WO2025065007A1 - Système et procédés de transport de modules pv - Google Patents

Système et procédés de transport de modules pv Download PDF

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Publication number
WO2025065007A1
WO2025065007A1 PCT/US2024/047998 US2024047998W WO2025065007A1 WO 2025065007 A1 WO2025065007 A1 WO 2025065007A1 US 2024047998 W US2024047998 W US 2024047998W WO 2025065007 A1 WO2025065007 A1 WO 2025065007A1
Authority
WO
WIPO (PCT)
Prior art keywords
support
module
conveyance
shuttle
conveyance shuttle
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/047998
Other languages
English (en)
Other versions
WO2025065007A4 (fr
Inventor
Kevin BASSALLECK
Dustin NEEL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gridworks Inc
Original Assignee
Gridworks Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gridworks Inc filed Critical Gridworks Inc
Priority to AU2024345875A priority Critical patent/AU2024345875A1/en
Publication of WO2025065007A1 publication Critical patent/WO2025065007A1/fr
Publication of WO2025065007A4 publication Critical patent/WO2025065007A4/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S30/00—Arrangements for moving or orienting solar heat collector modules
    • F24S30/40—Arrangements for moving or orienting solar heat collector modules for rotary movement
    • F24S30/42—Arrangements for moving or orienting solar heat collector modules for rotary movement with only one rotation axis
    • F24S30/425—Horizontal axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
    • F24S25/634—Clamps; Clips
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/10—Supporting structures directly fixed to the ground
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/30—Supporting structures being movable or adjustable, e.g. for angle adjustment
    • H02S20/32—Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S2025/01—Special support components; Methods of use
    • F24S2025/014—Methods for installing support elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S30/00—Arrangements for moving or orienting solar heat collector modules
    • F24S2030/10—Special components
    • F24S2030/15—Bearings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • Embodiments of the present invention are directed to systems and methods of installing solar photovoltaic (“PV”) modules in the field, and more particularly, systems and methods of conveying PV modules down the length of their supporting structure or torque tube.
  • PV solar photovoltaic
  • PV modules are typically installed in rows in a North-South direction so that the PV modules, when used in coordination with trackers, can track the sun as it moves from East to West through the day.
  • a row of PV modules is typically wired in series, each PV module and its associated tracker mechanism supported on a “torque tube” that extends from one end of the row to the other that supports all the PV modules in that row.
  • the torque tube is typically supported above the ground by piles spaced at various intervals along the torque tube.
  • Typical large-scale solar energy generation facilities require a great deal of skilled manual labor to install each PV module on its supporting structure.
  • the process typically involves transporting pallets or boxes of PV modules in a vehicle on an access road and distributing the pallets of PV modules in regular intervals within the rows, lifting the PV modules out of the boxes, manually carrying each PV module down the row of PV modules (that may not have a road adequate for the vehicle and which rows can be very long), lifting the PV module up and onto the torque tube and installing the PV module to its tracker and to the torque tube, and making all the electrical connections thereto.
  • Such method occurs for each PV module.
  • This process is not efficient due to the fact that it requires so much time to manually carry the PV modules, as well as the inefficiencies of distributing each pallet of modules throughout the rows across uneven terrain.
  • This process is dangerous to the laborers given the weight of PV modules and the exposure to the elements. This process risks damage or destruction to the PV modules given how far they have to be carried and lifted manually. Shortages in the skilled labor required for these tasks can make installation
  • Embodiments of the present invention relate to a system for conveying a photovoltaic (“PV”) module along a first support member
  • the system includes: a second support member capable of supporting the first support member above the ground; a conveyance shuttle including a receptacle for receiving a member of a PV module or a PV module support panel; a propulsion support configured to coordinate with a surface of the first support member; and the conveyance shuttle, when disposed on the first support member, is capable of conveying the PV module or PV module support panel along a length of the first support member.
  • the system further includes a PV support assembly that has a support panel, a support bar, a clamp, and a PV support assembly conveyance shuttle coordinating member.
  • the support panel is disposed on, secured to, or otherwise supported by the support bar.
  • the clamp is disposed at least partially above the support bar.
  • the PV support assembly conveyance shuttle coordinating member is disposed at least partially below the support bar.
  • a module area with power electronics is disposed on the conveyance shuttle.
  • the propulsion support also includes a wheel.
  • the conveyance shuttle also includes a magnet.
  • the wheel includes a groove sized and shaped to receive or coordinate with an edge of the first support member.
  • the conveyance shuttle is capable of receiving the PV support assembly conveyance shuttle coordinating member.
  • the second support member includes a bearing housing.
  • the system further includes a support bracket assembly with a bracket arm shaped and sized to contact a surface of the first support member, and the bracket arm is secured to and rotatable in relation to the support bar.
  • the system further includes a PV support assembly that includes a support panel, a support bar, a clamp, and a PV support assembly conveyance shuttle coordinating member.
  • the support panel is disposed on, secured to, or otherwise supported by the support bar;
  • the clamp is disposed at least partially above the support bar; at least two of the clamps hold the support bar, and the primary axis of the support bar is about perpendicular to the primary axis of the conveyance shuttle;
  • the PV support assembly conveyance shuttle coordinating member is disposed at least partially below the support bar;
  • the system further includes a module area with power electronics disposed on the conveyance shuttle;
  • the conveyance shuttle further includes a magnet;
  • the conveyance shuttle further includes a propulsion support with at least two grooved wheels sized and shaped to receive or coordinate with an edge of the first support member;
  • the second support member includes a bearing housing; and the conveyance shuttle is in communication with a shuttle support member.
  • Embodiments of the present invention also relate to a method for conveying a photovoltaic (“PV”) module along a first support member, where the method includes: installing a second support member into the ground that is capable of supporting the first support member above the ground; disposing a bearing housing on top of the second support member; inserting the first support member within the bearing housing, installing a conveyance shuttle on top of the first support member, where the conveyance shuttle has a receptacle for receiving a member of a PV module or a PV module support panel and a propulsion support configured to coordinate with a surface of the first support member; loading a PV module or a PV module support panel onto the conveyance shuttle; conveying the conveyance shuttle along the first support member; and releasing the PV module or PV module support panel from the conveyance shuttle.
  • PV photovoltaic
  • the method after the step of releasing the PV module or PV module support panel, also includes the step of securing the PV module or PV support panel to the first support member using a PV support assembly, where the PV support assembly includes a support panel, a support bar, a clamp, and a PV support assembly conveyance shuttle coordinating member.
  • the method also includes manually moving the conveyance shuttle along the first support member.
  • the method also includes self-propelling the conveyance shuttle along the first support member.
  • the method also includes conveying electrical equipment with the conveyance shuttle.
  • the method also includes the step of conveying electrical equipment with the conveyance shuttle.
  • Embodiments of the present invention also relate to a method for conveying a photovoltaic (“PV”) module along a first support member, where the method includes: installing a second support member into the ground that is capable of supporting the first support member above the ground; disposing a bearing housing on top of the second support member; inserting the first support member within the bearing housing; loading a PV module or a PV module support panel onto a conveyance shuttle, where the conveyance shuttle includes a receptacle for receiving a member of a PV module or a PV module support panel, and a propulsion support configured to coordinate with a surface of the first support member; conveying the conveyance shuttle along the first support member; and releasing the PV module or PV module support panel from the conveyance shuttle.
  • PV photovoltaic
  • One of the objectives of the present invention is to provide a PV module conveyance system that permits each PV module to be placed on one end of the torque tube and slid down the length of the torque tube past any number of piles that support the torque tube, to its point of installation on the torque tube.
  • Another objective of the present invention is to provide a mechanism that permits delivery of the electrical wiring of each PV module, or each series string of modules, to its point of installation and a raceway for the management of cables electrically connecting the PV modules.
  • FIG. 1 is an illustration from a perspective view of a PV module conveyance system according to an embodiment of the present invention
  • FIG. 2 is an illustration from a perspective view of a conveyance shuttle disposed within a channel of the torque tube according to an embodiment of the present invention
  • FIGS. 3A, 3B and 3C are illustrations of various views of a torque tube assembly according to an embodiment of the present invention, Fig. 3A showing a perspective view of a conveyance channel that is an independent object from the torque tube that fits within the torque tube, Fig. 3B showing a perspective view of a conveyance channel disposed within the torque tube, and Fig. 3C showing a cross-sectional view of a torque tube with a conveyance channel disposed within it.
  • FIGs. 4A and 4B are illustrations of various views of a rail clamp assembly according to an embodiment of the present invention, Fig. 4A showing a perspective view and Fig. 4B showing a side view;
  • FIGs. 5A and 5B are illustrations of various views of a rail support bracket assembly according to an embodiment of the present invention, Fig. 5A showing a perspective view and Fig 5B showing a side view;
  • FIGs. 6A, 6B and 6C are illustrations of various views of a conveyance shuttle coordinating with other components of the present invention according to an embodiment of the present invention, Fig. 6A showing a perspective view of a conveyance shuttle in coordination with a rail clamp assembly, Fig. 6B showing a perspective view of a conveyance shuttle in coordination with a rail clamp assembly supporting a PV module on its torque tube, and Fig. 6C showing a side view of a conveyance shuttle alone;
  • Fig. 7 is an illustration from a perspective view of a torque tube and bearing housing assemblies according to the present invention as they relate to the supporting piles;
  • FIG. 8 is an illustration from a perspective view of a torque tube with an external conveyance shuttle according to an embodiment of the present invention.
  • FIG. 9 is an illustration from a top angled view of a torque tube with an external conveyance shuttle according to an embodiment of the present invention.
  • FIG. 10 is an illustration from a top view of a torque tube with an external conveyance shuttle according to an embodiment of the present invention.
  • FIG. 11 is a close-up illustration from a perspective view of an external conveyance shuttle rolling over a torque tube according to an embodiment of the present invention
  • FIG. 12 is an illustration from a top angled view of an external conveyance shuttle carrying a PV module over a torque tube according to an embodiment of the present invention
  • FIG. 13 is an illustration from a side view of an external conveyance shuttle carrying a PV module over a torque tube according to an embodiment of the present invention
  • Fig. 14 is an illustration from an underside view of an external conveyance shuttle carrying a PV module over a torque tube according to an embodiment of the present invention
  • Fig. 15 is an illustration from a top view of an external conveyance shuttle carrying a PV module over a torque tube according to an embodiment of the present invention
  • Fig. 16 is an illustration from a side view of an external conveyance shuttle rolling on top of a torque tube according to an embodiment of the present invention
  • FIG. 17 is an illustration from a perspective view of an edge conveyance shuttle and edge torque tube according to an embodiment of the present invention.
  • Fig. 18 is an illustration from a frontal view of an edge conveyance shuttle and edge torque tube according to an embodiment of the present invention.
  • Fig. 19 is an illustration from a perspective view of an edge conveyance shuttle and edge torque tube after the rail support bracket assembly has been installed, according to an embodiment of the present invention.
  • the "top” of an object refers to that side or surface of an object furthest from the ground.
  • the “bottom” of an object is the side or surface opposite the top surface and closest to the ground. While it is solar power generation facilities that are described in relation to the figures herein, the invention is not limited to solar power generation facilities unless otherwise limited as such in the claims.
  • the terms “energy”, “power” and “electrical” are used interchangeably.
  • the terms “cable”, “wire” and “conduit” may be used interchangeably for ease of discussion.
  • PV photovoltaic
  • PV module an energy conversion device that takes in solar/photovoltaic energy from some external source and converts it into another form of energy, commonly electrical energy.
  • the external source may include, but is not limited to, the sun, an incandescent bulb, a light-emitting diode, or a combination thereof.
  • PV module shape may include, but is not limited to, square, hexagonal, octagonal, round, oval, other polygonal shapes, or a combination thereof.
  • Torque tube as used herein is defined in the specification and drawings as support for a row of PV modules that simultaneously allow rotation of the PV modules to track the movement of the Sun. Torque tubes may also provide housing or raceway for electrical circuity necessary to power and operate PV modules. Torque tubes may comprise of steel, iron, aluminum, or any combination of other materials that allow the torque tube to twist while the PV panels are rotated, but not break or snap during acceleration or deceleration. The term “torque tube” should not be limited to any device that rotates; it can also include any tube or static structure to which PV modules are secured or securable.
  • Piles as used herein is defined in the specification and drawings as support members for the torque tube. Piles may comprise of steel, iron, aluminum, or any combination of other materials, in any cross sectional shape. Piles may be driven into the ground or attached to a foundation (i.e., concrete bedding).
  • primary axis shall mean either as indicated or the line that is centered on the length of the object. If an object’s axis is referred to herein without clarifying its “primary axis”, then the axis shall be assumed to be its “primary axis” unless otherwise described or illustrated.
  • Fig. 1 shows photovoltaic (“PV”) module conveyance system 100.
  • PV module system 100 comprises of a plurality of PV modules 105, piles 115, and a torque tube assembly 110.
  • Torque tube assembly 110 ordinarily runs North to South or South to North.
  • PV modules 105 are generally positioned perpendicular to torque tube assembly 110 so that they can rotate East to West and follow the Sun throughout the day.
  • PV module 105 are connected to each other using electrical circuits in series.
  • Motor 300 rotates torque tube assembly 110 allowing PV module 105 to track the Sun throughout the day. Motor 300 can be positioned in various points long the torque tube assembly 110.
  • Fig. 2 shows a perspective view of conveyance shuttle 200 disposed within conveyance channel 125 of torque tube assembly 110.
  • Torque tube assembly 110 comprises conveyance channel 125 and torque tube 112.
  • Conveyance shuttle 200 is disposed in, within or along conveyance channel 125.
  • Conveyance shuttle 200 comprises shuttle structural support 120, vertical wheel 135, horizontal wheel 140, and integral clamping mechanism 130.
  • Integral clamping mechanism 130 further comprises integral clamping arm 176, which itself may comprise a plurality of clamps, projections, tabs or other objects capable of clamping or applying a pressure.
  • Vertical wheel 135 ensures conveyance shuttle 200 can move along the length of conveyance channel 125 and that it does not shift up or down while conveyance shuttle 200 is moving.
  • Horizontal wheel 140 ensures conveyance shuttle 200 does not shift left or right while conveyance shuttle 200 is transported along conveyance channel 125.
  • Conveyance shuttle 200 is transported within conveyance channel 125 along axis 150, which axis is oriented in the direction of the length of torque tube assembly 110.
  • Axis 150 is parallel to torque tube assembly 110, structural support 120, conveyance shuttle 200, conveyance channel 125, and torque tube 112. Electrical circuits to connect PV module 105 may be transported above conveyance shuttle 200 within conveyance channel 125.
  • Torque tube 112 is an example of a “first support member” as may be used in the claims.
  • Pile 115 is an example of a “second support member” as may be used in the claims.
  • conveyance shuttle 200 may comprise only vertical wheels 135, without horizontal wheels 140. In another embodiment, conveyance shuttle 200 may comprise only horizontal wheels 140, without vertical wheel 135. Conveyance shuttle 200 may comprise any number of wheels that allow it to move, but preferably at least two wheels. As used herein, the term “wheels” shall not be limited to the shape shown in the figures, but may also include any shape adequate to permit the object it supports to move, including but not limited to balls and cylinders, or a tracked mechanism. Conveyance shuttle 200 may be manually moved down the conveyance channel 125 or moved down the channel via a system of strings, cables, pulleys, or similar. In another embodiment, conveyance shuttle 200 may be self-propelled and integrate batteries, electric motors, controllers, sensors, and may be operated via remote control from a human operator or programmed to shuttle PV modules 105 along the torque tube 110 autonomously.
  • the depth of conveyance channel 125 is preferably such that when support shuttle 200 is disposed on the bottom of conveyance channel 125 and moving along down the length of conveyance channel 125, conveyance shuttle 200 is low enough below the top of torque tube assembly 110 that it does not interfere with any object supported by torque tube assembly 110, for example module clamp support bar 170 or PV support panel 160. Additionally, the depth of conveyance channel 125 is preferably adequate such that the cables for PV modules 105 can be placed at least partially within conveyance channel 125. In this way, conveyance channel 125 can act not only as the space in which conveyance shuttle 200 moves along the length of torque tube assembly 110, but also as the raceway or conduit for the cables necessary for the electrical connections of the PV modules 105.
  • Fig. 3A shows a perspective view of conveyance channel 125 separated from torque tube 112.
  • Conveyance channel 125 is, in some embodiments, an independent object from torque tube 112 itself.
  • conveyance channel 125 preferably comprises crimped edges 126 to coordinate with the shape of torque tube 112 such that conveyance channel 125 can simply be placed in and rest on torque tube 112.
  • Torque tube 112 as shown comprises an octagonal shape, but torque tube 112 may comprise any shape.
  • the conveyance channel 125 may be any shape suitable and may or may not be an independently formed piece from the torque tube 112.
  • torque tube 112 may be formed such that the conveyance channel 125 is integral to and a part of the shape of the torque tube 112 itself.
  • Fig. 3B shows a perspective view of conveyance channel 125 inserted into torque tube 112, resulting in torque tube assembly 110.
  • the crimped edges of conveyance channel 125 allow conveyance channel 125 to be disposed within torque tube 112 without falling all the way through.
  • Fig. 3C shows a cross-sectional view of torque tube assembly 110 from a front view. Conveyance channel 125 can be seen disposed within torque tube 112, creating torque tube assembly 110 with an octagonal shape.
  • Integrated conveyance channel may be a separate price integrated into or joined with the torque tube 112, ortorque tube 112 may be manufactured to integrate the conveyance channel 125 as a single and complete component.
  • Fig. 4A shows a perspective view of rail clamp assembly 155.
  • Rail clamp assembly 155 comprises PV support panel 160, module clamp support bar 170, module clamp 165, and integral tab 175.
  • module clamp support bar 170 is integral with (the same unitary object as) each of its module clamps 165.
  • Module clamp support bar 170 may comprise any number of module clamps 165 as adequate to secure it or coordinate with PV support panel 160.
  • module clamp support bar 170 is at least partially disposed within PV support panel 160.
  • Module clamps 165 are at least partially disposed of within module clamp support bar 170. Note that while PV support panel 160 can be a separate object from PV Module 105, they can also be the same object.
  • PV Module 105 and PV support panel 160 can be interpreted as the same object and those terms are sometimes used interchangeably herein.
  • Rail clamp assembly 155 is an example of a “PV support assembly” as may be used in the claims.
  • Integral tab 175 is an example of a “PV support assembly conveyance shuttle coordinating member” as may be used in the claims.
  • module clamp support bar 170 comprises at least one integral tab 175.
  • Integral tab 175 is preferably disposed of beneath module clamp support bar 170, on the opposite side of PV support panel 160 than module clamp 165. Integral tab 170 is inserted into conveyance channel 125 (not shown in Figs. 4A or 4B).
  • Rail clamp assembly 155 supports PV module 105 as they are loaded onto torque tube assembly 110 and positioned into place.
  • Module clamps 165 hold PV module 105 in place against PV support panel 160 as torque tube assembly 110 rotates to follow the sun throughout the day.
  • module support bar 170 is at least partially disposed on one side edge of PV support panel 160. In another embodiment, module support bar 170 is at least partially disposed on two side edges of PV support panel 160. In another embodiment, module support bar 170 is at least partially disposed on three side edges of PV support panel 160. In another embodiment, module support bar 170 is at least partially disposed of on four side edges of PV support panel 160.
  • Fig. 4B shows a side view of rail clamp assembly 155.
  • Three of module clamp 165 can be seen disposed of above module clamp support bar 170 and adjacent to PV support panel 160.
  • Integral tab 175 can be seen below module clamp support bar 170.
  • integral tab 175 may be disposed of halfway between both ends of module clamp support bar 170, such that the weight of PV support panel 160 is distributed equally on both sides of integral tab 175.
  • integral tab 175 may be disposed of anywhere along module clamp support bar 170 depending on the weight distribution of PV support panel 160 and PV module 105.
  • FIG. 5A shows a perspective view of torque tube assembly 110 with rail support bracket assembly 180 in place.
  • Rail support bracket assembly 180 comprises two rail support bracket arm 185 and one integral hardware tab 190 (not shown).
  • Module clamp support bar 170 with three module clamp 165 can be see disposed above support bracket assembly 180.
  • Support bracket assembly 180 is disposed around torque tube assembly 110.
  • Support bracket assembly 180 is transported along torque tube assembly 110 via conveyance shuttle 200 (not show).
  • Conveyance shuttle 200 is connected to module clamp support bar 170 and support bracket assembly 180 though integral tab 175.
  • Support bracket arms 185 are hingedly connected to module clamp support bar 170 at the ends further from torque tube assembly 110.
  • Support bracket arms 185 may rotate out parallel to torque tube assembly 110 so as to not interfere with pile 115 as support bracket assembly is transported along torque tube assembly 110.
  • Fig. 5B shows a side perspective view of support bracket assembly 180.
  • Two support bracket arm 185 can be seen locked together with integral hardware tab 190.
  • Integral hardware tab 190 allows support bracket arms 185 to rotate outwards when integral hardware tab 190 is open.
  • support bracket arms 185 are locked together.
  • Support bracket arm 185 may be of any shape or configuration necessary to affix the support bar 170 to the torque tube 110 once it is in the final position. It may or may not move along the torque tube 110 on the conveyance shuttle 200 or could be installed after conveyance is complete.
  • Fig. 6A shows a perspective view of module clamp support bar 170 connected to conveyance shuttle 200 via integral tab 175 and integral clamping arm 176.
  • Conveyance shuttle 200 comprises shuttle structural support 120, vertical wheel 135, horizontal wheel 140, and integral clamping mechanism 130.
  • Integral clamping mechanism 130 further comprises integral clamping arm 176.
  • integral clamping mechanism 130 is pulled up from shuttle structural support 120, integral clamping arm 176 is compressed around integral tab 175, locking module clamp support bar 170 to conveyance shuttle 200.
  • integral clamping mechanism 130 is pushed down towards shuttle structural support 120, integral clamping arm 176 is decompressed around integral tab 175, unlocking module clamp support bar 170 from conveyance shuttle 200.
  • integral tab 175 and integral clamping arm 176 may comprise other varieties of locking mechanisms such as clamps, adaptors, hinges, projections, bearings, hitches, hooks, adhesives, projections, holes etc.
  • Fig. 6B is a top perspective view of rail clamp assembly 155 being transported along torque tube assembly 110.
  • Module clamp support bar 170 can be seen disposed adjacent to PV support panel 160, ready to transport PV module 105 (not shown).
  • Module clamp support bar 170 is locked into conveyance shuttle 200 via integral tab 175 and integral clamping arm 176.
  • Support bracket arms 185 can be seen rotated outwards into open position parallel with torque tube assembly 110 (or parallel with the direction of travel of conveyance shuttle 200) so as to not interfere with pile 115 as rail clamp assembly 155 is transported along torque tube assembly 110.
  • Fig. 6C is a side perspective view of conveyance shuttle 200.
  • Conveyance shuttle 200 comprises shuttle structural support 120, vertical wheel 135, horizontal wheel 140, skate axle 136, and integral clamping mechanism 130.
  • Integral clamping mechanism 130 further comprises integral clamping arm 176. When integral clamping mechanism 130 is pulled up from shuttle structural support 120, integral clamping arm 176 is compressed and locked. When integral clamping mechanism 130 is pushed down towards shuttle structural support 120, integral clamping arm 176 is decompressed and unlocked.
  • Integral clamping mechanism 130 is an example of a “clamping arm” as may be used in the claims.
  • Fig. 7 shows a perspective view of torque tube assembly 110 with a bearing housing 205 in an open position and a bearing housing 205 in a closed position.
  • Bearing housing 205 further comprises bearing hinge 210 to open and close bearing housing 205.
  • Bearing housing 205 is at least partially disposed of in pile 115 and around torque tube assembly 110.
  • Bearing housing 205 allows torque tube assembly 110 to rotate to follow the Sun throughout the day.
  • Bearing housing 205 opens via bearing hinge 210 to allow conveyance shuttle 200 (not shown) to move through uninterrupted.
  • FIG. 8 shows a perspective view of external conveyance shuttle 310 disposed on top of torque tube 300.
  • torque tube 300 does not include conveyance channel 125 and is simply a standard commercially available torque tube comprising an octagonal crosssection shape.
  • Torque tube 300 can also have various other cross-sectional shapes, including any other polygonal shape including hexagonal, square, triangular etc.
  • External conveyance shuttle 310 comprises module clamp 315, first module area 320, second module area 325, magnet 335, and propulsion apparatus 330.
  • External conveyance shuttle 310 is disposed on, within or along torque tube 300.
  • Module clamp 315 comprises a plurality of clamps, projections, tabs or other objects capable of clamping or applying a pressure.
  • module clamp 315 When module clamp 315 is in a closed position, module clamp 315 is compressed around integral tab 175 (not shown in Fig. 8 but illustrated in other figures), locking module clamp support bar 170 (not shown) to external conveyance shuttle 310, or simply to the PV module 350 frame itself.
  • module clamp 315 When module clamp 315 is in an open position, module clamp 315 is decompressed around integral tab 175 (not shown), unlocking module clamp support bar 170 (not shown) from external conveyance shuttle 310.
  • First module area 320 comprises power electronics, wireless communications, or other electronic components capable of providing power and communications to external conveyance shuttle 310.
  • Second module area 325 comprises storage for batteries or other power storage device to supply external conveyance module 310 with power.
  • Magnet 335 comprises a ferrite magnet, an electromagnet, a neodymium magnet, a samarium cobalt (SmCo) magnet, an alnico magnet, a ceramic magnet, or any other kind of apparatus that produces an attractive force.
  • Magnet 335 applies a downward force on external conveyance shuttle 310 to torque tube 300.
  • magnet 335 keeps external conveyance shuttle 310 from falling off, being knocked off, or otherwise removed from torque tube 300.
  • Propulsion apparatus 330 allows external conveyance shuttle 310 to move freely along torque tube 300.
  • integral tab 175 and module clamp 315 may comprise other varieties of locking mechanisms such as clamps, adaptors, hinges, projections, bearings, hitches, hooks, adhesives, projections, holes etc.
  • external conveyance shuttle 310 comprises any number of propulsion apparatus 330 that allow it to move, but preferably at least two wheels.
  • the term “wheels” shall not be limited to the shape shown in the figures, but may also include any shape adequate to permit the object it supports to move, including but not limited to balls and cylinders, or a tracked mechanism.
  • External conveyance shuttle 310 may be manually moved down torque tube 300 via a system of strings, cables, pulleys, or similar.
  • external conveyance shuttle 310 may be self-propelled and integrate batteries, electric motors, controllers, sensors, and may be operated via remote control from a human operator or programmed to shuttle PV modules 105 along torque tube 300 autonomously. Electrical circuits to connect PV module 105 may be transported above external conveyance shuttle 310.
  • a plurality of external conveyance shuttle 310 may be in communication with one another via shuttle support bar 340.
  • Shuttle support bar 340 allows multiple external conveyance shuttle 310 to be used when transporting one or more PV module 105 along torque tube 300. Additionally, a plurality of external conveyance shuttle 310 in communication with each other via shuttle support bar 340 allows heavier loads to be carried along torque tube 300.
  • Fig. 9 shows a top angled view of external conveyance shuttle 310 disposed on top of torque tube 300.
  • Propulsion apparatus 330 are in communication with external conveyance shuttle 310 via propulsion support 331 .
  • Propulsion support 331 allows a plurality of propulsion apparatus 330 to be in communication with external conveyance shuttle 310.
  • propulsion support 331 allows external conveyance shuttle 310 to traverse along torque tube 300 by matching the contours of torque tube 300.
  • torque tube 300 comprises a polygonal cross-sectional shape which provides a plurality of straight surfaces or edges against which propulsion apparatus 330 can propel or contact.
  • External conveyance shuttle 310 is transported over torque tube 300 along axis 450, which axis is oriented in the direction of the length of torque tube assembly 110.
  • Axis 450 is parallel to torque tube assembly 110, external conveyance shuttle 310, torque tube 300, and shuttle support bar 340.
  • Fig. 10 shows a top perspective view of external conveyance shuttle 310 disposed on top of torque tube 300.
  • Module clamp 315, first module area 320, and second module area 325 can all be seen from a top view over external conveyance system 310.
  • two external conveyance shuttle 310 are in communication with one another via shuttle support bar 340, moving along axis 450.
  • FIG. 11 shows a close-up illustration from a perspective view of an external conveyance shuttle rolling over a torque tube, providing a better view of magnet 335.
  • Magnet 335 provides an attractive downward force to hold external conveyance system 310 in contact with torque tube 300.
  • Magnet 335 is preferably disposed between a surface of external conveyance system 310 and where torque tube 300 would be, or underneath external conveyance system 310.
  • magnet 335 may be substituted with another attractive device such as clamps, adhesives liquids, suction from vacuums, etc.
  • Fig. 12 shows external conveyance shuttle 310 carrying a PV module 350 over torque tube 300. Shown is a PV module 350 attached to external conveyance shuttle 310 for conveyance down torque tube 300. Any kind of shuttle clamps, brackets, or attachments that would clamp PV module 350 to torque tube 300 are omitted for clarity.
  • external conveyance shuttle 310 shuttles PV module 350 down torque tube 300, PV module 350 is then released from the shuttle clamps, and by holding PV module 350 up slightly, external conveyance shuttle 310 will move back towards the end of torque tube 300 to be reloaded with another PV module 300. From there the first PV module 350 is simply lowered down about 1 to about 2 inches and clamped to torque tube 300 once external conveyance shuttle 310 is cleared.
  • Fig. 13 shows a side view of external conveyance shuttle 310 carrying a PV module 350 over torque tube 300.
  • Fig. 14 shows an underside view of external conveyance shuttle 310 carrying a PV module 350 over torque tube 300.
  • Module clamp 315 can be seen in a closed position, compressing onto the frame of PV module 350, and locking PV module 350 to external conveyance shuttle 310.
  • two external conveyance shuttle 310 are used to clamp onto one end each of PV module 350.
  • the length of shuttle support 340 is adjusted to match the width of PV module 350.
  • Propulsion apparatus 330 and magnet 335 can be seen stabilizing and traversing external conveyance module 310 along torque tube 300.
  • Fig. 15 shows a top view of external conveyance shuttle 310 carrying a PV module 350 over torque tube 300. Second module area 325 can be seen left exposed, available for storage of batteries or other power storage device to supply external conveyance module 310 with power.
  • Fig. 16 shows a side view of external conveyance shuttle 310 rolling on top of a torque tube 300.
  • Two external conveyance shuttle 310 are in communication with one another via shuttle support 340.
  • external conveyance shuttle 310 can be used with a standard profile of torque tube 300 without requiring integration of conveyance channel 125 within it.
  • the same bearing housings 205 described elsewhere in this application are preferably employed that are open for external conveyance shuttle 310 and PV module 350 to pass by and be installed before they are clamped down to secure torque tube 300 once all PV module 350 forthat section have been conveyed into place.
  • edge torque tube 370 that fits an edge conveyance shuttle 355.
  • Figs. 17 and 18 show edge conveyance shuttle 355 comprising edge conveyance shuttle body 360 and grooved wheels 365.
  • edge torque tube 370 does not include conveyance channel 125 and instead includes concave side 385 and edges 375.
  • Edges 375 run the length of edge torque tube 370.
  • two of edges 375 are on opposite ends of concave side 385, and concave side 385 is the side of edge torque tube 370 that is furthest and substantially parallel to the ground.
  • Edge torque tube 370 further comprises compression holes 380. Compression holes 380 allow ventilation and access to the inside of edge torque tube 370.
  • Edge torque tube 370 can also have various other cross-sectional shapes, including any other polygonal shape including hexagonal, square, triangular etc.
  • Concave side 385 can be of varying depths to allow components to pass through between edge conveyance shuttle 355 and concave side 385.
  • Edge conveyance shuttle 355 comprises edge conveyance shuttle body 360 and grooved wheels 365.
  • Edge conveyance shuttle 355 is disposed on, within or along edge torque tube 370.
  • Edge conveyance shuttle body 360 allows a plurality of grooved wheels 365 to be used in one embodiment.
  • Grooved wheels 365 have a groove running through the center of the outer circumference that allows them to roll over edges 375 without slipping or sliding.
  • the groove in grooved wheels 365 rotates in a direction that is parallel to the primary axis of edge torque tube 370, which is parallel to the length of edges 375.
  • Edge conveyance shuttle 355 moves freely along edge torque tube 370.
  • Integral tab 175 (not shown) underneath module clamp support bar 170 locks into edge conveyance shuttle body 360 so that edge conveyance shuttle 355 can transport module clamp support bar 170, PV module 105, and/or PV support panel 160 along edge torque tube 370.
  • Fig. 19 shows edge conveyance shuttle 355 moving away along edge torque tube 370 after support bracket arm 185 of rail support bracket assembly 180 has been installed.
  • One of the objectives of the present invention is to provide methods of transporting PV modules along a torque tube without the need for strenuous manual labor.
  • the present invention allows PV modules to be loaded onto a torque tube and transported along it without the interference of piles.
  • the present invention also allows for PV modules to not have to be manually carried and transported via equipment down the length of the torque tube, requiring less physical labor, increasing safety, and reducing the risk of PV module breakage.
  • the novel conveyance channel allows a conveyance shuttle to not only move a PV module along a torque tube, but also move any necessary electrical circuits through the torque tube to their desired destination.
  • PV module system 100 can be employed in the field.
  • all components of PV module system 100 are manufactured before being delivered to the place of installation (the “Power Facility”), including piles 115 torque tube assembly 110, rail clamp assembly 155, support bracket assembly 180, and conveyance shuttle 200.
  • Piles 115 are installed into the ground at the Power Facility, preferably at a pre-determined distance from each other and such that the line they form is oriented in a North-South direction, and each with a bearing housing 205 disposed on their tops.
  • bearing housings 205 are opened and torque tube assembly 110 is placed on or in bearing housings 205 to extend between adjacent piles 115. Such may involve inserting conveyance channel 125 into torque tube 112 if those components of torque tube assembly 110 were independent objects.
  • PV modules 105 are manufactured and assembled to include or coordinate with rail clamp assemblies 155 and rail support bracket assembly 180. Such components can then be transported to the Power Facility in a vehicle, preferably on an access road that passes near a first end of the torque tube assembly 110 at the Power Facility.
  • Each module clamp support bar 170 is secured to conveyance shuttle 200 using any of the various mechanisms described herein, which may include inserting integral tab 175 into clamping arm 176 of integral clamping mechanism 130. Such may involve putting integral clamping mechanism 130 into a closed position such that clamping arms 176 clamp down and secure to tab 175.
  • Each rail support bracket assembly 180 is also opened, that is, put in a position in which each of support bracket arms 185 do not interfere with a bearing housing 205 as the PV Module 105 is conveyed down torque tube assembly 110. That may involve rotating each of support bracket arms 185 outwards as described herein. [0075] While bearing housings 205 are in their open position and with support bracket arms 185 in their open position, PV modules 105 can then be conveyed on conveyance shuttle 200 down the length of torque tube assembly 110 toward the second end of torque tube assembly 110 to the PV module’s intended location of installation on the torque tube assembly.
  • PV module 105 can easily be conveyed, along with all of the components necessary for its installation, past the bearing housings 205 and all the way to its position of installation, with much less labor or risk than traditional methods.
  • PV module 105 is released from conveyance shuttle 200 by putting it into its open position, which may involve opening clamping mechanism 130 by pushing down on its handle which opens clamping arms 176 to release tab 175.
  • tab 175 then simply rests within conveyance channel 125.
  • Both of the support bracket arms 185 which are on opposites sides of torque tube assembly 110 from each other, are then placed in their closed position, for example as shown in Figs.
  • Support bracket arms 185 support the weight of the PV module 105 while it is installed and in its operational position on torque tube assembly 110.
  • Hardware tab 190 on first support bracket arm 185 contacts the second bracket arm 185 so that weight is distributed between the first and second support bracket arms 185.
  • Hardware tab 190 may be bolted or otherwise attached to further secure first and second support bracket arms 185 to each other, but such may not be necessary.
  • conveyance shuttle 200 in its open position, would simply be conveyed back down to the first end of the torque tube assembly 110. There, the cables can be temporarily secured to conveyance shuttle 200 and sent back down toward the second end to the PV module requiring the cable. The cable can then be released from conveyance shuttle 200 and connected with the PV module 105.
  • groups of modules or individual module’s wiring connections are used interchangeably.
  • Embodiments of the present invention can include every combination of features that are disclosed herein independently from each other. Although the invention has been described in detail with particular reference to the disclosed embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and this application is intended to cover, in the appended claims, all such modifications and equivalents.
  • the entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference. Unless specifically stated as being “essential” above, none of the various components or the interrelationship thereof are essential to the operation of the invention. Rather, desirable results can be achieved by substituting various components and/or reconfiguring their relationships with one another.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Physics & Mathematics (AREA)
  • Sustainable Energy (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Photovoltaic Devices (AREA)
  • Supports For Pipes And Cables (AREA)

Abstract

Navette de transport pour transporter des modules photovoltaïques ("PV") le long d'un élément de support. La navette de transport comprend un réceptacle pour recevoir un élément d'un module PV ou d'un panneau de support de module PV, la navette de transport, lorsqu'elle est coordonnée avec l'élément de coordination de navette, étant capable de transporter le module PV ou le panneau de support de module PV le long d'une longueur de l'élément de support.
PCT/US2024/047998 2023-09-22 2024-09-23 Système et procédés de transport de modules pv Pending WO2025065007A1 (fr)

Priority Applications (1)

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AU2024345875A AU2024345875A1 (en) 2023-09-22 2024-09-23 Pv module conveyance system and methods

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US202363584784P 2023-09-22 2023-09-22
US63/584,784 2023-09-22
US202363605297P 2023-12-01 2023-12-01
US63/605,297 2023-12-01

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US20120023728A1 (en) * 2010-06-23 2012-02-02 Applied Materials, Inc. Apparatus And Methods For Transporting Large Photovoltaic Modules
CN111335456A (zh) * 2020-03-19 2020-06-26 常州工学院 一种柔性光伏可伸展窗户采光保温房
CN111335356A (zh) * 2020-04-01 2020-06-26 北京建工土木工程有限公司 管涵预制构件自动化装配系统及施工方法
US20220107117A1 (en) * 2020-10-05 2022-04-07 Nextracker Inc. D-shaped torque tube and bearing assemblies
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AU2024344275A1 (en) 2026-04-02
WO2025065001A1 (fr) 2025-03-27
WO2025065007A4 (fr) 2025-05-01

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