Abstract:
The present invention is a ballasted solar panel mounting system primarily for mounting solar panels to a roof. The mounting system reduces waste space by positioning the first and/or the last row of bases beneath the panel. This potentially provides room for an additional row of panels and generation of a greater amount of electricity per square foot of area. Additionally, the mounting system uses bases with upwardly extending posts that are integrally connected to the bases that support ballasts. Thus, all assemblies that require attaching one part of the system to another is done at an elevated level to reduce the amount of bending required by the installers. Moreover, the unique system for installing solar panels can be installed without a jig. In some instances, it can be installed with only a single reference line (e.g., chalk line). Additionally, the bases are configured to be stackable for inexpensive storage and distribution.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. application Ser. No. 12/779,256 filed May 13, 2010 which claims the benefit of U.S. Provisional Application No. 61/178,029 filed May 13, 2009 both application are incorporated by reference in their entirety. This application also claims the benefit of U.S. Provisional Application No. 61/380,073 filed Sep. 3, 2010 which is incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of Invention 
         [0003]    This invention relates generally to systems for mounting solar panels or photovoltaic cells and more specifically to ballasted roof mounted racking systems for mounting photovoltaic cells. 
         [0004]    2. Discussion of Related Art 
         [0005]    Solar energy provides the opportunity to generate electricity without consumption of fossil fuels and is considered clean technology. In recent years, the development of technology for solar thermal systems and photovoltaic systems has improved the overall viability of solar energy. Thus, the demand for solar energy has increased. Solar energy allows an individual or business to own and control its energy production free from dependence upon the power grid. Presently, solar power technology is the most accessible form of alternative fuel to the general population of the world. 
         [0006]    The cost of solar panel technology includes a significant investment in installation of the equipment. Thus, a technology advance that reduces the cost of installation makes this clean technology more viable and attractive from an investment perspective. The quality of installation also affects the efficiency of solar panel installation. The direction of the solar panels relative to the sun, the angle of the solar panels relative to the horizon, the density of solar panels in a given area, as well as position of solar panels relative to other panels can have a positive or negative effect on performance of the solar powered system. 
         [0007]    A large percentage of commercial solar panel systems are installed on generally flat roves of office buildings. Generally flat means that the roof is designed to be generally horizontal without a predefined pitch. It should be understood that while generally flat, flat roofs are often uneven due to settling of the building, construction imperfections, etc. A flat roof structure is an attractive place to locate a solar panel installation because there is often a large surface area of unused space. The traffic on a roof is restricted and there are relatively few obstructions of sunlight. Because access is restricted by design and by common security precautions, the likelihood of intentional or accidental damage or theft is naturally reduced. Consequently, there is a significant effort in the solar panel industry to design effective flat roof mounts or racks to support arrays of solar panels on flat roofs. 
         [0008]    The ability to assemble with one additional row of solar panels without causing overlap of the solar panels in sunlight or compromising optimal positioning would be a great advantage. Moreover, it would be advantageous if panels and their support structures could be easily assembled by a layperson (do-it-yourselfer) without formal training. It would be further advantageous if the system could be installed by hand without tools. It would be further advantageous if the product could be stacked or configured to ship a larger number of system components per unit of shipping volume and thereby reduce shipping costs. An additional advantage would be to have a system that can be easily adapted to avoid obstructions in the roof such as common rooftop fixtures without having to cut and resize parts of the solar panel system. Reducing installation time reduces labor cost making solar technology more accessible to the common individual. 
         [0009]    U.S. Pat. No. 4,269,173 to Kruger et al. discloses a mounting system for the ground or roof. The mounting system includes an array of rails and spars to which the panels are fastened. The mounting system is secured by screw or bolt by mounting brackets. Thus, it is required to penetrate the roofs water resistant barrier to secure this system. Such a system is undesirable because roof penetration potentially causes leaks in the roof. 
         [0010]    U.S. Patent Publication 2008/0210221 to Genschorek discloses a frame assembly that mounts solar panels at an angle for mounting on a flat structure such as a roof or ground. The frame system is supported by carrier profile elements with feet having holes forming connections to connect the carrier profile elements to the ground or roof surface—presumably by bolt, screw or penetrating fastener. 
         [0011]    U.S. Pat. No. 6,046,339, discloses a system for mounting solar panels in rows. A row of solar panels are supported by a row of insulation blocks that are interconnected and lay on the surface that supports the solar panel—such as a roof. Each insulation block supports a pair of left and right mounting brackets. The solar panel is attached to a support bracket in the front and to an extendible strut at the back side of the panel to elevate the panel. The system requires the panel shaped blocks to cover the entire area that receives solar panels. The bulk of the panel shaped insulation blocks is a deterring factor. 
         [0012]    U.S. Pat. No. 7,481,211 describes a ballasted system for supporting solar panels. The ballasted system includes a base and a support structure coupling the base to the solar panel. The system has multiple rows of solar panels mounted to the support structure. Support blocks are located at the corners of the support structure. The support structure supports multiple rows of panels on a single angled support structure. 
         [0013]    U.S. Patent Application No. 2009/0242014 to Leary discloses system device for mounting and retaining solar panels. The panels are supported at the corners by shoes. The panels are attached by an attachment module to rear and forward mounting holes. The attachment module includes a bolt actuated clamp that clamps to the underside lip of the solar panel. Another bolt is needed to attach the attachment mechanism to the shoe. Thus multiple steps of assembly are required making installation of this unnecessarily time consuming to install. 
         [0014]    U.S. Pat. No. 7,921,843 to Rawlings discloses a trough structure with two mounting ledges. One mounting ledge supports a row of panels at the back side of the solar panels. The other mounting ledge supports a row of panels at the front side of another row of solar panels. The trough receives a row of ballast blocks. The trough tends to trap moisture beneath the system and cause damming and pooling of rainwater. 
         [0015]    Thus, there still exists a need for a system that has many of the needs expressed above. The present invention addresses these and other needs. 
       SUMMARY OF THE INVENTION 
       [0016]    The present invention is a ballasted solar panel mounting system primarily for mounting solar panels to a flat roof. The mounting system reduces wasted space by positioning the first and/or the last row of bases beneath the panel. This potentially provides room for an additional row of panels and generation of a greater amount of electricity per square foot of area. Additionally, the mounting system uses bases with upwardly extending posts that are integrally connected to the bases that support ballasts. By integrally, it is meant that the two parts are permanently fastened together and require no additional fastening by the customer or user of the product. Such a permanent fastening system would include, a weld, rivet, nut and bolt, locking fastener, or other permanent fastening means. 
         [0017]    Because the legs are integrally attached to the base, further assembly required is done at the top end of the legs where the need for bending is minimized. Moreover, the unique system for installing solar panels can be installed without a jig. In some instances, it can be installed with only a single reference line (e.g., chalk line). Additionally, the bases are configured to be stackable for inexpensive storage and distribution. 
         [0018]    The solar panel mounting system of one embodiment comprises a first row of a plurality of generally horizontal first bases, a second row of a plurality of generally horizontal second bases, and a third row of a plurality of generally horizontal third bases. Each of the first bases, second bases and third bases have a short pair of upwardly extending posts affixed to one side of the base and a long pair of upwardly extending posts affixed to the other side. Each of the first bases, second bases and third bases are generally configured to be stacked on top of other of the first bases, second bases and third bases. When stacked, each of the bases abuts against the other of the bases and fit between the posts of the other of the bases. The respective short pair of posts and the long pair posts of each of the bases fit offset from and adjacent to the respective short pair and long pair of the other of the bases. 
         [0019]    One row of frames is supportably affixed to solar panels. The first row of frames have a front side and a back side, wherein the front side of the one row of frames is affixed to and supported by the short pair of posts of the first row of a plurality of generally horizontal first bases. Furthermore, the back side of the one row of frames is affixed to and supported by the long pairs of the second row of second bases. Additionally, a back row of frames are supportably affixed to solar panels. The back row of frames have a front side and a back side, wherein the front side of the back row of frames is affixed to and supported by the short pair of posts of the second row of a plurality of generally horizontal second bases. Furthermore, the back side of the back row of frames is affixed to and supported by the long pair of posts of the third row of a plurality of generally horizontal second bases. The third base is positioned directly beneath the back row of frames. 
         [0020]    In one embodiment, the present invention includes a solar panel mounting system. The solar panel mounting system includes a front base comprising a bottom surface and a top surface. The top surface receives ballast onto the surface to anchor the base without the need to fasten the base to the floor surface. The floor surface is defined as any surface that supports the solar panel mounting system. In one embodiment, the floor surface is a flat roof. The front base of the system of one embodiment further comprises an upwardly extending first pair of posts integrally affixed to one side of the front base. By front, it is meant the base that is placed at the front of multiple rows of bases. 
         [0021]    The system includes at least one middle base comprising a bottom surface and a top surface. The top surface receives a ballast. At least one middle base means that there can be a plurality of successive bases in the system or a plurality of rows of bases, where applicable. The number of rows is often determined by the area designated for installation with the objective to have as many rows of solar panels in the designated area. Thus, the invention is in no way limited to one, two or any number of middle bases or rows of middle bases, where applicable. The at least one middle base further comprises an upwardly extending first pair of posts integrally affixed to one side of the at least one middle base and upwardly extending second pair of posts integrally affixed to the other side opposite said one side of the at least one middle base. The system includes a back base that comprises a bottom surface and a top surface. The top surface receives a ballast. The back base further has an upwardly extending second pair posts integrally affixed to one side of the back base. Each of the second pair of posts of the at least one middle base and the back base are longer than each of the first pair of posts of the front base and the back base by a predetermined distance. 
         [0022]    The system of one embodiment further includes a first pair of support bars. The first pair of support bars is of a predetermined length and is attached at a first end location to a top end of the first pair of posts of the front base and attached at a second end location to a top end of the second pair of posts of the at least one middle base. In one embodiment, the support bars are integrally attached which means that they are attached by a permanent means such as welding riveting or affixing with a bolt or similar fastener provided that the bolt or similar fastener cannot be removed without cutting or altering or irreversibly damaging the general physical shape of bolt or fastener. The system also includes a second pair of support bars of said predetermined length attached at a first end location to a top end of the first pair of posts of the at least one middle base and attached at a second end location to a top end of the second pair of posts of the back base. The predetermined length and the predetermined distance are selected to position the rails at a predetermined angle. 
         [0023]    In one embodiment, the at least one middle base comprises two or more middle bases. The first pair of support bars is attached to a top end of the second pair of posts of the two or more middle bases and the second pair of support bars is attached to a top end of a first pair of posts of the two or more middle bases. 
         [0024]    In the system of one embodiment, each of the bottom surfaces engages a floor surface. 
         [0025]    In the system of another embodiment, the predetermined angle is a minimum of about 10 degrees from horizontal and a maximum of about 20 degrees from horizontal. 
         [0026]    In the system of yet another embodiment, the distance between the first pair of posts and the second pair of posts is larger than the width of the front base, middle base and back base. 
         [0027]    Optionally, at least one support bar of the first pair of support bars and at least one support bar of the second pair of support bars support a first solar panel and a second solar panel respectively. 
         [0028]    Typically, the at least one support bar of the first pair of support bars comprises at least one fastener to fasten the first solar panel and the at least one support bar of the second pair of support bars comprises at least one fastener to fasten the second solar panel. 
         [0029]    In one embodiment, each of the front base, the at least one middle base and back base comprises a generally vertical perimeter wall surrounding the top surface of the each said base, wherein the top surface and the perimeter wall define a receptacle into which the ballast is received. 
         [0030]    The first pair of posts of each of the front base and the at least one middle base and the second pair of posts of each of the back base and the at least one middle base are attached to the outer perimeter in one embodiment. 
         [0031]    Each of the front base, the at least one middle base and the back base comprises at least one orifice configured to drain water from the respective front base, the at least one middle base and the back base in another embodiment. 
         [0032]    The system or kit does not require fastening a part of the system to another part that is generally below the top end of the first pair of posts of the front base and the at least one middle base. 
         [0033]    In another embodiment, the bottom surface comprises a tread surface that elevates the base and engages a floor surface. The tread surface resists slipping against the floor compared to a material from which the base is generally made. Generally, the base is made of steel including galvanized steel, stainless steel or steel that is coated with a paint coating such as powder coating paint. 
         [0034]    In one embodiment, the first pair of support bars and second pair of support bars are U-shaped and receive the first pair of posts and the second pair of posts into the U-shaped channel. 
         [0035]    In another embodiment, the front base is placed directly under the first pair of support bars and the back base is directly under the second pair of support bars. 
         [0036]    In another embodiment there is a ballasted solar panel mounting kit. The kit comprises a front base having a bottom surface and a top surface. The top surface is configured to receive a ballast. The front base further comprises an upwardly extending first pair of posts integrally affixed to one side of the front base. The at least one middle base comprising a bottom surface and a top surface. The top surface is configured to receive a ballast wherein the at least one middle base further comprises an upwardly extending first pair of posts integrally affixed to one side of the at least one middle base and upwardly extending second pair of posts integrally affixed to the other side opposite said one side of the at least one middle base. 
         [0037]    The system of one embodiment further has a back base comprising a bottom surface and a top surface, wherein the top surface is configured to receive a ballast, wherein the back base further has an upwardly extending second pair posts integrally affixed to one side of the back base, wherein each of the second pair of posts of the at lease one middle base and the back base are longer than each of the first pair of posts of the front base and the at least one middle base by a predetermined distance. 
         [0038]    In the system of one embodiment, a first pair of support bars of a predetermined length is configured to be attached at a first end location of the first pair of support bars to a top end of the first pair of posts of the front base and attached at a second end location of the first pair of support bars to a top end of the second pair of posts of the at least one middle base. A second pair of support bars of said predetermined length is configured to be attached at a first end location of the second pair of support bars to a top end of the first pair of posts of the at least one middle base and attached at a second end location of the second pair of support bars to a top end of the second pair of posts of the back base. The predetermined length and the predetermined distance are selected to position the rails at a predetermined angle. 
         [0039]    In one embodiment, the at least one middle base comprises two or more middle bases that are configured be attached to the first support bar at a top end of a second pair of posts of the two or more middle bases and further is configured to be attached to the second support bar at a top end of a first pair of posts of the two or more middle bases. 
         [0040]    In another embodiment, the bottom surface is configured to engage a floor surface. 
         [0041]    In still another embodiment, at least one of the first pair of support bars is configured to support a first solar panel and at least one of the second pair of support bars is configured to support a second solar panel respectively. 
         [0042]    In yet another embodiment, each of the front base, the at least one middle base and the back base comprises at least one orifice configured to drain water from the base. 
         [0043]    In one embodiment, the first support bars and second support bars are U-shaped and are configured to receive the first pair of posts and the second pair of posts into the U-shaped channel. 
         [0044]    In another embodiment, the kit further comprises assembly instructions to place the front base beneath the first support bars and the back base beneath the second support bars. 
         [0045]    In still another embodiment, the one or more middle bases comprise at least a first middle base and a second middle base. The first middle base is generally configured to be stacked on the second middle base such that the second middle base fits between the respective first pair of posts and second pair of posts of the first middle base and the first pair of posts and the second pair of posts of the second middle base abut against the respective first pair of posts and the second pair of posts of the first middle base before the kit is assembled or when the kit is not assembled. 
         [0046]    In one embodiment, there is a method of mounting solar panels on a roof. The method comprises the step of providing a reference line. A first row of bases having an upwardly extending first pair of posts is provided. The first row of bases is spaced apart along the reference line. 
         [0047]    The method additionally comprises attaching first support bars to a top ends of the first pair of posts of the first row of bases. The first support bars are attached to a first location on the support bars. At least one middle row of bases is provided. The at least one middle row has upwardly extending first pair of posts on one side of the bases of the at least one middle row and upwardly extending second pair of posts on the other side of the bases of the at least one middle row opposite said one side. The first support bars is attached to the bases of the at least one middle row at a second location on the support bar at a top end of the second pair of posts of the bases of the at least one middle row. 
         [0048]    The first row of support bars are supported at a predetermined angle and the at least one middle row of bases are positioned without a jig or without additional measurement. The method further comprises attaching a front row of solar panels to the first row of support bars. An additional step of providing a back row of bases having upwardly extending second pair of posts on the other side of the bases of the back row opposite said one side is also part of the present invention. Second support bars are attached to the bases of the at least one middle row and the bases of the back row, wherein the bases of the at least one middle row are attached to the support bar at a first location on the support bar at a top end of the first pair of posts of the bases of the at least one middle row and the bases of the at least one back row are attached to the support bar at a second location along the support bar to a top end of the second pair of posts of the bases of the at least one middle row. The method also includes attaching a back row of solar panels to the second row of support bars. 
         [0049]    Typically, the front row of ballasts is positioned beneath the front row of solar panels of the method of one invention. Generally, the back row of ballasts is positioned beneath the back row of solar panels. 
         [0050]    In another embodiment, there is a method of installing a solar panel mounting system. The method comprises the steps of: 
         [0000]    (a) providing a front base comprising a bottom surface and a top surface, wherein the top surface is configured to receive a ballast, wherein the front base further comprises an upwardly extending first pair of posts integrally affixed to one side of the front base;
 
(b) positioning behind the front base at least one middle base comprising a bottom surface and a top surface, wherein the top surface is configured to receive a ballast, wherein the at least one middle base further comprises an upwardly extending first pair of posts integrally affixed to one side of the at least one middle base and upwardly extending second pair of posts integrally affixed to the other side opposite said one side of the at least one middle base;
 
(b) positioning behind the at least one middle base, a back base comprising a bottom surface and a top surface, wherein the top surface is configured to receives a ballast, wherein the back base further has an upwardly extending second pair of posts integrally affixed to one side of the back base, wherein each of the second pair of posts of the front base, the at least one middle base and the back base are longer than each of the first pair of posts by a predetermined distance;
 
(c) attaching a first pair of support bars of a predetermined length to a top end of the first pair of posts of the front base at a first end location of the first pair and at a second end location of the second pair to a top end of the second pair of posts of the at least one middle base;
 
(d) attaching a second pair of support bars of said predetermined length to a top end of the first pair of posts of the at least one middle base at a first end location of the second pair and attached at a second end location of the second pair to a top end of the second pair of posts of the back base, wherein the predetermined length and the predetermined distance are selected to position the rails at a predetermined angle;
 
(e) securing a first solar panel to at least one of the first pair of support bars; and
 
(f) securing a second solar panel to at least one of the second pair of support bars.
 
         [0051]    In one embodiment, the at least one middle base comprises two or more middle bases. The step of (a) attaching the first pair of support bars further comprises attaching the first pair of support bars to a top end of the second pair of posts of one of the two or more middle bases and the step of (b) attaching the second pair of support bars comprises attaching the second pair of support bars to a top end of the first pair of posts of one of the two or more middle bases. 
         [0052]    In one embodiment, each of the front base, the at least one middle base and back base comprises a generally vertical perimeter wall surrounding the top surface of the each said base. The method further comprises the step of placing a ballast within the perimeter wall. 
         [0053]    In another embodiment, there is an apparatus for securing a solar panel to a support, the apparatus comprising a clamping bracket having a passage and a lip configured to receive a solar panel under the lip. A cam actuated clamping mechanism having a cam press on the first end of a cam bolt and a nut on the other end of the cam bolt, the cam actuated clamping mechanism rotates the cam press from a first position to a second position that biases the clamping bracket against to support to clamp a solar panel there between. In one embodiment, the cam press is actuated from the first position to the second position by moving a cam lever and wherein the support further comprises a lock slot into which the cam lever can be moved to prevent movement of the cam press from the second position. 
         [0054]    As used in the present invention, the use of one, a, or other singular designations are intended to be non-limiting and unless otherwise indicated mean one or more. The use of a specific number is likewise non-limiting and is intended to mean the number or more, unless specifically defined otherwise. 
         [0055]    The present invention is described hereinafter in Detailed Description of the Invention in reference to the drawings and examples, which are intended to teach, describe and exemplify one or more embodiments of the invention and is in no way intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0056]      FIG. 1  is a side elevated view of the solar panel mounting system of one embodiment of the present invention. 
           [0057]      FIG. 2  is a front, sectional view of the solar panel mounting system of  FIG. 1  viewed along the line of  2 - 2 . 
           [0058]      FIG. 3  is a side elevated view of the solar panel mounting system of an embodiment of the present invention. 
           [0059]      FIG. 4  is a perspective view of the solar panel mounting system of one embodiment of the present invention. 
           [0060]      FIG. 5  is a front view of multiple bases or ballast trays of one embodiment of the present invention that are arranged in a stacked formation. 
           [0061]      FIG. 6  is an enlarged view of the area shown in region A of  FIG. 4 . 
           [0062]      FIG. 7  is an enlarged view of the area shown in region B of  FIG. 5 . 
           [0063]      FIG. 8  is a top enlarged view of the solar panel mounting system of  FIG. 1  viewed along the line of  8 - 8 . 
           [0064]      FIG. 9  is a rear perspective view of a solar panel mount unit of one embodiment. 
           [0065]      FIG. 10  is a perspective view of a solar panel mount unit of another embodiment. 
           [0066]      FIG. 11  is a pattern for cutting from a metal sheet the base of one embodiment of the present invention. 
           [0067]      FIG. 12  is a toolless fastening system to the fastening system of  FIG. 6 . 
           [0068]      FIG. 13  is a toolless fastening system to the fastening system of  FIG. 7 . 
           [0069]      FIG. 14  is a perspective view of a fastener of one embodiment of the present invention. 
           [0070]      FIG. 15  is a perspective view of a fastener of another embodiment of the present invention. 
           [0071]      FIG. 16  is a fastener system of another embodiment of the present invention. 
           [0072]      FIG. 17  is a side elevated view, partially cut away of a panel mounting system of one embodiment of the present invention. 
           [0073]      FIGS. 18-22  illustrate a rooftop installation process of the solar panel assembly of one embodiment of the present invention. 
           [0074]      FIG. 23  is a perspective view of a clamp of one embodiment. 
           [0075]      FIG. 24  is a persective view of clamp with a cam actuated press of one embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0076]    The present invention is a solar panel mounting system that is capable of being packaged for shipping in a compact and efficient manner. The assembly is more efficient requiring fewer steps, less bending and stooping on the part of the installer, and uses fastener systems that reduces or altogether eliminates the need for additional tools to install the racking system structure. The product is easy to install and can be installed without formal training by a layperson. 
         [0077]    One example of the present invention is illustrated in  FIG. 1  with reference to  FIG. 2 . The solar panel mounting system  10  comprises a plurality of base supports or bases  12  that are arranged to support a plurality of generally horizontal panel frames or support bars  24  or rails. The support bars  24  support a solar panel  30  that is affixed to the support bars  24  by panel clamps  26  and  28 . The base supports  12  have a ballast tray  18  that is affixed to a pair of upwardly extending long arms or long posts  14  and a pair of upwardly extending short arms or short posts  20 . The pair of long posts  14  and pair of short posts  20  extend vertically from the generally horizontal ballast tray  18 . The posts are potentially of various shapes. 
         [0078]    For example the posts  14  and  20  may be round, square, rectangular, or hexagonal. In one embodiment, the posts  14  and  20  are tubes with a generally square or rectangular cross sectional area. The width of the posts  14  and  20  generally corresponds to the inner dimension of the support bars  24  to be received within the support bars  24 . Optionally, the support bars  24  are generally U-shaped with a channel opening on the side of the posts  14  and  20 , optionally, facing toward the ballast tray  18 . A fixture site  16  is located at the top of the long post  14 . As used herein, the terms “top” bottom” or “end” are meant to designate the part of an object relatively close to the “top”, “bottom” or “end.” Its meaning is relative to the context and unless specifically defined to the contrary includes anywhere within the upper ⅛ of the entire length of the object to which reference is made. A similar fixture site  22  is located at the top of the short post  20 . The fixture sites  22  and  16 , in one embodiment are holes that receive a pin, rivet or nut and bolt fastener. In one embodiment, the fastener is a clevis pin, a hitch pin, a ball pin or a quick release pin. They can be any connector that is capable of attaching two portions of a frame together. The bases  12  or ballast trays  18  are generally constructed of steel and are treated to prevent oxidization of the bases  12  or ballast trays  18 . In one embodiment, the base  12  or ballast tray  18  is painted with powder coating. In another embodiment, the base  12  or ballast tray  18  is made of galvanized steel. In yet another embodiment, the base  12  or ballast tray  18  is made of stainless steel. 
         [0079]    The fixture sites  16  and  22  connect support bars  24  to the base or base support  12  at the top of the upwardly extending posts  14  and  20 . The support bar  24  is attached to the posts  14  and  20  at its front end  25  and a back end  27 . The support bar  24  is configured to support the solar panel  30  which is affixed to the support bar  24 . With reference to  FIG. 6 , the support bars  24 , of one embodiment, have a cross sectional U-shape forming a channel along the length of the support bar  24 . The top of the posts  14  and  20  are received into the channel of the U-shaped support bar  24 . In one embodiment, the solar panel  30  is supported by the support bars  24  by clamps  26  and  28  that clamp the solar panel securely to the support bar  24  under a lip  31  in each of the respective clamps  26  and  28 . The support bars  24  are likewise made of steel, aluminum or other similar high strength metal. They are treated or coated to reduce the likelihood of rust or oxidation including galvanizing or painting. Alternatively, the support bars  24  are made of stainless steel. 
         [0080]    The ballast tray  18  of the base support  12  of one embodiment has a length, a width and a height. The length is greater than the width. The ballast tray  18  has a front side  13  and a back side  15 . The distance between the front side  13  and the back side  15  corresponds to the width of the ballast tray  18 . The ballast tray  18  has a first end  17  and a second end  19  corresponding to the length of the ballast tray  18 . The front side  13  generally corresponds to the side that has long posts  14  affixed thereto and the back side  13  generally corresponds to the side that has short posts  20  affixed thereto. A person of ordinary skill in the art will recognize that the designation of “front” and “back” or “first” or “second” are for the purpose of orientation of the parts and are otherwise arbitrary and their designation can be interchanged without departing from the spirit and scope of the invention. The first end  17  and the second end  19  of the ballast tray  18  and base support  12  are arbitrary designations and can refer to either ends as oriented along the length of the ballast tray  18  and base support  12 . 
         [0081]    In one embodiment, the ballast tray  18  of the base support  12  supports and receives one of a various type of ballasts (not shown in  FIGS. 1 and 2 ). The ballast tray  18  can be a flat bottom pan that is configured to receive sand, gravel, cement or metal weights. It is preferable that the ballast tray  18  does not cause water to pool therein, but has one or more openings in the bottom of the ballast tray  18  to allow for drainage. 
         [0082]    With reference to  FIG. 8  and continued reference to  FIGS. 1 and 2 , the ballast tray  18  of one embodiment is a basket made by welding together four pieces of angle iron into a rectangular frame. Each angle iron has two flat sides  11   a  and  11   b  forming a right angle. The first side  11   a  is perpendicular to the second side  11   b . The angle irons are arranged to form a rectangular box having a peripheral lip on the bottom and four vertical sides. The first side  11   a  of each angle iron forms a perimeter lip  11   a  of the ballast tray  18  upon which ballasts are placed. The second side  11   b  forms the perimeter wall of the ballast tray  18 . The short posts  14  and the long posts  20  are welded to the second side  11   b  of the ballast tray  18 . The ends of the second side  11   b  are cut so that when the four angle irons are assembled in a box-like manner, each of the four sides are joined along four corner seams that are welded together by techniques that are known in the art. 
         [0083]    The bottom of the perimeter lip  11   b  is fitted with rubber treads (not shown). The treads in one embodiment have a peel off adhesive on one side that is pressed against the bottom of the second side  11   a  of each of the angle irons of the ballast tray  18 . Alternatively, the treads can be affixed with a two sided tape or a glue adhesive according to techniques that are known in the art. The rubber treads prevent slippage and raise the ballast tray  18  to permit improved drainage. In one embodiment, the rubber treads are textured. In another embodiment, the rubber treads are smooth. 
         [0084]    Optionally, the ballast tray  18  of the base support  12  receives a weight or ballast (not shown) for anchoring the solar panel system to a generally flat roof. The ballast is shaped to fit into the ballast tray  18 . In one embodiment, the ballasts are sized so that the combined area of one or more of the ballasts can be fit into the tray and anchor the tray to the ground without falling through the opening. 
         [0085]    The ballast tray  18  has a height that is a minimum of 1 inch and a maximum of 4 inches and preferably is about 2 inches to 2.5 inches high. The lip formed by the angle iron is likewise a minimum of 1 inch and a maximum of 4 inches, preferably about 2 inches to 2.5 inches. The ballast tray  18  has a width that is a minimum of about 8 inches and a maximum of about 3 feet. Preferably, the ballast tray  18  is about 18 inches wide. The length of the ballast tray  18  is a minimum of about 12 inches and a maximum of about 3 feet. Preferably the length of the ballast tray  18  is about 2.5 feet. Preferably, the length of the ballast tray  18  is aligned with the length of the solar panels  30  when installed. If the internal dimensions of the ballast tray  18  are three feet long and 1.5 feet wide, then the ballast of one embodiment could be slightly smaller than one foot wide by 1.5 feet long so that the ballast can be inserted into and removed from the trays. However, the ballast preferably fits snugly on the lip  11   a  of the ballast tray  18 . Sometimes, multiple ballasts are designed to fit into the ballast tray  18 . At least one of the length or width of the ballasts correspond to the internal width of the ballast trays  18  and the sum of the other of the length or width of the ballasts correspond to the internal length of the ballast trays  18  so that when the multiple ballasts are inserted side-by-side into the ballast trays  18 , they collectively fit into the ballast trays  18  and cannot be easily dislodged from a position above the lip  11   a  of the ballast trays  18  or fall through the opening defined by the lip  11   a  of the ballast tray  18 . 
         [0086]    On the front end of the ballast tray  18  is a pair of long posts  14 . As illustrated in  FIG. 1  with reference to  FIG. 2 , the long posts  14  are attached to the front side  13  of the ballast tray  18  at opposite ends of the ballast tray  18 . 
         [0087]    In one embodiment, the posts  14  and  20  are a square pipe made of roll formed steel. They are preferably welded to the front side  13  and back side  15  of the ballast tray  18  respectively. In another embodiment, the posts  14  and  20  are a three-sided elongate structure having a generally U-shaped cross-section. The back side  15  of the ballast tray  18  has affixed thereto short posts  20  that are aligned with and opposite the long posts  14  affixed to the front side of the ballast tray  18 . 
         [0088]    Optionally, the posts  14  and  20  are roll formed from a sheet into a four sided generally tubular shape with a longitundally extending channel that extend the length of one side of the post  14  and  20 . The posts  14  and  20  are affixed to the ballast tray  18  by welding the channel faced side  14  and  20  to the front side  13  and the back side  15 . 
         [0089]    The stacking of ballast trays  18  is illustrated with reference to  FIG. 5 . A second ballast tray  18 B is stacked on a first ballast tray  18 A. The second ballast tray  18 B fits between the respective short post  14 A and long post  20 A on each side of the first ballast tray  18 A. The second short leg  14 B abuts against the first short leg  14 A. The second long leg  20 B abuts against the first long leg  20 A. In this manner, the second ballast tray  18 B is oriented immediately above and slightly offset the first ballast tray by a distance generally equal to the width of the short and long posts  14 A and  20 A. The third ballast tray  18 C fits between the respective second short posts  14 B and second long posts  20 B on each side of the second ballast tray  18 B. The third short leg  14 C abuts against the second short leg  14 B. The third long leg  20 C abuts against the second long leg  20 B. In this manner, the third ballast tray  18 C is oriented immediately above and slightly offset the second ballast tray  18 B by a distance generally equal to the width of the second short post  14 B and the second long posts  20 B. 
         [0090]    A fourth ballast tray  18  D is shown lowered onto the third ballast tray  18 C by direction arrow  50 . The fourth ballast tray  18 D fits between the respective third short posts  14 C and third long posts  20 C on each side of the third ballast tray  18 C. The fourth short leg  14 D, when lowered into position will abut against the third short leg  14 C. The fourth long leg  20 D will abut against the third long leg  20 C. In this manner, the fourth ballast tray  18 D will be oriented immediately above and slightly offset the third ballast tray  18 C by a distance generally equal to the width of the third short post  14 C and the third long posts  20 C. The result of this unique design is that the ballast trays can be stacked in a compact and efficient manner for shipping increasing the number of units that can be shipped on a given pallet. 
         [0091]    Returning to  FIGS. 1 and 2 , the support bar  24  is attached to the attachment points  16  and  22  of a long post  14  of one ballast tray  18  at the back side  27  of the support bar  24  and a short post  20  of another ballast tray  18  at the front side  25  of the support bar  24 . In one embodiment, the long posts  14  and short posts  20  cooperate to position the solar panel  30  at an angle that is a minimum of 5 degrees and a maximum of 40 degrees from horizontal. Preferably the angle is a minimum of 5 degrees and a maximum of 30 degrees. In one preferred embodiment, the angle is preferably about 10 degrees from horizontal or 100 degrees from vertical. While a higher angle may intercept the sunlight at a more efficient angle, the panels  30  at a higher angle tend to block the sunlight of the panel behind the previous panel. Thus, a lower angle facilitates placing the panels  30  as close as possible together for maximum efficiency. Accordingly, in one embodiment, the long posts  14  are made of a 1.5 inch square metal tube or bar and have a length of about 1 foot, 1 and 7/16 inches. The short posts are, likewise, made of 1.5 inch tube or bar and have a length of about 6 and ⅞ inches. 
         [0092]    The panels  30  can be arranged in rows aligned along length of the panels  30  and base supports  12  including ballast trays  18  as illustrated in  FIG. 2 . A ballast tray  18  that supports a support bar  24  or pair of support bars  24  (not visible in  FIG. 2 ) on one extremity of a row of panels is an end ballast tray  18 . The support bars  24  that is supported by the ballast tray it supports is an end frame and the solar panel that it supports is an end panel  30 . The end ballast tray  18  is affixed to the end pair of support bars  24  so that the end ballast tray  18  is oriented beneath the respective end panel  30 . Every other base support  12  including ballast tray  18  that is not located on the end is attached to the respective ends of the base support  12  including ballast tray  18  so that the panels  30  fit as closely together as possible. 
         [0093]    The present invention is a solar panel mounting system  110  of an embodiment illustrated in  FIG. 3  with reference to  FIG. 4 . The solar panel mounting system  110  comprises a plurality of base supports or bases  112   f ,  112   m ,  112   b  that are arranged to support a plurality of generally horizontal panel frames or support bars  124 . In one embodiment, base  112   f  is configured to be received in the front row of a solar panel assembly and has only a short post  120 . The base  112   m  is a middle positioned base and has both short posts  120  and long posts  114 . The base  112   b  refers to a base that is positioned in the back row. Only the long posts  120  are connected to the support bars  124 . Thus, short posts  120  are optional on  112   b.    
         [0094]    In one embodiment, a pair of support bars  124  supports a solar panel  130  (See  FIG. 17 ). The panel  130  is attached to each support bar  124  by a pair of panel clamps  126  and  128 . The base supports  112   f ,  112   m , and  112   b  have a ballast tray  118  that is affixed to a pair of long arms or long posts  114  and a pair of short arms or short posts  120 . The pair of long posts  114  and pair of short posts  120  extend vertically from the generally horizontal ballast tray  118 . 
         [0095]    The support bars  124  are generally U-shaped with a channel opening on the side directed towards the posts  114  and  120  into which the top end of the posts  114  and  120  are received. A fixture site  116  is located at the top of the long post  114 . A similar fixture site  122  is located at the top of the short post  120 . The fixture sites  122  and  116 , in one embodiment, are holes that receive a pin or bolt. The means for connecting the posts  114  and  120  to the support bars  124  can be any connector that is capable of attaching two portions of a frame together—including a bolt, cotter pin, quick release pin, ball pin, clevis pin and hitch pin. 
         [0096]    The fixture sites  116  and  122  connect support bars  124  to the base  112  by corresponding fixture sites  122  and  116  that the support bar  124  has in its front end  125  and a back end  127 . The support bar  124  is configured to support the solar panel  130  which is affixed to the support bar  124 . As illustrated in  FIGS. 3 and 4 , the support bars  124  have a cross-sectional U-shape forming a channel along the length of the support bars  124 . The top of the posts  114  and  120  are received into the channel of the U-shaped support bar  124 . The solar panel  130  is supported by the support bars  124  by clamps  126  and  128  that clamp the solar panel  130  securely to the support bar  124  under a lip  131  (of  FIGS. 6 ,  7  and  16 ) in each of the respective clamps  126  and  128 . 
         [0097]    With reference to  FIGS. 6 and 16 , the front clamp  126  is described. The support bar  124  is attached to the short post  114  by a nut and bolt fastener  133 . The clamp  126  is attached to the support bar  124  by a nut  138  and bolt  132 . The bolt  132  passes through a hole in the clamp  125  surface  136  and a slot  134  in the support bar  124 . In one embodiment, the bolt  132  is a carriage bolt that is securely received into the slot  134  to prevent the bolt  132  from turning when its corresponding nut  138  is tightened. The slot  134  allows the bolt  132  to slide in the direction of the length of the support bar  124  a distance that is a minimum of 0.5 inches and a maximum of about 4 inches (preferably about 1 to 1.5 inches). The function of this slot  134  is to facilitate better fitting of the solar panel  130  caused by unevenness in the surface to which the solar panel  130  assembly  110  is mounted. The unevenness (although vertical in nature) causes slight horizontal misalignment that is rectified by some variance in the longitudinal placement of the panel  130 . 
         [0098]    The clamp  126  has a vertical height that corresponds to the thickness of the solar panel  130 . The vertical height is the sum of spacers  135  and  137 . The panel  130  is placed under lip  131 . The clamp  126  is then tightened by turning nut  138  in a tightening direction. 
         [0099]    With reference to  FIGS. 7 and 16 , the rear clamp  128  is described. The support bar  124  is attached to the long post  120  by a nut  138  and bolt  132  fastener  133 . The bolt  132  passes through a hole in the clamp surface  136  and a slot  134  in the support bar  124 . In one embodiment, the bolt is a carriage bolt that is securely received into the slot to prevent the bolt  132  from turning when its corresponding nut  138  is tightened. The slot  134  allows the bolt  132  to slide in the direction of the length of the support bar  124  a distance that is a minimum of 0.5 inches and a maximum of about 4 inches (preferably about 1 to 1.5 inches). The function of this slot  134  is to facilitate better fitting of the solar panel  130  caused by unevenness in the surface to which the solar panel assembly  110  is mounted. The unevenness (although vertical in nature) causes slight horizontal misalignment that is rectified by some variance in the longitudinal placement of the panel  130 . 
         [0100]    The clamp  126  has a vertical height that corresponds to the thickness of the solar panel  130 . The vertical height is the sum of spacer  135  and  137 . The panel  130  is placed under lip  131 . The clamp  126  is then tightened by turning nut  138  in a tightening direction. 
         [0101]    In one embodiment illustrated in  FIG. 9  with reference to  FIG. 11 , the base support  212  is cut and shaped from a single sheet of metal  200 . The ballast tray  218  is cut into a generally cruciform shape with an intersecting crux  211   a  and four outwardly extending appendages  211   b ,  211   c ,  211   d , and  211   e  that each extend at right angles from adjacent appendages. The center of the crux can be removed to form an opening  202  in the bottom  211   a  of the ballast tray. Appendages  211   b ,  211   c ,  211   d  and  211   e  of the ballast tray  218  are folded upward along fold lines  203   b ,  203   c ,  203   d  and  203   e  until perpendicular to bottom  211   a  of the ballast tray and touching to form seams  204  with adjacent appendages. The seams  204  are welded according to techniques that are known in the art to form the generally box shape of the ballast tray. In one embodiment, the length of the appendages  211   b ,  211   c ,  211   d  and  211   e  are the same and form sides of equal height. In another embodiment, it is recognized that the length of the sides to which upwardly extending long posts  214  and short posts  220  are attached correspond proportionally to the strength of the posts. Thus, increasing the length of the appendages corresponding to these sides may be advantageous. 
         [0102]    Thus, in one embodiment, the front side  213  formed from appendage  211   b , and the back side  215  formed from appendage  211   c  are longer than the first end  217  formed from appendage  211   d  and the second end  219  formed from appendage  211   e . Thus when folded to form the ballast tray, the front side  213  and the back side  215  are longer than the first end  217  and second end  219 . In one embodiment the front side and the back sides have a minimum height of two inches and a maximum height of four inches—preferably about three inches. The first end  217  and the second end have a minimum height of one inch and a maximum height of three inches—preferably about 2 inches. 
         [0103]    With continued reference to  FIGS. 9 and 11 , the short posts  220  and the long posts  214  of the base are formed from metal sheet  200 . Specifically the posts  214  and  220  are cut from the metal that is cut away from metal sheet  200  to form the opening  202 . A pair of short posts  220  is needed for each support base  212 . The posts are roll formed and folded along seam lines  204  and  205  to form generally tubular posts with a square or rectangular cross sectional area. Likewise, a pair of long posts  214  is needed for each support base  212 . These posts are roll formed and folded along seam lines  206  and  207  to form generally tubular posts with a square or rectangular cross sectional area. However, it will be appreciated by a person of ordinary skill in the art that the posts can be formed into a wide variety of tubular shapes without departing from the spirit and scope of the present invention including without limitation round, hexagonal or octagonal shapes. 
         [0104]    It is desirable, in one embodiment, to have the inner channel of the posts  214  and  220  to be open so that the inside of the post  214  and  220  can be exposed to protective treatment including coating. As noted above, the posts  214  and  220  can be powder coated, painted, galvanized or otherwise treated to extend the life of the posts  214  and  220  and to preserve the strength. 
         [0105]    In one embodiment the posts  214  and  220  are four sided tubular members with a channel running up the middle of the fourth side. The forming of an open fourth side with a longitudinally extending ridge along the posts  214  and  220  greatly improve the strength of the posts  214  and  220  without requiring thicker metal parts for the posts  214  and  220 . Moreover, orienting the posts  214  and  220  so that the side of the post  214  and  220  with the open face is attached to the front side  213  and back side  215  greatly reinforces the strength of the base support  212  without requiring posts of a metal thickness that is greater than the base support  212 . The posts  214  and  220  are attached to the front side  213  and back side  215  by means of welding or other means known in the art. 
         [0106]      FIG. 10  sets forth a base support  212   f  for use in the front row of solar panel assembly so that it can be fit under the solar panel and provide additional space for more efficient placement of the panels. The base support  212   f  is similar to other base supports for placement in the front row, except that the base support  212   f  of  FIG. 10  is formed from a single sheet of metal similar to the base support  212  of  FIGS. 9 and 11  and follow the manufacturing steps disclosed above except that the front side does not have long posts  214  affixed to it. Thus, the outwardly extending appendage  111   b  has a length that is the same as outwardly extending appendages  111   d  and  111   e.    
         [0107]    With continued reference to  FIGS. 3 and 4 , the bottom of the perimeter lip  111   a  is fitted with rubber treads (not shown). The treads in one embodiment have a peel off adhesive on one side that is pressed against the perimeter lip  111   a  of the ballast tray  118 . Alternatively, the treads can be affixed with a two sided tape or a glue adhesive according to techniques that are known in the art. The rubber treads prevent slippage and slightly raise the basket to permit improved drainage. In one embodiment the rubber treads are textured. In another embodiment, the rubber treads are smooth. 
         [0108]    Optionally, the ballast tray  118  receives a weight or ballast for anchoring the solar panel system to a generally flat roof. The ballast is shaped to fit into the ballast tray. The ballasts are sized so that the combined area of one or more of the ballasts can be fit into the ballast tray  118  and anchor the tray to the ground. 
         [0109]    In one embodiment, the ballast tray  118  has a height that is a minimum of 1 inch and a maximum of 4 inches and preferably is about 2.5 inches high. The lip formed by the angle iron is likewise a minimum of 1 inch and a maximum of 4 inches, preferably 2.5 inches. The ballast tray has a width that is a minimum of about 8 inches and a maximum of about 3 feet. Preferably, the ballast tray  118  is about 1.5 feet wide. The length of the ballast tray  118  is a minimum of about 1 foot and a maximum of about 3 feet. Preferably the length of the ballast tray  118  is about 2.5 feet. Preferably, the length of the ballast tray  118  is aligned with the length of the solar panels when installed. If the internal dimensions of the ballast tray  118  are three feet long and 1.5 feet wide, then the ballast of one embodiment could be slightly smaller than one foot wide by 1.5 feet long so that the ballast can be inserted into and removed from the ballast trays  118 . However, the ballast fit snugly on the lip  111   a  of the ballast tray  118 . Sometimes, multiple ballasts are designed to fit into the ballast tray  118 . At least one of the length or width of the ballasts correspond to the internal width of the ballast trays  118  and the sum of the other of the length or width of the ballasts correspond to the internal length of the ballast trays  118  so that when the multiple ballasts are inserted side-by-side into the ballast trays  118 , they collectively fit and cannot be easily dislodged from a position above the lip  111   a  of the ballast trays  118 . 
         [0110]    The panels  30  are arranged from front to back as shown in  FIG. 1 . The first row of panels  30  is supported by the short posts  14  of a row of ballast trays  18 . The ballast trays  18  are oriented in front of the first row of panels  30  in the embodiment shown in  FIG. 1 . In another embodiment illustrated in  FIG. 3 , the long posts  120  are removed from the first row of ballast trays  118  and the base is reversed so that the short post  114  supports the support bar  124  and the ballast trays  118  of the first row are oriented beneath the first row of panels  130 . The back side of the panel  130  is supported by a long post  120  from a second row of ballast trays  118  which in turn support a second row of panels  130  by the short posts  114  of the second row of ballast trays  118 . This pattern continues until the last row of panels is supported by long posts  120  of a last row of ballast trays  118 . However, the orientation of the last row of ballast trays is reversed so that the last row of ballast trays  118  are directly beneath the last row of solar panels  130 . This saves a space for roof installation that is equal to the width of two ballast trays and the length of an entire row of ballast trays. 
         [0111]    With reference to  FIG. 12 , an alternative clamp mechanism is disclosed. The clamp mechanism includes a similar clamp bracket  326  that is previously described in  FIGS. 6 and 7 . Likewise, the support bar  324  of the present embodiment is attached to the short post  314  by a nut and bolt. The clamp bracket  326  is attached to the support bar  324  by a nut and bolt  333 . Preferably, the cam actuated clamp mechanism  332  is pre-attached for efficient field installation. The cam actuated clamp mechanism  332  passes through a hole in the clamp bracket  326  surface  336  and a slot  334  in the support bar  324 . In one embodiment, the clamp mechanism  332  has an at least partially threaded bolt shaft that is securely received into the slot  334 . The slot  334  allows the bolt to slide in the direction of the length of the support bar  324  a distance that is a minimum of 0.5 inches and a maximum of about 4 inches (preferably about 1 to 1.5 inches). The function of this slot  334  is to facilitate better fitting of the solar panel caused by unevenness in the surface to which the solar panel assembly (not shown) is mounted. The unevenness (although vertical in nature) causes slight horizontal misalignment that is rectified by some variance in the placement of the longitudinal placement of the panel. 
         [0112]    The clamp  326  has a vertical height that corresponds to the thickness of the solar panel not shown. The vertical height is the sum of spacers  335  and  337 . The panel (not shown) is placed under lip  331 . The cam actuated clamp mechanism  332  forces the lip  331  against the surface of the support bar  324  clamping the solar panel (not shown) between the lip  331  and the support bar  324  by means of the cam actuated clamp mechanism  332 . 
         [0113]    The features of the cam actuated clamp mechanism  332  are described with reference to  FIG. 14  and  FIG. 15  illustrating two, similar embodiments of a cam actuated clamp mechanism  332 . For reference identical parts of each cam actuated clamp mechanism  332  will have identical reference numbers. The cam actuated clamp mechanism  332  of  FIGS. 14 and 15  comprise a cam press  304  eccentrically connected to a cam bolt  303  at the head  305  of the cam bolt  303 . The cam bolt  303  has cam bolt head  305 , a cam bolt shaft  309  which is threaded at the end opposite to the cam bolt head  305 . A nut  310  is threadably received onto the cam bolt shaft  309  opposite to the cam bolt head  305 . 
         [0114]    The cam bolt head  305  is received within an access slot in the cam press  304 . The cam press  304  is eccentrically attached to the cam bolt head  305  by a pivot pin  307 . A pair of cam lobes  311  is defined as the portion of the generally cylindrical cam press  304  that protrude farthest from the pivot pin  307  axis. The generally cylindrical cam press  304  is attached to a cam lever  308  which aids in the rotation of the eccentric cam press  304  relative to the cam bolt head  305  to position the cam lobes  311  at various radial angles to the cam bolt shaft  309  relative to the pivot pin  307  axis. The cam lever  308  can also rotate the cam press  304  and cam bolt  303  relative to the axis of the cam bolt shaft  309 . In one embodiment shown in  FIG. 15 , the cam lever  308  is fitted with a press plate  312  that more comfortably enables axial rotation of the cam bold shaft  309 . 
         [0115]    The clamp  326  operates to secure the solar panel to the support bar  324 . The solar panel is positioned under the lip  331  of the clamp bracket  336 . The cam lever is rotated to position the cam lobes  308  in a direction opposite to the cam bolt shaft  309 . The nut  310  is hand tightened. Then the cam lever  308  is rotated to position the cam lobes  311  in the same direction as the cam bolt shaft  309 . This causes the cam lobes  311  to be wedged against the bottom of the support bar  324  and bias the support bar  324  against the lip  331  to secure the solar panel to the support bar  324 . 
         [0116]    With reference to  FIG. 13  and continued reference to  FIGS. 14 and 15 , the cam actuated clamp mechanism  332  includes a similar clamp bracket  328  that is previously described in  FIGS. 6 and 7 . Likewise, the support bar  324  of the present embodiment is attached to the long post  320  by a bolt  333 . The clamp bracket  328  is attached to the support bar  324  by a cam actuated clamp mechanism  332 . Preferably, the cam actuated clamp mechanism  332  is pre-attached for efficient field installation. The cam actuated clamp mechanism  332  passes through a hole in the clamp bracket  328  surface  336  and a slot  334  in the support bar  324  and operates by compressing the clamp bracket  326  against the support bar  324  to clamp the solar panel against the support bar  324 . In one embodiment, the cam actuated clamp mechanism  332  has an at least partially threaded cam bolt  303  that is securely received into the slot  334 . The slot  334  allows the bolt  303  to slide in the direction of the length of the support bar  324  a distance that is a minimum of 0.5 inches and a maximum of about 4 inches (preferably about 1 to 1.5 inches). The function of this slot  334  is to facilitate better fitting of the solar panel caused by unevenness in the surface to which the solar panel assembly (not shown) is mounted. The unevenness (although vertical in nature) causes slight horizontal misalignment that is rectified by some variance in the placement of the longitudinal placement of the panel. 
         [0117]    The clamp  326  has a vertical height that corresponds to the thickness of the solar panel (not shown). The vertical height is the sum of spacers  335  and  337 . The panel (not shown) is placed under lip  331 . The clamp  326  forces the lip  331  against the surface of the support bar  324  clamping the solar panel (not shown) between the lip  331  and the support bar  324  by means of the cam actuated clamp mechanism  332 . 
         [0118]    The clamping process begins when by rotating the cam lever  308  to position the cam lobes  311  to protrude in a direction generally opposite the cam bolt shaft  309 . The nut  310  is hand tightened. Then the cam lever  308  is rotated to position the cam lobes  311  in the same direction as the cam bolt shaft  309 . This causes the cam lobes  311  to be wedged against the bottom of the support bar  324  and bias the support bar  324  against the lip  331  to secure the solar panel to the support bar  324 . 
         [0119]    With reference to  FIG. 23  and  FIG. 24 , a toolless clamp mechanism of another embodiment, includes a similar clamp bracket  426  as disclosed that is previously described in  FIGS. 6 and 7 . The clamp bracket has a vertical height that corresponds generally to the thickness of the panel (shown previously as panel  120  in  FIG. 6 ). The vertical height is the sum of vertical spacers  435  and  437 . The bracket forms a lip  431  under which the panel  120  is inserted. A clamp plate  436  is formed with a seat  440  and a hole  442  for receiving a cam actuated tool less clamping mechanism  432  illustrated in  FIG. 24 . The cam actuated clamp mechanism  432  comprise a cam press  404  pivotally and eccentrically connected to a cam bolt  403  at the head  405  of the cam bolt  403 . The cam bolt  403  has cam bolt head  405 , a cam bolt shaft  309  which is threaded at the end opposite to the cam bolt head  405 . A nut  410  is threadably received onto the cam bolt shaft  409  opposite to the cam bolt head  405 . 
         [0120]    The cam press  404  is received into a seat  440  and the cam bolt shaft  409  passes through hole  442  from the cam press  404  on the upper side of the clamp plate  436 . The cam bolt  409  passes through an opening (slot or hole) in the rail (not shown) in a similar manner that the bolt  132  passes through opening  134  in  FIG. 6  to couple the clamp  126  of  FIG. 6  to a respective rail. Comparatively the cam bolt  409  couples the clamp  426  to its respective rail (not shown). A nut  410  is threadably received onto the cam bolt shaft  409 . Movement of the nut  410  towards the cam press  404  shortens the distance between the clamp plate  436  and the rail to which the clamp  426  is coupled thus tightening or clamping the solar panel  120  between the clamp lip  431  and the rail to which the clamping mechanism  426  is coupled. 
         [0121]    The cam press  404  is fastened to the cam bolt head  405  by pin  407 . The cam bolt head  404  has a lobe  411  that is rotatable between a first position where the cam handle  408  is upward in a relatively relaxed position to a second position where the cam handle  408  is rotated downward and the cam lobe is positioned between the cam bolt head  405  and the cam seat  440 . The cam handle  408  is positioned in a first relaxed position. The cam nut  410  is comfortably tightened by hand until snug. The cam handle  408  is then pushed downward to position the cam lobe  411  between the cam bolt head and the clamp plate  436 . This forces lip  431  towards the rail through which the clamp bolt shaft  409  passes and results in the solar panel  120  to be clamped between the rail (not shown) and the lip  431 . Friction between the cam lobes  411  and the clamp seat  440  holds the mechanism in a clamped position. 
         [0122]    With reference to  FIG. 17 , a panel assembly is planned for a floor surface that is in one embodiment a rooftop  108 . A front base  112   f  is placed in position and is aligned with a reference line along the front of the base and a second reference line along the side of the base. These two reference lines are the only reference points needed to install the entire solar panel system. A middle base  112   m  is aligned behind the front base  112   f  along the second reference line (not shown). A support bar  124  is affixed to a short post  120  at the front end and a long post  114  at the back side by bolting the support bar  124  at attachment points  122  and  116  of the respective front base  112   f  and middle base  112   m . A second support bar does not need to be attached to the opposite side of the front base  112   f  and the middle base  112   m.    
         [0123]    Now with reference to  FIG. 18 , a row of front bases  112   f  are aligned along a first reference line. A second row of bases  112   m  (shown partially cut away) are aligned behind the front row of bases  112 . Pairs of support bars  124  are attached to the respective pairs of the short rods of the front row  112   f  and the long rods  114  of the second row of bases  112   m.    
         [0124]    With reference to  FIG. 19 , a first row of bases  112   f  and a second row of bases  112   m  (shown in partial) are assembled with support bars  124  extending there between as described above. Panel  130  is placed upon the rails  124  and is secured as described in one or more embodiments above. In one embodiment, front corner solar panel  130  is supported by one rail from two different bases  112   f  and  112   m  placed side by side. Thus, the solar panel  130  spans the space between adjacent bases. This arrangement results in greater stability due to the overall interconnectedness of the system. 
         [0125]    With reference to  FIG. 20 , a front row of panels  130  are affixed to multiple bases  112   f . Additionally, a column of bases  112   m  are behind the front base  112   f . The column of bases  112   m  are aligned with their long rod  114  towards the front base  112   f  and their short rods  120  towards the back. The column of bases  112   f ,  112   m  and  112   b  can be aligned by the second reference line extending along the column of bases  112 . Each base  112   m  between the front row of bases  112   f  and the back row of bases  112   b  on this end row is attached by at least one support bar  124  to the base in front of it and a second support bar  124  to the base in back of it. The last base (or back base)  112   b  in the column has the short rod  120  oriented towards the front row  112   f  and the long rod  114  oriented towards the back. The back base  112   b  is nonetheless connected by the long bar  114  so that the back base  112   b  is placed under the solar panel  130  when it is affixed. 
         [0126]    As shown in  FIG. 21 , this pattern is continued to complete the successive rows and columns of bases  112   f ,  112   m  and  112   b . The solar panels  130  are attached to the support bars  124  that extend between each base. Thus, each solar panel  130  is connected to at least two rows of bases and two columns of bases for a total of four bases affixed to each panel. This interconnectedness between the solar panels  130  and the bases  112   f ,  112   m  and  112   b  contributes to the stability and storm resistance the overall system. Solar panels  130  and corresponding bases can be removed where roof obstructions  140  such as heating, ventilation and air conditioning units are located. The bases immediately in front of an obstruction  140  can be oriented in the same manner of a back row base  112   b . The bases immediately behind the obstructions  140  use front bases  112   f  with only a pair of small rods  120  attached thereto so that the front base  112   f  can be oriented beneath the solar panel that it supports. This reduces trip hazards in the areas surrounding the obstructions.