Description:FIELD OF THE INVENTION
Present invention relates to a frame for photovoltaic (PV) module manufacturing and mounting. Present invention more specifically relates to a modular frame of composite construction for manufacturing of photovoltaic (PV) module in photovoltaic (PV) systems in which an extruded profile of Aluminum material with rolled profile insert made up of Steel material is used.
Proposed modular composite frame is designed for manufacturing and mounting of photovoltaic (PV) modules in residential, commercial and utility scale ground mount photovoltaic (PV) systems.
Proposed modular frame of composite construction is (i) having better mechanical strength, (ii) having improved corrosion resistance, (iii) light in weight, (iv) with auto alignment feature, (v) easy to manufacture and (vi) economic. It eliminates damage of the photovoltaic (PV) module due to dynamic loading because of wind load by firmly holding it on the mounting structure. It prevents loosening of mounting fasteners and hence of the photovoltaic (PV) module due to dynamic loading on the photovoltaic (PV) module. It is with enhanced durability, ease of mounting and having a prolonged service life of 27-30 years in line with the life span of the photovoltaic (PV) module. The proposed frame design minimizes carbon foot print.
BACKGROUND OF THE INVENTION
A frame used in photovoltaic (PV) modules provides mechanical strength to it. Further, frame is used for: (i) manufacturing of photovoltaic (PV) modules and mounting it on module mounting structures, (ii) protecting photovoltaic (PV) modules from outdoor environmental conditions such as rain, high humidity, moisture ingress etc., (iii) protecting photovoltaic (PV) modules from damage in extreme weather conditions (high wind speeds and heavy snow loading) and (iv) prolonged module operation for intended lifetime in outdoor environment. The frames presently in use are typically made of metal such as Aluminum alloy, steel or plastic or polymers such as polyvinylchloride (PVC). Silicon sealant is filled in the sections of the frame to ensure adhesion and water tightness post curing (hardening).
Clamping is most important external factor responsible for breakage of glass in frameless photovoltaic (PV) modules. Glass/glass modules are more sensitive to glass breakage. Failure may occur either at the time of installation of the photovoltaic (PV) modules or while the photovoltaic (PV) modules are in service. Factors responsible for failure may include: (i) poor geometrical design of clamp (i.e. sharp edges, too short and too narrow clamps), (ii) improper position of clamps on the module, (iii) application of excessive clamping pressure during the mounting phase, (iv) failure of material due to wind load acting on the photovoltaic (PV) module, (v) failure of material of the photovoltaic (PV) module or frame including mounting frame due to environmental effect and (vi) loosening of the clamps used for mounting the photovoltaic (PV) modules over the period of time.
DESCRIPTION OF THE RELATED ART
The invention and development of various frame design have evolved for mounting of the photovoltaic (PV) modules overcoming one or more challenges faced by the industry.
Frame design for improving flexibility while installation of the photovoltaic frame is addressed. Indian patent application number 118/DELNP/2010 discloses a solar module with a frame for mounting to a structure that can withstand wind and snow loading without failing and without increasing the mass of the solar module over conventional frames and provides flexibility during installation to allow for irregularities in the structure, such as without drilling additional holes in the frame.
Frame with different profiles and made up of materials like aluminum and steel for mounting of photovoltaic (PV) module is reported. Indian patent application number 3014/CHENP/2012 discloses frames built by using extruded profile members of aluminum alloys that surround the actual solar panels. Utility patent number CN217789623U discloses a support frame for solar photovoltaic panel, including the steel frame, the steel frame is buckled by a thin-walled steel plate and is formed and has the advantages of high strength and difficult deformation, and can form a regular accommodating cavity, thereby being beneficial to the installation of the corner connectors of the combined frame. Utility patent number CN219107373U discloses an aluminum profile for a solar photovoltaic panel frame, which comprises an aluminum profile main body along with a reinforcing long strip block to strengthen the integral strength of the whole solar photovoltaic panel frame, so that the service life of the solar photovoltaic panel frame can be effectively prolonged under the condition of natural environment, potential safety hazards such as fracture and collapse of the solar photovoltaic panel frame are reduced and the cost of photovoltaic power generation is reduced. Patent number DE19700873A1 discloses a solar collector frame consists of S-shaped profile for fastening of solar modules and solar panels over a pad with a two Chen U-shaped profile wherein the two U-shaped profiles arranged one above the other and on opposite sides are open.
Specific design of the frames for mounting of photovoltaic (PV) modules is reported to suit particular requirements. Patent number EP1860705A1 discloses a solar cell module and solar cell array provided with a notch having a predetermined opening width on an upper surface portion (light receiving surface portion) of the module frame of the solar cell module to improve the drainage of the light receiving surface. Indian patent application number 202311017890 discloses a solar panel frame that forms an overlap with an adjoining frame of a 2nd solar panel and uses less number of fasteners in comparison to a conventional frame structure of a solar module. Indian patent application number 202341074683 discloses frames of specific design for incorporating solar panels so that solar panels itself can be installed to act as a roof.
FIG. 1 shows most common design of a frame (1) used for mounting of photovoltaic (PV) modules used in industry. The frame (1) as per FIG. 1 is made up of an extruded aluminum profile (2). It is mounted on a mounting structure using a mounting bolt (3).
The frame as per FIG. 1 which is made from single material with a major focus on aesthetic feature is suffering from certain common drawbacks. The frame as per FIG. 1 is with lower mechanical load bearing capacity. Weight of aluminum required for the frame is 5.45 gram per Watt. As production of one ton of aluminum adds 4.80 tons CO2 to atmosphere, higher aluminum requirement means higher carbon footprint. Maximum mechanical structural load of 2400 Pa can be applied to existing aluminum frame and results in 866 MPa loading on the frame. Numerous frame fatigue issues and photovoltaic (PV) module damage issues are reported so far in field deployment. The existing aluminum frame as per FIG. 1 consist of predefined fixed mounting holes and are suitable for only one kind of mounting system. Less solar glass area can rest on existing aluminum frame as per FIG. 1 resulting in less strength.
OBJECT OF THE INVENTION
Principal object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that is modular in design and is of composite construction of two different material aluminum and steel.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that provides larger supporting surface area for the photovoltaic (PV) module for better stability.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that can withstand higher snow and wind loading.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that reduces an overall weight of aluminum material per KW of installed capacity of photovoltaic system.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that is provided with self-alignment feature.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that prevent loosening of fasteners because of dynamic loading to which they are subjected to.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that reduces maximum stress generated in the frame structure and thereby allowing for the use of lower thickness.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that uniformly distribute clamping load and service load on frame cross-section.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that is having better corrosion resistance.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module in which clamping fastener position can be adjusted at any longitudinal position of the frame to match with position of predrilled mounting holes in the mounting structure.
Further object of the present invention is to provide a frame for supporting and holding the photovoltaic (PV) module that is having prolonged life of 27-30 years.
The aluminum frames as per prior art used for mounting of photovoltaic (PV) module in practice have fatigue and fracture problems due to excessive vibration in case of high wind and snow loading specifically in harsh weather conditions. In such events, the photovoltaic (PV) module gets damaged, frame gets damaged, photovoltaic (PV) modules get ripped off from the mounting structure etc. All of these require replacement of affected photovoltaic (PV) modules in the fields and cause huge loss to the photovoltaic (PV) module manufacturer and the photovoltaic (PV) plant owner.
The proposed modular composite frame made up of aluminum and steel components is having better compressive and tensile strength than aluminum frames as per prior art used for mounting of photovoltaic (PV) modules and will lead to enhanced photovoltaic (PV) module durability, reliability and prolonged lifespan.
SUMMARY OF THE INVENTION
Present invention relates to a modular frame of composite construction for mounting of photovoltaic (PV) modules in photovoltaic (PV) systems in which an extruded profile of Aluminum material with rolled profile insert made up of Steel material is used.
The modular composite frame for photovoltaic module manufacturing and mounting is consisting of a main frame made up of an extruded profile of aluminum material and a sleeve insert made up of a rolled profile of steel material assembled with the main frame. The main frame supporting and holding a photovoltaic (PV) module is mounted and fastened on a mounting structure using the sleeve insert configured to fasten the main frame with a mounting structure using t-bolts. The main frame is provided with a support profile surface for resting the photovoltaic (PV) module, an upper cantilever profile for securing the photovoltaic (PV) module from opposite side of the support profile surface and a box profile along with a pair of u-shaped groove for accommodating the sleeve insert. The sleeve insert is provided with a groove, a t-bolt head engaging surface, a neck and a pair of main frame engaging profile.
The modular composite frame which is made by assembling components made from two different materials provides better mechanical load bearing capacity without compromising aesthetic feature and results into axisymmetric loading on modular composite frame and the mounting structure with reference to axis of the t-clamp. This results into improved life cycle of the modular composite frame with more uniform stress distribution in the material.
Weight of the modular composite frame is approximately 18-20 percent more than the frame as per prior art but it is approximately 10-12 percent cheaper than the frame as per prior art. Higher weight of the modular composite frame increases overall sturdiness of the structure.
Maximum stress generated in the material is reduced drastically for the modular composite frame. The modular composite frame prevents loosening of the fasteners and resulting vibrations due to dynamic in service loads acting on the modular composite frame because of spring back effect in the sleeve insert at applied clamping force. The modular composite frame is having improved life span with more uniform stress distribution in the material and especially suitable for upcoming bigger photovoltaic (PV) modules (e.g. 700 Wp).
Use of the modular composite frame as per new design reduces CO2 emission to atmosphere by approximately 10 percent. The modular composite frame is suitable for any kind of mounting structure. It is a universal frame for all type of the photovoltaic (PV) module mounting applications. There is a continuous longitudinal groove in the modular composite frame and is completely flexible with respect to any mounting hole location requirement. Further, there is no restriction on mounting hole’s size and dimension. More solar glass area rest on the modular composite frame due to wider a support profile surface resulting in more stability of mounting of the photovoltaic (PV) module.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention as per the present patent application are described with reference to the following drawings in which like elements are labeled similarly. The present invention will be more clearly understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a schematic diagram showing most common design of a frame (1) made up of an extruded aluminium profile (2) for manufacturing and mounting of photovoltaic (PV) modules.
FIG. 2 is a schematic diagram showing modular composite frame (100) for the photovoltaic (PV) module manufacturing and mounting as per present invention.
FIG. 3 is a schematic diagram showing mounting of the modular composite frame (100) on the mounting structure (105) along with the photovoltaic (PV) module (104) held in it.
FIG. 4 is a schematic diagram showing the t-bolt adjustment direction at any longitudinal position of the modular composite frame (100).
FIG. 5 (a-b) is photographs showing damage witnessed in the photovoltaic (PV) module.
FIG. 6 (a-b) is photographs showing failure due to ripping off of the photovoltaic (PV) module from the mounting structure.

List of designations/ reference numbers in figure
1. a frame as per prior art
2. an extruded aluminum profile
3. a mounting bolt
100. a modular composite frame
101. a main frame
102. a sleeve insert
103. t-bolts
104. a photovoltaic (PV) module
105. a mounting structure
106. a support profile surface
107. an upper cantilever profile
108. a box profile
109. a pair of u-shaped groove
110. a groove
111. a t-bolt head engaging surface
112. a neck
113. a pair of main frame engaging profile
114. a head of the t-bolt
115. a threaded shank of the t-bolt
116. a nut
117. a pair of resting surface
118. an axis of the t-bolt
119. a minimum clearance between an inner surface (120) of the box profile (108) and an outer surface (121) of a sleeve insert (102)
120. an inner surface of the box profile (108)
121. an outer surface of the sleeve insert
122. an axis of the sleeve insert
123. a dimension of the neck (112)
124. a minimum clearance between an inner surface (125) of a sleeve insert (102) and an outer surface (126) of a t-bolt (103)
125. an inner surface of a sleeve insert (102)
126. an outer surface of a t-bolt (103)
DETAILED DESCRIPTION OF THE INVENTION
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or its uses.
The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered as a part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms and directives thereof are for convenience of description only and do not require that the apparatus be constructed or operated in a particular manner unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar references to a relationship wherein structures are secured or attached either directly or indirectly through intervening structures, as well as both movable and rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.
Present invention relates to a modular frame of composite construction for manufacturing and mounting of photovoltaic (PV) module in photovoltaic (PV) systems in which an extruded profile of Aluminum material with rolled profile insert made up of Steel material is used.
As shown in FIG. 3, the modular composite frame (100) for photovoltaic (PV) module manufacturing and mounting is consisting of a main frame (101) and a sleeve insert (102) assembled with the main frame (101). The main frame (101) supports and holds the photovoltaic (PV) module (104). The main frame (101) supporting and holding the photovoltaic (PV) module (104) is mounted and fastened on a mounting structure (105) using the sleeve insert (102) assembled with the main frame (101) and configured to fasten the main frame (101) with the mounting structure (105) using t-bolts (103).
As shown in FIG. 2, the main frame (101) is made up of a longitudinal extruded profile of aluminum material. As shown in FIG. 2, the main frame (101) is provided with a support profile surface (106), an upper cantilever profile (107) extending from the support profile surface (106), a box profile (108) along with a pair of u-shaped groove (109) formed beneath the support profile surface (106). The support profile surface (106) supports the photovoltaic (PV) module (104). The upper cantilever profile (107) secures and holds the photovoltaic (PV) module (104) from an opposite side of the support profile surface (106). The sleeve insert (102) is assembled with the box profile (108) by accommodating it inside the box profile (107) and supporting a pair of main frame engaging profile (113) provided on the sleeve insert (102) into the pair of u-shaped groove (109) of the main frame (101).
The sleeve insert (102) is made up of a longitudinal rolled profile of steel material. As shown in FIG. 2, the sleeve insert (102) provided with a groove (110), a t-bolt head engaging surface (111), a neck (112) and a pair of main frame engaging profile (113). The groove (110) is of such geometry and dimensions that accommodate a head (114) portion of the t-bolt (103) and allow it to slide freely longitudinally in the sleeve insert (102). In unclamped condition, bottom surface of the head (114) of the t-bolt (103) rest freely on the t-bolt head engaging surface (111) of the sleeve insert (102). The t-bolt head engaging surface (111) act as one of the clamping surface for mounting of the modular composite frame (100) on the mounting structure (105) using the t-bolt (103) and a nut (116). A dimension (123) of the neck (112) is kept such that it accommodate a threaded shank (115) of the t-bolt (103) and allow it to slide longitudinally in the sleeve insert (102) while resting the t-bolt (103) on the t-bolt head engaging surface (111). Because of such a construction of the sleeve insert (102), as shown in FIG. 4, the t-bolt can be adjusted at any longitudinal position of the modular composite frame (100) to match with predrilled mounting holes provided on the mounting structure (105). In assembled condition, the pair of main frame engaging profile (113) of the sleeve insert (102) rest on an internal surface of the pair of u-shaped groove (109). As shown in FIG. 3, upon tightening of the nut (116), the t-bolt (103) clamps the sleeve insert (102) by generating axial force on the t-bolt head engaging surface (111) and the pair of main frame engaging profile (113) to rigidly mount the main frame (101) on the mounting structure (105) by a pair of resting surface (117).
As shown in FIG. 2, inner dimensions of the box profile (108) and outer dimensions of the sleeve insert (102) are decided such that a minimum clearance (119) is maintained between an inner surface (120) of the box profile (108) and an outer surface (121) of the sleeve insert (102) in assembled condition. As shown in FIG. 2, inner dimensions of the sleeve insert (102) are decided such that a minimum clearance (124) is maintained between an inner surface (125) of the sleeve insert (102) and an outer surface (126) of the t-bolt (103) in assembled condition. This feature allows for automatic local alignment of an axis (122) of the sleeve insert (103) with an axis (118) of the t-bolt (103) upon tightening of the nut (116) on the mounting structure (105) after resting the modular composite frame (100) using the pair of resting surface (117) on the mounting structure (105) and passing the t-bolt (103) through the pre-drilled hole provided on the mounting structure (105). The minimum clearance (119) is in a range of 0.5-1.0 mm and the minimum clearance (124) is in a range of 0.8-1.5 mm.
Length of the main frame (101) and the sleeve insert (102) assembled with the main frame (101) is configured to accommodate and support total length of the photovoltaic (PV) module (104).
The modular composite frame (100) for photovoltaic (PV) module mounting is made by assembling components made from two different materials. The main frame (101) is made up of a longitudinal extruded profile of aluminum material. Whereas, the sleeve insert (102) is made up of a longitudinal rolled profile of steel material. In assembled condition, such a construction provides better mechanical load bearing capacity without compromising aesthetic feature. Further, geometry of the modular composite frame results into axisymmetric loading on modular composite frame (100) and the mounting structure (105) with reference to axis of the t-clamp (103). This results into improved life cycle of the modular composite frame (100) with more uniform stress distribution in the material.
Weight of aluminum and weight of steel used per Watt capacity of the photovoltaic (PV) module is 3.81 gram and 2.90 gram respectively. So overall combined material weight of 6.71 gram per Watt capacity of the photovoltaic (PV) module is used. In conventional frame made up of only aluminum, 5.45 gram of aluminum per Watt capacity of the photovoltaic (PV) module is used. Weight of the modular composite frame is approximately 18-20 percent more than the frame as per prior art but it is with approximately 10-12 percent cheaper than the frame as per prior art. (cost of extruded aluminum sections is considered at INR 200 per Kg and cost of rolled steel sections is considered as INR 70 per Kg). Little large weight of the modular composite frame increases overall sturdiness of the structure.
Maximum Mechanical structural load of 3200 Pa can be applied to modular composite frame resulting into maximum stress of 213 MPa in the modular composite frame material. Maximum Mechanical structural load of 2400 Pa can be applied to the aluminum frame as per prior art resulting into maximum stress of 866 MPs in the frame material. Numerous frame fatigue issues and photovoltaic (PV) module damage issues are reported so far in field deployment as shown in FIG. 5 (a-b) and FIG. 6 (a-b). This shows that maximum stress generated in the material is reduced drastically for the modular composite frame.
As clamping of the modular composite frame (100) on the mounting structure (105) is done using the sleeve insert (102) made up of a steel material, it prevents loosening of the fasteners due to dynamic in service loads acting on the modular composite frame because of springback effect in the sleeve insert (102) at applied clamping force. Springback property of the sleeve insert material also prevents vibrations of the fatigue loading issue in the modular composite frame (100). This results into improved life cycle of the modular composite frame (100) with more uniform stress distribution in the material. Upcoming bigger photovoltaic (PV) modules (e.g. 700 Wp) require more mechanical strength of the mounting frame for its mounting on the mounting frame, suitable for all terrain.
One ton production of aluminum results into 4.8 ton of CO2 emission whereas one ton production of steel results into 1.8 ton of CO2 emission. Hence, over all CO2 emission to the atmosphere per Watt capacity of the photovoltaic (PV) module thereby photovoltaic (PV) plant as per present frame of composite construction is 23.51 gram against addition of 26.2 gram of CO2 emission to the atmosphere per Watt capacity of the photovoltaic (PV) module thereby photovoltaic (PV) plant as per prior art design. Hence, use of the modular composite frame (100) as per new design reduces CO2 emission to atmosphere by approximately 10 percent.
The modular composite frame (100) is suitable for any kind of mounting structure. It is a universal frame for all type of the photovoltaic (PV) module mounting applications. There is a continuous longitudinal groove in the modular composite frame (100) and is completely flexible with respect to any location of the mounting hole provided in the mounting structure (105). Further, there is no restriction on mounting hole’s size and dimension.
More solar glass area rest on the modular composite frame (100) due to wider a support profile surface (106) resulting in more stability of mounting of the photovoltaic (PV) module (104). Silicon sealant is filled in the sections of the frame to ensure adhesion and water tightness post curing. The sleeve insert (102) made up of rolled profile of steel material is completely enclosed inside the main frame (101) resulting into better sealing with sealant and hence the modular composite frame (100) is found to be with better corrosion resistance. , Claims:We Claim:
1. A modular composite frame (100) for photovoltaic module manufacturing and mounting comprising of:
a main frame (101) for supporting and holding the photovoltaic (PV) module (104) and;
a sleeve insert (102) assembled with the main frame (101);
characterized in that
the sleeve insert (102) assembled with the main frame (101) is configured to fasten the main frame (101) with a mounting structure (105) using t-bolts (103),
the main frame (101) is made up of an extruded profile of aluminium material,
the main frame (101) is having a support profile surface (106) for resting the photovoltaic (PV) module (104), an upper cantilever profile (107) extending from the support profile surface (106) for securing the photovoltaic (PV) module (104) from an opposite side of the support profile surface (106) and a box profile (108) along with a pair of u-shaped groove (109) formed beneath the support profile surface (106) for accommodating the sleeve insert (102),
the sleeve insert (102) is made up of a rolled profile of steel material and,
the sleeve insert (102) is having a groove (110) for accommodating a head (114) of the t-bolt (103), a t-bolt head engaging surface (111) for resting the t-bolt (103), a neck (112) accommodating a threaded shank (115) of the t-bolt (103) and a pair of main frame engaging profile (113) for mounting of the main frame (101) on the mounting structure (105).
2. The modular composite frame (100) for photovoltaic module manufacturing and mounting as claimed in claim 1, wherein a length of the main frame (101) is configured to accommodate a length of the photovoltaic (PV) module (104).
3. The modular composite frame (100) for photovoltaic module manufacturing and mounting as claimed in claim 1, wherein dimensions of the groove (110) is configured to accommodate and slide the head (114) of the t-bolt (103) longitudinally inside the sleeve insert (102).
4. The modular composite frame (100) for photovoltaic module manufacturing and mounting as claimed in claim 1, wherein a dimension (123) of the neck (112) is configured to accommodate and slide a threaded shank (115) of the t-bolt (103) longitudinally inside the sleeve insert (102) while resting the t-bolt (103) on the t-bolt head engaging surface (111).
5. The modular composite frame (100) for photovoltaic module manufacturing and mounting as claimed in claim 1, wherein the t-bolt can be adjusted at any longitudinal position of the modular composite frame (100) to match with predrilled mounting holes provided on the mounting structure (105).
6. The modular composite frame (100) for photovoltaic module manufacturing and mounting as claimed in claim 1, wherein upon tightening of a nut (116), the t-bolt (103) clamps the sleeve insert (102) by generating axial force on the t-bolt head engaging surface (111) and the pair of main frame engaging profile (113) to rigidly mount the main frame (101) on the mounting structure (105) by a pair of resting surface (117).
7. The modular composite frame (100) for photovoltaic module manufacturing and mounting as claimed in claim 1, wherein inner dimensions of the box profile (108) and outer dimensions of the sleeve insert (102) maintains a minimum clearance (119) between an inner surface (120) of the box profile (108) and an outer surface (121) of the sleeve insert (102) in assembled condition for automatic local alignment of an axis (122) of the sleeve insert (103) with an axis (118) of the t-bolt (103) upon tightening of the nut (116) on the mounting structure (105) after resting the modular composite frame (100) using the pair of resting surface (117) on the mounting structure (105) and passing the t-bolt (103) through the pre-drilled hole provided on the mounting structure (105).
8. The modular composite frame (100) for photovoltaic module manufacturing and mounting as claimed in claim 1, wherein inner dimensions of the sleeve insert (102) maintains a minimum clearance (124) between an inner surface (125) of the sleeve insert (102) and an outer surface (126) of the t-bolt (103) in assembled condition.