U.S. patent application number 17/337234 was filed with the patent office on 2021-12-23 for flat tile solar panels.
The applicant listed for this patent is Erthos IP LLC. Invention is credited to Michael GLADKIN, Willie HAMMACK, James Scott TYLER.
Application Number | 20210399678 17/337234 |
Document ID | / |
Family ID | 1000005826289 |
Filed Date | 2021-12-23 |
United States Patent
Application |
20210399678 |
Kind Code |
A1 |
TYLER; James Scott ; et
al. |
December 23, 2021 |
Flat Tile Solar Panels
Abstract
An earth mount-enabled utility-scale solar photovoltaic array
has plural rows of solar panels supported on the ground s to
establish an earth orientation of the solar panels. Edge portions
of the panels rest on a ground support area and provide mechanical
support, and an end curb member abuts at least one edge of the
arrangement. The panels are interconnected in at least one
series-connected string extending in at least two rows so that the
string has a total distance between terminal ends of the series
connection less than a lengthwise dimension of the solar panels
constituting the string, routed to reduce "home run" connections at
the end of the string.
Inventors: |
TYLER; James Scott; (Tempe,
AZ) ; HAMMACK; Willie; (Tempe, AZ) ; GLADKIN;
Michael; (Flagstaff, AZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Erthos IP LLC |
Tempe |
AZ |
US |
|
|
Family ID: |
1000005826289 |
Appl. No.: |
17/337234 |
Filed: |
June 2, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16682517 |
Nov 13, 2019 |
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17337234 |
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62903369 |
Sep 20, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02S 40/42 20141201;
H02S 40/36 20141201; H02S 20/10 20141201; H02S 30/10 20141201 |
International
Class: |
H02S 20/10 20060101
H02S020/10; H02S 30/10 20060101 H02S030/10; H02S 40/36 20060101
H02S040/36; H02S 40/42 20060101 H02S040/42 |
Claims
1. A utility-scale PV array comprising PV modules in adjacent rows
having flexible inter-module joints, wherein the modules contact
the ground.
2. The array of claim 1, wherein the modules are adjacent within a
row.
3. The array of claim 2, wherein the flexible inter-module joints
comprise connectors.
4. The array of claim 3, wherein the modules contact and are
supported by the ground in an azimuth-independent earth
orientation.
5. The array of claim 4, wherein some of the modules are supported
by contact with the ground at edge frames.
6. The array of claim 5, wherein the modules rest on native
topography or a smoothed or substantially flat portion of the
ground.
7. The array of claim 6, wherein connecters link rows.
8. The array of claim 7, wherein connecters link individual
modules.
9. The array of claim 8 wherein the module contacts the ground
without an intervening support structure.
10. The array of claim 9, wherein the utility scale array is earth
mounted.
11. An array comprising: adjoining rows of modules; and a means to
support module edge frames on or near the ground in an earth
orientation, wherein the modules contact the ground without a
structural support between the modules.
12. The array of claim 11 further comprising a retention means for
linking modules.
13. The array of claim 12, wherein the modules proximally link
through connectors to form an interconnected array.
14. The array of claim 13, wherein the links are flexible.
15. The array of claim 14, wherein the links are between some
modules in the same row and between some modules in separate
rows.
16. The array of claim 15 further comprising a means to
interconnect the modules in a series-connected string.
17. The array of claim 16, wherein the series-connected string
extends along at least two rows of adjacent or closely adjacent
modules and the string has terminal ends with a distance between
ends less than a lengthwise dimension of the string modules.
18. The array of claim 17, wherein the sting uses the at least two
rows to route the series connections so that a string starting with
a first end termination extends along a direction of the at least
two rows and returns along an opposite direction of the at least
two rows.
19. The array of claim 1, further comprising electrical
interconnections between the modules to form series-connected
strings, wherein the strings extend between modules along at least
two rows and the string has terminal ends with a distance between
ends less than a lengthwise dimension of the string.
Description
RELATED APPLICATIONS
[0001] The present Patent application claims priority to U.S.
patent application Ser. No. 16/682,517, filed Nov. 13, 2019,
pending, which claims priority to Provisional Patent Application
No. 62/903,369, filed Sep. 20, 2019, both of which are incorporated
into this document by this reference.
BACKGROUND
Technical Field
[0002] The disclosed technology relates to mounting of solar panels
using a terrestrial or ground-based mounting system.
Background Art
[0003] Solar panels, also called solar modules, are assemblies of
multiple photovoltaic (PV) cells hardwired together to form a
single unit, typically as a rigid piece, although it is also
possible to provide flexible solar panels. Groups of solar panels
are aggregated into an array. The panels are also wired together to
form a string, which are in turn connected to a power receiving
unit, typically an inverter or other controller which provides an
initial power output. One or more solar arrays form a solar
plant.
[0004] A silicon-based photovoltaic (PV) module, also commonly
referred to as crystalline silicon (C_Si), is a packaged, connected
assembly of typically 6.times.12 photovoltaic solar cells. For
utility scale installations, the solar panels comprise a plurality
of solar cells hardwired into a single unit, which is the module or
panel. In a typical application, the panel is made up of component
solar cells. In the above example of 6.times.12, this would be 72
solar cells, although this can vary significantly according to
design choice. The individual solar cells may be fabricated in any
convenient manner, and if desired can be separately fabricated and
mounted onto a panel substrate or can be directly fabricated onto
the substrate. There are other types of PV module technology in use
today such as "thin film" and variations of silicon-based
technology. Of the thin film, at least two module technologies
stand out. The first is CdTe (Cadmium Tellurium), also known as
CadTel. The second is known as CIGS or CIS (Copper, Indium,
Gallium, Selenium or simply Copper, Indium, Selenium).
[0005] Several panels are connected to form an array in a procedure
called "stringing". The number of panels making up a string can
vary, but in a typical application, this can be 17-29 panels
depending on both the environmental condition as well as the rated
voltage of the module selected (string voltage). The size of an
array is limited by power transmission limitations, including
limiting maximum voltage and current at the array. The panels
within an array are connected in one or more series and one or more
parallel strings. A series string is a set of panels which are
series-connected to one another. This increases the power output of
the string without a corresponding increase in current, but results
in an increase in voltage. Since it is necessary to limit the
maximum voltage output of the string as well as the maximum current
output of the array, the array is often divided into multiple
strings of a common voltage while summing the currents.
[0006] The number of panels in a string is given by way of
non-limiting example, as this is a function of design
considerations relating to panel voltage and related circuit
parameters of the strings and arrays.
[0007] The arrays are in turn connected to power conversion and
power transmission circuitry. This is accomplished by the internal
connection of the solar cells within a panel, followed by
connections between panels in an array, followed by connections to
an inverter either directly or through wiring harnesses. The
inverter is the first circuit providing the output of the solar
plant. The inverter is connected to further output circuitry, which
is connected to transmission circuitry. The details can vary, for
example for systems with local power connections, but in most solar
power systems, the first connection for power conversion,
distribution and transmission is the inverter. In other words, the
strings are connected either directly or through wiring harness
connections to the inverter.
[0008] The disclosed techniques seek to reduce the levelized cost
of energy (LCOE) created by modern utility scale solar PV power
plants. The utility scale solar PV power plant is unique from the
many other forms of solar power electricity production. Due to the
nature of the size, energy cost, safety, regulations, and operating
requirements of utility scale power production, the components,
hardware, design, construction means and methods, operations and
maintenance all have both specific and unique features which afford
them the designation "utility scale".
[0009] Since the inception of PV technology, the technology has
been an inherently expensive solution for power production. The PV
cells contained within the heart of the solar modules have been
both expensive to manufacture and relatively inefficient. Over the
past 40 years, significant strides have been made on all fronts of
PV cell and module manufacturing and technology, which have brought
their price down to a point which has made the cost of solar based
energy generation equal to and even less than all other forms of
power generation in certain geographical areas.
[0010] When the technology was in its infancy, significant
development was directed to handling and positioning the PV cells
and their larger assemblies called modules. This development
focused on what is now commonly referred to as "dual axis
tracking". This concept seeks to keep the PV cells at perpendicular
to the sun's rays--throughout the day and the year. This method
sought to extract the maximum energy from the cells to offset the
very expensive module cost.
[0011] As the price and efficiency of the cells and then modules
improved, the costs of dual axis trackers became prohibitive
relative to the cost of the panels. This resulted in the
development two supplemental technologies now known as "fixed
title" racking and "single-axis tracking". Further developments
included adaptation for these newer systems to roof-top mounting on
home, office, commercial and industrial buildings. Fixed title and
single-axis tracking methods are often categorized as "ground
mount" technologies which separate them from the "roof mount"
technologies. The ground mount reference is simply that they are
not associated with a building rather they are supported by
free-standing structures with their own foundations.
[0012] Safety and regulatory requirements are generally applied to
both secluded solar PV power plants and roof-top systems but are
different for utility scale solar photovoltaic power plants than
for solar photovoltaic installations which are not in a protected
area, as will be described. A utility scale PV power plant
typically operates at 1500 volts DC for the module. These modules
are not allowed in applications other than utility scale due to the
regulatory requirements on the voltage (EMF). Specifically,
exceeding 600 volts on the DC side places the system in a category
which requires alternative safety, and operating requirements on
the system. Examples include requiring a secured fence surrounding
the power plant which doesn't allow the public with unfettered
access to the higher voltages as well as specific training
requirements and certifications for individuals who will be
accessing the utility scale solar plant.
[0013] The operation of utility scale solar voltaic power plants is
distinguished by typical operation at EMF exceeding 600 volts. This
is established by several different code requirements, including
the (US.) National Electrical Code (NEC), the International
Electrotechnical Commission [3] (IEC, or Commission
Electrotechnique Internationale), and its affiliates. Electrical
connections between enclosures exceeding 600 volts are required to
be secured in an enclosure such as a room or fenced area which is
restricted to trained or qualified personnel. For the purposes of
this disclosure, such an enclosure will be described as a
"protected area". A non-limiting example of such a "protected area"
is referenced in NEC Article 110, Part C, which provides the
general requirements for over 600-volt applications. There can be
variations in the voltage, as it is possible to design arrays that
can safely operate at higher voltages in unprotected
environments.
[0014] These distinctions just two examples of what separate
utility scale solar PV power plants from other approaches such as
"solar roads", or "personal use solar power devices".
[0015] As for the continued push to reduce the price of energy from
the power plant, for reference, a utility scale solar plant can
make electricity in the Southwestern US at $0.040/kWh as of the
beginning 2019. With the same technology in the PV cell's--other
than the voltage, a rooftop mounted system will average out to
roughly $0.12/kWhr. This is a 3.times. difference in energy cost
using what is essentially the same PV cell technology. The reasons
for this drastic reduction in price go far beyond the cell and the
module, and in many cases are only allowed to happen inside the
utility scale plant.
[0016] Solar panels, when deployed, for example in large solar
farms, are typically mounted on racks with the racks orienting the
panels toward the sun. In the case of gimballed racks, called
trackers, the panel is pivoted to face the sun throughout the day,
with some systems also accounting for solar elevation or otherwise
account for the effect of the sun's analemma. The advantages of
fixed racking solar panels and of tracking are of course to
increase efficiency, both in establishing an alignment normal to
the sunlight and to utilize the physical area of the solar cells
more efficiently.
[0017] A fixed title rack system typically is positioned at
-25.degree. from horizontal, with the angle dependent on various
factors including the latitude of the installation site. If a panel
is mounted 25.degree. normal to the sunlight, it will convert
approximately the same percentage of impinging light, but the
amount of impinging light will be the cosine of the angle from
normal. Taking the example of 25.degree., the impinging light is
approximately 90% that of a normal alignment, with some additional
loss from the fact that the alignment of the solar cells is at an
angle to solar light impingement. A tracker will generate 8%-11%
more energy than can be expected from fixed rack-mounted panels
depending upon geography and array configuration. If the cost of
solar panels is relatively high, this loss from misalignment is
significant, but as costs of solar panels decreases, the costs
resulting from inefficient alignment decreases to an extent that it
may be more cost-effective to increase the area of the panel and
forego the expense of racking or tracking.
[0018] Off the ground, there is no need to sustain ground-caused
damage. More generally, the nature of solar cells is such that they
are generally waterproof and durable. As an example, it is common
for solar modules to be tested and certified to withstand hail of
up to 25 mm (one inch) falling at 23 m/sec. While it is possible to
clean solar panels, as a practical matter, racked solar panels are
not cleaned because the expense is not justified by expected energy
loss resulting from dirt and dust accumulation. As an example, in
Southern California, estimated energy loss from dirt and dust is
6%/year, but if the panels were cleaned, the loss would approximate
1%/year.
[0019] One consideration in mounting solar panels on racks or
trackers is the albedo effect, resulting from sunlight reflecting
from the ground, resulting in back side heating. This issue is
addressed in various ways, the most common of which is coating the
back side of the solar panels with a white coating. A common
coating for this purpose is a white pigmented Tedlar.RTM. PVF, sold
by EI duPont de Neumours, of Wilmington, Del. The Tedlar.RTM.
offers protection, but when pigmented white, reflects most of the
back side light. A disadvantage is that, as a white coating, the
white pigmented Tedlar.RTM. tends to retard heat discharge through
the back side.
[0020] The voltage output of solar arrays is constrained.
Conceptually, a solar array, or for that matter a portion of an
entire solar plant, could be series-wired to provide electrical
power transmission voltage. In addition, for a need to segment a
solar plant for redundancy, maintenance and to avoid arcing to the
ground, solar panels are voltage limited by their construction due
to the potential of arcing through the glass and backing. In
typical configurations, the array output voltage (series voltage of
the panels in each string) is 1500 volts, with lower voltages such
as 600 volts for residential applications and other applications
where untrained personnel are likely to be present. Therefore,
conventionally, solar arrays are limited in voltage. To limit the
voltage, panels are arranged in groups called strings, which are in
turn connected to the inverter through harnesses. It has been
necessary to provide harnessing arrangements due to the physical
arrangement of the strings on the trackers or racks. In a typical
tracker system, three sets of strings are used on a single tracker
assembly. To connect those strings to the inverter, harnesses of
varying configurations are used, although this number can change
according to the length of the rack and other considerations.
[0021] The harnesses themselves are a significant cost factor.
Since the system is voltage-limited, the total power output of the
plant translates to substantial wiring costs for harness systems.
Similarly, power losses through the wiring harness translates to
additional costs. Therefore, it is desired to provide a
configuration which reduces the length of cable runs in connection
harnesses.
[0022] One wiring harness configuration used with racked modules is
called "skip stringing" or "leapfrog wiring". In skip stringing,
wiring harnesses bypass alternate panels to provide efficient
wiring by limiting cabling to approximately the distance between
alternating modules. The ability to achieve connections extending
over a longer distance without a proportional increase in cabling
allows positive and negative connections to be placed closer to the
inverter, reducing the amount of harness conductors needed to
connect to the inverter. Since the panels are alternately
connected, the alternate panels within the same physical row can
provide a return circuit, thereby reducing the distance between an
end panel and the inverter. Ideally, one positive or negative pole
connection for connecting the string to the inverter is only one
panel away from the other pole connection to the inverter. This
reduces the length of the "home run" wire but requires that each
link skip alternate panels to return along the same row.
[0023] While it would be possible to string panels across two or
more rows, doing so would result in shortening of the rows, which
increases costs. Skip stringing wiring is used because, by skipping
adjacent panels, the length of a given string is maintained while
providing for a return connection along the same row. This
effectively doubles the length of a string over the length that
would exist if the string were extended across two rows.
[0024] This system of stringing accommodates the polarities of the
panels; however, this technique still requires wiring harnesses in
the connection. In addition, these techniques still require
additional harnesses to connect between the respective ends of the
strings and the inverter. Since adjacent rows of panels are
separated by a space corresponding to the cast shadow of racked
panels, it becomes impractical to string panels across rows.
[0025] Another issue involving rack- or tracker-mounted solar
panels is the effect of wind. High wind forces, which in certain
geographies reach hurricane force strength, often preclude the
construction of solar power plants in those regions, or
significantly increase the expense of doing so. In addition, the
modules themselves are easily damaged by high winds requiring
significant repair and replacement expenditures. In addition to
obvious damage resulting from the direct forces of wind, the
negative effects of cyclic loading can result in "microcracking".
This "micro-cracking" damage occurs over time causing accelerated
degradation rates of the module cells. This micro-cracking has
become a serious issue for the industry influencing long-term
module warranties.
[0026] Another issue involving racked- or tracker-mounted solar
panels is the effect of environmental corrosion due to corrosive
soils and corrosive air such as salt spray. For example, typical
power plants use driven steel piles which are sized as small as
possible to counter the effects of wind loading on the overall
structure. The design of the piles must consider the corrosion of
the steel or other materials, and still be able to last for 25
years. The more corrosive the soil, the thicker the posts will be
designed and used as sacrificial steel to ensure the 25-year life.
Similar issues exist for geographies near the oceans where salt
spray environments exist.
[0027] A membrane mounting system for solar panels is described in
US Provisional Application No. 2013/0056595 to Tomlinson, which
shows a mounting system in which a plurality of standoff mounts is
secured to a substrate or membrane in a parallel grid system.
Mounting rails are secured onto the standoff mounts, and attachment
rails are either secured to opposing side edges of the panels,
incorporated into the panels, or incorporated into a supporting
carrier for the panels.
SUMMARY
[0028] An earth mount enabled utility scale solar photovoltaic
array is comprised of a plurality of solar panels supported on the
ground to establish an earth orientation of the solar panels and
positioned in a closely adjacent arrangement or an abutting
arrangement of plural rows of the solar panels. The solar panels
are supported on the ground at panel edge portions, through an
interstitial layer buffering the plurality of solar panels from the
ground, to provide said support of the solar panels by the ground
through the interstitial layer.
[0029] The solar panels are interconnected in at least one
series-connected string, with the string extending along adjacent
or closely adjacent solar panels along at least two rows so that
the string has a distance between terminal ends of the series
connection less than a lengthwise dimension of the solar panels
constituting the string. The interconnection comprises wiring
connections engaging terminal connections on the plurality of
photovoltaic panels in the series-connected string, the wiring
connections arranged to connect adjacent panels in an arrangement
utilizing at least two rows of panels in the series-connected
string connection, in which the string uses said at least two rows
to route the connections, The wiring connections are arranged so
that a string starting with a first end termination extends along a
direction of said at least two rows and returns along an opposite
direction of said at least two rows, which reduces or eliminates
"home run" connections at the end of the string.
[0030] The earth orientation reduces the cost of the photovoltaic
array by eliminating costs associated with providing and installing
elevated supports for the solar panels. The earth orientation also
provides a flat orientation that permits cleaning with automated
horizontal surface cleaning equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a schematic diagram showing a corner bracket used
for attachment to a solar panel.
[0032] FIG. 2 depicts corner bracket 101 attached to solar
panel.
[0033] FIGS. 3A-3D are schematic diagrams showing solar panels
connected using individual corner brackets and a hold-down clamp.
FIG. 3A shows a hold-down clamp. FIG. 3B shows the clamp engaging
the corner brackets. FIG. 3C shows the clamp anchored and FIG. 3D
is a top view.
[0034] FIG. 4 is a cross-sectional view of the clamping arrangement
of FIGS. 1-3.
[0035] FIGS. 5A and 5B are schematic diagrams showing a
configuration of corner brackets, in which horizontal support is
used to secure panels. FIG. 5A shows a configuration for a clamp.
FIG. 5B shows a configuration in which a bracket extends in a
straight line connecting two modules.
[0036] FIGS. 6A and 6B are schematic diagrams showing a solar panel
with its edge frame resting on the ground. FIG. 6A shows a furrow
placement. FIG. 6B shows an end stop or curb member positioned at
the edge of an array.
[0037] FIGS. 7A-7F are schematic diagrams showing configuration of
corner brackets, in which a single disk supports four panels at
corners of the panels.
[0038] FIG. 7A is a perspective view of the corner bracket
supporting four panels, with the panels in cut-away view. FIG. 7B
shows the arrangement of the corner bracket.
[0039] FIG. 7C shows a bottom support. FIG. 7D shows a
cross-section of the corner bracket with a cinch pin. FIG. 7E shows
the corner bracket and cinch pin gripping an anchor cable. FIG. 7F
shows the corner bracket with the cinch pin securing panels.
[0040] FIGS. 8A-8C are schematic diagrams showing configuration of
a spring clip arrangement used to link panels with a minimal gap
between panels. FIG. 8A shows the spring clip in profile. FIG. 8B
shows the spring clip in an elevation view.
[0041] FIG. 8C shows the spring clip engaging one solar panel.
[0042] FIGS. 9A and 9B are schematic diagrams showing the spring
clip of FIGS. 8A-8C gripping panels. FIG. 9A shows two adjacent
panels held by a spring clip. FIG. 9B shows the gripping
arrangement of the spring clip.
[0043] FIGS. 10A and 10B are schematic diagrams showing a wiring
connection layout for adjacent solar panels.
[0044] FIG. 11 is a graphic diagram showing a sample output for a
single clear sky day of the operation of a solar power plant. The
horizontal axis represents time. The vertical axis on the left
represents the available sunlight, or "solar insolation". The
vertical axis on the right indicates the power output of the power
plant.
[0045] FIGS. 12A-12D are schematic diagrams showing a layout of a
solar array for a commercial solar power plant. FIG. 12A shows a
partial string array of three strings of panels arranged in six
rows. FIG. 12B expands 12A to show a string array comprising 18
strings with a string inverter depicted in the center. FIG. 12C
further expands 12B to show 6 string arrays further co-located to
one another.
[0046] FIG. 12D further expands 12C to show a complete solar
array.
DETAILED DESCRIPTION
[0047] Overview
[0048] The disclosed technology provides a technique for generating
electricity using either commercially available, utility scale,
solar PV (e.g., CSi, CdTe, CIGS, CIS) modules, or new and novel
adaptations of commercially available, utility scale, solar PV
modules, or new module technologies, a plurality of which are
mounted in such a way as to be both in direct contact with the
earth's surface and parallel to the same. This establishes an earth
orientation of the solar PV modules, as distinguished from a solar
orientation, although contouring of the soil and other mounting
considerations will consider the angle of the sun.
[0049] The modules are placed in a grid pattern both edge to edge
and end to end as if tiles on the floor of a house. The "utility
scale" nature of the modules limits the application of said system
to voltages exceeding 600 volts DC which ensures the system is
placed "behind the fence" whereby limiting access to trained
professionals. There can be variations in the threshold voltage, as
it is possible to design arrays that can safely operate at higher
voltages in unprotected environments, a non-limiting example being
800-volt arrays for unprotected areas. The method of attachment of
the modules to one another or to the earth is not limited by this
application. This arrangement of modules substantially reduces wind
loading effects of the modules. The arrangement of the modules
electrically is in such a way as to allow for both series and
parallel connections, and eliminates, but does not preclude the
need for discrete wiring harnesses and harness supporting means
used by traditional utility scale solar plant PV power plant
systems. This arrangement of modules provides for significant
advantages with the use of commercially available string/micro
inverters but does not preclude the use of industry standard
central inverters or alternate power conversion and transmission
technologies.
[0050] This arrangement of modules in conjunction with the use of
active electrical protective devices such as ground fault
interruption and arc fault interruption, fully eliminates the need
and subsequent use of electrical grounding and bonding of the
modules to the structure for purposes of personal protection per
code compliance. In contrast, these devices, when used in
conjunction with conductive module support structures do not meet
the protection levels necessary for code compliance, and thusly
require the use of bonding and grounding of the modules.
[0051] This arrangement of modules fully eliminates the need and
subsequent use of steel and steel structures in the power plant
thereby reducing and/or eliminating the natural weathering effects
of corrosion while enhancing life expectancy of the power plant
from a minimum requirement of 25 years to greater than 40 years.
This system does not preclude the use of steel, coated or otherwise
for site-specific applications.
[0052] The arrangement of modules allows for both commercially
available and new techniques for module cleaning and/or dust
removal from the modules surface, increasing the effective energy
production rate of the modules.
[0053] The arrangement of modules and disclosed technology
significantly reduce the negative effects of high wind forces on
the modules. These wind forces, which in certain geographies reach
hurricane force strength, often preclude the construction of solar
power plants in those regions, or significantly increase the
expense of doing so. In addition, the modules themselves are easily
damaged by high winds requiring significant repair and replacement
expenditures. By removing the modules from the direct forces of
wind, the negative effects of cyclic loading, the "micro-cracking"
is effectively eliminated.
[0054] The disclosed technology allows for both commercially
available and new or novel methods for module cooling from the
backside of the modules' surface including evaporative cooling,
alternate high emissivity coatings, the addition of "air vents" on
the edge of the module frame, the addition of various enhanced heat
transfer materials and or methods, thereby increasing the effective
energy production rate of the modules. The positioning of the
modules on the ground results in avoiding indirect sunlight and
heat from ground exposed to sunlight from heating the backsides of
the modules. As a result, rather than being a source of additional
heat, the ground beneath the modules becomes more of a heat sink.
To take further advantage of this, the modules are coated on the
backside with a dark or heat transmitting coating to promote
radiant heat transfer to the ground or airspace beneath the
modules.
[0055] The disclosed technology increases the power density per
acre of land. The quantity of acres used per unit of power
production is reduced by more than 50% from traditional utility
scale solar plant PV power plants.
[0056] The disclosed technology allows the PV array to follow the
existing contour of the land whereby the need for land preparation
such as mass grading, plowing, tilling, cutting, and filling as is
typically needed for utility scale solar plant PV power plants can
be significantly reduced and even eliminated.
[0057] The disclosed technology inherently results in an effective
decrease in annual module performance yield as measured in kWhrs
per kWp as compared to traditional solar PV power plant systems
because of not being oriented to the sun as are the trackers and
racks. While the energy performance is significantly reduced, the
reductions in electrical losses due to wiring, energy losses due to
module cleaning, costs materials and construction, construction
schedule and risk result in an overall reduction in produced energy
price (LCOE) of greater than 10% over current technologies.
[0058] The disclosed technology provides a system for a solar PV
module directly mounted to the earth. In one non-limiting
configuration, a bracket assembly utilizes the module frame as the
structural support system by securing the four corners of the solar
PV module frame directly to the earth leaving no air gap between
the earth, frame corners, and bracket assembly. Earth mounting with
no air gap reduces wind loading and uplift forces, and eliminates
shading from panel to panel, has zero or minimal row spacing
requirement, and increases the ground coverage ratio. This earth
mounted PV system orients the PV panels parallel to existing
topography and the solar panel arrays can be positioned at any
azimuth angle.
[0059] Solar panels, sometimes called solar modules, are configured
as tiles suitable for installation directly on the earth and are
configured to take advantage of the cooling and heat sinking
effects of the earth. In placing the panels, attachment brackets
may be used. The panels are snapped into or otherwise secured to
the attachment brackets, retaining a solar array on the ground or
near the ground. The ground placement allows a low-cost
configuration in that it avoids the requirements for mounting the
panels on racks and avoids shadows and the consequential need for
spacing between rows.
[0060] Since the panels are not mounted on racks, the requirements
for wind tolerance are significantly reduced. This also reduces the
need to anchor the panels because there are no racks to mount, and
since the panels are on the ground, there is substantially less
lifting due to wind conditions.
[0061] The mounting may use attachment brackets which connect
adjacent panels together. While it is possible to anchor the
brackets to the ground, the anchoring requirements, meaning
anchoring force, is greatly reduced because the panels are not
supported above-ground in the wind at an angle to the horizontal.
Instead, the panels rest substantially flat on the ground or near
the ground.
[0062] The brackets secure the panels to each other and maintain a
fixed positioning of the panels to stabilize the panels in a
desired position. Anchor stakes augment this stability but need
only secure the panels against forces experienced when laid flat on
the ground, which is substantially lower than the force incurred in
rack-mounted or tracker mounted configurations.
[0063] The lack of shadows is in part the effect of the panels not
being tilted. This results in reduced power conversion as compared
to panels oriented toward the sun, but if the total costs of the
array without racks compares favorably with the loss of output from
flat placement, flat placement can be cost-effective.
[0064] The lack of shadowing between adjacent rows of panels falls
into this economic balance. The reason there is no shadowing is
that the shadowing is created by the racking, and more
specifically, from the angled positioning of the racked panels.
Since racking is not used, there is no shadowing, which allows
configurations which close the gaps between sequential rows.
Elimination of the gaps establishes a two-dimensional connection
array, meaning closely adjacent panels extend in a row-wise
direction as well as across sequential rows because sequential rows
are also adjacently positioned. In other words, gaps between
sequential panels from row-to-row closely approximate gaps between
sequential panels along the rows.
[0065] This adjacent positioning allows wiring connections or
harnesses to take advantage of the adjacent relationships across
two or more rows, thereby reducing the need for harness
connections. In a particular arrangement, "home run" harness
connections, commonly referred to as "whips", are significantly
reduced because adjacent rows can be connected without "skip
stringing" or "leapfrog wiring". In an alternate arrangement,
sequential connections can be made with "next" panels in adjacent
rows, thereby reducing the length of connections required for "skip
stringing" or "leapfrog wiring".
[0066] The elimination of racking affords an additional advantage
when it comes to harnessing. Since there are no racks, the need to
extend the length of racks is reduced to the need to limit the
voltages of the strings, without consideration of the costs of the
racks, or in the case of trackers, the cost of tracker drive
mechanisms. This, in turn, allows the strings to terminate at both
ends of the strings close to the inverters. In this respect, having
multiple strings terminate close together allows inverters to be
positioned close to the end terminations of the strings.
[0067] Mounting System
[0068] FIG. 1 is a schematic diagram showing a corner bracket 101
used for attachment to a solar panel. Depicted are flat body 111,
inner panel attachment flange 112 outer panel attachment flange 113
and linking flange 114. Inner and outer attachment flanges 112, 113
are formed to mate with an outer frame of a solar panel (201, FIG.
2). Outer panel attachment flange 113 is in a middle position
because linking flange 114 is intended for attachment outside of
outer attachment flange 113.
[0069] Also depicted in FIG. 1 is frame grip 122, which is depicted
as an angled or wedge portion of inner attachment flange 112. It is
noted that the configuration of frame grip 122 is dependent on the
physical configuration of the solar panel's frame to which corner
bracket 101 mates.
[0070] FIG. 2 depicts corner bracket 101 attached to solar panel
201.
[0071] FIGS. 3A-3D are schematic diagrams showing solar panels 201
connected using individual corner brackets 101 and a hold-down
clamp 301. Hold-down clamp 301 is used to link corner brackets 101,
with clamp flanges 314 on clamp 301 engaging linking flanges 114 on
brackets 101. Clamp flanges 314 may also closely fit against outer
attachment flanges 113 for added stability, according to design
choice. Also depicted is anchor bolt or pin 321 (FIG. 3C), which is
used to secure hold-down clamp 301 to the ground or other
supporting surface. Anchor bolt or pin 321 is given as a
non-limiting example, as any suitable anchoring mechanism can be
used, provided corner brackets 101, hold-down clamp 301 or another
part can be secured to the anchoring mechanism.
[0072] A cross-section of the arrangement is depicted in FIG. 4.
While adjacent corner brackets 101, 101 are depicted as abutting,
in the depicted arrangement, corner brackets 101, and hence panels
201 have lateral play, as the primary function of corner brackets
101 and hold-down clamp 301 is to retain panels 201 in place on the
ground (vertical positioning), with lateral movement inherently
limited. So long as the connecting cables or "strings" can tolerate
the implied variations, the positional tolerance would not affect
the assembly. Other physical variations can be employed, so long as
the clamping and hold-down functions are accomplished.
[0073] FIGS. 5A and 5B are schematic diagrams showing a
configuration of corner brackets, in which horizontal support is
used to secure panels. FIG. 5A shows a configuration for a clamp
501 in which top and bottom corner flanges 511, 512 are used. FIG.
5B shows a configuration in which a bracket 531 extends in a
straight line connecting two modules 201. By using interlocking
links, opposing brackets 501-501 can be locked together, and
secured by the weight of the panels 201, with or without the use of
anchor bolts or pins 321 (FIG. 3C) or another suitable anchoring
device.
[0074] In addition to simpler mounting, the flat mounting system
makes some maintenance tasks easier. By way of non-limiting
example, cleaning equipment can be operated across the tops of the
panels, as will be described.
[0075] Furrow Mounting
[0076] The earth-oriented mounting lends to directly placing the
panels on the ground without the use of corner brackets or other
external bracing. In the case of solar panels with frames, the
frame can be rested on the ground, which, in turn, provides
mechanical support for the panels. FIGS. 6A and 6B are schematic
diagrams showing a solar panel 601 with its edge frame 611 resting
on the ground.
[0077] Referring to FIG. 6A, the ground is prepared by generally
smoothing the ground to desired contours for the panels 601.
Furrows 621 are dug by mechanical means, and the panels 601 are
placed on the ground with their edge frames 611 resting against the
sides of furrows 621. Furrows 621 serve to positionally stabilize
the panels 601 and provide the mechanical support for the panels
601. While it is possible for the panels 601 to directly rest on
the ground on parts of the panels 601 other than the edge frames
611, the support by the frames 611 reduces mechanical force applied
to the active parts of the panels 601 and leaves additional room
for electrical connections. Thus, the furrows 621 are formed as
grooves, depressions or channels dug into the ground to receive the
edge frames 611.
[0078] While smoothing and prior ground preparation is described,
it is possible in some circumstances to avoid some of the grading
and contouring steps. It is also possible that some ground
conditions allow direct placement of the edge frames 611 with the
edge frames 611 securing the panels 601 to the ground without a
specially prepared furrow. The smoothing facilitates orienting the
panels substantially parallel to the ground.
[0079] FIG. 6B shows an end stop or curb member 635 positioned at
the edge of an array. Curb 635 can be made of any convenient
low-cost material and serves to retard movement of the panels along
the edges of the array. Since adjacent panels within the array abut
one another or are otherwise near each other, the only place for
lateral movement would be along the edges of the array, which is
prevented by curb 635. Curb 635 also directs surface water over the
tops of the panels 601, which reduces the potential for washout of
the soil and lifting of the panels 601 caused by surface water.
Additionally, causing surface water to flow over the tops of panels
601 has some benefit in keeping the panels 601 clean. These
advantages are also useful in installations in which corner
brackets or other brackets are used to support solar panels.
[0080] The depiction of FIG. 6B shows water flow on the upslope
side of the array, in which water may have sufficient velocity to
flow upward over to top, as indicated by the arrows. Water that
pools at curb 635 would be able to flow laterally parallel to curb
635 or percolate into the ground.
[0081] Furrows 621 are given by way of non-limiting example. In
many installations, it is possible to directly support the panels
601 or the edge frames 611 directly on the ground without digging
furrows. In some soil conditions, the edge frames 611 will sink
into the soil, whereas in other conditions, the edge frames 611
will remain substantially at the top surface of the ground. It is
further expected that the panels 601 will rest against the ground
without the use of the edge frames 611, either because the edge
frames 611 can sink below a level at which the panels will rest on
the ground, or in cases in which panels are constructed without
edge frames.
[0082] Alternate Mounting Systems
[0083] FIGS. 7A-7F are schematic diagrams showing configuration of
corner brackets, in which a single disk supports four panels at
corners of the panels.
[0084] FIG. 7A is a perspective view of the corner bracket
supporting four panels, with the panels in cut-away view. FIG. 7B
shows the arrangement of the corner bracket. FIG. 7C shows a bottom
support. FIG. 7D shows a cross-section of the corner bracket with a
cinch pin. FIG. 7E shows the corner bracket and cinch pin gripping
an anchor cable. FIG. 7F shows the corner bracket with the cinch
pin securing panels.
[0085] The configuration of FIGS. 7A-7F allows simplified mounting,
and further facilitates the use of anchor cables. The anchor cable
can be any convenient anchoring system, such as a cable anchoring
system produced by American Earth Anchors of Franklin, Mass. (US),
one variation being the Model 3ST60QV anchor system, which uses a
pivoting spade attached to wire rope. The wire rope is swaged or
cinched by a swage fitting such as an American Earth Anchors
Quickvice QV18 swage fitting (Quickvice is a trademark of American
Earth Anchors). The anchor system sold by American Earth Anchors is
given by way of non-limiting example, as a wide variety of
convenient anchoring systems can be used.
[0086] Advantageously, since the panels are resting on the ground,
they are not generally exposed to sufficient upward force to lift
them upward. Therefore, the soil anchoring system need only provide
intermittent anchoring support, for example when exposed to weather
events resulting in strong winds.
[0087] FIGS. 8A-8C are schematic diagrams showing configuration of
a spring clip arrangement used to link panels with a minimal gap
between panels using spring clip 801. FIG. 8A shows spring clip 801
in profile. FIG. 8B shows spring clip 801 in an elevation view.
FIG. 8C shows spring clip 801 engaging one solar panel. Spring clip
801 comprises a flat sheet 811, folded to outer frame support 813
(for the outer frame sides of solar panels), with raised retainer
lips 814, and two inner frame supports 817 (for inner frame edges
of the solar panels), with raised retainer lips 818. As can be seen
in FIG. 8C, solar panel 201 is retained with its outer frame
resting against outer frame support 813 and held down by retainer
lip 814. The corresponding inner frame support 817 is hidden from
view in FIG. 8C. Stake holes 823 (FIGS. 8B and 8C) facilitate
anchoring spring clip 810 to the ground, for example by use of an
anchor stake or an alternate anchoring system such as the
above-mentioned cable anchoring system produced by American Earth
Anchors.
[0088] FIGS. 9A and 9B are schematic diagrams showing the spring
clip of FIGS. 8A-8C gripping panels. FIG. 9A shows two adjacent
panels 201 held by spring clip 801. FIG. 9B shows the gripping
arrangement of spring clip 801. As can be seen in FIG. 9A, the
arrangement is such that adjacent solar panels 201-201 fit closely
together, which reduces the gap between the adjacent solar panels
and reduces the tendency of the solar panels 201 to lift when
exposed to strong winds.
[0089] To install solar panels 201 into spring clip, the panels are
positioned in place and downward pressure is applied to cause the
panels 201 to snap into place.
[0090] It is further possible to restrain the panels by other
techniques. By way of non-limiting example, adjacent panels can be
linked together. Other linkages include cables or rods routed
through support edges of the panels. The cables or rods can extend
across multiple panels or across the length or width of the
array,
[0091] Backside Cooling
[0092] A further advantage of mounting the modules on the ground or
just above the ground is that cooling from the backside of the
modules' surface is easily accomplished. Cooling techniques can
include, by way of non-limiting example, evaporative cooling,
alternate high emissivity coatings, the addition of "air vents" on
the edge of the module frame, and the addition of various enhanced
heat transfer materials and or methods. The increased cooling, by
reducing the operating temperature, increases the effective energy
production rate of the modules. The positioning of the modules on
the ground results in avoiding indirect sunlight and heat from
ground exposed to sunlight from heating the backsides of the
modules. As a result, rather than being a source of additional
heat, the ground beneath the modules becomes more of a heat sink.
To take further advantage of this, the modules are coated on the
backside with a dark or heat transmitting coating to promote
radiant heat transfer to the ground or airspace beneath the
modules. By way of non-limiting example, the dark or heat
transmitting coating is provided as black-pigmented Tedlar.RTM.
PVF, sold by EI duPont de Neumours, of Wilmington, Del., or a dark
Tedlar.RTM. coating sold as "Tedlar.RTM. Charcoal".
[0093] Ventilation of the backside can be accomplished by a variety
of techniques. By way of non-limiting example, outlet vents can
connect to one or more vertical stacks to use convection to remove
warm air. Alternatively, DC power can be used to operate fans
either when power is produced or when peak power is sensed. Inlet
vents can use separate supply tubing or louvers cut into edge
frames of the modules.
[0094] Stringed Panels
[0095] FIGS. 10A and 10B are schematic diagrams showing a wiring
connection layout for adjacent solar panels 201. FIG. 10A shows an
array of three strings of panels arranged of in six rows. FIG. 10B
shows connection details. Adjacent panels 301 within a row are
series-connected. At one end of the row, the series connection
extends to the next row, and then returns to the starting end. The
end connections are in turn connected to inverter 1015. Inverter
1015 converts the power for downstream power use in the usual
manner. While one inverter 1015 is shown, multiple inverters 1015
can be used, to place the inverter connection closer to the
terminal ends of the rows.
[0096] This arrangement limits the length of the series connection,
and thereby limits output voltage of the array itself to
permissible levels. A typical voltage limit for a string of arrays
is 1500 volts, although in residential installations and other
installations where non-qualified personnel are present are
typically limited to lower voltages, such as 600 volts. The
arrangement conveniently limits the voltage to the series output by
limiting the length of the respective strings (i.e., the number of
panels connected in series).
[0097] The stringing technique works because, without racking or
trackers, the length of the rows can be made shorter. Additionally,
since there is no separate pathway between adjacent rows, running
harnessing between rows is less complicated. By way of non-limiting
example, the length of the rows can be several panels to produce
half the maximum design voltage (to accommodate the return run).
The individual panels are provided with terminal leads or pigtails,
which are directly connected to each other. This arrangement
eliminates the need to provide "home run" harness connections to
link the end of a string of panels to an inverter connection at the
end of the row. The end-of-row connection must still be connected
to the nearest inverter if the inverter is not situated immediately
at the end of the row, but the intermediate connections required to
extend a string to the end of a much longer row are eliminated.
Additional reduction in harnessing connections can be achieved
using individual inverters at the ends of the respective pairs of
rows.
[0098] Power Output
[0099] FIG. 11 is a graphic diagram showing a sample output for a
single clear sky day of the operation of a solar power plant. The
horizontal axis represents time, specifically a sample of daylight
hours from roughly 7 a.m. to roughly 7 p.m., where "solar noon" is
represented by the peak of the graph. The vertical axis on the left
represents the available sunlight, or "solar insolation" as
measured in watts per meter squared (W/m2) or the typical amount of
energy available from the sun during a given day. The curve which
peaks out at 1000 W/m2 is representative of a typical day of
sunlight. The peak, as represented by "noon" is solar noon, not to
be confused with the 12 o'clock hour, which typically varies from
solar noon. The vertical axis on the right indicates the AC power
output of the power plant, as well as the DC power potential of the
power plant, on common scales of MW, or megawatts. The actual AC
power output of the plant is represented by the two lower curves.
The curve characterized by the double hump is a typical sample of a
tracker type solar plant, with a maximum delivered power of 1 MW
(in this example). The sharp dip in the tracker curve is emblematic
of a cloud moving across the power plant between the plant and the
sun. The other lower curve represents the earth-oriented power
plant power curve, also with a maximum delivered power of 1 MW. The
two dotted lines extending above the power curves represent the
additional unused portion of DC power available. The smaller of the
two curves, which peaks out at 1.25 is the tracker power plant,
while the taller curve, peaking out at 1.45 is the earth-oriented
power plant.
[0100] The AC power output of the power plant is intentionally
limited for practical reasons, mostly related to grid capacity to
absorb large amounts of power during a small part of the day.
Therefore, the AC power output shows a flat peak at 1.00 MW on this
graph. The excess power is either not used or applied to
alternative uses such as energy storage. If alternative energy
storage is limited or not available, then it is possible to use the
additional energy to support the grid in volt-ampere reactive units
(vars, sometime given as VARs), or other power functions other than
direct increases in power output (MW). Alternatively, the excess
power con be purchased as surplus power by the grid utility or
transported across the grid for use at a remote location.
[0101] An economic advantage of the earth-oriented arrangement of
the solar modules results from the relative economics of the DC
power generation components as opposed to the total cost of
operations of the power plant. As depicted in FIG. 11, the two
power curves have an arbitrary limit of 1 MW. This limit is set by
the utility company, to which the power is sold. This limit is a
function of the needs of the utility company at the point of
interconnection of the power plant and cannot be exceeded by
contract nor design. An important point of note is that the
available DC power from the earth-oriented power plant is greater
than the available DC power from the tracker power plant as is
depicted in FIG. 11. This fact is a result of the difference in
power plant design, function, and economics. The earth-oriented
power plant has more DC power available because it has more modules
in use for the same size AC. This is due to the elimination of the
additional physical hardware required to hold the modules in space
as well as the amount of land required to house the quantity of
modules mounted on racks sufficiently spaced apart as to not shade
one another. The earth-oriented plant has an intrinsic advantage
over the tracker and fixed title plant in that it can contain more
DC as a percentage of the design output which translates to the AC
size. The additional DC power in the power plant has intrinsic
value when available. This is true for any solar plant sized with a
DC:AC ratio greater than 1.0. Since it cannot be used to deliver
real power to the grid (the delivery of which results in revenues
for the power plant owner), it is maintained as potential power,
waiting to be dispatched when and if needed. There are multiple
ways this intrinsic value is captured and can bring value to the
asset owner.
[0102] First, during periods of intermittent cloud cover, the
clouds may only cover portions of the power plant. The balance of
the plant is available to run full power. The potential power of
the additional DC has the effect of allowing the plant to ride
through lower light conditions from clouds while still delivering
100% of the AC power plant capacity allowed by the grid connection.
If there is greater DC potential, the power plant can ride through
larger clouds, and slower moving clouds without going below 100%
capacity. This effect is currently not calculated in the industry
as it is currently impossible to make these measurements. As such,
approximations are used. The accuracy of these approximations can
only be determined by empirical means. What can be said is that the
additional DC potential will result in some amount of benefit that
is greater than zero.
[0103] Second, the utility operator receiving real power from the
power plant has developed the means to use the potential DC power
to the benefit of their system. This benefit comes in the form
supplemental voltage, and frequency regulation of the grid by
adjusting the power factor control capabilities of the connected
set of inverters. Modem solar power operators have become aware of
this benefit and are now selling this portion of the available
power in the form of vars to the utility. The additional DC
potential of the earth-oriented plant brings additional vars
available to be sold as compared to a non-earth-oriented solar
plant of the same AC power rating.
[0104] Third, as the use of solid-state batteries or other energy
storage or conversion means have become more financially viable,
the ability to convert the potential DC power from the solar plant
into potential DC energy, stored in the storage means, allows for
the direct transfer of the potential DC power into the sale of real
energy to the grid at times when the sun is not available or other
valuable use of the energy. The additional DC potential of the
earth-oriented plant brings additional energy potential available
to be sold as compared to a non-earth-oriented solar plant of the
same AC power rating.
[0105] Solar Plant Layout
[0106] FIGS. 12A-12D are schematic diagrams showing a layout of a
solar array for a commercial solar power plant. FIG. 12A shows a
partial string array of three strings of panels arranged in six
rows. FIG. 12B expands 12A to show a string array comprising 18
strings with a string inverter depicted in the center. The inverter
1015 is connected to the strings for purposes of converting the DC
power from the strings to AC power. FIG. 12C further expands 12B to
show 6 string arrays further co-located to one another. FIG. 12D
further expands 12C to show a complete solar array 1220 comprised
of 18 string arrays, 18 string inverters, 324 strings, and a single
medium voltage transformer which receives power from the six sets
of three series-connected string inverters. A utility scale solar
power plant typically comprises one or more of these arrays.
[0107] Cleaning
[0108] The flat orientation of the panels also provides advantages
as far as cleaning is concerned. Panels in a flat arrangement can
easily be cleaned by an automated warehouse street sweeper. Such
cleaning devices, such as the FyBot `L` (trademark of FyBots of
Voisins-le-Bretonneux, France), a commercially available fully
autonomous warehouse sweeping robot, similar in operation to
home-use robotic vacuum cleaners such as the Roomba (trademark of
iRobot Corporation), and the automated cleaning technique was
tested with a Roomba 690-type cleaner. While cleaning is more
important for earth-oriented solar panels, the ability to use
low-cost automated cleaning allows frequent cleaning at
significantly less cost than would be incurred in if one were to
institute a regimen for cleaning rack-mounted arrays. The
implementation of a low-cost cleaning regimen on earth-oriented
arrays results in soiling loss reductions from typically 6% for
fixed title and 3.5% for trackers, non-cleaned, down to less than
1% for the cleaned earth-oriented array.
[0109] Referring again to FIGS. 12A-12D, to traverse gaps between
the portions of the arrays, bridges 1233 are provided to connect
gaps within the array to allow the automated warehouse street
sweeper to automatically traverse the gaps. Similar bridges can be
provided between arrays as well, to allow the cleaning operation to
continue automatically across multiple arrays.
[0110] It will be understood that many additional changes in the
details, materials, steps, and arrangement of parts, which have
been herein described and illustrated to explain the nature of the
subject matter, may be made by those skilled in the art within the
principle and scope of the invention as expressed in the appended
claims.
* * * * *