techview
Shedding Light on Solar System Installation
I
t’s no secret that the process of converting metal to plastic brings many benefi ts such as greater design freedom, part consolidation and mass reductions. But for many, this
replacement of materials brings doubt. Specifi cally, there’s a common misperception that a plas- tic material’s performance cannot easily be predicted like that of steel or aluminum. At BASF, we are virtually eliminating those fears by introducing Ultrasim, a predictive technology tool, into the product development of parts molded using BASF materials.
Using highly sophisticated material characterization methods and analysis techniques, designers and engineers can now account for the infl uence of the injection mold- ing process of a thermoplastic with 90–95% accuracy. Under the counsel of a team of BASF experts, the various components can be designed and tested for structural performance with static loads and impact (crash) loads, vibration and acoustic response, as well as fatigue and creep-type loading.
Contrary to other analysis tools, Ultrasim can identify the point and level of failure and correct it before signifi cant investments are made, helping avoid any costly surprises that may arise during the development phase. Essentially, it helps provide our customers with the confi dence they need when making material selection and design decisions. And, we can use Ultrasim for all types of industries from automotive to industrial to consumer. One example is when BASF used this expertise to advance solar mounting technol- ogy to meet the Department of Energy’s goal of reducing installation cost by 70% by 2020. The fi rst company to introduce polymer injection molding to the photovoltaics (PV) racking industry in North America, Sollega, wanted to design a solar racking solution to not only reduce costs but also to eliminate barriers in making the installation process easier and more widely adopted. BASF brought its material, design and processing know- how to Sollega, and together they developed a ballasted commercial fl at-roof mounted solar racking solution, the FastRack510, made of high-performance, lightweight mate-
Marios Lambi Manager, Application Development & Computer Aided Engineering BASF Performance Materials
rial. The mount uses BASF’s plastic Ultramid, which has a 40- year proven history in demanding applications where it must retain its shape and strength in the most brutal environments. In general, PV mounts are subjected to challenging cli- mates such as high ultraviolet radiation, extreme fl uctuating cold and hot temperature, humidity, snow loading and high winds from hurricanes. The Ultramid polyamide material used in this application includes ultraviolet inhibitors, exhibits no corrosion, has minimal fatigue at high temperatures (up to 95°C) and maintains extraordinary strength at low tempera- tures (–40°C). The material also offers good chemical resis- tance and electrical insulation, as well as handles long-term direct contact with PVC roof membranes.
The fi rst company to introduce polymer injection molding to the PV racking industry in North America, Sollega, wanted to design a solution to not only reduce costs but also to make the installation process easier.
With its universal, one-piece, stackable design, manu-
facturers and contractors can ship enough racking material in a shipping container measuring a standard 40’ (12 m) for a 500-kW solar installation. Once onsite, the mounts arrive preassembled and ready to accommodate commercial PV modules at 5° or 10° tilt angles. With fewer parts to ship and an easier onsite process, manufacturers can save money in overall installation costs. Sollega and BASF’s combined expertise brought a total material weight reduction of 3.7 lb (1.7 kg) compared to an older design made with high-density polyethylene. Despite its light weight, the glass-reinforced polyamide (nylon) can hold more than 200 times its own weight and still retain its strength.
43 — Energy Manufacturing 2015
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