As the global energy transition accelerates, photovoltaic power generation has become a key pillar of the green energy system. In the construction of photovoltaic power plants, mounting systems—though seemingly simple—play a crucial role. Not only do they support the photovoltaic modules, but they also directly impact the plant’s power generation efficiency, safety, and long-term reliability. In recent years, the field of PV mounting design has been undergoing a quiet yet profound transformation. From material selection to structural optimization, and from seismic performance to connection details, innovation and breakthroughs are everywhere, driving the entire industry toward greater efficiency, safety, and cost-effectiveness.
Traditional PV mounting designs have often focused on basic support functions. However, as PV application scenarios grow increasingly complex—ranging from flat deserts and Gobi regions to undulating hills and mountains, from vast agricultural greenhouses to limited commercial and industrial rooftops, and even to harsh coastal tidal flats and high-altitude areas—a single design solution is no longer sufficient to address these diverse challenges. This has compelled engineers to adopt a systems-oriented approach and provide comprehensive engineering solutions. Among these, seismic performance, the main structure of the mounting system, and fasteners—which may seem minor but are crucial—constitute three closely interrelated and indispensable core dimensions of this solution.
First, innovative seismic bracket design is key to safeguarding the power plant’s lifeline. Geological disasters such as earthquakes often cause catastrophic damage to photovoltaic power plants; consequently, the seismic resistance of mounting systems has evolved from an “optional feature” to a “mandatory requirement.” Modern seismic design is no longer limited to simply increasing material thickness but incorporates the concepts of dynamic analysis and flexible energy dissipation. For example, by employing elastic connection nodes or damping devices capable of controlled deformation, the mounting system can absorb and dissipate energy through controlled deformation under seismic waves, thereby protecting the main structure and PV modules from direct impact. At the same time, detailed simulations based on seismic zone parameters specific to different regions allow for more targeted mechanical design of the mounting system. This optimizes material usage while ensuring safety, achieving a balance between safety and cost-effectiveness.
Second, breakthroughs in the main structure of PV mounting systems are reflected in three aspects: materials, form, and intelligence. In terms of materials, in addition to the continuous upgrading of high-performance steel, the application of aluminum alloys, composite materials, and even special steels with enhanced weather resistance is becoming increasingly widespread; these materials excel in reducing self-weight and enhancing corrosion resistance. In terms of structural form, the widespread adoption of tracking mounts represents a significant breakthrough; their technological evolution from single-axis to dual-axis systems has significantly improved power generation efficiency. Even more cutting-edge is the design of Building-Integrated Photovoltaic (BIPV) mounting systems, which integrate PV modules directly into building facades or structural elements. This requires mounting designs to combine structural mechanics, architectural aesthetics, and functions such as waterproofing and thermal insulation, serving as a prime example of interdisciplinary innovation. Furthermore, intelligent elements have been embedded into mounting systems. Through the integration of sensors and actuators, the systems can automatically detect and adjust to environmental factors such as sun position, wind speed, and snow accumulation, thereby enhancing the overall adaptability of the power plant.
Moreover, fasteners, serving as the “joints” connecting the entire mounting system, are often underestimated in terms of their technological innovation, yet they directly determine the system’s structural integrity and long-term durability. In harsh outdoor environments, loosening, corrosion, or failure of fasteners can trigger a chain reaction of structural issues. Current innovations focus on anti-loosening designs and long-term corrosion protection. For example, using nuts with self-locking mechanisms, bolts pre-coated with microcapsule sealants, or applying the torque-angle method for precise tightening can effectively prevent loosening caused by vibration. In terms of corrosion protection, advanced surface treatment processes such as Dacromet and hot-dip galvanizing with alloying have significantly extended the service life of fasteners in saline, alkaline, and high-humidity environments. These breakthroughs in detail ensure the stability and reliability of mounting systems over decades of operation.
In summary, innovation and breakthroughs in photovoltaic mounting system design represent an evolutionary journey—from macro-structures to micro-details, from passive load-bearing to active adaptation, and from single-function components to system integration. Seismic-resistant brackets, the main mounting structure, and fasteners are interlinked, collectively forming a robust and efficient integrated engineering solution. In the future, with the further integration of technologies such as new materials, smart manufacturing, and digital twins, PV mounting system design will inevitably become smarter, lighter, and more scenario-specific, laying a solid physical foundation for building a more resilient and efficient global PV energy network. This exploration of mounting systems is far from over; it is supporting a brighter future for clean energy with its sturdy arms.
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