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Distributed manufacturing for distributed generation: 3-D printed solar photovoltaic module mounting mechanisms for wood racking

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  • Jamil, Uzair
  • Sadat, Seyyed Ali
  • Pearce, Joshua M.

Abstract

Solar photovoltaic (PV) wood-based rack designs support distributed manufacturing, have lifetimes equivalent to PV warranties, have lower embodied energy and carbon emissions and cost less than conventional racking. Unfortunately, wood racking does not enable the standard front surface attachments. To overcome this challenge this study introduces novel 3D printed clamps for front-surface PV mounting on wood racking. Four topologies (square spacer, H-shaped spacer, U-shaped clamp and T-shaped clamp) of 3D printed parts are designed, modeled and analyzed using finite element analysis (FEA) for PETG, ASA and PC. The designs were fabricated, field tested and economically analyzed. The highest stress was observed in U-shaped spacer for spacer (4.53 MPa – PC material), bolt (32.01 MPa – PETG material) and frame (37.30 MPa) and for washer in the H-spacer (42.77 MPa). Mises stresses for all designs, however, are found within allowable limits qualifying the clamping technique to be adopted for future installations. Financial analysis of the clamps found up to 66 % savings for the solutions. The T-shaped clamp is the recommended mounting technique with the lowest stresses while square spacer provides the least cost. The practical implications of the results indicate that 3D printing could provide an economic means of mounting PV modules and reducing solar energy costs.

Suggested Citation

  • Jamil, Uzair & Sadat, Seyyed Ali & Pearce, Joshua M., 2024. "Distributed manufacturing for distributed generation: 3-D printed solar photovoltaic module mounting mechanisms for wood racking," Renewable Energy, Elsevier, vol. 228(C).
    • Handle: RePEc:eee:renene:v:228:y:2024:i:c:s0960148124007195
    DOI: 10.1016/j.renene.2024.120651
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    References listed on IDEAS

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    1. Ed Sells & Sebastien Bailard & Zach Smith & Adrian Bowyer & Vik Olliver, 2009. "RepRap: The Replicating Rapid Prototyper: Maximizing Customizability by Breeding the Means of Production," World Scientific Book Chapters, in: Frank T Piller & Mitchell M Tseng (ed.), Handbook of Research in Mass Customization and Personalization (In 2 Volumes), chapter 28, pages 568-580, World Scientific Publishing Co. Pte. Ltd..
    2. B. T. Wittbrodt & J.M. Pearce, 2015. "Total U.S. cost evaluation of low-weight tension-based photovoltaic flat-roof mounted racking," Post-Print hal-02119670, HAL.
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    4. Branker, K. & Pathak, M.J.M. & Pearce, J.M., 2011. "A review of solar photovoltaic levelized cost of electricity," Renewable and Sustainable Energy Reviews, Elsevier, vol. 15(9), pages 4470-4482.
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