FIELD OF INVENTION
The present invention relates to a mounting rail for micromorph
solar photovoltaic modules and the method of mounting. More particularly the
invention relate to the development of a low cost, easy to fabricate mounting rail.
BACKGROUND OF THE INVENTION
Presently, there are commercially available mounting rails suitable
for framed micromorph modules but these mounting rails has highly complex
design and requires dye for extrusion. This fabrication process available for
mounting rails is complex in nature and leads to increase in the overall cost of the
mounting of modules.
Further, the available mounting rails are of aluminum alloy and are
not suitable for direct mounting on MS structure.
The solar PV technology seeks to convert energy from sun to
electricity and reduces the demand of conventional sources of electricity, such as
coal, gas etc. Typically, a solar module consists of PV cells connected in series and
parallel to yield a specific current and voltage at its output. Solar panels or
modules are usually made rectangular in shape and of convenient size for
handling. To protect the solar cells from harsh environmental conditions, cells are
encapsulated with transparent resilient polymers into a rigid glass laminate.
Modules are typically framed to increase rigidity of the laminate and to protect
fragile glass edge of the laminate from cracking. This makes laminates or modules

suitable for mounting on roof top, solar farm or other similar structure.
Presently, for installation of photovoltaic solar modules at roof top,
modules are elevated to a height and positioned over the rail and clamped in the
desired position. The modules are visually positioned over the plumb line and
tightened while holding them in a place. This requires relatively more manpower
for installation. Also, if the first module is misaligned then entire row will be askew
as well as if a module fails in the array, it will not be easy to replace the same.
It is thus an object of the present invention to provide a system and
a method for mounting micromorph modules over the structure so that mounting
can be carried out by single/two installers in a safer manner and which consumes
overall less time compared to prior method of installation. Also, objective is to
design a common rail for two micromorph modules so that mounting process
becomes easy by simply sliding the modules between the rails.
The present invention has overcome the problems existed in the
prior art by adopting the simple design. The invented mounting rails comprise of
MS fat strip and square cross sectional MS rods which are easily available in the
building construction market. The mounting rail can be easily fabricated by simple
electric arc welding.
The invented mounting rails take less time in fabrication and
installation as compared to prior art.

OBJECTS OF THE INVENTION
Therefore, it is an object of the invention to propose a mounting rail
for micromorph solar photovoltaic modules which is low cost and easy to fabricate.
Another object of the invention is to propose a mounting rail for
micromorph solar photovoltaic modules and the method of mounting which makes
the module installation very simple with minimum manpower in a safer manner.
A further object of the invention is to propose a mounting rail for
micromorph solar photovoltaic modules and the method of mounting which takes
less time in mounting the framed micromorph solar photovoltaic modules over the
Mild Steel structure.
A still further object of the invention is to propose a mounting rail for
micromorph solar photovoltaic modules and the method of mounting which is
capable of accommodating two framed micromorph modules with common fixing
arrangement.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig.l- Shows a side view of a Photovoltaic module installation according to the
invention.
Fig.2 - Shows the frame of the micromorph modules.
Fig.3 - Shows a mounting rail according to invention
Fig.4 - Shows a mounting rail providing a common fixing arrangement for two
framed micromorph modules.
Fig.5 - Shows a side view of the mounting rail according to invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE
INVENTION
The mounting rail (1) for micromorph modules (Ml, M2) is a "T"
shaped rail made of a mild steel (MS) flat strip (9) welded with square cross
sectional MS rebar (10) when that T' can be directly welded over the MS support
structure (3) to provide rigidity for mounting of framed micromorph modules (Ml,
M2). The mounting rail (1) developed facilitates the module installation simply by
sliding the modules in between the rails.
The present invention finds application in mounting the framed
micromorph solar photovoltaic (PV) modules over the mild steel (MS) structure so
that mounting can be carried out by minimum manpower in a safer manner and
takes less time as compared to prior mounting rail design and method of
installation.
Thus the present invention discloses a simple, easy to fabricate, low
cost mounting rail for solar PV modules. The mounting rail disclosed in this
invention would find use in any PV power plant/system.
In solar farms, roof top mounted PV system or BIPV; the PV modules
(Ml, M2) are mounted in strings and electrically interconnected. As the PV
modules are rectangular or square in shape, most of the modules are installed in
multiple rows in close proximity to match general foot print of the mounting
surface. Such arrangement of multiple rows of modules is known as array.
The mounting rail (1) provides a mounting arrangement to install an
array of framed micromorph modules at slanted roof or surface. The PV modules
are mounted on the slanted roof or structure by sliding mechanism. Fig 1 shows
the side view of mounting rail arrangement.

The mounting rail (1) for micromorph modules (Ml, M2) is a ,VT"
shaped rail comprising of mild steel (MS) strips (9) and square cross sectional MS
rod (10). The material used in this design is easily available in local construction
market. For fabricating this mounting rail, dimensions of the frame attached with
micromorph modules were measured.
The detail of the frame F of the micromorph module (Ml, M2) is
illustrated in fig 2. As the frame has a groove width (4) of only 4.5 mm between
the two aluminum notches and the depth of this groove is 8.5 mm (Z). This space
is utilized for the sliding module (Ml, M2) onto the mounting rail (1).
The mounting rail (1) is composed of MS strip (5) of 35 mm width
and 4.2 mm thickness (6) and of length 1100 mm(8) and square cross section
rebar (10) of 15 mm x 15 mm cross section (Y). The details of the dimensions of
mounting rail are illustrated in fig 3. Both the sides of the square block (10) are
welded over the MS strip using electic arc welding.
The joint becomes strong after cooling down and the welding debris
is smoothened by the grinder. This block is welded with the MS structure (3) by
electric arc forming a mounting rail. The module is easily mounted in this rail by
simply sliding through the rail.
Thus, one mounting rail (1) provides a common fixing arrangement
for two framed micromorph modules (Ml, M2). Hence, the mounting can be done
easily by simply sliding the modules into the rail from both sides. The dimension of
common path is illustrated in fig 4.

The gap of X=3 mm between the two modules has been left
intentionally to withstand under the thermal expansion of the modules.
More than 30 modules are installed using this technique which
reduces the overall cost of fabrication as well as the installation time.
ADVANTAGES OF THE MOUNTING ARRANGEMENT OF THE
PHOTOVOLTAIC MODULES
1) It is a simple and inexpensive arrangement for mounting thin film
photovoltaic modules with specially designed aluminium channel as frames.
2) The arrangement facilitates the mounting of a pair of photovoltaic modules
on a mounting rail.
3) Provides adequate mechanical strength to the mounting rail by fabricating it
with welding of two orthogonal Mild Steel (MS) components and also by
welding one of the components to the underlying MS structure.
4) Since more than 30 modules are installed using this technique, the overall
cost of fabrication as well as installation time are reduced.

WE CLAIM
1. Mounting rail for micromorph solar photovoltaic modules comprising;
a flat strip (9) welded with both sides of a square cross sectional rebar (10)
for making a mounting rail (1);
Characterised in that,
the mounting rail (1) is made to a T' shape rail (1) which is welded over
the mild steel support (3) for providing a common fixing arrangement for
two framed micromorph modules (Ml, M2).
2. Mounting rail as claimed in claim 1, wherein the rail is composed of mild
steel strip (9) of 35 mm width and 4.2 mm thickness (6) and of length 1100
mm (8) wherein the square cross section rebar (10) is of 15 mm x 15 mm
(Y x Y) cross section.
3. A method of mounting the micromorph solar photovoltaic modules (Ml,
M2) on a mounting rail (1) comprising;
welding mild steel strips (9) with square cross sectional mild steel rod (10)
to form a T' shaped mounting rail.
welding the T' shaped rail on the mild steel support (3) to provide rigidity
for mounting of framed micromorph modules (Ml, M2);
mounting the modules by sliding them (Ml, M2) into the mounting rail from
both sides utilizing the space provided by the groove (4) of the frame (F)
between the two aluminium notches when a gap (x) of 3 mm between the
modules (M1, M2) is provided to withstand the thermal expansion of the
modules.

ABSTRACT

A flat strip (9) is welded with both sides of a square cross sectional
rebar (10) for making a 'T' shape mounting rail (1). This mounting rail (1) is
welded to a mild steel support (3) for providing a common fixing arrangement for
two framed micromorph modules (M1, M2). The modules (M1, M2) are mounted
by sliding them into the mounting rails from both sides utilizing the space provided
by the frame (F) between the two aluminium notches. A gap (X) of 3 mm is
provided between the two modules (M1, M2) to withstand the thermal expansion
of the modules (M1, M2).