Embedded Files
Overview
Overview
Helix is SunPower's product line for commercial market sector and provides productized solutions for roof and carports. Helix Carport V2 is the second generation of SunPower's carport family and is the first attempt to productize solar-carports.
Design and development of a solar carport system involved defining carport architecture, layout, allowable loads, component loads, design, analysis and testing, and manufacturing, system installation and field support. The project allowed to understand energy modeling, and embark on three research projects.
Project Contributions
Project Contributions
Defined Carport Architecture
Defined Carport Architecture
Created an energy model to evaluate effect of carport architecture(s)
Embarked on a research project that created a geometric shading model for a row of solar carports
Created a cost model to evaluate the effect of carport architecture on structural costs
Created five product configurations that could be customized to any project site in the US
Led Structural Design for Solar Canopy
Led Structural Design for Solar Canopy
Created a fully-customizable solar-canopy architecture while reducing canopy costs by more than 30%
Designed all components in the canopy assembly. This includes cold-formed purlins, PV module attach hardware and purlin coupler
Designed to comply with UL2703
Concepts developed and modeled in SolidWorks
Performed mechanical and structural design and analysis for components using hand calculations, structural code checks (AISI S100) and using Abaqus
Embarked on two research projects that investigated buckling instability and minor-axis capacity of the new design solution
Developed DFMEA and performed DFM analysis
Led Solar Canopy Design Validation Testing
Led Solar Canopy Design Validation Testing
Performed the first four-point bend test on long-span beams with PV modules as bracing member
Designed test fixture for component and assembly tests
Designed electro-mechanical controllers for load application
Data acquisition performed using LabView. Instruments modeled include inline load cell, potentiometer, and LVDT
Data analysis performed using Python and Microsoft Excel
Qualification of Production Tooling
Qualification of Production Tooling
Collaborated with domestic and Asian suppliers to develop and qualify production tooling for components
Collaborated on roll forming, forging, and casting tooling
Defined PPAP requirements: developed control plans, quality control requirements, reviewed PFMEA and suggested process improvements
System Installation and Field Support
System Installation and Field Support
Trained contractors for system installation
Trained engineers for system design
Collaborated with contractors and project engineers to resolve component and assembly issues related to design
Page updated
Google Sites
Report abuse