Photovoltaic bracket: solid support and new development trend of photovoltaic system

Amidst the global energy transition, photovoltaic power generation, with its clean and sustainable advantages, has become a significant force in the new energy sector. While photovoltaic mounting systems, as the "framework" of photovoltaic systems, do not directly participate in electricity conversion, they nonetheless play a crucial role in the installation stability, power generation efficiency, and service life of photovoltaic modules. This article will focus on the core functions of photovoltaic mounting systems, thoroughly analyzing their classification, material selection, performance requirements, and exploring future development directions for the industry.

1. Definition and Core Functions of Photovoltaic Mounting Systems

Photovoltaic mounting systems are supporting structures used to secure photovoltaic modules (such as panels). They primarily consist of columns, beams, braces, and connectors. Their core functions can be summarized in three key areas:

Precise Positioning and Angle Adjustment: Based on the latitude and sunlight conditions of the installation site, photovoltaic modules are secured at the optimal tilt angle (usually close to the local latitude to maximize solar radiation reception), ensuring efficient year-round solar energy absorption.

Load-Bearing and Protection: Resistant to natural forces such as wind, snow, and earthquakes, they also bear the weight of the photovoltaic modules themselves, preventing deformation, displacement, or damage, and ensuring the long-term, safe operation of the system. Adaptable to Complex Environments: Customized structural designs enable stable installation of modules in diverse application scenarios, such as rooftops, ground, water surfaces, and hillsides, adapting to diverse terrain and building conditions.

II. Main Categories and Application Scenarios of Photovoltaic Mounting Systems

Based on their installation method, motion characteristics, and application scenarios, photovoltaic mounting systems can be categorized into the following types, each with significant differences in functionality and applicable scenarios:

(I) Classification by Motion Characteristics

Fixed Mounting Systems

Structural Features: The mounting angle is fixed, requiring no adjustment after installation. This results in a simple structure, low cost, and minimal maintenance.

Application Scenarios: Suitable for areas with stable sunlight conditions and moderate power generation efficiency requirements, such as large-scale ground-mounted photovoltaic power plants and rooftop distributed photovoltaic projects. For example, in ground-mounted photovoltaic power plants in the North my country Plain, fixed mounting systems have become the mainstream choice due to their cost-effectiveness and ease of installation.

Advantages and Disadvantages: Advantages include high reliability and a long lifespan (typically comparable to the lifespan of a photovoltaic system, approximately 25 years). Disadvantages include the inability to adjust to changes in the solar azimuth angle, resulting in a 10%-20% lower power generation than tracking mounting systems. Tracking Mounts
Single-Axis Tracking Mounts: These mounts rotate around a horizontal axis, adjusting their azimuth (e.g., east-west) as the sun rises and sets, increasing power generation by 10%-15%. They are suitable for ground-based power plants with long periods of sunlight and flat terrain, such as the Gobi Desert in northwest my country.
Dual-Axis Tracking Mounts: These mounts rotate bidirectionally around both the horizontal and vertical axes, simultaneously tracking the sun's azimuth and altitude. They increase power generation by 20%-25% compared to fixed mounts. However, these mounts are complex and costly (approximately 1.5-2 times that of fixed mounts), and require high control systems and maintenance. They are primarily used in projects requiring extremely high power generation efficiency, such as high-efficiency photovoltaic power plants and scientific research demonstration projects.
(II) Classification by Application Scenario
Ground-based photovoltaic mounts are classified into pile-driven, concrete-foundation, and screw-pile types. They are suitable for open areas (such as wasteland, deserts, and farmland). The screw-pile type requires minimal soil excavation and is therefore suitable for ecologically sensitive areas. Rooftop PV mounting systems are divided into sloped roof mounting systems (using the roof's slope for direct mounting, eliminating the need for additional angle adjustment) and flat roof mounting systems (raising the modules to facilitate ventilation and heat dissipation while preventing water accumulation). They are widely used on industrial and residential rooftops.
Water-surface PV mounting systems utilize floating structures (such as high-density polyethylene floats) to mount PV modules on the surface of lakes, reservoirs, and fish ponds. They combine power generation with water conservation, making them suitable for areas with abundant water resources but limited land, such as East and South my country.
Flexible mounting systems utilize flexible structures such as steel cables and anchor rods, replacing traditional rigid mounting systems. They can span complex terrain such as valleys and gullies, and can be installed over greenhouses and farms, enabling the integrated utilization of "PV + Agriculture" and "PV + Aquaculture." PV Mounting Material Selection: Balancing Performance and Cost
The mounting material directly impacts its strength, corrosion resistance, and cost. Currently, there are three main types of materials:

1. Aluminum Alloy Mounting

Performance Advantages: Low density (approximately 2.7g/cm³), lightweight, and easy to transport and install; excellent corrosion resistance, requiring no additional anti-corrosion treatment (especially suitable for corrosive environments such as coastal areas and high humidity); strong plasticity, allowing for processing into complex structures.

Disadvantages and Applications: Lower strength than steel and higher cost, primarily used in weight-sensitive applications such as rooftop photovoltaics and small ground-mounted power plants.

2. Steel Mounting

Performance Advantages: High strength (tensile strength can reach over 345MPa) and strong load-bearing capacity, suitable for areas with high wind and snow loads; low cost and excellent value, making it the mainstream choice for large-scale ground-mounted photovoltaic power plants. Disadvantages and Improvements: Rust-prone, requiring anti-corrosion treatments such as hot-dip galvanizing (zinc layer thickness ≥ 85μm) and spray coating to extend lifespan (hot-dip galvanized brackets can last over 20 years); heavy, requiring high-quality foundations.

3. Composite Brackets

Performance Advantages: Made from a composite of glass fiber, resin, and other materials, they offer corrosion resistance, insulation, and lightweight properties (40% lighter than steel); they are EMI-free and suitable for specialized applications (such as photovoltaic projects near substations).

Disadvantages and Prospects: Cost is high (approximately 2-3 times that of steel brackets), and long-term aging resistance remains to be verified. Currently, their application scope is limited, but with advances in material technology, they are expected to replace some metal brackets in high-end applications.​
IV. Core Performance Requirements for Photovoltaic Mounting Systems
Photovoltaic mounting systems must meet stringent performance standards to withstand long-term outdoor operation, primarily including the following:
Structural Strength and Stability: They must pass national or industry standard load tests (such as GB/T 38946-2020, "Specifications for Photovoltaic Mounting System Structural Design") and withstand wind loads ≥1.5 kN/m² and snow loads ≥1.0 kN/m². This rating may be increased to 2.0 kN/m² or higher in some high-altitude, snowy areas.
Corrosion Resistance: They must meet specific corrosion resistance levels for different environments. For example, coastal areas must meet Class C5 (corrosion rate ≤0.01 mm/year in salt spray environments) and industrially polluted areas must meet Class C4.
Installation Ease: Modular design and standardized components reduce on-site welding and drilling, improving construction efficiency. For example, some mounting systems offer "quick-install" connectors that can reduce the installation time of a single mounting system to less than 10 minutes. Compatibility: Compatible with PV modules of varying sizes and weights (such as common 166mm, 182mm, and 210mm modules), it also meets the installation requirements of inverters, combiner boxes, and other equipment, facilitating system integration.
V. Development Trends in the PV Mounting Industry
With the advancement of PV power generation technology and the expansion of its application scenarios, the PV mounting industry is moving towards higher efficiency, intelligentization, lightweighting, and integration.
Efficiency: Tracking Mount Penetration Increases: In the context of grid parity, increasing power generation is key to reducing the cost per kilowatt-hour. According to industry data, the global penetration rate of tracker mounts reached 35% in 2024 and is expected to exceed 50% by 2030. The use of dual-axis tracking mounts in high-efficiency module projects is expected to further increase.

Intelligent: Integrating the Internet of Things and digital management: New scaffolding systems are equipped with tilt sensors, wind speed sensors, and intelligent controllers to monitor scaffold status in real time and automatically adjust their angle based on sunlight and wind speed (e.g., automatically leveling the scaffolding in windy weather to reduce wind loads). Furthermore, remote monitoring and fault warnings are enabled through the IoT platform, reducing manual maintenance costs.

Lightweight and Green: On the one hand, the use of materials such as high-strength aluminum alloys and thin-walled steel reduces scaffold weight while maintaining strength (e.g., one brand's lightweight steel scaffold weighs 30% less than traditional steel). On the other hand, the promotion of recyclable materials (such as aluminum alloys and hot-dip galvanized steel) reduces environmental pollution after scaffolding is scrapped.

Integration: Deeply integrating with scenarios: The "PV+" model promotes the integrated design of scaffolding systems with other industries. For example, "PV+energy storage" scaffolding integrates storage battery installation space, while "PV+agriculture" scaffolding customizes height and spacing based on crop height, achieving a win-win model of "power generation above, planting below."

VI. Conclusion

Although PV scaffolding is an "auxiliary component" of the PV system, it is the core foundation for ensuring the safe and efficient operation of the system. From fixed mounts to tracking mounts, from metal materials to composite materials, and from single-function support to intelligent, integrated systems, the development of photovoltaic mounts has consistently resonated with the advancement of photovoltaic power generation technology. In the future, as the new energy industry continues to expand, photovoltaic mounts will play a more important role in improving power generation efficiency, adapting to complex scenarios, and promoting green transformation, becoming an indispensable part of the global energy revolution.