Introduction: Racking Systems – From Passive Support to Intelligent Core

In 2024, the photovoltaic (PV) racking industry has undergone a profound transformation, moving beyond its traditional role as a passive structural support to become an intelligent, value-adding core component of solar power plants. Driven by the need for higher efficiency, adaptability to complex terrains, and standardized performance metrics, manufacturers worldwide have introduced significant innovations in tracking technology, flexible mounting structures, and attachment solutions.

From Arctech's SkyWings tracker powering the world's largest PV plant on a coal mining subsidence area, to the release of China's first smart tracker testing standard, and from LONGi's flexible PV mount patent to S-5!'s 50 new patents for metal roof attachments, 2024 has been a year of remarkable progress for the PV racking sector.

Part One: Smart Tracking Technology Takes Center Stage

1.1 Arctech's SkyWings: 7.41% Capacity Boost on Challenging Terrain

In November 2024, Arctech, a global solar tracking and racking solutions provider, announced that its 1P single-axis dual-row solar tracking system, SkyWings, enabled the on-time grid connection of the Mengxi Blue Ocean Photovoltaic Power Station in Ordos, China – the world's largest single-capacity solar plant built on a coal mining subsidence area .

Key Performance Metrics:

Annual average grid-connected capacity enhanced by 7.41%

Normal operation maintained at wind speeds up to 18 m/s (Level 8 gale)

AI algorithm-driven power generation boost of up to 8% through real-time shading avoidance

The SkyWings system incorporates Arctech's synchronous multi-point drive mechanism and an innovative torque tube design with exceptional bending and torsion resistance . To accommodate the irregular, undulating topography of the subsidence area, Arctech provided a customized solution with terrain-following capabilities: tolerance for undulation between adjacent rows is set at 20% in the east-west direction and 15% in the north-south direction .

Agrivoltaics Integration:
The system design also prioritizes agricultural compatibility. Arctech tailored the post height to maximize space beneath the solar panels, enabling farmers to cultivate crops and raise livestock underneath. The project is expected to generate 5.7 billion kWh annually, saving 1.71 million tons of standard coal and reducing CO₂ emissions by approximately 4.7 million tons – equivalent to planting 62,700 hectares of trees .

Environmental Innovation:
To mitigate pollution and ecological damage to the grassland, SkyWings employs one-piece H-shaped steel piles with on-site static pressure construction, eliminating the need for concrete. After 25 years of operation, approximately 90% of the steel pipe piles remain suitable for recycling, reducing waste discharge by around 60% compared to traditional concrete piles .

1.2 China's First Smart Tracker Testing Standard Released

A major milestone for the industry arrived in September 2024 with the release of China's first smart tracker standard, "T/CPIA0082-2024 – Test Method for Intelligent Tracking Performance of PV Trackers," led by Trina Solar and jointly developed by 15 organizations including mounting companies, third-party agencies, design institutes, universities, and EPCs . The standard took effect on September 15, 2024.

Why Smart Tracking Matters:
As flat, easily developable land becomes increasingly scarce, more PV projects are being built on challenging terrains such as mountains, gobi deserts, and wastelands. Conventional tracking technology cannot resolve shading losses caused by uneven terrain during the back-tracking phase in the morning and evening. Moreover, conventional tracking algorithms are optimized only for sunny conditions, wasting diffuse radiation on cloudy days .

Three Smart Tracking Technology Directions:

High-scattering irradiance weather optimization – Using meteorological data, generation data, and cloud cameras to dynamically optimize tracking angles under diffuse light conditions

Back-tracking optimization – Identifying shading scenarios on complex terrain through generation data and terrain measurements

Bifacial module optimization – Establishing bifacial irradiance models or using reference arrays to determine optimal tracking angles for bifacial modules 

The standard provides clear specifications for testing methods for all three optimization functions, giving project owners a benchmark for evaluating different smart tracking solutions and providing the industry with unified technical references .

SPIC Field Test Validation:
China's State Power Investment Corporation (SPIC) released its 2024 field test report from the National Photovoltaic and Energy Storage Field Testing Platform in Daqing, Heilongjiang Province. The three-year data (2022-2024) comparing mounting structure performance showed that dual-axis trackers achieved the highest average yield increase of 24.58% compared to fixed 45° tilt structures, followed by vertical single-axis trackers (19.14%), 25° inclined single-axis (17.65%), 10° flat single-axis (15.90%), and 15° inclined single-axis (12.28%) .

Part Two: Flexible PV Mounts – Innovation for Complex Applications

2.1 LONGi Green Energy Obtains Flexible PV Mount Anchor Patent

In December 2024, China's National Intellectual Property Administration announced that LONGi Green Energy Technology Co., Ltd. had been granted a patent for a "Flexible PV Mount Anchor Structure and PV Power Generation System" (Authorization Announcement No. CN 222122134 U), filed in April 2024 .

Technical Innovation:
The anchor structure includes a frame body with first and second fixing members spaced apart along a first direction. A调节 component is positioned between them, featuring a cable fixing member with cable holes for securing cables. A rotating connector connects the调节 component to both fixing members, with the axis of the rotating connector perpendicular to the axis of the cable holes .

This design enables flexible PV mounts to maintain structural integrity while accommodating the dynamic loads and movements inherent in flexible mounting systems, addressing a key technical challenge for large-span and complex terrain applications.

2.2 Industry Applications: Flexible Mounts Gain Traction

The adoption of flexible PV mounts has accelerated in 2024, particularly for projects on mountains, hills, and沟壑 areas where traditional rigid mounts are cost-prohibitive. Flexible mount systems offer several advantages:

Lower pile density and reduced construction costs

Simplified structure with enhanced safety features

Effective utilization of idle land resources

Suitability for agrivoltaics and other dual-use scenarios

These systems are proving particularly valuable for China's large-scale "PV + ecological restoration" projects in western regions.

Part Three: Metal Roof Attachments – S-5! Achieves 50 New Patents in 2024

3.1 Unprecedented Patent Activity

S-5!, the global leader in solar attachment solutions for metal roofs, announced in December 2024 that it had been granted 50 new patents in 2024 alone, bringing its total patent portfolio to 194 since its first patent application in 1991 .

Global Patent Distribution:

European Union: 12

China: 9

United States: 8

India: 6

Australia: 4

Others: New Zealand (2), United Kingdom (2), South Africa (2), Costa Rica (1), Kuwait (1), Mexico (1), Saudi Arabia (1), Turkey (1) 

3.2 New Product: Protea™ Rail-less Solar Mounting Solution

Most notably, the Indian Patent Office granted S-5! patent #423672-001 for its new Protea™ PV rail-less solar mounting solution, designed for mounting framed solar modules to trapezoidal metal roofs while providing certified electrical bonding and grounding .

3.3 Third-Party Certifications

S-5! also achieved significant third-party certifications in 2024:

FM Approvals listing to FM 4478 for the Ensolro System (including PVKIT HUR 2.0), capable of withstanding wind uplift forces up to 150 psf in high-wind and hurricane zones

Florida Product Approvals (FPA) for High Velocity and Hurricane Zone (HVHZ) – a rigorous approval for high wind zones 

These achievements make S-5! the first metal roof mounting system manufacturer in its product category to achieve these industry-defining accreditations .

3.4 Real-World Application: Vertical PV Array in Colorado

In August 2024, Solar Power World reported on a striking application of S-5! technology at Vaisala's new U.S. headquarters in Louisville, Colorado. The project incorporated a vertical façade standing seam wall-mounted array secured using S-5!'s PVKIT rail-less solar mounting solution .

Project Highlights:

492-panel rooftop solar array (101 kW tilted array + 228 kW metal rooftop systems)

Vertical façade array mounted on standing seam wall

Wind load requirement: Withstand winds up to 145 mph

Aesthetic priority: Low-profile, sleek appearance complementing Scandinavian minimalist design

Namaste Solar, the installation contractor, noted that the PVKIT solution was a natural choice given aesthetics as a top priority. "Our crews loved installing this system and said they would be perfectly happy installing more projects just like this," said Briana Morris, commercial principal engineer at Namaste Solar .

The S-5! clamps act as wind clamps ("External Seam Clamps"), measurably increasing the structure's wind uplift resistance capacity. Over time, the solar system will offset 69% of the building's electrical consumption, achieving an Energy Use Intensity rating of 28 – making it one of Colorado's most sustainable office buildings .

Part Four: Innovative Foundation Solutions – Reducing Cost and Environmental Impact

4.1 Nuance Energy's Earth Anchor Technology

In September 2024, Nuance Energy Group announced significant updates to its OSPREY PowerRack™ system, featuring innovative Earth Anchor Technology that dramatically reduces installation time and site disruption .

Performance Metrics:

16-day installation for a fully trained 16-person crew (traditional systems take ~60 days)

No concrete or pile-driving – eliminates geotechnical studies and concrete curing

Handheld tool installation – no heavy machinery required

72-inch cable anchors driven into the ground for stabilization

Thomas Boguess, Finance Manager at Nuance Energy, stated: "Our Earth Anchor System allows for nimble, fast deployment, making it easy for installers to scale up quickly and tackle multiple projects without being constrained by the need for heavy machinery" .

After installation, Nuance Energy conducts pull-testing to verify the holding capacity of each anchor, confirming structural integrity and stability.

4.2 DIY Ballast-Supported Racking Systems

Academic research published in 2024 has also advanced the understanding of low-cost racking alternatives. A study in the journal Designs presented ballast-supported foundation designs for open-source solar PV racking, offering viable alternatives for sites where ground-penetrating footings are not technically or economically feasible .

The research proposed two ballast designs (single-line post systems and double-line post systems, both built on a 4 kW basis) that eliminate the need for drilling holes and pouring concrete while remaining cost-effective and allowing user modifications .

Part Five: Industry Outlook – Key Trends for 2025 and Beyond

Based on 2024 developments, several key trends are shaping the future of PV racking systems:

1. Standardization of Smart Tracking
The release of China's first smart tracker testing standard (T/CPIA0082-2024) establishes a unified framework for evaluating intelligent tracking performance. As more projects adopt this standard,电站 owners will have clearer benchmarks for technology selection, and the industry will benefit from reduced coordination costs .

2. Terrain-Following and Agrivoltaics Integration
Projects like Arctech's SkyWings installation demonstrate that tracking systems can be effectively deployed on challenging terrain while enabling agricultural activities beneath panels. This dual-use approach addresses land-use concerns and opens new markets for PV development .

3. Rail-less Solutions for Metal Roofs
S-5!'s patent activity and successful project installations confirm that rail-less direct-attach solutions are gaining market acceptance. The combination of certified electrical bonding, high wind resistance, and aesthetic appeal makes these systems attractive for commercial and industrial rooftop applications .

4. Accelerated Installation Technologies
Innovations such as Nuance Energy's earth anchor system demonstrate that reducing installation time from 60 days to 16 days is achievable. This acceleration directly improves project economics by reducing labor costs and enabling faster time-to-revenue .

5. Flexible Mounts for Complex Terrain
As large-scale PV development shifts to mountainous and reclaimed land areas, flexible mounting systems will play an increasingly important role. LONGi's patent activity in this space suggests continued innovation in anchor and cable tensioning technologies .

In a Nutshell

2024 has been a transformative year for PV racking systems. From Arctech's terrain-following SkyWings delivering 7.41% capacity gains on a coal mining subsidence area, to China's first smart tracker standard providing industry-wide benchmarks, and from LONGi's flexible mount innovations to S-5!'s 50 new patents and Nuance's earth anchor technology – the industry is moving decisively toward smarter, more adaptable, and faster-to-deploy racking solutions. These innovations are not just improving racking systems themselves; they are fundamentally reshaping what is possible for PV power plants in challenging locations and applications.