Although small solar photovoltaic (PV) systems avoid most soft costs, they still have a relatively high $/W value due to racking costs. In order to fulfill the promise of small-scale plug-and-play solar, a do-it-yourself PV rack design is provided and analyzed here for six criteria: (1) made from locally-accessible renewable materials, (2) 25-year lifetime to match PV warranties, (3) able to be fabricated by average consumers, (4) able to meet Canadian structural building codes, (5) low cost and (6) that it is shared using an open-source license. The open-source wood-based fixed-tilt ground-mounted bifacial photovoltaic rack design evaluated here was found to be appropriate throughout North America. Economic analysis of the bill of materials showed the racking system ranges from 49% to 77% less expensive compared to commercial proprietary racking in Canada. The racking design, however, is highly dependent on the cost of lumber that varies widely throughout the world. Even for an absolute lower-cost design in Togo due to a lower fixed tilt angle and lower loads from lack of snow, it was not found to be economic because of the relatively high cost of wood. The recent volatile lumber market warrants local evaluation from those considering the use of the open-source design. This design, however, provides for a PV rack that can be manufactured with distributed means throughout most of the world enabling more equitable access to solar energy to support a circular bioeconomy.
Fixed-tilt mechanical racking, consisting of proprietary aluminum extrusions, can dominate the capital costs of small-scale solar photovoltaic (PV) systems. Recent design research has shown that wood-racking can decrease the capital costs of small systems by more than 75% in North America. To determine if wood racking provides enough savings to enable labor to be exchanged profitably for higher solar electric output, this article develops a novel variable tilt angle open-source wood-based do-it-yourself (DIY) PV rack that can be built and adjusted at exceptionally low costs. A detailed levelized cost of electricity (LCOE) production analysis is performed after the optimal monthly tilt angles are determined for a range of latitudes. The results show the racking systems with an optimal variable seasonal tilt angle have the best lifetime energy production, with 5.2% more energy generated compared to the fixed-tilt system (or 4.8% more energy, if limited to a maximum tilt angle of 60°). Both fixed and variable wooden racking systems show similar LCOE, which is only 29% of the LCOE of commercial metal racking. The results of this study indicate that the novel variable tilt rack, whether used as a small-scale DIY project or scaled up to fulfill larger energy demands, provides both the lowest cost option even when modest labor costs are included and also may provide specific advantages for applications such as agrivoltaics.
Open-source technological development is well-known for rapid innovation and providing opportunities to reduce costs and thus increase accessibility for a wide range of products. This is done through distributed manufacturing, in which products are produced close to end users. There is anecdotal evidence that these opportunities are heavily geographically dependent, with some locations unable to acquire components to build open hardware at accessible prices because of trade restrictions, tariffs, taxes, or market availability. Supply chain disruptions during the COVID-19 pandemic exacerbated this and forced designers to pivot towards a la carte-style design frameworks for critical system components. To further develop this phenomenon, a case study of free and open-source solar photovoltaic (PV) racking systems is provided. Two similar open-source designs made from different materials are compared in terms of capital costs for their detailed bill of materials throughout ten locations in North, Central and South America. The differences in economic optimization showed that the costs of wood-based racks were superior in North America and in some South American countries, while metal was less costly in Central and South America. The results make it clear that open hardware designs would be best to allow for local optimization based on material availability in all designs.
Vertical bifacial solar photovoltaic (PV) racking systems offer the opportunity for large-scale agrivoltaics to be employed at farms producing field crops with conventional farming equipment. Unfortunately, commercial proprietary vertical racks cost more than all types of conventional PV farm racking solutions. To overcome these cost barriers, this study reports on the development of a new wood-based PV racking design. The open-source design consists of a hinge mechanism, which reduces mechanical loading and enables wood to be used as the main structural material, and is the first of its kind. This open-source vertical wood-based PV rack is (i) constructed from locally accessible (domestic) renewable and sustainable materials, (ii) able to be made with hand tools by the average farmer on site, (iii) possesses a 25-year lifetime to match PV warranties, and (iv) is structurally sound, following Canadian building codes to weather high wind speeds and heavy snow loads. The results showed that the capital cost of the racking system is less expensive than the commercial equivalent and all of the previous wood-based rack designs, at a single unit retail cost of CAD 0.21. The racking LCOE is 77% of the cost of an equivalent commercial racking system using retail small-scale component costs, and is 22%, 34%, and 38% less expensive than commercial metal vertical racking, wood fixed tilt racking, and wood seasonal tilt racking costs, respectively. Overall, wooden vertical swinging PV racking provides users with a low-cost, highly available alternative to conventional metal vertical racking, along with a potential increase in energy yield in high wind areas thanks to its unique swinging mechanism.
Using bolts through the back of a solar photovoltaic (PV) module frames to attach them to racking is time consuming and awkward, so commercial PV installations use clamping technologies on the front. Conventional and proprietary clamps are costly and demand access to supply chains for uncommon mechanical components that limits deployment velocity. To overcome these challenges, this study presents new open-source downward-fastened and side-fastened aluminum (Al) framing designs, which are easy to install and compatible with metal and wood racks. The proposed parametric open source designs are analyzed through finite element methods (FEM) simulations and economic analysis is performed to compare to conventional PV frame at both the module and system levels. The FEM results showed all the frames have acceptable mechanical reliability and stability to pass IEC 61215 standards. The results show the new frame (with bottom width of 29 mm and thickness of 1.5 mm) have about a 2% land use efficiency penalty, but have better mechanical stability (lower stress and deflections), are easier to install and have reduced material economic costs (2%) compared to conventional frames. The results are promising for the use of the new PV frame designs for distributed manufacturing targeted at specific applications.
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