A Complete Guide to Solar Mounting Systems: From Types and Selection to New Industry Development Trends
In the wave of global energy structure transformation towards cleanliness and low carbon, solar power generation has become a key new energy industry developed by various countries due to its advantages of renewable resources and zero pollution emissions. As the core support structure of the solar power generation system, the solar mounting system directly determines the installation stability, power generation efficiency, and service life of photovoltaic modules. This article will deeply analyze the core component of the solar panel system - the solar structure mounting system, focus on introducing the characteristics and applications of key components such as solar ground mounts and solar mounting brackets, explain the advantages of the solar panel system kit in detail, provide scientific selection and installation guidelines, and finally look forward to the future development direction of the industry.
I. Solar Mounting System: The "Load-Bearing Framework" of the Solar Panel System
The efficient operation of the solar panel system is inseparable from a stable support structure. The solar structure mounting system is the core hub connecting photovoltaic modules and the installation foundation. Its main function is to fix the solar panels in a preset position (ground, roof, water surface, etc.), ensure that the modules can receive sunlight at the optimal angle, and resist the impact of natural forces such as wind, rain, snow, and earthquakes.
According to data from the International Energy Agency (IEA), the global installed photovoltaic capacity exceeded 1.5 terawatts in 2024, among which the market scale of the solar structure mounting system reached 32 billion US dollars, accounting for 15%-20% of the total cost of the solar power generation system. A high-quality mounting system can not only increase the power generation efficiency of photovoltaic modules by 2%-5% but also extend the system's service life to more than 25 years; on the contrary, inferior mounts may cause deformation and displacement of modules, and even lead to safety accidents, resulting in huge economic losses.
The core components of the solar structure mounting system include solar mounting brackets, guide rails, connectors, foundation components, etc. Among them, the solar mounting bracket, as a key component for directly fixing photovoltaic modules, its material and structural design directly affect the overall performance of the mounting system. At present, the mainstream mounting systems can be divided into three categories according to the installation scenario: ground mounts, roof mounts, and water surface mounts. Among them, the solar ground mount has a wide range of applications and flexible installation, accounting for more than 60% of the applications in large-scale photovoltaic power plants.
II. Analysis of Core Products: From Mount Types to System Kits
(I) Solar Ground Mount: The Preferred Solution for Large-Scale Power Plants
Solar ground mounts are mounting systems directly installed on the ground foundation, suitable for open areas, farmland, barren mountains, and other scenarios, especially for large-scale centralized photovoltaic power plants. Its core advantages lie in adjustable installation angles and flexible module arrangement, which can optimize the tilt angle according to the local latitude to maximize the use of solar resources.
In terms of structural form, solar ground mounts are mainly divided into two types: fixed-tilt mounts and tracking mounts. Fixed-tilt mounts have a simple structure and low cost, and the modules are installed at a preset fixed angle, which is suitable for projects with limited budgets and flat terrain; tracking mounts use a motor-driven system to make the modules rotate in real time with the sun's azimuth angle, and their power generation efficiency is 15%-20% higher than that of fixed mounts. However, they have higher costs and complex maintenance, and are mostly used in projects with abundant solar resources and high requirements for power generation efficiency.
In terms of material selection, the solar mounting brackets of solar ground mounts are mostly made of aluminum alloy, hot-dip galvanized carbon steel, and stainless steel. Aluminum alloy mounts are lightweight, corrosion-resistant, and have good processing performance, making them suitable for humid and rainy areas; hot-dip galvanized carbon steel mounts have high strength and strong load-bearing capacity, with moderate costs, and are currently the most widely used materials; stainless steel mounts have excellent corrosion resistance but high costs, and are mostly used in coastal areas with high salt spray or projects in special environments.
Taking a 50MW centralized photovoltaic power plant as an example, this project adopts fixed-tilt solar ground mounts made of hot-dip galvanized carbon steel. The tilt angle of the mounts is set to 30° according to the local latitude, and they are fixed through concrete strip foundations. This not only resists the impact of local level 12 typhoons but also achieves an annual power generation of 68 million kWh, generating 3 million kWh more than the traditional mounting system.
(II) Solar Mounting Bracket: The "Connection Core" of the Mounting System
Solar mounting brackets are components in the solar mounting system that directly fix photovoltaic modules. According to their functions, they can be divided into side clamps, middle clamps, adjustable brackets, etc. Side clamps are used to fix the edge positions of modules, middle clamps are used to connect two adjacent modules, and adjustable brackets are used to fine-tune the installation angle and horizontal position of modules to ensure that the modules are arranged neatly and bear force evenly.
High-quality solar mounting brackets need to meet three requirements: first, meeting strength standards to bear the weight of modules, wind and snow loads, and seismic forces; second, strong compatibility to adapt to photovoltaic modules of different sizes and thicknesses; third, corrosion resistance and durability, and the surface treatment process must meet the requirements of long-term outdoor use. At present, the mainstream surface treatment methods include hot-dip galvanizing, anodizing, and powder coating. Among them, the corrosion resistance life of hot-dip galvanized carbon steel brackets can reach more than 20 years, and the surface of anodized aluminum alloy brackets has higher hardness and is not easy to scratch.
In practical applications, the selection of solar mounting brackets needs to match the module specifications and installation scenarios. For example, when installing large-size (182mm, 210mm) photovoltaic modules, it is necessary to select thicker middle clamps with stronger load-bearing capacity; in roof installation scenarios, lightweight aluminum alloy side clamps should be used to reduce the load pressure on the roof.
(III) Solar Panel System Kit: A Convenient Choice for Small-Scale Projects
The solar panel system kit is a complete set of systems that integrates solar panels, solar structure mounting systems, inverters, cables, and other components, specially designed for distributed photovoltaic projects such as households and small 工商业. Its biggest advantage is "one-stop procurement and foolproof installation", which eliminates the need for users to match components by themselves and greatly reduces the difficulty of selection and installation.
A standard solar panel system kit usually includes: 2-20 photovoltaic modules (power 200W-400W per module), matching solar mounting brackets (roof or ground type), 1 inverter, cables and connectors, installation tools, etc. According to different installation scenarios, it can be divided into two categories: roof kits and ground kits. Roof kits adopt lightweight mounts, which are fixed on the roof load-bearing structure through expansion bolts without damaging the roof waterproof layer; ground kits include simple solar ground mounts, suitable for small-area sites such as family courtyards and balconies.
Taking a household photovoltaic project as an example, choosing a 5kW solar panel system kit, which includes 12 410W photovoltaic modules, aluminum alloy roof mounts, a 5kW inverter, and a full set of accessories, the installation cycle only takes 2-3 days, saving 50% of the time cost compared to installing components purchased separately. At the same time, the kits provided by brand manufacturers have undergone compatibility testing, resulting in higher system matching and 3%-5% higher power generation efficiency than self-matched systems.
(IV) Solar Structure Mounting System: An Overall Solution for Full-Scenario Adaptation
The solar structure mounting system is an overall solution covering mount design, production, and installation. According to different installation scenarios, the structural form can be optimized accordingly. In addition to the mainstream ground and roof systems, it also includes special types such as water surface mounting systems, agrivoltaic mounting systems, and BIPV (Building-Integrated Photovoltaics) mounting systems.
The water surface mounting system is installed in water areas such as lakes and reservoirs, and the solar panels and mounts are supported by floating bodies, which do not occupy land resources and can reduce water evaporation, making it suitable for areas with tight land resources; the agrivoltaic mounting system adopts a high-mount design, and crops can be planted under the mounts, realizing a three-dimensional agricultural model of "power generation on the top and farming on the bottom" and improving the comprehensive utilization rate of land; the BIPV mounting system is integrated with the building facade and roof structure, serving as both a building material and a power generation system, combining aesthetics and practicality.
For example, an "agrivoltaic" photovoltaic power plant adopts a solar structure mounting system with a height of 3 meters. Vegetables and Chinese medicinal materials are planted under the mounts, achieving an annual power generation of 120 million kWh while driving the income increase of surrounding farmers, realizing a win-win situation of economic and social benefits.
III. Scientific Selection and Installation: The Key to Improving System Performance
(I) Guide for Selecting Solar Structure Mounting Systems
Select according to project scale: For large-scale centralized power plants, solar ground mounts (tracking or fixed-tilt) are preferred, combined with hot-dip galvanized carbon steel mounts to balance cost and performance; for distributed household projects, solar panel system kits are recommended to simplify the installation process; for small 工商业 projects, roof mounts or small ground mounts can be selected according to the roof conditions.
Select according to the installation environment: In coastal areas, stainless steel or anodized aluminum alloy mounts should be selected, equipped with solar mounting brackets with high wind resistance; in snowy areas, high-strength mounts should be selected to ensure that they can bear the snow load; for roof installation, the load-bearing capacity of the roof should be considered, and lightweight aluminum alloy mounts should be preferred.
Select according to lighting conditions: In areas with abundant solar resources, tracking solar ground mounts can be selected to maximize power generation benefits; in areas with general lighting conditions, fixed-tilt mounts are sufficient to reduce costs.
(II) Installation Points and Precautions
Foundation construction: For the foundation of solar ground mounts, concrete foundations, spiral pile foundations, or prefabricated pile foundations should be selected according to the geological conditions to ensure that the foundation is firm and avoid settlement; before installing roof mounts, the load-bearing capacity of the roof should be checked, and the waterproof layer should be well protected to prevent water leakage.
Mount assembly: Assemble the solar mounting brackets and guide rails according to the design drawings to ensure that the connectors are tight and the error is controlled within ±2mm; special clamps should be used when installing modules, and the force should be moderate to avoid crushing the module glass or deforming the aluminum frame.
Angle adjustment: For fixed-tilt mounts, the tilt angle should be accurately adjusted according to the local latitude (generally latitude ±5°); for tracking mounts, the motor-driven system should be debugged to ensure tracking accuracy; after installation, the flatness of the modules should be checked to avoid affecting power generation efficiency due to uneven tilt.
Post-maintenance: Regularly check the tightness of the solar mounting brackets and replace rusted or damaged parts in a timely manner; for tracking mounts, regularly lubricate the motor and clean the debris on the guide rails to ensure smooth operation.
IV. Development Trends of the Solar Mounting System Industry
(I) Technological Upgrading: Parallel Development of Intelligence and Lightweight
With the development of photovoltaic modules towards large size and high power, the mounting system is upgrading towards intelligence and lightweight. On the one hand, intelligent mounting systems integrate sensors and IoT modules, which can monitor data such as wind speed, light intensity, and module temperature in real time, and automatically adjust the mount angle to optimize power generation efficiency; on the other hand, the application of new materials such as carbon fiber composites and high-strength aluminum alloys reduces the weight of the mount by more than 30% while maintaining high-strength performance.
For example, an enterprise has launched an intelligent solar ground mount that uses AI algorithms to predict the sun's trajectory and adjust the module angle in advance, increasing the power generation efficiency by an additional 5% compared to traditional tracking mounts; the solar mounting brackets made of carbon fiber materials have a weight only 1/4 of that of carbon steel, but the load-bearing capacity is increased by 20%.
(II) Green Development: Environmental Protection Materials and Recycling
Driven by the "dual carbon" goal, the industry has increasingly high requirements for the environmental protection of mounting systems. On the one hand, the application proportion of environmentally friendly materials such as recycled aluminum alloys and recyclable carbon steel is constantly increasing; on the other hand, modular design has become a trend, and the mounting system can be disassembled and recycled to reduce resource waste. In addition, green processes are promoted in the production process to reduce energy consumption and pollutant emissions, such as replacing traditional galvanizing processes with chromium-free passivation technology to reduce heavy metal pollution.
(III) Integrated Integration: Integration with Energy Storage and Smart Grids
In the future, the solar structure mounting system will no longer be a single support structure but a comprehensive energy platform deeply integrated with energy storage systems and smart grids. For example, energy storage batteries are integrated into the mount foundation to realize electrical energy storage; through the wireless communication module on the mount, the power generation data is transmitted to the smart grid dispatching center in real time to realize peak shaving, valley filling, and on-demand power supply.
(IV) Market Pattern: Explosive Demand in Emerging Markets
With the global photovoltaic industry shifting to emerging markets, the demand for solar structure mounting systems in Southeast Asia, Africa, South America, and other regions is growing rapidly. Most of these regions have tropical and subtropical climates, which have higher requirements for the corrosion resistance and wind load resistance of the mounts. At the same time, they prefer fixed-tilt solar ground mounts and solar panel system kits with lower costs. Domestic enterprises, relying on the advantages of a complete industrial chain, are accelerating their layout in emerging markets and promoting the international development of mounting systems.
V. Conclusion
As the core support of the solar panel system, the performance of the solar structure mounting system is directly related to the benefits and safety of solar power generation projects. Solar ground mounts have become the mainstream choice for large-scale power plants due to their flexible adaptability; solar mounting brackets, as key components, determine the stability of the mounts; solar panel system kits provide convenient solutions for small-scale projects. In practical applications, scientific selection and standardized installation are the keys to exerting the performance of the mounting system, and paying attention to the industry trends of intelligence, greenization, and integration will help grasp the core direction of industrial development.
In the future, with the continuous innovation of technology and the upgrading of market demand, the solar mounting system will develop towards higher efficiency, more environmental protection, and more intelligence, providing a solid support for the sustainable development of the global solar industry. Whether it is large energy enterprises or ordinary household users, choosing a high-quality solar mounting system is a wise choice to realize the use of clean energy and reduce energy costs.
