Array Generator

Array Generator

This video demonstrates the complete workflow for creating and configuring a new Array Definition in the HELIOS 3D Array Generator. It guides the user through every important configuration step required to build a reusable mounting system template for photovoltaic projects.

The tutorial begins by opening the Array Generator and creating a new array definition. A new database entry is created by selecting the appropriate component category and assigning a unique name. Once the editor opens, the user can begin configuring the structural and mechanical properties of the array.

The first configuration step is selecting the Array Type. The video explains how the chosen array type determines the basic construction principle of the mounting system. Next, a photovoltaic module is selected from the module database. As soon as the module is assigned, HELIOS 3D displays its dimensions and immediately updates the graphical preview, allowing the user to verify that the selected module matches the intended design.

The tutorial continues with the definition of the module layout. Parameters such as module orientation, the number of rows and columns, horizontal and vertical spacing, and optional additional distances between module groups are configured. Each modification is reflected instantly in the preview, making it easy to understand how the array geometry changes with every setting.

After defining the module arrangement, the video focuses on the mechanical properties of the array. The user specifies mounting rail heights, side overhangs, reference heights, permissible tilt angle ranges, default inclination, and the maximum allowable terrain slope. These parameters define the structural characteristics of the mounting system and ensure that later placement calculations are based on realistic construction constraints.

The next section introduces the Post Definition. Here, support post rows are created and positioned beneath the array. The tutorial demonstrates how post locations can be added, adjusted, mirrored, and distributed symmetrically or asymmetrically. The graphical preview updates continuously, allowing users to verify that the support structure aligns correctly with the module layout.

The video also explains how post definitions are linked to database components. Existing post types can be assigned, edited, or replaced, enabling the array definition to use real construction elements stored in the HELIOS 3D database. This ensures that future projects automatically use the correct structural components during placement.

Throughout the tutorial, the user repeatedly reviews the live preview to verify every configuration step before continuing. This immediate visual feedback makes it easy to identify incorrect settings and understand how individual parameters influence the final mounting system.

Finally, the completed array definition is saved to the database. The video concludes by showing that the newly created definition is now available for future photovoltaic projects and can be selected whenever a compatible mounting system is required. Once saved, the array definition becomes part of the reusable HELIOS 3D component library, allowing planners to create consistent and standardized PV layouts efficiently across multiple projects.

Video chapters

The video begins with an introduction to the HELIOS 3D Array Generator, one of the core tools for creating reusable photovoltaic mounting systems. Instead of defining every mounting structure individually for each project, the Array Generator allows engineers to create standardized array definitions that can be reused across multiple installations. These definitions store all geometric, structural, and technical parameters required for automated PV layout generation.

The tutorial explains that every array definition represents a complete description of a mounting table, including the module arrangement, rack geometry, support structure, post positions, and engineering limitations. Once saved, these definitions become part of the component database and can be selected directly during project planning. This standardized workflow significantly reduces engineering effort, improves consistency between projects, and ensures that all generated layouts are based on validated construction data.

The workflow starts by selecting the New command in the Array Generator. This creates a completely new database record that will contain all information required to describe a mounting system. At this stage, no geometry exists yet; instead, the software prepares an empty configuration template.

Creating a dedicated array definition allows engineers to separate different mounting concepts, manufacturers, module sizes, or customer-specific rack systems. Each definition can later be modified independently without affecting other projects. This modular approach simplifies maintenance of large component libraries and enables companies to build standardized engineering databases for different customers and product families.

The newly created array definition must be stored inside a component folder. These folders organize mounting systems into logical categories such as manufacturers, project templates, rack families, or customer-specific libraries. Proper folder organization becomes increasingly important when maintaining hundreds or even thousands of array definitions.

The video also explains that folder management is performed within the database administration rather than inside the Array Generator itself. By assigning the array definition to the correct folder from the beginning, engineers ensure that future users can easily locate the correct mounting system during project planning.

After selecting the storage location, the new array definition receives a descriptive name. The naming convention should uniquely identify the mounting system and ideally include relevant engineering information such as module type, table dimensions, rack manufacturer, number of rows and columns, or other distinguishing characteristics.

Consistent naming conventions simplify project planning and reduce the likelihood of selecting an incorrect array during later placement. Especially in large engineering environments with many similar mounting systems, meaningful names significantly improve usability and database maintenance.

Once the basic information has been confirmed, the Array Definition editor opens. The complete configuration is divided into two main pages. The first page contains the parameters that define the physical geometry of the table, including module arrangement, support dimensions, inclination settings, spacing rules, and structural properties. The second page focuses on the support structure, allowing engineers to configure post rows, post positions, and structural components.

Together, these configuration pages fully describe the mechanical behaviour of the mounting system and provide all information required for automatic array placement inside HELIOS 3D.

One of the first engineering decisions is selecting the appropriate Array Type. This choice determines the overall structural concept of the mounting system and activates different configuration options throughout the editor. Fixed-tilt systems, east-west systems, and tracker systems all require different geometric calculations and support structures.

Selecting the correct array type at the beginning ensures that subsequent configuration parameters correspond to the intended rack design. It also guarantees that later placement calculations, shadow analyses, and structural validations use the correct engineering model.

The photovoltaic module is selected from the HELIOS 3D module database. Immediately after assignment, the software imports the module dimensions and technical properties into the array definition. The graphical preview updates automatically and displays the physical dimensions of the selected module.

Since the module dimensions determine the overall table size, row spacing, support geometry, and shadow calculations, this step establishes the geometric basis of the entire mounting system. The optional bitmap only affects visual rendering and 3D scene generation and has no influence on engineering calculations or placement algorithms.

The arrangement of the photovoltaic modules is defined by specifying the number of rows and columns together with the module orientation. Modules may be placed in portrait or landscape orientation depending on the selected rack design and manufacturer specifications.

These parameters determine the final dimensions of the table and directly influence structural loading, support spacing, installation logistics, and the overall appearance of the PV field. Every modification immediately updates the graphical preview, allowing engineers to verify that the table dimensions correspond to the intended mounting concept before continuing with further structural configuration.

Module spacing is configured by defining the horizontal and vertical gaps between adjacent photovoltaic modules. These distances represent the physical clearance required for mounting clamps, thermal expansion, installation tolerances, and maintenance access. In addition to the standard spacing, HELIOS 3D allows the definition of module groups with additional gap distances. This feature is particularly useful for introducing service aisles, expansion joints, or larger installation gaps between predefined groups of modules.

Because these spacing values directly affect the overall dimensions of the mounting table, they influence later row spacing calculations, shadow analysis, and the required project area. Carefully defining realistic module gaps ensures that the generated array corresponds closely to the actual construction system and manufacturer specifications.

The Module Support Thickness defines the vertical height of all structural components located between the photovoltaic modules and the supporting posts. This includes elements such as purlins, girders, mounting rails, and intermediate support profiles, while the posts themselves are excluded from this value. Although it appears to be a simple geometric parameter, the support thickness directly influences the three-dimensional representation of the mounting system and several engineering calculations within HELIOS 3D.

For fixed-tilt systems, the support thickness determines the physical depth of the rack structure beneath the module plane. For tracker systems, it additionally defines the maximum possible rotation distance of the tracker axis. Because the rack body occupies physical space, this value also affects clearance calculations, shadow distances, and collision detection. Engineers should therefore enter the real structural height supplied by the mounting system manufacturer to ensure that the generated rack geometry accurately represents the final installation.

Overhang values define how far structural components extend beyond the photovoltaic module area. These extensions may include purlins, girders, rails, clamps, or other rack elements that project past the outer module edges. Separate values can be defined for the top, bottom, left, and right sides of the table.

Although these components do not increase the active photovoltaic area, they enlarge the physical footprint of the mounting system. HELIOS 3D therefore considers these values during spacing calculations, shadow analysis, collision checks, and row-distance validation. Entering realistic overhang values ensures that the software evaluates the true structural dimensions of the rack instead of considering only the module dimensions. This is particularly important when neighbouring arrays are placed close together or when minimum clearance distances must be maintained.

The array height must be referenced to a defined structural point. HELIOS 3D allows the height to be referenced either to the Front Edge Height of the module plane or to the Post Height. The selected reference determines how all subsequent elevation values are interpreted throughout the placement process.

For most fixed-tilt mounting systems, the front edge of the module plane provides the most intuitive reference because this dimension is commonly specified during project planning. Tracker systems, on the other hand, frequently use the post height since the rotating module table moves independently of the supporting structure. Selecting the correct reference ensures that elevation calculations, clearance checks, and exported construction data correspond to the intended engineering specifications.

The minimum and maximum inclination angles specify the technical operating range of the mounting system. These limits describe the allowable module tilt defined by the rack manufacturer and are stored as part of the array definition. During project planning, HELIOS 3D compares the inclination required by the project with these predefined limits.

If a project requires an inclination outside the permitted range, the software can identify the inconsistency and prevent the use of an unsuitable mounting system. This validation mechanism helps engineers avoid unrealistic configurations while ensuring that every generated layout remains within the structural capabilities of the selected rack system.

The Default Module Inclination is primarily a visualization parameter. It defines the inclination shown in the Array Definition preview and serves as the reference geometry when configuring support posts and other structural elements. Although the value influences how the mounting system is displayed during editing, it does not restrict the inclination used later during project placement.

Keeping a representative default inclination improves the readability of the array preview and provides a realistic reference while defining post positions, support geometry, and structural relationships. It therefore serves as a practical engineering reference during the creation of the array definition.

This chapter defines how the mounting system behaves on uneven terrain. The Maximum Slope specifies the steepest terrain on which the selected rack system may be installed. During automatic placement, HELIOS 3D compares the local terrain slope with this limit and can prevent the placement of tables that exceed the structural capabilities of the mounting system.

The Distance Reference determines how distances between neighbouring arrays are measured on sloping terrain. Depending on the selected option, distances can be evaluated relative to the module surface or to the physical rack body. This distinction becomes particularly important for complex support structures, trackers, or racks without conventional posts, where the structural envelope differs from the photovoltaic module plane.

The tutorial now switches to the second configuration page, where the complete support structure is defined. This section contains all settings required to position the supporting posts beneath the module table. Depending on the selected rack concept, the software supports conventional post layouts as well as special configurations such as shared posts between neighbouring tables.

Although the demonstration focuses on a standard fixed-tilt system, the same workflow can later be adapted for more complex structural concepts. Separating the support configuration from the module geometry keeps the array definition organized and allows engineers to modify the structural design without changing the module layout itself.

Each support post receives a default embedment depth that is used for visualization and structural representation. In addition, the position of each post row can be defined using different reference methods. Engineers may specify the row position relative to the module plane or by defining an absolute horizontal distance from the front edge of the table.

This flexibility allows the same module arrangement to be combined with different support concepts while maintaining identical photovoltaic geometry. Selecting the appropriate positioning logic ensures that the generated support structure accurately reflects the manufacturer’s construction drawings and installation requirements

Support rows are now created beneath the module table. New rows can be added whenever additional structural support is required, and individual posts are inserted into each row. Initially, HELIOS 3D creates a basic configuration with posts positioned near the outer boundaries of the table.

From this starting point, engineers can gradually build the complete support structure by adding further posts, adjusting their locations, and verifying the resulting geometry in the live preview. The immediate graphical feedback makes it easy to evaluate structural stability and confirm that the support arrangement matches the intended mounting concept before continuing with more advanced post configurations.

Some mounting systems require an asymmetrical support structure because of terrain conditions, structural calculations, or manufacturer specifications. In these cases, the number of posts and the spacing between them can be configured individually. Instead of distributing posts evenly across the table, distances are measured from the table boundary to the first post and then sequentially between neighbouring posts.

This approach provides maximum flexibility when modelling complex rack systems and allows engineers to reproduce manufacturer-specific support layouts without introducing unnecessary construction compromises.

For conventional rack systems, symmetrical post arrangements provide a simpler and more balanced structural solution. Equal boundary distances are defined on both sides of the table, while additional posts are inserted automatically as the post counter increases.

This method produces evenly distributed support loads, simplifies manufacturing, and reduces the amount of manual configuration required. Symmetrical layouts are therefore commonly used for standard fixed-tilt mounting systems and represent the preferred configuration whenever no structural constraints require an asymmetrical design.

After the structural layout has been established, the total number of support posts can be refined. Adding or removing posts automatically recalculates the spacing between neighbouring supports, allowing engineers to evaluate different structural concepts with minimal effort.

Each post can also be linked to a Post Definition stored in the HELIOS 3D database. These database objects contain the dimensions and technical properties of the actual construction components used during installation. Associating the array definition with standardized post records ensures that future projects use consistent engineering data and simplifies bill-of-material generation and construction documentation.

The Array Generator provides several productivity tools for creating complex support structures. Existing post rows can be duplicated instead of being recreated manually, and copied rows may be repositioned by defining a new offset relative to the front edge of the table.

These functions significantly reduce modelling time for larger mounting systems that contain multiple identical support rows. They also help maintain consistent spacing throughout the entire structure while minimizing manual editing and reducing the risk of configuration errors.

The support structure is now complete and undergoes a final engineering review. The user verifies the post arrangement, confirms that all support rows have been positioned correctly, and checks whether additional structural requirements need to be applied. At this stage, special configurations such as aligned post rows or multiple rows sharing identical positions can still be introduced if required by the mounting system.

Performing this final verification before saving ensures that the generated array definition accurately represents the intended construction and can be reused without further modification in future photovoltaic projects.

After all module parameters, structural settings, and post configurations have been verified, the completed array definition is saved to the database. Saving permanently stores every geometric and engineering parameter entered throughout the tutorial and closes the editing session.

From this point onward, the mounting system becomes available throughout HELIOS 3D and can be selected whenever a project requires this particular rack configuration. This workflow allows companies to build a centralized engineering library containing validated mounting systems for consistent project execution.

The tutorial concludes by demonstrating that the newly created array definition is immediately available within the component database. Engineers can now select this mounting system during PV layout creation without repeating the configuration process.

Because every geometric, structural, and technical parameter has been stored in a reusable database record, subsequent projects benefit from a standardized and validated engineering workflow. This approach improves planning efficiency, ensures consistent mounting system configurations across multiple installations, and reduces the effort required to prepare future photovoltaic projects.