DESC:SOLAR MODULE MOUNTING APPARATUS

Field of the invention

The present invention relates to a solar module installation and more particularly, to a solar module mounting apparatus for installing solar modules on a rooftop.

Background of the invention

Solar modules are traditionally mounted on the rooftops using rooftop mounting systems to maximize their exposure to sunlight for maximizing the electricity generation. Numerous solar mounting structures for rooftop installation of solar modules/ photovoltaic (PV) panels are available in market.

However, the currently deployed rooftop mounting structures are associated with following shortcomings:
1. Strength: The rooftop mounting structures are not designed in accordance with the design code, and therefore lack robustness and strength required for withstanding speed of the wind. Particularly, at high wind speeds up to 180 kmph, the rooftop mounting structures gets ripped off from Galvanized Iron (GI) rooftop thereby damaging the solar power plant installed thereon. Additionally, at such high wind speeds, even the PV panels are blown off from the rooftop mounting structures.

2. Performance of the Solar Modules: The generation from the solar modules highly depends on the mounting structure. To sustain high wind speeds, the mounting structure is usually designed with less height so that the amount of air blowing between the roof and the Solar panel is low and the panel is not ripped off the roof. The 50 mm clearance (height) of the mounting structures from the GI roof reduces the amount of air circulated beneath the PV panel thereby leading to heating of the PV panel and in turn affecting performance thereof.
3. Safety: Height of the rooftop mounting structures is maintained around 50 mm causing heating of the solar modules mounted thereon. Due to decreased height, the interconnection cable between the solar modules which is carrying DC current touches the rooftop thereby causing heating of the cable due to heating of the rooftop during summer season. Heating of the cable damages the cable insulation causing leakage current which can lead to short circuit and fire hazards. During rainy season, the interconnection cable lies in continuous contact with water thereby raising incidents of electric shocks and short circuits. Additionally, the interconnection cable connecting the PV panels touches the GI rooftop thereby causing hazardous outcomes due to current leakage. Further, the mounting structures are heavy making it difficult for laborers to carry the mounting structure at high altitude and install them on the rooftop. Due to heavy weight, installation by the laborers raises concerns regarding laborer safety and overall weight bearing capacity of the rooftop pursuant to such installation.

4. Accessibility: Difficulty in accessing rear part of the PV module/panel for interconnection of cables during the installation of the PV module on the mounting structure having 50 mm clearance (height). Thus, it becomes difficult to visually identify faults like improper riveting, improper installation of mounting rail on the crest and other faults. It also becomes difficult to access the rear part of the solar modules due to inaccessibility.

5. Compatibility with different PV panels: Change in dimension of the PV panels requires changing drills of the mounting structure. This process of re-drilling of the mounting structures reduces strength of the mounting structures.

6. Installation: Huge quantity of components of the mounting structure assembly needs to be carried and then installed on the rooftop thereby consuming sufficient amount of time with every increase in number of mounting structures. Addition of even a single component leads to increase in the installation time. Due to complicated and time-consuming installations of the mounting structure on the GI roof, installations of the solar power plants get prolonged.

Therefore, there exists a need to provide a rooftop solar module mounting apparatus that addresses the afore-stated shortcomings of the existing rooftop mounting systems. Further, there exists a need to provide a rooftop mounting apparatus that minimizes the risk of the solar module lift-off. Moreover, there exists a need for a robust and cost effective mounting apparatus for solar module installation on the rooftop.

Objects of the invention

An object of the present invention is to provide a solar module mounting apparatus for installation of solar modules/ photovoltaic panels on a rooftop.

Another object of the present invention is to improve the performance of the solar modules through proper ventilation.

Another object of the present invention is to provide a solar module mounting apparatus that withstands high velocity winds up to 180kmph.

Yet another object of the present invention is to eliminate the fire hazards due to the leakage current when the interconnection DC cable is in continuous contact with the GI roof in summer and rainy season.

Still another object of the present invention is to provide a solar module mounting apparatus that is portable, cost effective and offers easy installation and is compatible with different dimensions of the solar modules on the rooftops.

Summary of the invention

Accordingly, the present invention provides a solar module mounting apparatus. The solar module mounting apparatus comprises a mounting rail and a clamp assembly. The mounting rail is fixed on a rooftop. The mounting rail provides support for resting a solar module thereon. The mounting rail has an aerodynamic shape to sustain high wind speeds. The mounting rail includes a means for securing cable configured on a top portion of a side thereof. The means for securing cable are projections that are configured equidistantly on the top portion of one side of the mounting rail to prevent a cable passing there through from touching the rooftop thereby avoiding heating of the cable and thus eliminate short circuit and fire hazards.

The clamp assembly is configured on the mounting rail using a rail nut. The clamp assembly includes a first mounting clamp and a second mounting clamp. The first mounting clamp is disposed at a middle portion of the mounting rail for securing the solar module thereon. The second mounting clamp is disposed at two opposite ends of the mounting rail to facilitate holding extreme outer sides of an adjacently placed solar module onto the mounting rail.

The solar module mounting apparatus is capable of withstanding winds with a speed of 180 kmph. The solar module mounting apparatus has a height of 100 mm that provides maximum air circulation beneath the solar panels thereby causing effective cooling of the solar module mounted thereon and thus increasing the performance of the entire solar power plant.

Brief description of the drawings

The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein
Figure 1 shows a perspective view of a rooftop installed with a solar module mounting apparatus of the present invention;

Figure 2 shows a top planar view of Figure 1;

Figure 3a shows a sectional view of the solar module mounting apparatus, in accordance with the present invention;

Figure 3b shows another sectional view of the solar module mounting apparatus, in accordance with the present invention;

Figure 4 shows a top perspective view of a mounting rail of the solar module mounting apparatus, in accordance with the present invention;

Figure 5 shows a side perspective view of the mounting rail of the solar module mounting apparatus, in accordance with the present invention;

Figures 6 and 7 show a top view of the rooftop installed with a solar module using the solar module mounting apparatus of the present invention;

Figures 8-22 show graphical representation of top pressure and side pressure simulation testing on the solar module mounting apparatus of the present invention; and

Figures 23-35 show graphical representation of uplift pressure and side pressure simulation testing on the solar module mounting apparatus of the present invention.

Detailed description of the invention

The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiments.

The present invention provides a solar module mounting apparatus. The apparatus is capable of withstanding winds with a speed of 180 kmph. In addition, the apparatus is designed with maximum height to provide maximum air circulation thereby causing effective cooling of a solar module mounted thereon. Cooling of the solar module in turn increases the power output thereby achieving maximized results.

The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description and in the table below.

Referring to figures 1-7, a solar module mounting apparatus (100) (hereinafter referred to as “the apparatus (100)”) in accordance with the present invention is shown. The apparatus (100) is adapted to mount a solar module (110) thereon at an installation site. The solar module (110) is alternatively referred as solar panel or photovoltaic (PV) panel or PV module. In an embodiment, the installation site includes but not limiting to a rooftop (120). In another embodiment, the apparatus (100) is adapted to be easily installed on multiple surfaces of the rooftop (120) using rivets to facilitate mounting of the solar module (110) on the rooftop (120). In yet another embodiment, the apparatus (100) is mounted on a metal roof using rivets thereby reducing time required for installation at the installation site. In yet another embodiment, the apparatus (100) is made up of aluminum and is manufactured by process of extrusion.

The apparatus (100) comprises a mounting rail (10) and a clamp assembly (not numbered). The mounting rail (10) is fixed on the rooftop (120) using a fastener. The mounting rail (10) provides support for resting the solar module (110) thereon thereby reducing the time required for installation of the solar module (110) on the rooftop (120). In an embodiment, the mounting rail (10) has an aerodynamic shape to sustain high wind speeds and designed to have varied customized length depending upon the distance between crest of sheet.

The mounting rail (10) includes a means for securing cable (5) configured on a top portion of a side thereof. In an embodiment, the means for securing cable (5) are projections that are configured equidistantly on the top portion of one side of the mounting rail. The means for securing cable (5) prevents a cable (130) passing there through from touching the rooftop (120) thereby avoiding heating of the cable (130) and thus preventing short circuit and fire hazards.

The clamp assembly is configured on the mounting rail (10) using a rail nut (40). The clamp assembly is provided to mechanically secure/ mount the solar module (110) onto the mounting rail (10). The clamp assembly includes a first mounting clamp (20) and a second mounting clamp (30). The first mounting clamp (20) and the second mounting clamp (30) facilitate clamping of the solar module (110) on the mounting rail (10). The first mounting clamp (20) is disposed at a middle portion of the mounting rail (10) for securing the solar module (110) thereon. Particularly, the first mounting clamp (20) facilitates secure engagement and holding together of the solar module (110) disposed adjacently onto the mounting rail (10). The second mounting clamp (30) is disposed at two opposite ends/sides of the mounting rail (10) to facilitate securing/ holding extreme outer sides of the adjacently placed solar module (110) onto the mounting rail (10). The clamp assembly facilitates rapid installation/mounting of the solar module (110) on the mounting rail (10).

In another aspect, the present invention provides a method of installation of the solar module (110) onto the apparatus (100). The method is achieved in conjunction with the components of the apparatus (100). The method involves resting and fastening of the solar module (110) onto the mounting rail (10) using the clamp assembly. The method of installation of the solar module (110) using the apparatus (100) of the present invention is robust and easy.
In accordance with the present invention, the apparatus (100) is adapted to withstand high velocity winds. In an embodiment, the apparatus (100) is tested and found to be capable of withstanding winds with a speed of 180 kmph which suits almost all terrains in India. However, it is understood here that the apparatus (100) can be designed to withstand any wind speed in other alternative embodiments. In addition, the apparatus (100) is designed with maximum height to provide maximum air circulation beneath the solar panels thereby causing effective cooling of the solar module (110) mounted thereon and thus increasing the performance of the entire solar power plant. Cooling of the solar module (110) in turn increases the power output thereby achieving maximized results. Increase in height provides additional space thereby allowing DC cable management. In an embodiment, the apparatus (100) is designed with a height of 100 mm. However, it is understood here that the apparatus (100) is compatible with varied dimensions of the solar module (110) mounted thereon and upon requirements of the installation site.

In accordance with the present invention, simulation testing is carried on the apparatus (100). Specifically, top pressure and side pressure simulation testing of about 1275 Pascal is performed on the apparatus (100). Table 1 provides details of force and moment reactions at fixed supports. Figures 8-22 show graphical representation of top pressure and side pressure simulation testing on the solar module mounting apparatus (100) of the present invention.
Table 1:
Further, uplift pressure and side pressure simulation testing of about 2100 Pascal is performed on the apparatus (100). Table 2 provides details of force and moment reactions at fixed supports. Figures 23-35 show graphical representation of uplift pressure and side pressure simulation testing on the solar module mounting apparatus (100) of the present invention.

Table 2:

Advantages of the invention

1. Strength: The apparatus (100) withstands a wind speed of 180 kmph acting on surface thereof. Even at 180 kmph wind speed the apparatus (100) firmly holds the solar module (110) and prevents the solar module (110) from getting blown off.
2. Performance of the Solar Modules: 100 mm elevation (height/ clearance) of the apparatus (100) from the GI roof allows air to pass through the panel/solar module (110) and helps in the cooling of the PV panels/solar module (110) and thus increasing the solar module life and performance of the entire solar power plant.
3. Safety: The apparatus (100) is designed to be elevated from the rooftop (120) thereby preventing the interconnection/ DC cable carrying current from touching the roof and avoiding heating thereof. Further, incidents of electric shocks/ short circuits and fire hazards due to the interconnection/ DC cable lying in continuous contact with water are eliminated. In addition, being light in weight, the apparatus (100) allows easy installation in less time along with eliminating labor safety and rooftop weight bearing capacity related concerns.
4. Installation: The apparatus (100) requires less installation time with reduced no. of components to assemble on the rooftop. Faster installation reduces labor cost and facilitates customer to start using the solar power within a short time span.
5. Accessibility: Easy accessibility to rear part of the PV panel/ solar module (110). 100 mm height allows accessibility to the rear part of the solar modules and also identification of faults through visual inspection becomes easy.
6. Compatibility with different PV panels: The apparatus (100) is designed to provide flexibility in dimensions of the PV panel/solar module (110) without additional drilling.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the claims of the present invention.
,CLAIMS:We claim:

1. A solar module mounting apparatus (100), the apparatus (100) comprising:
a mounting rail (10) fixed on a rooftop (120), the mounting rail (10) adapted to provide support for resting a solar module (110) thereon, the mounting rail (10) having a means for securing cable (5) configured on a top portion of a side thereof; and
a clamp assembly configured on the mounting rail (10) using a rail nut (40), the clamp assembly having,
a first mounting clamp (20) disposed at a middle portion of the mounting rail (10) for securing the solar module (110) thereon, and
a second mounting clamp (30) disposed at two opposite ends of the mounting rail (10) to facilitate holding extreme outer sides of an adjacently placed solar module (110) onto the mounting rail (10).

2. The apparatus (100) as claimed in claim 1 is capable of withstanding winds with a speed of 180 kmph.

3. The apparatus (100) as claimed in claim 1 has a height of 100 mm that provides maximum air circulation thereby causing effective cooling of the solar module (110) mounted thereon and thus increasing the life of the solar module (110) and performance of the entire solar power plant.

4. The apparatus (100) as claimed in claim 1, wherein the mounting rail (10) has an aerodynamic shape to sustain high wind speeds.

5. The apparatus (100) as claimed in claim 1, wherein the means for securing cable (5) are projections that are configured equidistantly on the top portion of one side of the mounting rail to prevent a cable (130) passing there through from touching the rooftop (120) thereby avoiding heating of the cable (130) and thus preventing short circuit and fire hazards.

Dated this 05th day of July 2019 Prafulla Wange
(Agent for Applicant)
(IN/PA/2058)