OneRoof: Design and Development of a Residential Solar System

Overview

OneRoof is SunPower's new product line for the residential solar market. The system provides an integrated roofing and PV attach solution, along with seamless tile integration and junction box installation. The system is easy to install and designed to be completely modular.

Design and development of OneRoof involved defining system architecture, layout, and allowable loads, component loads, design, analysis and testing, manufacturing, system installation and field support.

Project Contributions

Led Structural Design of OneRoof

  • Defined allowable structural loads on OneRoof

  • Applied ASCE 7-16, SEAOC 2017 to define product configurations and product SKUs to address majority of the US market

  • Performed structural design and analysis using hand calculations, NDS 2018, and Abaqus

  • Designed to comply with UL2703, UL580 and UL1897

Led Component and System Design Validation and Certification Testing

  • Defined product design validation testing strategy

  • Created and designed all test fixtures for component and system validation and UL certification testing (UL2703, UL580 and UL1897)

  • Data acquisition with LabView. Data analysis with Microsoft Excel

Led Mechanical Design of OneRoof Components

  • Designed mechanical clips for supporting members

  • Performed hand calculations and finite element analysis using Abaqus

  • Concepts developed using SolidWorks