feet respectively are
coupled to the first and second grooves, the first and second
stiffeners optionally are at an angle of approximately 120-160
degrees to one another. Additionally, or alternatively, the first
and second feet can be the same lengths as one another.
[0010] Under another aspect, a method is provided for supporting
first and second photovoltaic modules. The method can include
providing first and second elongated stiffeners respectively
configured to be coupled to the first and second photovoltaic
modules so as respectively to support the first and second
photovoltaic modules. The method also can include respectively
coupling first and second feet to first and second grooves
respectively provided within first and second ballasts. The first
and second stiffeners can be rotatably coupled to one another with
a first stiffener hinge, the first foot and the first stiffener can
be rotatably coupled to one another with a first foot hinge, and
the second foot and the second stiffener can be rotatably coupled
to one another with a second foot hinge. At least one of the first
stiffener hinge and the first and second foot hinges can include a
respective mechanical stop inhibiting rotation of that hinge beyond
a respective predetermined angle.
[0011] In some configurations, the first and second foot hinges
optionally each includes a respective mechanical stop inhibiting
rotation of that hinge beyond the respective predetermined angle.
In some configurations, the first and second ballasts optionally
each includes an elongated piece of concrete having at least two
grooves provided therein. In some configurations, the first
stiffener is configured to be coupled along an edge of the first
photovoltaic module, and the second stiffener is configured to be
coupled along an edge of the second photovoltaic module.
[0012] In some configurations, third and fourth elongated
stiffeners optionally are configured to be coupled to the first and
second photovoltaic modules so as respectively to support the first
and second photovoltaic modules. The method further optionally can
include respectively coupling third and fourth feet to the first
and second grooves. The third and fourth stiffeners can be
rotatably coupled to one another with a second stiffener hinge, the
third foot can be rotatably coupled to the third stiffener with a
third foot hinge, and the fourth foot can be rotatably coupled to
the fourth stiffener with a fourth foot hinge. In some
configurations, the first and third stiffeners optionally are
parallel to one another and configured to be coupled to an
underside of the first photovoltaic module, the second and fourth
stiffeners optionally are parallel to one another and configured to
be coupled to an underside of the second photovoltaic module.
[0013] In some configurations, the first stiffener further
optionally is configured to be coupled to a third photovoltaic
module so as to support the third photovoltaic module; and the
second stiffener further optionally is configured to be coupled to
a fourth photovoltaic module so as to support the fourth
photovoltaic module.
[0014] In some configurations, when the first and second feet
respectively are coupled to the first and second grooves, the first
and second stiffeners optionally are at an angle of approximately
180 degrees to one another. As a further option, the first and
second feet can be different lengths than one another. In some
configurations, when the first and second feet respectively are
coupled to the first and second grooves, the first and second
stiffeners optionally are at an angle of approximately 120-160
degrees to one another. Additionally, or alternatively, the first
and second feet can be the same lengths as one another.
[0015] In some configurations, the method optionally further can
include receiving a crate storing the first and second feet folded
parallel to the first and second photovoltaic modules by respective
rotation of the first and second foot hinges and the first and
second stiffeners folded parallel to one another by rotation of the
first stiffener hinge. The method optionally further can include
removing the first and second photovoltaic modules coupled to the
folded first and second stiffeners coupled to the folded first and
second feet from the received crate. The method optionally further
can include respectively unfolding the first and second feet by
rotating the first and second foot hinges, unfolding the first and
second stiffeners by rotating the first stiffener hinge, inserting
the unfolded first foot into the first groove, and inserting the
unfolded second foot into the second groove. The method optionally
further can include adhering the first foot into the first groove,
and adhering the second foot into the second groove.
[0016] Under still another aspect, an assembly is provided for
supporting photovoltaic modules. The assembly can include first,
second, and third elongated ballasts, each including first and
second grooves and being arranged substantially parallel to one
another. A first system of the assembly can include first and
second elongated stiffeners respectively coupled to and supporting
first and second photovoltaic modules and first and second feet
respectively coupled to the first groove of the first ballast and
the first groove of the second ballast, as well as a first
stiffener hinge rotatably coupling the first and second stiffeners
to one another, a first foot hinge rotatably coupling the first
foot to the first stiffener, and a second foot hinge rotatably
coupling the second foot to the second stiffener. A second system
of the assembly can include third and fourth elongated stiffeners
respectively coupled to and supporting third and fourth
photovoltaic modules and third and fourth feet respectively coupled
to the second groove of the second ballast and the first groove of
the third ballast, as well as a second stiffener hinge rotatably
coupling the third and fourth stiffeners to one another, a third
foot hinge rotatably coupling the third foot to the third
stiffener, and a fourth foot hinge rotatably coupling the fourth
foot to the fourth stiffener.
[0017] Optionally, the assembly further can include a vehicle
configured to drive along the first and second ballasts. The
vehicle can include first and second wheels contacting the first
ballast, third and fourth wheels contacting the second ballast, and
a body coupled to the first, second, third, and fourth wheels. In
some configurations, the third and fourth wheels optionally contact
the second ballast within a gap between the second photovoltaic
module and the third photovoltaic module. In some configurations,
the body optionally is configured to pass over the first and second
photovoltaic modules as the vehicle drives along the first and
second ballasts. In some configurations, the body optionally is
configured to pass under the first and second photovoltaic modules
as the vehicle drives along the first and second ballasts. In some
configurations, the first and second ballasts optionally each
further includes a third groove disposed between the first and
second grooves. The first and second wheels optionally can contact
the third groove of the first ballast, the third and fourth wheels
optionally can contact the fourth groove of the second ballast.
[0018] In some configurations, at least one of the first stiffener
hinge and the first and second foot hinges optionally includes a
respective mechanical stop inhibiting rotation of that hinge beyond
a respective predetermined angle; and at least one of the second
stiffener hinge and the third and fourth foot hinges optionally
includes a respective mechanical stop inhibiting rotation of that
hinge beyond a respective predetermined angle. In some
configurations, the first stiffener optionally is configured to be
coupled along an edge of the first photovoltaic module, and wherein
the second stiffener is configured to be coupled along an edge of
the second photovoltaic module. In some configurations, the first
stiffener further is configured to be coupled to and support a
fifth photovoltaic module, and the second stiffener further is
configured to be coupled to and support a sixth photovoltaic
module.
[0019] Under yet another aspect, a method is provided for
supporting photovoltaic modules. The method can include providing
first, second, and third elongated ballasts, each including first
and second grooves and being arranged substantially parallel to one
another. The method can include providing a first system, the
providing of which can include providing first and second elongated
stiffeners respectively configured to be coupled to first and
second photovoltaic modules so as respectively to support the first
and second photovoltaic modules; and respectively coupling first
and second feet to the first groove of the first ballast and the
first groove of the second ballast. The first and second stiffeners
can be rotatably coupled to one another with a first stiffener
hinge, the first foot and the first stiffener can be rotatably
coupled to one another with a first foot hinge, and the second foot
and the second stiffener can be rotatably coupled to one another
with a second foot hinge. The method also can include providing a
second system, the providing of which can include providing third
and fourth elongated stiffeners configured to be coupled to third
and fourth photovoltaic modules so as respectively to support the
third and fourth photovoltaic modules, and respectively coupling
third and fourth feet to the second groove of the second ballast
and the first groove of the third ballast. The third and fourth
stiffeners can be rotatably coupled to one another with a second
stiffener hinge, the third foot and the third stiffener can be
rotatably coupled to one another with a third foot hinge, and the
fourth foot and the fourth stiffener stiffener can be rotatably
coupled to one another with a fourth foot hinge.
[0020] In some configurations, the method optionally further can
include providing a vehicle configured to drive along the first and
second ballasts. The vehicle can include first and second wheels
contacting the first ballast, third and fourth wheels contacting
the second ballast, and a body coupled to the first, second, third,
and fourth wheels. In some configurations, the third and fourth
wheels optionally contact the second ballast within a gap between
the second photovoltaic module and the third photovoltaic module.
In some configurations, the body optionally passes over the first
and second photovoltaic modules as the vehicle drives along the
first and second ballasts. In some configurations, the body
optionally passes under the first and second photovoltaic modules
as the vehicle drives along the first and second ballasts. In some
configurations, the first and second ballasts optionally each
further includes a third groove disposed between the first and
second grooves. In some configurations, the first and second wheels
optionally contact the third groove of the first ballast, and the
third and fourth wheels optionally contact the fourth groove of the
second ballast.
[0021] In some configurations, at least one of the first stiffener
hinge and the first and second foot hinges optionally includes a
respective mechanical stop inhibiting rotation of that hinge beyond
a respective predetermined angle, and at least one of the second
stiffener hinge and the third and fourth foot hinges optionally
includes a respective mechanical stop inhibiting rotation of that
hinge beyond a respective predetermined angle. In some
configurations, the first stiffener optionally is configured to be
coupled along an edge of the first photovoltaic module, and the
second stiffener optionally is configured to be coupled along an
edge of the second photovoltaic module. In some configurations, the
first stiffener further optionally is configured to be coupled to a
fifth photovoltaic module so as to support the fifth photovoltaic
module, and the second stiffener further optionally is configured
to be coupled to a sixth photovoltaic module so as to support the
sixth photovoltaic module.
[0022] In some configurations, the method further optionally can
include receiving a crate storing the first system in a shipping
configuration, which can include the first and second feet folded
parallel to the first and second photovoltaic modules by respective
rotation of the first and second foot hinges, and the first and
second stiffeners folded parallel to one another by rotation of the
first stiffener hinge. The crate further optionally can store the
second system in a shipping configuration, which can include the
third and fourth feet folded parallel to the third and fourth
photovoltaic modules by respective rotation of the third and fourth
foot hinges, and the third and fourth stiffeners folded parallel to
one another by rotation of the second stiffener hinge. The method
optionally can include removing the folded first system from the
shipped crate, removing the folded second system from the shipped
crate, and unfolding the first system into an installation
configuration, which can include respectively unfolding the first
and second feet by rotating the first and second foot hinges, and
unfolding the first and second stiffeners by rotating the first
stiffener hinge. The method optionally also can include unfolding
the second system into an installation configuration, which can
include respectively unfolding the third and fourth feet by
rotating the third and fourth foot hinges, and unfolding the third
and fourth stiffeners by rotating the second stiffener hinge. The
method also can include inserting the unfolded first foot into the
first groove of the first ballast, inserting the unfolded second
foot into the first groove of the second ballast, inserting the
unfolded third foot into the second groove of the second ballast,
and inserting the unfolded fourth foot into the first groove of the
third ballast. Optionally, the method further can include adhering
the first foot into the first groove of the first ballast, adhering
the second foot into the first groove of the second ballast,
adhering the third foot into the second groove of the second
ballast, and adhering the fourth foot into the first groove of the
third ballast.
BRIEF DESCRIPTION OF DRAWINGS
[0023] FIGS. 1A and 1B schematically illustrate perspective views
of an individual dual tilt, ballasted racking system holding
photovoltaic panels, according to certain configurations.
[0024] FIG. 2 schematically illustrates a perspective view of an
assembly of dual tilt, ballasted racking systems such as
illustrated in FIGS. 1A-1B, according to certain
configurations.
[0025] FIG. 3 schematically illustrates a perspective view of
certain components of an assembly of dual tilt, ballasted racking
systems holding photovoltaic panels, according to certain
configurations.
[0026] FIGS. 4A and 4B respectively schematically illustrate
perspective views of alternative embodiments of a hinge for use in
a dual tilt, ballasted racking system, according to certain
configurations.
[0027] FIG. 5 illustrates a flow of exemplary operations in a
method for assembly and installation of a dual tilt, ballasted
racking system, according to certain configurations.
[0028] FIG. 6 illustrates a dual tilt, ballasted racking system
during different stages of assembly and installation, according to
certain configurations.
[0029] FIG. 7 schematically illustrates a perspective view of an
alternative dual tilt, ballasted racking system, according to
certain configurations.
[0030] FIG. 8 schematically illustrates perspective view of an
assembly of dual tilt, ballasted racking systems such as
illustrated in FIG. 7, according to certain configurations.
[0031] FIGS. 9A and 9B schematically illustrate perspective views
of another alternative embodiment of a dual tilt, ballasted racking
system, according to certain configurations.
[0032] FIG. 10 schematically illustrates a perspective view of an
assembly of dual tilt, ballasted racking systems such as
illustrated in FIGS. 1A-1B together with an exemplary vehicle,
according to certain configurations.
[0033] FIG. 11 schematically illustrates a perspective view of an
assembly of dual tilt, ballasted racking systems such as
illustrated in FIGS. 1A-1B together with another exemplary vehicle
configured to clean the assembly, according to certain
configurations.
[0034] FIG. 12 schematically illustrates a perspective view of foot
hinges rotatably coupling stiffeners to feet, according to certain
configurations.
[0035] FIGS. 13A-13C schematically illustrate perspective views of
alternative foot hinges, according to certain configurations.
[0036] FIGS. 14A-14B schematically illustrate perspective views of
a stiffener hinge, according to certain configurations.
[0037] FIGS. 15A-15D schematically illustrate an alternative
ballasted racking system, according to certain configurations.
DETAILED DESCRIPTION
[0038] Systems and methods for dual tilt, ballasted photovoltaic
module racking are provided herein. According to various
embodiments provided herein, photovoltaic (PV) power plants that
include solar panels at two or more orientations or tilts can have
advantages over a PV power plan that includes solar panels at only
a single orientation or tilt. Orientation can refer to the slope
and/or direction of a PV panel relative to a fixed vector, such as
a horizontal arrow pointing north. A dual-orientation system can
include solar modules at two orientations. In one non-limiting
example, the orientations can be a 15 degree slope facing east and
a 15 degree slope facing west, but the modules may face any
direction and may have any suitable angle or slope. A
dual-orientation system can also be referred to as a dual-tilt
system.
[0039] Certain embodiments of a dual-tilt system, as compared to a
single-tilt system, may produce more power per unit land area,
experience lower wind loads, better handle loads that exist, and
have a broader curve of power production. For example, an
embodiment of a dual-tilt system with modules facing east and west
may produce more power in the mornings and/or afternoons than can a
single-tilt system. Embodiments of a dual-tilt system may produce
more power per unit area of land or surface space. A dual tilt
system may have more panel density on a site than a single tilt
system. For example, the panels may be placed closer together
without shading.
[0040] FIGS. 1A and 1B schematically illustrate perspective views
of an individual dual tilt, ballasted racking system 100 holding
first and second photovoltaic (PV) panels 102, according to certain
configurations. FIG. 1A illustrates a top view of the system, and
FIG. 1B illustrates an underside view of the system. Each of the
first and second photovoltaic panels (also referred to as modules)
102 is coupled to and supported by at least first and second
stiffeners 104. The PV panels 102 respectively can be fastened to
the stiffener(s) 104 using any suitable coupling mechanism(s), such
as adhesive or mechanical fasteners between the stiffeners and the
frame of the PV panel, which frame can be or include metal. Each
stiffener 104 meets and is rotatably coupled to another stiffener
104 at a location between the first and second photovoltaic panels
102 at a respective stiffener hinge 106. Each stiffener 104 can be
rotatably connected to a respective foot 108 at a foot hinge
110.
[0041] In some configurations, at least one of the stiffener
hinge(s) 106 and the first and second foot hinges 110 optionally
can include a respective mechanical stop inhibiting rotation of
that hinge beyond a respective predetermined angle, e.g., so as to
stop rotation approximately at an angle at which the system can be
fixedly coupled to concrete ballast 112. FIG. 12 schematically
illustrates a perspective view of foot hinges 110 rotatably
coupling stiffeners to feet, according to certain configurations.
The foot hinge 110 can be located near the end of the stiffener
104. The hinge is positioned so that the foot 108 can start in a
folded position where it is substantially parallel to the stiffener
104 and under the panel. The foot hinge 110 allows the foot 108 to
rotate to an angle between approximately 90.degree. and 180.degree.
from the stiffener. For the panel to be at a 15.degree. tilt, the
foot 108 would be at a 105.degree. angle from the stiffener 104.
The foot can have a shape such that mechanical interference between
it and the stiffener 104 occur when the foot 108 unfolds to the
desired angle for installation.
[0042] In some embodiments, the hinge mechanism between modules can
include stiffeners 104, which may be offset from one another,
joined by a rod. In various embodiments, the rod may be continuous
and span the width of one or more modules, or there may be a short
rod at each hinge location. In some embodiments, the rod may be
held in place by one or more cotter pins or bent tabs. For example,
FIGS. 14A-14B schematically illustrate perspective views of a
stiffener hinge, according to certain configurations. Hinge 106
illustrated in FIGS. 14A-14B includes a hinge pin 1402 having a
bent tab.
[0043] In some embodiments, the structural members that support the
modules of a dual-orientation system may be mounted on a ballasted
foundation. In one nonlimiting example, the ballasted foundation
can include an extruded concrete rail that optionally may have
grooves. The module support members may be secured to the ballasted
foundation with an adhesive, such as construction epoxy, embedded
in the concrete, bolted to the concrete, or otherwise suitably
fastened to the concrete. For example, in FIGS. 1A-1B, each of the
feet 108 can be coupled to a groove provided in a ballast, such as
a concrete ballast foundation 112, each of which can have at least
two grooves provided therein. The feet 108 can be adhered to the
groove of the ballast with construction epoxy or another suitable
type of adhesive. The feet 108 alternatively can be wet-set into
the concrete, or a mechanical fastener can be used to attach the
feet to another metal part that is fastened into the concrete. The
ballast 112 can be or include precast concrete, concrete formed in
place, or slip-formed concrete.
[0044] The particular angle of the photovoltaic modules relative to
one another and to the ground can be determined, in part, by the
respective angles of the foot hinges and stiffener hinge(s), the
respective lengths of the feet and the photovoltaic modules, and
the spacing of the ballasts from one another. In the nonlimiting
configuration illustrated in FIGS. 1A-1B, the feet 108 are the same
lengths as one another. However, one or more of the feet can have
different lengths than one or more other of the feet, e.g., such as
described with reference to FIGS. 15A-15D. Additionally, in the
nonlimiting configuration illustrated in FIGS. 1A-1B, when the
first and second feet respectively are coupled to the first and
second grooves, the first and second stiffeners are at an angle of
approximately 120-160 degrees to one another. As a result, the
photovoltaic panels each can be at an angle of about 10-30 degrees
relative to the ground. However, the system components readily can
be adjusted so as to arrange the photovoltaic modules 102 at any
other suitable angle(s) relative to the ground and/or relative to
one another, e.g., as described with reference to FIGS. 15A-15D.
The modules each can be arranged at a different, independently
selected angle relative to the ground.
[0045] In the nonlimiting configuration illustrated in FIGS. 1A-1B,
each photovoltaic module can be supported by one stiffener or by a
plurality of stiffeners. For example, a first photovoltaic module
102 can be coupled to first and second elongated stiffeners 104
each of which is rotatably coupled to a respective foot via a foot
hinge 110, and a second photovoltaic module 102 can be coupled to
third and fourth elongated stiffeners 104 each of which is
rotatably coupled to a respective foot via a foot hinge 110. The
first stiffener 104 can be rotatably coupled to the third stiffener
104 via a first stiffener hinge 106, and the second stiffener 104
can be rotatably coupled to the fourth stiffener 104 via a second
stiffener hinge 106. In the exemplary configuration illustrated in
FIGS. 1A-1B, the stiffeners 104 attached to the first photovoltaic
panel 102 can be parallel to one another and coupled to an
underside of the first photovoltaic module; and the stiffeners
attached to the second photovoltaic panel can be are parallel to
one another and configured to be coupled to an underside of the
second photovoltaic module. In other configurations such as
described with reference to FIG. 7, the stiffeners can be coupled
along edges of respective photovoltaic modules. Additionally, or
alternatively, in configurations such as described with reference
to FIGS. 7 and/or FIGS. 9A-9B, the stiffeners can be coupled so as
to support multiple photovoltaic modules.
[0046] In some embodiments, dual-orientation structures may span
segments of ballasted foundation. Illustratively, a single section
of ballasted foundation may support one module assembly, two module
assemblies, or more than two module assemblies. In some
embodiments, a module assembly can include two or more modules with
folding support legs that are attached in a hinged configuration.
For example, FIG. 2 schematically illustrates a perspective view of
an assembly 200 of dual tilt, ballasted racking systems such as
illustrated in FIGS. 1A-1B, according to certain configurations. As
shown in FIG. 2, a number of dual tilt racking systems 210 can be
aligned in rows on concrete ballasts 112 . . . 115. One or more of
the concrete ballasts 112 . . . 115 can be shared by adjacent
racking systems. For example, assembly 200 can include first,
second, and third elongated ballasts 112, 113, 114 each having
first and second grooves and arranged substantially parallel to one
another. A first system 210 can be configured similarly as system
100 described with reference to FIGS. 1A-1B, system 700 described
with reference to FIG. 7, or system 900 described with reference to
FIGS. 9A-9B. For example, in a manner similar to that described
with reference to FIGS. 1A-1B, first system 210 can include first
and second elongated stiffeners 104 respectively coupled to and
supporting first and second photovoltaic modules 102, and first and
second feet 108 respectively coupled to the first groove of the
first ballast 112 and the first groove of the second ballast 113. A
first stiffener hinge 106 can rotatably couple the first and second
stiffeners to one another, a first foot hinge 110 can rotatably
couple the first foot 108 to the first stiffener 104, and a second
foot hinge 110 can rotatably couple the second foot 108 to the
second stiffener 104. A second system 220 can be configured
similarly as the first system 210 and can share the second ballast
113 with the first system 210. For example, second system 220 can
include third and fourth elongated stiffeners 104 respectively
coupled to and supporting third and fourth photovoltaic modules
102, and third and fourth feet respectively coupled to the second
groove of the second ballast 113 and the first groove of the third
ballast 114. A second stiffener hinge 106 can rotatably couple the
third and fourth stiffeners 104 to one another, a third foot hinge
110 can rotatably couple the third foot 108 to the third stiffener
104, and a fourth foot hinge 110 can rotatably couple the fourth
foot 108 to the fourth stiffener 104. The stiffener hinges 106
and/or foot hinges optionally can include respective mechanical
stops inhibiting rotation of those hinges beyond a respective
predetermined angle in a manner such as provided herein.
[0047] It should be appreciated that any suitable number of support
systems can be coupled to any of the ballasts 112 . . . 115 in like
manner. For example, a plurality of systems 210 can be arranged
adjacent and parallel to one another along the first and second
ballasts 112, 113, and a plurality of systems 220 can be arranged
adjacent and parallel to one another along the second and third
ballasts 113, 114 and can share the second ballast with systems
210. Similarly, a plurality of systems 230 can be arranged adjacent
and parallel to one another along the third and fourth ballasts
114, 115 and can share the third ballast with systems 220.
Accordingly, by providing any suitable number of ballasts shared by
support systems as provided herein, a solar power plant can be
scaled to any desired size with a relatively low number of
components and with relative ease of installation such as described
with reference to FIGS. 5-6.
[0048] FIG. 3 schematically illustrates a perspective view of
certain components of an assembly of dual tilt, ballasted racking
systems holding photovoltaic panels, according to certain
configurations. More specifically, FIG. 3 schematically illustrates
a detailed view of the sides of multiple dual tilt racking systems
100. Photovoltaic (PV) panels 102 are supported by stiffeners (not
shown) which are connected to feet 108, which stand in grooves of
the ballast 112. Feet from multiple racking systems can be located
in the same groove in the ballast 112, e.g., such as described with
reference to FIGS. 2 and 8. In the example illustrated in FIG. 3,
one exemplary configuration of ballast 112 consists essentially of
concrete having three parallel grooves provided therein. First and
second grooves 301, 302 can have substantially the same dimensions
as one another and can be configured so as to receive respective
feet of photovoltaic support structures such as described herein
with reference to FIG. 1, 7, or 9, for examples. Third groove 303
can be disposed between first and second grooves 301, 302 and can
be configured so as to receive a vehicle wheel such as described
with reference to FIG. 11, e.g., can be deeper and wider than the
first and second grooves 301, 302.
[0049] In some embodiments, the hinge mechanism between modules may
include a locking mechanism that locks the structural members in an
angled position. This locking mechanism may resist the weight of
the modules and keep the hinged connection at the proper angle. For
example, FIGS. 4A-4B respectively schematically illustrate
perspective views of alternative embodiments of a hinge for use in
a dual tilt racking system, according to certain configurations.
More specifically, FIGS. 4A-4B schematically illustrate detailed
views of two different embodiments of the stiffener hinge 106 with
the PV panels omitted for clarity. When unfolding the dual-tilt
racking system 100, a mechanical lock can be used to secure the two
stiffeners 104 at the appropriate angle relative to one another.
FIG. 4A schematically illustrates images of a fully-unfolded
embodiment (top) and an embodiment of the stiffeners at angle for
deployment (bottom). The edges of the stiffeners 104 are formed so
as to lock with one another when they are aligned. For example, the
stiffeners 104 can lock because of mechanical interference of the
ends of the stiffener pieces and/or because of folded pieces at the
ends of the stiffeners which interfere mechanically with one
another at 402. FIG. 4B schematically illustrates detailed side
views of an alternative embodiment of the stiffener hinge. The top
image of FIG. 4B illustrates the two stiffeners 104 fully unfolded,
and the bottom image of FIG. 4B illustrates the two stiffeners
angled and locked in the angle appropriate for deployment. In this
embodiment, one of the stiffeners 104 includes a hole 404 near the
end. The other stiffener 104 includes a corresponding pin mechanism
406. The hole and pin are arranged so that when the pin 406 is
aligned with the hole 404, the pin slides into the hole to create a
mechanical lock and to inhibit or prevent the two stiffeners from
rotating with respect to one another. The pin 406 can be actuated
by a spring, by hand, or by other means. Configurations for locking
two stiffeners 104 such as shown in FIGS. 4A and 4B can also or
alternatively be used to lock a foot 108 with a stiffener 104 at
the foot hinge 110.
[0050] In some embodiments, modules can have racking hardware
attached to them before they are shipped to the power plant site in
a folded position. Racking hardware may be attached to one or more
of the module back surface, to one side, to two sides, or in other
configurations. In some embodiments, hinged units including one or
more modules may be configured so as to snap together during the
installation process. In some embodiments, two or more modules that
are attached together can be folded into a compact configuration
for shipping. For example, modules can be shipped from the factory
with mounting hardware (e.g., racking hardware) pre-installed so
that they can simply be unfolded and put in place at the power
plant site. In some embodiments, mounting hardware can include, for
example, processed sheet metal, hat channel, module mounting
clamps, and/or other materials. In some embodiments, modules may be
shipped from the factory (e.g., with mounting hardware installed)
in groups of two or more modules or as single modules.
[0051] In some embodiments, modules may be put into a folded
position for more efficient packaging and shipment from the factory
to the power plant installation site. For example, modules may be
packaged and folded in assemblies that include two or more modules
(with one or more structural supports and legs attached) or they
may be packaged as single modules (with one or more structural
supports and legs attached). For example, FIG. 5 illustrates a flow
of exemplary operations in a method 500 for assembly and
installation of a dual tilt, ballasted racking system and FIG. 6
illustrates a dual tilt, ballasted racking system during different
stages of assembly and installation (such as during the operations
of FIG. 5), according to certain configurations. Any suitable
racking system can be assembled and installed, e.g., such as
described with reference to FIG. 1, 7, or 9A-9B. First,
fully-folded racking systems packaged in a crate are shipped to
site for assembly (operation 502 of FIG. 5). A crate of such
racking systems is illustrated at stage 600 of FIG. 6. Each folded
racking system can be prepared, for example, by respectively
folding the feet of that system parallel to the photovoltaic
modules by rotating the respective foot hinges; and respectively
folding the stiffeners of that system parallel to one another by
rotating the stiffener hinge(s). Alternatively, each racking system
can be assembled in a completely folded or partially folded state,
and any remaining folding completed prior to packaging the racking
system into the crate. Any suitable number of the folded systems
(e.g., first and second photovoltaic modules coupled to folded
first and second stiffeners coupled to folded first and second
feet) can be packed into a crate which then is shipped to a site
for assembly.
[0052] Next, a racking system is removed from a crate (operation
504 of FIG. 5), e.g., such as illustrated at stage 602 of FIG. 6.
Such operation can include, for example, removing the first and
second photovoltaic modules coupled to the folded first and second
stiffeners coupled to the folded first and second feet from the
shipped crate. Next, the feet are unfolded from the stiffeners, and
the stiffeners are unfolded from one another (operation 506 of FIG.
5), e.g., such as illustrated at stage 604 of FIG. 6. Such
unfolding steps need not be performed simultaneously as one
another. Such operation can include, for example, respectively
unfolding the first and second feet by rotating the first and
second foot hinges (at the same time or at different times than one
another); and unfolding the first and second stiffeners by rotating
the first stiffener hinge (at the same time or at different times
than the feet are unfolded). Optionally, the stiffener hinge(s)
and/or foot hinge(s) are rotated until they lock in place at the
appropriate respective angle (operation 506 of FIG. 5), e.g.,
angles such as illustrated at stage 606 of FIG. 6. The racking
system is located at the desired spot on the concrete ballast and
fastened in place on the concrete ballast (operation 508 of FIG.
5), e.g., as illustrated at stage 608 of FIG. 6. For example, the
unfolded first foot can be inserted into the groove of a first
ballast and secured thereto, e.g., adhered thereto, and the
unfolded second foot can be inserted into the groove of a second
ballast and secured thereto, e.g., adhered thereto. It should be
appreciated that any suitable number of racking systems can be
shipped, unfolded, and coupled to any suitable number of ballasts
so as to provide an assembly of racking systems.
[0053] In some embodiments, racking hardware (e.g., structural
components) may be attached to one or more of the module back
surface (e.g., as illustrated in FIGS. 1A-1B), to one side, to two
sides, or in other suitable configurations. For example, FIG. 7
schematically illustrates a perspective view of an alternative dual
tilt racking system 700, according to certain configurations. This
configuration includes first and second PV panels 102 that
respectively are coupled to and supported by first and second
stiffeners 704. Stiffeners 704 are joined between the panels at a
stiffener hinge 706 and that are joined at respective foot hinges
710 to feet 708 at the ends of the stiffeners. In this
configuration, only one stiffener 704 is mounted on each respective
PV panel 102 and is secured at the edge of the panel. The stiffener
704 can be secured to the respective PV panel 102 with adhesive,
with fasteners attached to the frame of the panel, or with clamps
or clips that use a friction grip on the PV panel and a fastener on
the stiffener, or otherwise suitably secured to the panel.
[0054] FIG. 8 schematically illustrates perspective view of an
assembly of dual tilt racking systems such as illustrated in FIG.
7, according to certain configurations. Similarly as in FIG. 2, the
feet 708 of the racking system 700 are secured to a ballast 112
(e.g., within a groove of a concrete ballast). As shown in FIGS. 7
and 8, the first racking system 700 placed on the concrete ballast
112 can include first and second stiffeners 704 located along
respective edges of first and second PV panels 102. An additional
racking system disposed adjacent to the first racking system can be
configured similarly as the first racking system 700, and can share
the stiffeners 704 of the first racking system, which are exposed.
Accordingly, the first stiffener of a first racking system can be
configured to be coupled to and support both a first photovoltaic
module of the first racking system and a first photovoltaic module
of an adjacent racking system; and the second stiffener of the
first racking system can be configured to be coupled to and support
both a second photovoltaic module of the first racking system and a
second photovoltaic module of the adjacent racking system.
[0055] FIGS. 9A and 9B schematically illustrate perspective views
of another alternative embodiment of a dual tilt, ballasted racking
system 900, according to certain configurations. FIG. 9A
illustrates a top view of system 900, and FIG. 9B illustrates a
view of the underside of system 900. In this embodiment, multiple
solar panels 902 can be mounted on each side of the racking system.
For example, a first stiffener 904 of system 900 can be configured
to support at least first and second photovoltaic modules, and
optionally three or more photovoltaic modules, and a second
stiffener 904 of system 900 can be configured to support at least
first and second photovoltaic modules, and optionally three or more
photovoltaic modules. Such an arrangement can be used to form a
relatively large racking system or to enable the use of relatively
small form-factor PV panels. Similar to the example shown in FIGS.
1A-1B, each side of the racking system 900 can include stiffeners
904 connected to the underside of photovoltaic modules 902, and
respectively are rotatably coupled by stiffener hinges 906 to
stiffeners 904 of the other side of the racking system. Each
stiffener 904 is rotatably coupled to a respective foot 908 at a
foot hinge 910. The feet 908 stand on ballasts 912, e.g., within a
groove of a concrete ballast such as described elsewhere
herein.
[0056] In some embodiments, a ballasted dual-tilt system may be
configured such that it is compatible with operation and
maintenance vehicles. For example, a cleaning vehicle may be
configured to travel on one or more ballasted rails to clean the
modules. The cleaning vehicle may be supported by the structural
members at the top of the arch where the two slopes meet. A
vegetation management vehicle may be configured to be supported by
the rails and travel under the PV modules. In some embodiments, the
ballasted rails may also or alternatively serve as pathways for
system technicians to walk on.
[0057] For example, FIG. 10 schematically illustrates a perspective
view of an assembly of dual tilt racking systems such as
illustrated in FIGS. 1A-1B together with an exemplary vehicle 1000,
such as a maintenance vehicle configured to clean the assembly,
according to certain configurations. The vehicle 1000 includes four
wheels or wheel sets 1002, and these wheels can roll along the
ballast 112, which also acts as a track. For example, vehicle 1000
can include first and second wheels contacting a first ballast 112,
third and fourth wheels contacting a second ballast, and a body
coupled to the first, second, third, and fourth wheels. The wheels
and track act to support the vehicle 1000 and to guide it as it
moves along the ballast 112. The vehicle can be self-powered, such
as with a battery or with an engine, or can be externally powered,
such as by people or by electrical wires. An on-board battery could
be swapped out, charged by a charger connected to an external
source, or charged by an onboard solar panel. The vehicle 1000 can
include a control system and communications system so that the
vehicle can operate autonomously, collect data, and transmit data.
The body of vehicle 1000 can be configured to pass under the first
and second photovoltaic modules as the vehicle drives along the
first and second ballasts. In the example shown in FIG. 10, vehicle
1000 is short enough to fit under the dual tilt racking systems 100
so that it can travel down an entire row without disturbing any
equipment. The maintenance vehicle 1000 can be used for a variety
of tasks such as trimming vegetation, deploying herbicide,
deploying insecticide, capturing visible-spectrum or infrared
images of the ground, structure, or solar panels, carrying a
person, carrying equipment, or conducting other maintenance or
diagnostic tasks. It should be appreciated that vehicle 1000 can be
used with an assembly of any suitable racking systems, e.g., such
as illustrated in FIG. 1, 7, or 9A-9B.
[0058] FIG. 11 schematically illustrates a perspective view of an
assembly of dual tilt racking systems such as illustrated in FIGS.
1A-1B together with another exemplary vehicle 1100, such as a
maintenance vehicle configured to clean the assembly, according to
certain configurations. FIG. 11 schematically illustrates a
perspective view of multiple rows of dual tilt racking systems 100
arranged on ballast 112. A vehicle 1100 is shown located on the
concrete tracks 112 and above the solar racking systems. The
vehicle 1100 includes four wheels or wheel sets 1102 that roll on
the ballast 112. The wheels and track support the vehicle and guide
it down the row. For example, vehicle 1100 can include first and
second wheels contacting a first ballast 112, third and fourth
wheels contacting a second ballast 112, and a body coupled to the
first, second, third, and fourth wheels. The third and fourth
wheels can contact the second ballast 112 within a gap between the
photovoltaic module of a first racking system and the photovoltaic
module of a second racking system that shares the second ballast
with the first racking system. Optionally, the ballasts 112 can
include grooves configured to receive wheels of vehicle 1100, e.g.,
groove 303 such as illustrated in FIG. 3. For example, the first
and second wheels of the vehicle can contact the groove of a first
ballast 112, and the third and fourth wheels of the vehicle can
contact the fourth groove of a second ballast 112. The body of
vehicle 1100 can be configured to pass over the photovoltaic
modules coupled to those ballasts as the vehicle drives along those
ballasts.
[0059] The maintenance vehicle 1100 illustrated in FIG. 11 can be
powered and controlled similarly as the maintenance vehicle 1000
shown in FIG. 10. For example, solar panels 1106 can partially or
wholly power the vehicle. The vehicle 1100 can also include power
electronics 1104, a control system, and other onboard equipment.
The vehicle 1100 can be used to clean the solar panels, with
cleaning implements 1108. Additionally, or alternatively, the
vehicle 1100 can also be used to capture images of the panels,
infrastructure, or surrounding environment either in the visible
spectrum or in the infrared spectrum. Additionally, or
alternatively, the vehicle 1100 can be used to clear snow.
Additionally, or alternatively, the vehicle can also be used to
transport workers, transport equipment, or to carry panels or
racking systems that have been removed from the overall system. It
should be appreciated that vehicle 1100 can be used with an
assembly of any suitable racking systems, e.g., such as illustrated
in FIG. 1, 7, or 9A-9B.
[0060] FIGS. 13A-13C schematically illustrate perspective views of
alternative foot hinges, according to certain configurations, in
which 1302 is a foot, 1304 is a stiffener, and 1306 is the foot
hinge. In one example, the feet 1302 rotate 90 degrees from a
folded position for shipping to an unfolded position for
installation. The axis of rotation can be about an axis parallel to
or perpendicular to the long dimension of the stiffener 1304. In
one example, the foot 1302 can have a bent tab on the end, and a
fastener (such as a bolt), can go through this tab and through a
tab on the end of the stiffener 1304. The fastener can serve both
to connect the foot to the stiffener at hinge 1306 and also to
serve as the pivot point for rotation of the hinge. With such a
foot design, a locking mechanism can be omitted at the stiffener
hinge between the panels.
[0061] Note that a dual-orientation system may include hinged legs
that, in their stored or folded position, are perpendicular to the
structural members that are attached to the module. During
installation, magnets can be used to manage the foldable legs,
e.g., in a manner such as described in U.S. Pat. No. 9,453,660, the
entire contents of which are incorporated by reference herein. The
legs can be any suitable length so that the modules are positioned
at any desired height above the ground. The hinges between the legs
and structural members can include a grounding mechanism that forms
a continuous electrical path between the components, e.g., in a
manner such as described in US patent publication no. 2016/0365823,
the entire contents of which are incorporated by reference
herein.
[0062] In some embodiments, a hinged connection between modules
(with optional attachment of structural members and support legs)
may be used in a single-tilt configuration. The assembly can fold
into a compact configuration for shipment in a manner similar to
that described above with reference to FIGS. 5-6. For example,
FIGS. 15A-15D schematically illustrate an alternative ballasted
racking system, according to certain configurations. Similarly as
for racking system 100 described with reference to FIGS. 1A-1B,
each of the first and second photovoltaic modules 102 is coupled to
and supported by at least first and second stiffeners 1508. Each
stiffener 1508 meets and is rotatably coupled to another stiffener
1508 at a location between the first and second photovoltaic panels
102 at a respective stiffener hinge 1506. The stiffeners 1508 of a
first photovoltaic module 102 can be rotatably connected to
respective feet 1502 at foot hinges (not specifically labeled), and
stiffeners 1508 of a second photovoltaic module 102 can be
rotatably connected to respective feet 1504 at foot hinges (not
specifically labeled). Feet 1502 and feet 1504 can be different
lengths than one another. For example, the front legs 1502 can be
shorter than the rear legs 1504. When the feet 1502 and 1504
respectively are coupled to the grooves of ballasts (not shown),
the first and second stiffeners are at an angle of approximately
180 degrees to one another, and as a result the photovoltaic
modules 102 can be substantially parallel to one another.
Illustratively, a system such as shown in FIGS. 15A-15D can be
oriented toward the equator, e.g., pointed South in the Northern
Hemisphere. The photovoltaic modules 102 can be in the same plane
as one another in the illustrated configuration, but it should be
appreciated that the modules could be oriented at different angles
than one another (e.g., can be at a 15 degree tilt and a 30 degree
tilt or other suitable angles, respectively). In either single-tilt
or dual-tilt configurations, the modules optionally may be used to
block or deflect wind at the edges of the power plant system or
array section.
[0063] In exemplary embodiments such as illustrated in FIGS. 2, 8,
and 9A-9B, a dual-tilt photovoltaic system can include a foundation
that includes one or more, or two or more, ballasted rails. The
groups of modules, or arrays (or assemblies) may have a height of
one module, or they may include any suitable number of columns of
two or more modules. For example, FIGS. 9A-9B depict an embodiment
of a system that utilizes columns that include or are composed of
three modules. Any suitable number of columns, each including any
suitable number of modules, can be included.
[0064] Some embodiments of a dual-orientation system, such as
illustrated in FIGS. 1A-1B and 9A-9B, may include one or more
structural members (such as stiffeners) that are attached to the
back surface (such as the backsheet or glass surface) of the
modules. These members can include hinged mechanisms (such as
stiffener hinges) that, for example, can allow two attached modules
to fold relative to each other. Hinged mechanisms (such as foot
hinges) can also or alternatively allow support legs (such as feet)
to rotate between stowed and deployed positions. The slope of the
modules may be greater or less than the slope of the exemplary
modules shown in FIGS. 1A-1B and 9A-9B.
[0065] In one exemplary configuration, a system is provided for
supporting first and second photovoltaic modules. The system can
include first and second elongated stiffeners respectively
configured to be coupled to and support the first and second
photovoltaic modules. The system also can include first and second
feet respectively configured to be coupled to first and second
grooves respectively provided within first and second ballasts. The
system also can include a first stiffener hinge rotatably coupling
the first and second stiffeners to one another, a first foot hinge
rotatably coupling the first foot to the first stiffener, and a
second foot hinge rotatably coupling the second foot to the second
stiffener. At least one of the first stiffener hinge and the first
and second foot hinges can include a respective mechanical stop
inhibiting rotation of that hinge beyond a respective predetermined
angle. Examples of such a system are provided herein with reference
to FIGS. 1A-1B, 2, 3, 4A-4B, 7, 8, 9A-9B, 12, 13A-13C, 14A-14B, and
15A-15D.
[0066] In another exemplary configuration, a method is provided for
supporting first and second photovoltaic modules. The method can
include providing first and second elongated stiffeners
respectively configured to be coupled to the first and second
photovoltaic modules so as respectively to support the first and
second photovoltaic modules. The method also can include
respectively coupling first and second feet to first and second
grooves respectively provided within first and second ballasts. The
first and second stiffeners can be rotatably coupled to one another
with a first stiffener hinge, the first foot and the first
stiffener can be rotatably coupled to one another with a first foot
hinge, and the second foot and the second stiffener can be
rotatably coupled to one another with a second foot hinge. At least
one of the first stiffener hinge and the first and second foot
hinges can include a respective mechanical stop inhibiting rotation
of that hinge beyond a respective predetermined angle. Examples of
such a method are provided herein with reference to FIGS. 1A-1B, 2,
3, 4A-4B, 5, 6, 7, 8, 9A-9B, 12, 13A-13C, 14A-14B, and 15A-15D.
[0067] In yet another exemplary configuration, an assembly is
provided for supporting photovoltaic modules. The assembly can
include first, second, and third elongated ballasts, each including
first and second grooves and being arranged substantially parallel
to one another. A first system of the assembly can include first
and second elongated stiffeners respectively coupled to and
supporting first and second photovoltaic modules and first and
second feet respectively coupled to the first groove of the first
ballast and the first groove of the second ballast, as well as a
first stiffener hinge rotatably coupling the first and second
stiffeners to one another, a first foot hinge rotatably coupling
the first foot to the first stiffener, and a second foot hinge
rotatably coupling the second foot to the second stiffener. A
second system of the assembly can include third and fourth
elongated stiffeners respectively coupled to and supporting third
and fourth photovoltaic modules and third and fourth feet
respectively coupled to the second groove of the second ballast and
the first groove of the third ballast, as well as a second
stiffener hinge rotatably coupling the third and fourth stiffeners
to one another, a third foot hinge rotatably coupling the third
foot to the third stiffener, and a fourth foot hinge rotatably
coupling the fourth foot to the fourth stiffener. Examples of such
an assembly are provided herein with reference to FIGS. 2, 3, 8,
10, and 11.
[0068] In still another exemplary configuration, a method is
provided for supporting photovoltaic modules. The method can
include providing first, second, and third elongated ballasts, each
including first and second grooves and being arranged substantially
parallel to one another. The method can include providing a first
system, the providing of which can include providing first and
second elongated stiffeners respectively configured to be coupled
to first and second photovoltaic modules so as respectively to
support the first and second photovoltaic modules; and respectively
coupling first and second feet to the first groove of the first
ballast and the first groove of the second ballast. The first and
second stiffeners can be rotatably coupled to one another with a
first stiffener hinge, the first foot and the first stiffener can
be rotatably coupled to one another with a first foot hinge, and
the second foot and the second stiffener can be rotatably coupled
to one another with a second foot hinge. The method also can
include providing a second system, the providing of which can
include providing third and fourth elongated stiffeners configured
to be coupled to third and fourth photovoltaic modules so as
respectively to support the third and fourth photovoltaic modules,
and respectively coupling third and fourth feet to the second
groove of the second ballast and the first groove of the third
ballast. The third and fourth stiffeners can be rotatably coupled
to one another with a second stiffener hinge, the third foot and
the third stiffener can be rotatably coupled to one another with a
third foot hinge, and the fourth foot and the fourth stiffener
stiffener can be rotatably coupled to one another with a fourth
foot hinge. Examples of such a method are provided herein with
reference to FIGS. 2, 3, 5, 6, 8, 10, and 11.
[0069] While various illustrative embodiments of the invention are
described herein, it will be apparent to one skilled in the art
that various changes and modifications may be made therein without
departing from the invention. For example, the present systems and
methods are not limited to use with photovoltaic modules, and
instead can be applied to solar collectors including any type of
solar module (e.g., a module such as used with a concentrated solar
power system, such as a parabolic trough or heliostat), or any
other type of structure. All such changes and modifications that
fall within the true spirit and scope of the invention are
encompassed by the following claims.
* * * * *