New: Patent from the USA – Install solar parks up to 30% cheaper and 40% faster and easier – with explanatory videos!

Up to 30% cheaper: This revolution in solar park construction makes clean energy significantly more economical

In today's world, where large-scale solar farms form an indispensable pillar of the global energy transition, the industry's focus is shifting. It is no longer just about increasing module efficiency, but increasingly about optimizing the entire construction process. While photovoltaic technology itself has made impressive progress in recent years, assembly techniques are often still based on traditional, time-consuming, and potentially material-damaging processes. A new, assemble-ready assembly system now represents a fundamental paradigm shift. It was specifically developed to massively accelerate the construction of ground-mounted solar systems, maximize the service life of the systems, and significantly improve the overall economic viability of solar projects. This approach addresses the biggest challenges in modern solar farm construction: time pressure, cost efficiency, and long-term reliability.

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• ModuRack is leading the solar industry from the “panel era” to the “system era”

The core innovation: even load distribution instead of localized voltage peaks

The heart of this technological advancement is the conscious departure from conventional clamp fastening, which has been the standard for decades. In conventional systems, the solar modules are fixed to a support profile at four or more individual points by clamps. These clamps are screwed onto the sensitive module frame, thereby creating a concentrated load. These concentrated forces lead to high mechanical stresses in the module assembly. Particularly under weather influences such as strong gusts of wind, which lead to vibrations, or heavy snow loads in winter, these stress peaks can lead to invisible microcracks in the glass and, even more seriously, in the underlying solar cells. Such cell cracks are not visible to the naked eye, but cause a gradual but unstoppable decline in the module's performance. Over the years, this effect accumulates and shortens the effective lifespan and profitability of the entire system.

The new mounting system addresses this systemic weakness with a fundamentally different, more intelligent concept. Instead of clamping the modules at specific points, they are inserted into a continuous, specially shaped support rail and held securely there. This design ensures that all occurring forces – be they static loads from snow or dynamic loads from wind – are evenly distributed across the entire length of the module frame. Stress peaks, which are the main cause of microcracks , are thus eliminated from the outset. The mechanical integrity of the solar module is maintained throughout its entire service life. This not only ensures consistently high performance for decades, but also protects the investment and maximizes the solar farm's energy yield.

Drastic reduction of overall project costs and construction time

The sophisticated technical and logistical advantages of this system lead to a remarkable increase in economic efficiency. The sum of the optimizations throughout the entire project enables a reduction in total construction costs of up to 30 percent, which significantly increases the attractiveness of investing in solar parks. A key lever here is the massive reduction in installation time. Thanks to clever click mechanisms that completely replace the time-consuming alignment, positioning, and screwing of individual clamps, the pure installation effort for the modules in the field can be reduced by up to 40 percent. This enormous time saving is directly reflected in significantly lower labor costs, which represent one of the largest cost items in the construction of ground-mounted systems.

Furthermore, the accelerated and uncomplicated assembly process optimizes coordination and workflows across the entire construction site. In a solar park, various trades, such as civil engineering, piling teams, installation crews, and electricians, often work in parallel or sequentially under extreme time pressure. Because module assembly is completed much more quickly, friction points and costly waiting times for subsequent work, such as cabling by electricians, are minimized. This leads to a smoother and shorter overall project progress and reduces the risk of delays, which are often associated with high contractual penalties. Finally, the modular design of the system also contributes significantly to cost reduction. The lower material and storage requirements due to a reduced number of individual parts not only eases the burden on construction site logistics but also directly reduces material costs and the capital tied up in inventory.

Konrad Wolfenstein

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The expansion of renewable energy is crucial, but installing solar farms is often time-consuming and costly. A new video demonstrates a potentially groundbreaking innovation that could fundamentally change this process: ModuRack's "MagicSolar System." In an impressive time-lapse demonstration, it shows how a complete array of 26 solar modules is fully assembled in just 18 minutes – compared to the 45 minutes estimated for a conventional system.

This massive time savings is just one of the advantages. The system is characterized by drastically reduced complexity and material usage. Instead of the 849 individual parts of a conventional system, the MagicSolar system requires only 263 components. Steel consumption also drops from 350 kg to 305 kg per assembled unit. This efficiency is directly reflected in the costs and enables enormous cost savings.

The manufacturer also places great importance on safety and ease of maintenance. The video demonstrates how easy it is to check the correct locking and complete grounding of each individual module. A special highlight for ongoing operation: Each module can be removed individually if necessary without affecting neighboring panels. This combination of speed, cost savings, and sophisticated design positions the system as a promising candidate for increasing the efficiency and profitability of solar projects worldwide.

A redefined installation process: simplicity, speed and security

Another key advantage of the system is its exceptional ease of installation, which fundamentally transforms the daily work of the installation teams. The entire process is described as remarkably intuitive and ergonomic. Instead of laboriously and time-consumingly aligning individual clamps, holding them in place, and tightening them with a cordless screwdriver, the installers can click the solar modules directly into the prepared support rails with a simple, fluid hand movement. An audible click signals secure and correct locking.

This process not only drastically reduces the installation time per module, but also minimizes the risk of errors, which is a major factor in the manual tightening of thousands of terminals. Incorrect torque settings or forgotten screws are a thing of the past. Intuitive handling also makes the system accessible to less specialized assembly teams. In times of acute skills shortages, this is an invaluable advantage, as companies can respond more flexibly to staffing bottlenecks and deploy new employees more quickly. The physical strain on the installers is also reduced, as less overhead work is required and the handling of heavy tools is eliminated.

Superior technical performance and maximum durability

The sophisticated design of the mounting system leads to a measurably improved overall technical performance of the solar park over its entire service life of 25 years or more. By consistently avoiding microcracks , the solar modules maintain their specified nominal output over a significantly longer period. This ensures that the projected energy yields, which form the basis for financing and power purchase agreements (PPAs), are actually achieved and often even exceeded.

At the same time, the stable, flat mounting increases the resilience of the entire system to the harsh conditions of an open-air installation. Strong wind loads, vibrations, and the impact of snow masses are better absorbed and distributed by the system, significantly increasing its mechanical resilience. This leads to lower maintenance and repair costs over the operating life and ensures the longevity of the entire investment. The robustness of the system guarantees reliable operation even in exposed locations with extreme weather conditions.

The modular principle: Logistical excellence for large-scale projects

The assembly system follows a consistent modular principle, which is particularly advantageous for large-scale projects such as solar farms. The radical reduction in the number of different components simplifies the entire logistics chain from production to construction site. For project developers and EPC companies, this means significantly simpler warehousing, as fewer different parts need to be stored and managed. On the vast expanse of a solar farm construction site, the risk of mix-ups or missing small parts is reduced, accelerating workflows and avoiding costly downtimes.

Economically, this results in another positive effect: Concentrating on a few, standardized system components enables the purchase of larger quantities at better conditions. These economies of scale further reduce the overall costs of the mounting system and strengthen the competitiveness of solar projects. Optimized logistics means fewer truck trips to the project site, less space required for on-site storage, and faster distribution of materials to the respective assembly sections, further streamlining and making the entire construction process more efficient.

In the world of renewable energies, every efficiency improvement counts, especially in the construction of large-scale solar power plants, where time directly translates into money. The video presents "ModuRack," an innovative mounting system for ground-mounted solar systems that addresses precisely this issue and fundamentally rethinks the entire installation process.

The core of the innovation lies in a highly modularized and simplified design. Instead of numerous individual parts and complex screw connections, the system relies on pre-assembled components and intelligent plug-in connections. The animation impressively demonstrates how the main beams are attached to the foundations and how the cross rails are subsequently installed using a simple hook-and-lock mechanism.

The decisive time advantage becomes apparent during the installation of the solar modules themselves. Instead of the conventional method, in which each panel must be laboriously secured from above with clamps, the modules are simply inserted into the designated rails (a so-called "lay-in" system). This "drop-in" approach eliminates one of the most time-consuming and labor-intensive steps in the installation of large solar fields.

In summary, the animation demonstrates a system designed for maximum efficiency and scalability. By reducing components, simplifying assembly processes, and eliminating small-scale work, it promises to significantly reduce installation time and associated labor costs, making it a potentially groundbreaking solution for the rapid expansion of solar farms.

Novel photovoltaic solution for reducing costs and saving time: Xpert.digital

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Konrad Wolfenstein

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You can contact me by filling out the contact form or simply call me on +49 89 89 674 804 (Munich) . My email address is: wolfenstein ∂ xpert.digital

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