Development of a Mechanical Finite Element Model Utilising Module Displacement Test Data to Optimise the Module Design for an Applied Load

PV (Photovoltaic) modules must withstand many different types of loads while in operation. The primary mechanical loads are due to wind and snow. Thus, it is important to understand how those loads are transmitted to the components of the PV module in order to optimise module performance. Analytical models are highly mathematical, detailed, and complex in nature. Numerical simulation such as the Finite Element Method (FEM) is much more useful because many variations between PV products and installation methods exist due to details in frame geometry, glass thickness, support structure, and clamping application. A global mechanical finite element (FE) displacement model was created that would allow engineering analysis of mechanical performance that can be used to make mechanical design decisions in order to maximise performance. Then, a case study was performed in which the FE model results were compared against real test data. To generate the test data, the PV module was placed on a mechanical load test machine in order to measure the vertical displacement under load. During the test, load was applied and the displacement of components measured. The clamp distance to the edge was changed as a variable so a global optimum could be found that minimised vertical displacement and thus be considered the optimum location for installation. By installation at this location, displacement will be minimised and the system will allow for maximum performance.