Introduction: From “Passive Support” to “Active Empowerment”

In 2024, the global PV racking system industry experienced a dual drive of technological breakthroughs and market transformation. Driven by the dual‑carbon goals and energy security demands, PV racking has evolved from a “supporting component” of power plant construction into a “core technology unit” that enhances power generation efficiency, conquers complex terrains, and reduces the levelized cost of electricity.

From breakthroughs in intelligent tracking algorithms to large‑scale applications of flexible mounts, from material and process innovations to the emergence of open‑source designs, the 2024 PV racking market exhibits four prominent characteristics: intelligence, scenario‑specific design, green development, and standardisation.

Part One: Intelligent Tracking – Driven by Standardisation and AI Algorithms

Tracking mounts, which can increase power generation by 15‑25% by adjusting module angles in real time, have become “standard equipment” for large‑scale ground power plants. In 2024, the intelligent tracking field achieved milestone progress in both standardisation and technological innovation.

1.1 Trina Solar: Leading the Release of China‘s First Intelligent Tracker Standard

In 2024, Trina Solar completed its enterprise standard for “Wind Load Design Calculation of Horizontal Single‑Axis PV Trackers” and led the drafting of China’s first intelligent tracker standard, “T/CPIA 0082‑2024 – Test Method for Intelligent Tracking Performance of PV Trackers”, which came into effect on 15 September 2024.

The release of this standard fills a gap in China‘s test methods for intelligent trackers, providing project owners with a unified technical benchmark for evaluating different smart tracking solutions. Trina Solar’s Spanish Intelligent PV System R&D Centre also passed acceptance in 2024, focusing on the development and commercialisation of intelligent PV tracker products.

Technological breakthrough: Trina Solar‘s new‑generation intelligent tracking system has obtained TÜV SUD product certification. Field data show that on top of the generation increase provided by conventional trackers, the system can deliver an additional 2‑4% annual average gain, and over 10% on cloudy/rainy days. This breakthrough upgrades tracking mounts from simple “sun‑following” to true “intelligent sensing”.

1.2 Patent development: Knee‑brace support system improves wind stability

In September 2024, Three Gorges Dongshan Energy Investment Co., Ltd. and PowerChina Wuhan Iron Tower Co., Ltd. jointly filed a patent for a “Knee‑brace support system” (Publication No. CN 119135042 A).

Technical solution: The system includes a main beam, multiple support brackets and an adjustment unit. Each support bracket consists of a PV support frame, a hanger plate and diagonal braces distributed on both sides of the hanger plate. The adjustment unit includes a drive assembly and a brake assembly, which can rotate the hanger plate on the main beam, effectively reducing the probability of PV panel twisting during high winds and significantly improving system stability.

Part Two: Flexible Mounts – The “Key Player” for Conquering Complex Terrain

As PV development extends from flat areas to mountains, ravines, tidal flats, water surfaces and other complex terrains, flexible mounts – with their advantages of lower pile density, larger spans and greater ground clearance – became a technology hotspot in 2024.

2.1 NengHui Technology: Customised Flexible Mount Solution Released

At the SNEC exhibition in June 2024, NengHui Technology officially released its customised flexible mount solution, systematically addressing challenges such as complex installation terrain, high construction difficulty and poor wind resistance.

Technical approach: Unlike early single‑cable‑structure designs, NengHui does not restrict itself to a single type (single‑layer cable, double‑layer cable, fish‑belly cable truss, beam‑string structure, etc.). Instead, for each project‘s specific characteristics, it provides standardised flexible mount design services through a six‑step process: layout, material selection, modelling and calculation, structural analysis, foundation design, and construction drawing production.

Stringent material selection: Main cables use unbonded prestressed steel strands of 15.2 mm or 17.8 mm diameter with a tensile strength of 1860 MPa. Aluminium alloy connectors, anti‑loosening anchors and V‑shaped cones are all national‑standard high‑strength components with excellent fatigue load performance, anti‑loosening performance and rust resistance.

Application scenarios: The solution can be adapted to deserts, gobi areas, steep mountains, sewage treatment plants, fish ponds and farmlands, among other complex terrains.

2.2 DAS Solar: Fourth‑Generation Flexible Mount System Withstands Category 17 Typhoon

In December 2024, Chinese PV module manufacturer DAS Solar released its fourth‑generation flexible PV mounting system, which has been successfully deployed in a 70 MW fishery‑solar hybrid project in Hainan.

Technical parameters:

Real‑world validation: The system successfully withstood Super Typhoon Yagi (Category 17) and passed TÜV Rheinland‘s on‑site inspection, performing excellently in both visual and EL micro‑crack tests. It also passed wind tunnel tests conducted by Nanjing University of Aeronautics and Astronautics, remaining stable at wind speeds of 46 m/s (equivalent to a Category 14 typhoon).

Technical innovations: The system uses a spatial cable‑net structure – pre‑stressed tensioning in the east‑west direction controls mid‑span deflection, while a stabilising cable system in the north‑south direction reinforces the structure. A mechanical locking design prevents bolt loosening caused by wind‑induced vibration, reducing the risk of micro‑cracks.

Part Three: Material and Process Innovations – Zn‑Al‑Mg Coated Steel and Patented Clamps

3.1 HUEG: Zn‑Al‑Mg Coated Steel Mounts + Patented Clamp Design

In December 2024, Chinese PV mounting manufacturer HUEG (Hua Ding New Energy) released a new C‑section ground mounting system made of zinc‑aluminium‑magnesium (Zn‑Al‑Mg) coated steel, featuring a patented new portable clamp design.

Material breakthrough: The system is manufactured using Zn‑Al‑Mg coated steel, which offers excellent corrosion resistance and self‑healing properties, with a design life exceeding 35 years.

Patented clamp: Unlike traditional systems that require multiple flange holes in the rails, HUEG‘s design eliminates this need, enhancing bending resistance and overall stability. The clamp design reportedly increases system strength by 20%.

Technical parameters:

Maximum snow load: 3.6 kN/m²

Maximum wind load: 46 m/s

Tilt angle range: 0‑45°

Warranty period: 15 years

3.2 Trina Solar: Overseas R&D Platform and Patent Portfolio

In 2024, Trina Solar filed 20 core patent applications related to tracking mounts, including 12 invention patents, 8 utility model patents, and 4 PCT international patents. This patent portfolio covers multiple technical directions such as intelligent control algorithms, mechanical structure design, and system integration, providing a solid technological barrier for Trina‘s global tracker market competition.

Part Four: Low‑Cost and Open‑Source Mounts – Academic Research Promotes Affordable PV

In 2024, academia also made important progress in low‑cost, open‑source PV mounts, providing technical support for PV adoption in developing countries and residential markets.

4.1 Wood‑and‑cable variable tilt mount

A study published in the journal Designs in 2024 developed two novel variable tilt mount designs – the first stilt‑mounted designs that allow manual tilt angle adjustment from 0° to 90° by varying cable length.

Economics: The system can save one‑third to two‑thirds of the capital expenditure of commercially available alternatives, is easy to build, and requires minimal manufacturing operations. The design is particularly suitable for agrivoltaic settings, providing farm workers with shaded, ergonomic access for planting, weeding and harvesting.

4.2 Ballasted foundation open‑source mounts

Another 2024 study proposed ballasted foundation designs that eliminate the need for drilling and concrete pouring, applicable to both fixed‑tilt and variable‑tilt systems.

Cost analysis: Although ballasted designs are about 25% more expensive than conventional concrete foundations, the overall cost of the DIY system remains economically advantageous. Sensitivity analysis shows that users can trade off dimensional freedom against cost savings. Overall, all wood‑based PV mounting systems provide users with cost‑effective, easy‑to‑DIY alternatives to conventional metal mounts.

Part Five: Industry Trend Summary – Five Evolutionary Directions for PV Mounts in 2024

Outlook

Looking ahead to 2025 and beyond, the PV racking industry will continue to deepen development in the following directions:

Deepening intelligence: The integration of AI algorithms and digital twin technology will further improve the generation gain and reliability of tracking mounts

Scenario‑specific customisation: Dedicated mounting solutions for agrivoltaics, offshore PV, floating PV and other special scenarios will continue to emerge

Green manufacturing: The use of environmentally friendly materials such as Zn‑Al‑Mg coated steel and bio‑based materials will become more widespread

Standardisation progress: From intelligent tracking test methods to structural design codes, the industry standard system will become increasingly refined

Continuous cost optimisation: Open‑source and low‑cost designs will further lower the barrier to PV installation, promoting global energy affordability

In a Nutshell

In 2024, PV racking systems are undergoing a profound transformation from “passive support” to “active empowerment” – intelligent tracking is smarter, flexible mounts are tougher, new materials are more durable, and open‑source designs are more affordable – building a solid foundation for the global energy transition.