Trends and Topics Case Studies Innovative Rexroth slide-in photovoltaic module mounting system reduces material costs, speeds installation time for Bosch Solar Energy project Challenge: Provide a mounting system for quick and easy installation of micromorph thin-film solar modules at Robert Bosch Corporation automotive proving grounds facility Rexroth Solution: Innovative slide-in panel mounts made from Rexroth aluminum structural framing, plus framing accessories Rexroth Results: Reduced installation times, decreased by an estimated 50 percent by using slide-in mounting system vs. traditional bracket system Reduced material costs, decreased by an estimated 40 percent, since installation brackets and clamps are no longer required Complete mounting unit securely encloses modules Aluminum framing is rugged and weather-resistant for more durability and a cleaner look Download the complete case study (PDF - KB) Solar panel installation at a Bosch automotive facility includes innovative slide-in mounting technology from Rexroth – which can reduce panel installation time by up to 50 percent. Bosch Solar Energy (San Mateo, CA www.bosch-solarenergy.com) manufactures crystalline silicon and micromorph thin-film solar modules for customers throughout the world. The Bosch Proving Ground, an automotive testing facility in Flat Rock, MI, proved to be an ideal geographic location to install 50kW worth of the company’s ground-mount photovoltaic technologies. To speed up the installation, the company used an innovative slide-in mounting system featuring aluminum structural framing from another member of the Bosch Group, Bosch Rexroth Corporation (Hoffman Estates, IL www.boschrexroth-us.com). The Proving Ground, a controlled environment used for evaluating Bosch automotive technologies installed on cars, trucks, motorcycles and other vehicles, features a 1.4- mile test track loop with a three-lane banked turn and a 25-acre vehicle dynamics pad with a hydroplaning surface. The campus offers plenty of space with few interfering tree lines. In addition, the facility receives a large amount of sunlight throughout the year and has a significant amount of open space available for a large number of solar modules. “Generally speaking, solar panels are mounted on rooftops or on the ground. However, if they are mounted on top of buildings, there are space constraints with structures on the roof, like HVAC units and skylights. The Proving Ground had plenty of land to use and the facility is in an ideal spot,” said Helen Nigg, director of sales for Bosch Solar Energy. The solar installation, which encompasses nearly 20,000 square feet, includes one array of Bosch crystalline silicon modules and two arrays of Bosch micromorph thin-film solar modules. A subsidy from Michigan utility provider DTE Energy partially funded the project, which marks the beginning of Bosch’s North American alternative energy efforts. Rexroth’s slide-in PV module mounting system securely encloses each module. The framing system is easy to install. Once the initial framing is in place, the PV modules are simply slid into place. The end result is quicker installation with a durable frame that’s rugged and weather-resistant. The first thin-film array—arranged in a 10,670 square foot area—includes two rows of 189 modules each measuring about 51 inches by 43 inches. The modules consist of thin photovoltaic film placed between two pieces of glass. The second thin-film array, using about 5,800 square feet, contains 96 thin-film modules in two rows. The crystalline silicon array—about 3,000 square feet—contains two rows of modules that each measure about 65 inches by 39 inches. While crystalline silicon has traditionally been used in photovoltaic technology and can easily convert sunlight to energy, thin-film modules are less costly to produce and can provide excellent energy yields in low light. Both solar technologies were used in the installation to facilitate real-time data collection on the performance and efficiency of each type of solar technology in various sunlight and cloud cover conditions. Based on this data, Bosch Solar Energy can best determine which technology would be most suited for a client’s particular location or application. To help reduce installation time on the project, Bosch Solar Energy opted to use an innovative slide-in module mounting system made with Rexroth aluminum structural framing and designed specifically for installing micromorph thin-film solar modules. Download the complete case study (PDF - KB)