JP7847367B2 - Solar panel installation device and solar panel installation method - Google Patents

Description

This invention relates to a solar panel installation device and a solar panel installation method for installing solar panels, for example, on the roof or rooftop of a building.

Conventionally, as a solar panel installation device for installing rectangular solar panels, a solar panel mounting frame was provided for attaching the solar panel, and a solar panel support was provided, which had a base-side fixing part at its lower end that could be attached to the base and a mounting frame fixing part at its upper end for attaching the solar panel mounting frame. This solar panel support was required to stabilize the installation of one side of the solar panel and the opposite side at the other end. Therefore, multiple solar panel support devices were arranged on both the one and the other end of the solar panel mounting frame, and each was fixed to the base with bolts or the like (see, for example, Patent Document 1).

Japanese Patent Publication No. 2017-150672

With the conventional solar panel installation devices described above, approximately 10 to 15 years after the solar panels are installed on the rooftop or other substrate of a building, maintenance work such as waterproofing may be required on the rooftop or other substrate.
For example, waterproofing work may involve applying a waterproof sheet to the substrate. However, in conventional methods, the solar panel mounting frame, to which the solar panel is attached, must be removed from the solar panel support before waterproofing work can be carried out.
In particular, when many solar panels are installed, the removal process is time-consuming and incurs extra costs. Furthermore, the need to temporarily store the numerous removed solar panels during maintenance presents a problem in terms of storage space.

Therefore, the objective of this invention is to resolve the above-mentioned problems and to enable repair work, such as waterproofing, to be performed on solar panel installation areas on rooftops and other roofs with simple procedures and without hindering the storage of numerous solar panels.

The first characteristic configuration of the present invention is a solar panel support comprising a pair of solar panel mounting frames for attaching solar panels, a base-side fixing portion at the lower end that can be attached to a base, and a mounting frame fixing portion at the upper end that can be attached to one end of each of the pair of solar panel mounting frames. A pivot mechanism is provided at the mounting frame fixing portion to pivotally support each of the pair of solar panel mounting frames so that the solar panels can swing up and down, and their other ends can move closer to and further apart from each other. Furthermore, an upright posture holding device is provided to allow the pair of solar panel mounting frames to be erected to swing the solar panels upward, and to hold them in a position where their other ends are close together.

According to the first characteristic configuration of the present invention, the solar panel mounting frame for attaching the solar panel is attached to the mounting frame fixing part of the solar panel support at one end of each pair, and a pivot mechanism is provided at the mounting frame fixing part that pivotally supports each of the pair of solar panel mounting frames so that the solar panel can swing up and down, and the other ends of the frames can move closer to and further apart from each other. A standing posture holding device is provided that allows each of the pair of solar panel mounting frames to be erected in order to swing the solar panel upward, and to be held in a position where the other ends of the frames are close together. As a result, when performing maintenance on rooftops or roofs, such as waterproofing work, the pair of solar panels can be swung upward by the pivot mechanism provided at the mounting frame fixing part, thereby exposing a large portion of the substrate on the rooftop or roof where the solar panel was installed, making it easy to perform maintenance such as waterproofing work with less effort.
Furthermore, by providing an upright posture holding device that allows the pair of solar panels, which are swung upward, to be held in a position where their other ends are close together by erecting the solar panel mounting frames for each panel, it becomes possible to store a large number of solar panels without difficulty and to perform maintenance work.

A second characteristic feature of the present invention is that the upright posture holding device is configured to connect the other ends of a pair of upright solar panel mounting frames, thereby preventing the solar panel mounting frames from swinging up and down.

According to the second characteristic configuration of the present invention, by simply connecting the other ends of a pair of solar panel mounting frames with an upright posture holding device, their vertical movement can be easily prevented, thereby improving work efficiency.

A third characteristic feature of the present invention is the provision of a stopper device on the mounting frame fixing portion that prevents the other end of the solar panel mounting frame from swinging upward and tipping over to the opposite side when the solar panel is in an upright position, by contacting one end of the solar panel mounting frame with the stopper device.

According to the third characteristic configuration of the present invention, the stopper device makes it easier to stabilize the upright position of the solar panel mounting frame to prevent it from falling to the opposite side, thereby improving the safety of maintenance work.

A fourth characteristic feature of the present invention is that, in the solar panel mounting frame, support legs that can be placed on the substrate are attached to the other end.

According to the fourth characteristic configuration of the present invention, the support legs attached to the solar panel mounting frame allow for easy and stable installation of the solar panel in a position that receives sunlight when placed on the substrate. Furthermore, when the solar panel swings upward, the other end of the solar panel mounting frame rises along with it, exposing a larger portion of the substrate and facilitating maintenance work.

A fifth characteristic feature of the present invention is that the support leg is designed to allow for the installation of a weight that presses against the substrate while it is placed on the substrate.

According to the fifth characteristic configuration of the present invention, by simply adding a weight, a solar panel in a light-receiving position that receives sunlight from above while its support legs are placed on a base can be stabilized even when strong winds are acting on it.
Therefore, by adding a separate weight, the solar panel mounting frame and support legs can be made lighter while still maintaining stability. This allows for easy vertical movement of the solar panel, reducing the effort required for maintenance.

The sixth characteristic feature of this invention is that, while each of the other ends of the solar panel mounting frame is swung downward to bring it close to the base, a locking device is provided, which prevents the solar panel from swinging upward, between the solar panel support and the solar panel mounting frame, or between adjacent solar panel mounting frames, and which can be unlocked.

According to the sixth feature configuration of the present invention, by providing a locking device that prevents the solar panel from swinging upward while each of the other ends of the solar panel mounting frame is swung downward to bring it close to the substrate, the solar panel can be easily installed in a stable position to receive sunlight. Furthermore, by unlocking the locking device, when the solar panel swings upward, it rises together with the other ends of the solar panel mounting frame, exposing a larger portion of the substrate and making maintenance work easier.
Furthermore, a locking device provided between the solar panel support and the solar panel mounting frame, or between adjacent solar panel mounting frames, mechanically prevents the solar panel support from swinging up and down, thereby enabling stable installation of the solar panel.

The seventh characteristic feature of this invention is that, while each of the other ends of the solar panel mounting frame is swung downward to bring it close to the base, a locking device is provided on the pivot mechanism that prevents the solar panel from swinging upward, and this locking device can be released.

According to the seventh characteristic configuration of the present invention, when installing a solar panel on a substrate, the other ends of the solar panel mounting frame can be lowered and swung to bring them close to the substrate, allowing for easy and stable installation in a position that receives sunlight. Furthermore, when the locking device is released and the solar panel swings upward, the other ends of the solar panel mounting frame rise together, exposing a larger portion of the substrate and making maintenance work easier.
Furthermore, by providing a locking device that prevents the solar panel from swinging upward on the pivot mechanism in a way that allows it to be unlocked, the locking device can be made more compact.

The eighth characteristic feature of the present invention is the provision of a solar panel auxiliary support device, which has a detachable mounting frame fixing portion at its upper end and a substrate-side fixing portion at its lower end that allows for attachment to the substrate, respectively, on the other end of the solar panel mounting frame.

According to the eighth characteristic configuration of the present invention, when raising the other end of the solar panel mounting frame in order to swing the solar panel upward, it becomes possible to detach the other end of the solar panel mounting frame from the mounting frame attachment/detachment fixing part of the solar panel auxiliary support, which is fixed to the base. Furthermore, both the one end and the other end of the solar panel can be reliably and stably fixed to the base even when subjected to vertical and lateral external forces caused by strong winds or seismic activity.

The ninth characteristic feature of the present invention is that the mounting frame attachment/detachment fixing part is provided with an operating mechanism that allows attachment and detachment of the solar panel to the solar panel mounting frame from above while the solar panel is installed along the substrate.

According to the ninth feature configuration of the present invention, since the other end of the solar panel mounting frame can be attached to and detached from the solar panel mounting frame from above, even when multiple solar panels are installed along the substrate, the operation of releasing the solar panel from the auxiliary support and swinging it upward becomes easier.

The tenth characteristic feature of the present invention is that the mounting frame attachment/detachment fixing portion is configured to allow the attachment of one pair of solar panel mounting frames and another adjacent pair of solar panel mounting frames so that they are arranged side by side along the surface of the solar panel.

According to the tenth feature configuration of the present invention, two pairs of solar panel mounting frames adjacent to each other can be installed on a single solar panel auxiliary support, thereby increasing the installation efficiency of the solar panels.

The eleventh characteristic configuration of the solar panel installation method of the present invention is that, when installing the solar panel installation device, the output cable device that spans between the pair of solar panel mounting frames and another adjacent pair of solar panel mounting frames is positioned so that it is located at one end of each of the solar panel mounting frames, and the solar panels are then attached to the solar panel mounting frames.

According to the eleventh characteristic configuration of the present invention, when the solar panels are oscillated vertically, the output cable device that connects the pair of solar panel mounting frames to another adjacent pair of solar panel mounting frames is located near the pivot mechanism. Therefore, the cables are not pulled, allowing the solar panels to be individually oscillated vertically, thus preventing electrical wiring problems during maintenance.

This is a perspective view of the solar panel installation device in its installed state. This is a perspective view of a solar panel installation device with the solar panels swung upwards. This is an exploded perspective view of a solar panel support. This is a disassembled perspective view of the solar panel support in its assembled state. This is a diagram illustrating the operation of the key components that control the vertical oscillation of the solar panel. This is a perspective view of a solar panel mounting and position fixing device. This is a perspective view illustrating the operation of a solar panel mounting device in its installed state, specifically for attaching solar panels. This is a perspective view showing the installation status of the solar panel support bracket. This is an exploded perspective view of a solar panel support bracket.

Embodiments of the present invention will be described below with reference to the drawings.
As shown in Figure 1, the solar panel 3 is fixed to a building (an example of a base 2) such as a concrete floor on a roof or a veranda using the solar panel installation device 1 of the present invention.

As shown in Figures 1 and 2, the solar panel installation device 1 includes a solar panel mounting frame 4 for attaching the solar panel 3, a solar panel support 7 with a base-side fixing part 5 at its lower end that can be attached to the base 2, and a mounting frame fixing part 6 at its upper end that can be attached to one end of the solar panel mounting frame 4, and a support leg 8 that can be placed on the base 2 attached to the other end of the solar panel mounting frame 4.

As shown in Figures 3 and 4, the solar panel support 7 is divided into upper and lower sections: a base-side support member 9 with a base-side fixing portion 5, and an external support member 10 with a mounting frame fixing portion 6. A connecting portion 13 is provided at the upper end of the base-side support member 9 and the lower end of the external support member 10, allowing them to be connected to each other by connecting bolts 11 and nuts 12.

The base-side fixing portion 5 of the base-side support member 9 has an anchor bolt insertion hole 15 formed so that it can be fixed to the base 2 by an anchor bolt 14, and the connecting portion 13 has a first elongated hole 16 for inserting a connecting bolt 11.
A second insertion slot 17 for the connecting bolt 11 is formed in the connecting portion 13 of the object support member 10, and the first insertion slot 16 and the second insertion slot 17 are formed so that the longitudinal directions of each slot intersect each other in the lateral direction.
Therefore, the other object support member 10 is configured to be able to adjust its relative position to the base support member 9 in a two-dimensional lateral direction, and to rotate around the vertical axis in a twisting direction to fix and connect its relative position.

As shown in Figures 3 to 5, the mounting frame fixing portion 6 of the object support member 10 is provided with a pair of pivot mechanisms 18 that pivotally support the solar panel mounting frame 4 so that each of the multiple solar panels 3 can swing up and down.
In other words, each pivot mechanism 18 has bolt insertion holes 20 formed in each of the two side walls 19 that stand opposite each other, and bolts 21 and nuts 22 are attached to these opposing pairs of bolt insertion holes 20. A metal cylindrical sheath tube 23 is loosely fitted to the bolt 21 that extends between the two side walls 19 so as to be rotatable around the coaxial axis of the bolt 21, and a pivot shaft 24 is formed on the sheath tube 23 so as to pivot the solar panel mounting frame 4 so as to be able to swing up and down.

Furthermore, a stopper device 25 is formed by ribs attached to each of the side walls 19 to prevent the other end of the solar panel mounting frame 4 from swinging upward and tipping over to the opposite side when the solar panel 3 is in an upright position, by contacting one end of the solar panel mounting frame 4 with it.
As shown in Figures 2 and 6, a standing position holding device 26 is detachably provided to allow the other end of a pair of solar panel mounting frames 4 attached to the other object support member 10 to be swung upward so that the solar panel 3 is in an upright position, and to maintain that upright position.
Furthermore, the upright posture holding device 26 is provided with a pair of wing screws 27, and by tightening and rotating the wing screws 27, the pair of solar panel mounting frames 4 are clamped and their upright postures are maintained.

As shown in Figures 1, 2, 5, and 7, the solar panel 3 is pivotally supported by a pivot mechanism 18 so that each of the pair of solar panel mounting frames 4 can swing up and down, with their other ends freely moving closer to and further apart from each other. Furthermore, another pair of solar panel mounting frames 4, different from the pair of solar panel mounting frames 4, can be mounted side-by-side along the surface of the solar panel 3. In short, one solar panel support 7 is configured to accommodate four sets of solar panel mounting frames 4 that can swing up and down.

As shown in Figure 7, the solar panel mounting frame 4 is formed by assembling arm members 4A and cross members 4B, each made of metal angle, in a grid pattern and connecting them with bolts. The solar panel 3 is placed on a pair of cross members 4B, and panel fastening brackets 28 are detachably attached to securely clamp the edges of the solar panel 3.

Furthermore, instead of using the panel fastening brackets 28 to secure the solar panel 3 to the solar panel mounting frame 4, the solar panel 3 may be directly fixed to the solar panel mounting frame 4 via bolts.

As shown in Figure 1, the pair of solar panel mounting frames 4 are installed with a gentle slope, where one end on the pivot side is slightly higher than the other end, and the sides become lower towards the left and right. Furthermore, by aligning the pivot sides of these frames with the north-south direction (S-N in the figure), each of the left and right solar panels 3 receives sunlight equally throughout the day.

In the installation of the solar panel 3, as shown in Figures 1, 2, and 7, the solar panel mounting frame 4 is pivotally fixed to the solar panel support 7 at one end, while the other end is positioned to receive sunlight from above with the support legs 8 resting on the base 2. To stabilize it in this light-receiving position, a weight (not shown) that normally presses the support legs 8 against the base 2 is detachably attached.

Furthermore, the aforementioned weight is not necessarily required unless the solar panel 3, when attached to the solar panel mounting frame 4, is significantly heavy and therefore would be lifted by strong winds.

However, the other end of the solar panel mounting frame 4 to which the support legs 8 are attached may be the other end of the arm member 4A, or the left and right intermediate sections of the crossbar member 4B located on the other end side, from both ends to the center. In other words, the position where the support legs 8 are attached is collectively referred to as the other end of the solar panel mounting frame 4.

Furthermore, when installing the solar panel mounting device, the output cable device that spans between one pair of solar panel mounting frames 4 and another adjacent pair of solar panel mounting frames 4 is positioned so that it is located at one end of each solar panel mounting frame 4.
In other words, when the solar panels 3 are swung up and down by attaching one end of each solar panel mounting frame 4 to the pivot mechanism 18 of the mounting frame fixing part 6, even if a pair of solar panels 3 and adjacent solar panels 3 are connected to each other by output cable devices such as connectors and cables that electrically connect them, the solar panels 3 can be individually swung up and down without the cables being pulled, thus preventing electrical wiring problems during maintenance.

[Another embodiment]
Other embodiments are described below.
In addition, in the following other embodiments, the same reference numerals are used for components similar to those in the above embodiment.
(1) In order to stabilize the solar panel 3 in a light-receiving position, a locking device (not shown) that prevents the solar panel 3 from swinging upward while the support legs 8 are placed on the base 2 may be provided in a lockable and unlockable manner between the solar panel support 7 and the solar panel mounting frame 4, or between multiple adjacent solar panel mounting frames 4.
(2) In order to stabilize the solar panel 3 in a light-receiving position, a locking device (not shown) that prevents the solar panel 3 from swinging upward while the support legs 8 are placed on the base 2 may be provided on the pivot mechanism 18 in a way that allows it to be unlocked.
<3> As shown in Figures 1, 2, and 7, the support legs 8 are provided approximately in the center of the longitudinal direction of the crossbar member 4B in the solar panel mounting frame 4. However, they may also be provided in locations other than the center, or in pairs at each end, or at the other end of the arm member 4A. The location where the support legs 8 are provided, including these locations, will be referred to as the other end side of the solar panel mounting frame 4. Similarly, in the solar panel support 7, the location where the solar panel mounting frame 4 is attached to the mounting frame fixing part 6 may also be the middle or both ends of the crossbar member 4B attached to the mounting frame fixing part 6, in addition to one end of the arm member 4A in the solar panel mounting frame 4. This will be referred to as attaching the one end side of the solar panel mounting frame 4 to the mounting frame fixing part 6.
<4> In the solar panel mounting frame 4, instead of providing support legs 8 on the other end, a solar panel auxiliary support 30 may be provided, as shown in Figures 8 and 9, which has a mounting frame attachment/detachment fixing part 30B at its upper end that allows the other end to be attached and detached, and a base-side fixing part 30A at its lower end that can be attached to a base. In order to swing the solar panel 3 upward, when raising the other end of the solar panel mounting frame 4, the other end of the solar panel mounting frame 4 may be detached from the mounting frame attachment/detachment fixing part 30A of the solar panel auxiliary support 30, which has the base-side fixing part 30A fixed to the base.
Furthermore, the base-side fixing part 30A and the mounting frame attachment/detachment fixing part 30B are formed from separate metal fittings and are configured to be connectable to each other with bolts 31A and nuts 31B.
Furthermore, in Figures 8 and 9, the other end portions of two adjacent solar panel mounting frames 4 are configured to be detachably fixed to one solar panel auxiliary support 30.
In this case, one end and the other end of the solar panel 3 can be securely and stably fixed to the substrate even when subjected to vertical and horizontal external forces caused by strong winds or seismic activity.
<5> When providing the solar panel auxiliary support 30, as shown in Figures 8 and 9, the connection structure of the solar panel mounting frame 4 to the mounting frame attachment/detachment fixing part 30B is provided such that an operating mechanism 32 can be attached and detached from above when the solar panel 3 is installed roughly along the base 2, and the other end of the solar panel mounting frame 4 is released from the solar panel auxiliary support 30 and swung upward, and the release operation is made easy when a number of solar panels 3 are arranged and fixed in a roughly planar manner on the base 2.
The operating mechanism 32 is constructed by providing an elongated bolt insertion hole 32A at the other end of the arm member 4A, and a bolt insertion hole 32B that is longer in a direction different from the bolt insertion hole 32A in the mounting frame attachment/detachment fixing part 30B, and providing a bolt 32C that can be inserted into these bolt insertion holes 32A and bolt insertion hole 32B, and a nut 32D that connects to the bolt 32C.
Furthermore, the mounting frame attachment/detachment fixing part 30B is provided with large elongated holes 32E in the bolt insertion holes 32A and 32B, for inserting the bolt 32C from below, bolt head and all (Figure 9).
(6) The stopper device 25 is made of ribs, but it may be made of other structures.
<7> The upright posture holding device 26 is not limited to the one shown in Figure 6, but may also be made of a flexible material other than metal, or a chain-like object that can connect the other ends of a pair of erected solar panel mounting frames 4, and in this case it may be permanently attached to one side of the pair of solar panel mounting frames 4.
(8) The mounting position of the upright posture holding device 26 is not limited to the height shown in Figure 2, but can be mounted at any height that facilitates attachment and detachment.
<9> The solar panel support 7 is composed of separate components, the base support member 9 and the other object support member 10, but it may also be formed as a single unit.
<10> In the embodiment shown, the pair of pivot mechanisms 18 provided on the solar panel support 7 have pivot shafts 24 of the same height, but they may be of different heights.

Furthermore, as mentioned above, reference numerals have been used to facilitate comparison with the drawings; however, this notation does not limit the present invention to the configuration shown in the attached drawings. Naturally, the invention can be implemented in various forms without departing from the spirit of the invention.

2 Substrate 3 Solar panel 4 Solar panel mounting frame 5 Substrate-side fixing part 6 Mounting frame fixing part 7 Solar panel support 8 Support legs 18 Pivot mechanism 26 Upright posture holding device 30 Solar panel auxiliary support 30A Substrate-side fixing part 30B Mounting frame attachment/detachment fixing part 32 Operating mechanism

Claims (11)

A pair of solar panel mounting frames is provided for attaching solar panels.
A solar panel support is provided, which has a base-side fixing part at the lower end that can be attached to a base, and a mounting frame fixing part at the upper end that can be attached to one end of each of the pair of solar panel mounting frames.
A pivot mechanism is provided in the mounting frame fixing part that pivotally supports each of the pair of solar panel mounting frames so that the solar panels can swing up and down, and their other ends can move closer to and further apart from each other.
A solar panel installation device is provided with an upright posture holding device that erects a pair of solar panel mounting frames so that the solar panel can be swung upward, and the other ends of each frame are positioned close together. The solar panel installation device according to claim 1, wherein the vertical position fixing device is configured to connect the other ends of a pair of vertically erected solar panel mounting frames, thereby preventing the solar panel mounting frames from swinging up and down. The solar panel mounting device according to claim 1 or 2, wherein a stopper device is provided on the mounting frame fixing portion to prevent the solar panel from falling to the opposite side when the other end of the solar panel mounting frame swings upward and the solar panel is in an upright position, by contacting one end of the solar panel mounting frame with the other end of the mounting frame. The solar panel mounting device according to claim 1 or 2, wherein a support leg capable of being placed on the substrate is attached to the other end of the solar panel mounting frame. The solar panel installation device according to claim 4, wherein the support legs are configured to allow for the installation of weights that press against the substrate while the legs are placed on the substrate. The solar panel installation device according to claim 1 or 2, wherein a locking device for preventing the upward swinging of the solar panel is provided, in a lockable and unlockable manner, between the solar panel support and the solar panel mounting frame, or between adjacent solar panel mounting frames, while each of the other ends of the solar panel mounting frame is swung downward to bring it close to the base. The solar panel mounting device according to claim 1 or 2, wherein a locking device is provided on the pivot mechanism, which can be unlocked, to prevent the solar panel from swinging upward while each of the other ends of the solar panel mounting frame is swung downward to bring it close to the base. The solar panel installation device according to claim 1 or 2, wherein a solar panel auxiliary support is provided, comprising a mounting frame attachment/fixing portion at its upper end for detachability to the other end of the solar panel mounting frame, and a base-side fixing portion at its lower end for attachment to a base. The solar panel installation device according to claim 8, wherein the mounting frame attachment/detachment fixing part is provided with an operating mechanism that allows attachment and detachment of the solar panel to the solar panel mounting frame from above while the solar panel is installed along the base. The solar panel installation device according to claim 8, wherein the mounting frame attachment/detachment fixing section is configured to allow mounting of the pair of solar panel mounting frames and another pair of adjacent solar panel mounting frames so that they are arranged side by side along the surface of the solar panel. When installing the solar panel installation device described in claim 10,
A method for installing solar panels, wherein an output cable device that spans between the pair of solar panel mounting frames and another adjacent pair of solar panel mounting frames is positioned so that it is located at one end of each of the solar panel mounting frames, and the solar panels are attached to the solar panel mounting frames.