Case Study Compiled by
CAD Model of the Solar MMS
Brief of case study
This case study explores how CFD and FEA analysis were applied to optimize the structural stability of a Solar Module Mounting Structure (MMS) under varying wind loads. The CFD simulation incorporated velocity gradients specified by IS 875 at the inlet for different terrain categories. By analyzing aerodynamic forces, wind-induced stresses, and connection integrity, the study highlights key improvements such as optimized wind load distribution, identification and mitigation of critical regions with high stress concentrations, evaluation of connections, and enhanced resistance to dynamic wind forces. The refined design ensures regulatory compliance with IS 801 and IS 875 standards, improves structural reliability, and optimizes section sizes for a cost-effective and durable MMS solution.
Challenegs faced by client
- IS 875 Velocity Profile for CFD – Implementing the IS 875 velocity profile for CFD analysis to accurately simulate wind effects on roof-mounted solar structures.
- Wind-Induced Load Variations – Managing dynamic wind pressures across different structural components under varying wind directions.
- Aerodynamic Complexity – Understanding airflow patterns around the MMS to ensure accurate load distribution and prevent localized high-pressure zones.
- Structural Deflections & Stability – Minimizing deformations and ensuring structural integrity under extreme wind loads.
- Connection Strength Assessment – Evaluating the load-bearing capacity of bolted joints to prevent structural failures along with bolt checks.
- Material Optimization – Balancing strength and cost-effectiveness by optimizing section sizes while maintaining compliance with safety standards.
- Regulatory Compliance – Ensuring adherence to IS standards for wind load resistance and structural deflection limits.
- Computational Complexity – Managing high-fidelity meshing and solver settings for accurate CFD & FEA simulations while optimizing computational time.
technology used by shirsh
- IS Velocity Profile – Generated velocity profile curves for different terrain categories according to IS 875, to simulate real-world flow conditions and its effects on the Solar MMS.
- 3D Geometric Modeling – Developed a detailed CAD model incorporating standard section sizes and connection details.
- Advanced Meshing Techniques – Applied Polyhex core mesh for CFD and Hex quadratic elements for FEA to ensure accurate resolution of flow behavior and structural deformations.
- Computational Fluid Dynamics (CFD) Software – Simulated wind load and Pressure distributions and aerodynamic forces acting on the structure.
- Turbulence Modeling – Used k-ω turbulence model to predict wind flow patterns and pressure variations across the structure.
- Finite Element Analysis (FEA) Software – Evaluated structural deformations, stresses, and load-bearing capacity of MMS components.
- Bolt Pretension & Contact Modeling – Simulated real-world bolt loads and frictional contact interactions to ensure connection stability.
- Optimization Techniques – Iterative solver methods used to refine section sizes for a cost-effective and structurally stable design
engineering solutions and methodology adopted
For the structural analysis of the Solar Module Mounting Structure the primary objective of the project was ensuring structural stability under dynamic wind loads while evaluating joints and joint systems of the structure. The client provided us with key inputs, including the 2D layout of the solar MMS, equipment details, and the locations of structural members such as beams and joints. Additionally, wind load data, and dynamic load conditions, were shared to ensure a comprehensive analysis.
Using this data, our team created a detailed 3D model of the Solar MMS, accurately representing the structural design intended by the client. Based on this CAD model, an external aerodynamic domain was created to account for both near wall and mean flow behavior. A high-quality computational mesh of the domain was generated, incorporating Polyhex core meshing with prism layers to resolve boundary layers accurately. The boundary condition – a flat velocity profile of the basic windspeed was applied to simulate wind-flow over the structure.
To meet the actual design approach, we modified the input velocity boundary conditions to closely approximate the velocity profile put forth according to IS 875. This was achieved by creating a mathematical equation that incorporates the different coefficients considered while calculating the design windspeed. The equation generated can also be modified to include different terrain categories. With the new velocity profile as the input, the CFD simulation was carried out for a roof mounted structure and subsequently, the FE Analysis of the structure was performed based on the pressure gradients and wind loads obtained from the CFD analysis.
The initial FEA simulation highlighted zones that resulted in excessive stress concentrations around the bolts and other structural connections. These inefficiencies posed risks to the structural integrity and long-term stability of the solar MMS. To mitigate these problems, a non-linear analysis was performed with the addition of plates at the sections where stress concentrations were observed. The simulation results demonstrated a substantial reduction in stress and deformation values, bringing them within acceptable limits according to IS Standards.
With these refinements, the final design achieved optimal structural performance. The stress values were well within the safety limits, and the overall design was optimized to reduce material costs while maintaining structural integrity. The client approved the addition of plates at joint sections to increase local section thickness, which provided additional stiffness and stability, thereby significantly reducing stress concentrations and ensuring the long-term durability of the solar MMS.
Through a combination of precise engineering, advanced CFD and FEA simulations, and strategic optimizations, we successfully transformed the solar MMS design. The outcome was a highly efficient and stable structure that met all regulatory requirements while optimizing material usage, setting a new benchmark in solar infrastructure design.
Velocity Contour of the Roof-mounted Solar MMS
Stress Contour in the Structural Members
benefits to client
Optimized Structural Integrity for Solar MMS
Enhanced Wind Load Resistance
- Achieved a robust Solar MMS design capable of withstanding dynamic wind loads, ensuring long-term durability and stability.
- Identified critical pressure zones and optimized sections to distribute loads evenly and avoid structural failure.
Efficient Load Distribution & Structural Stability
- Accurately assessed the impact of wind flow around the structure, leading to a design that minimizes stress and deformation.
- Evaluated potential failure locations and incorporated solutions to prevent damage under extreme wind conditions.
Optimized Connections & Structural Integrity
- Ensured secure load-bearing connections using advanced FEA simulations and bolt pretension models.
- Validated connection strength, guaranteeing the MMS withstands wind-induced forces.
Regulatory Compliance & Safety
- Velocity profile equation generated conformed to IS 875 providing better accuracy, aligning CFD results with calculations.
- Complied with IS 801 standards for structural stability and deflection limits, ensuring safety.
- Ensured that the MMS meets regulatory guidelines, providing a safe and compliant solution.
Cost-Effective Design Optimization
- Optimized structural section sizes, reducing material costs while maintaining stability and safety.
- Ensured the design remained cost-efficient while achieving a high performance and reliable structure.
Enhanced Reliability & Longevity
- Improved resistance to dynamic wind loads, enhancing the overall lifespan of the Solar MMS and reducing maintenance needs.
- Optimized design choices led to a more reliable and resilient system for long-term performance.
This CFD and FEA-driven approach provided a stable, cost-effective, and compliant Solar MMS design, ensuring durability and long-term reliability under dynamic wind conditions.
About Client
SolarSquare is a leading provider of rooftop solar solutions in India, specializing in the design, installation, and maintenance of solar panel systems for residential homes, housing societies, and small commercial establishments With an experienced team, SolarSquare focuses on making rooftop solar accessible to all. Their services encompass solar assessments, custom solar designs, installation, and after-sales support to customers. By leveraging advanced engineering solutions and a customer-centric approach, SolarSquare empowers homeowners and businesses to reduce their carbon footprints, achieve energy independence, and contribute to a sustainable future.
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