Solar module rail coupling for solar tracker

Abstract

A coupling system for use with a solar tracker includes a saddle defining a U-shaped profile extending between opposing first and second end portions, the saddle defining a channel configured to selectively receive a module rail and defining a slot through first and second side surfaces adjacent the first end portion; and a clip assembly slidably supported within the channel and including a clip having a generally U-shaped profile defining a crown portion interposed between a pair of legs having upturning tabs and extending from the crown portion and terminating at respective hooks, the pair of legs having a plurality of tabs extending from the crown portion. Wherein the clip assembly is configured to transition from a first open position to a second closed position in which the flip-up tab is received within the slot of the saddle, and the hook of each of the pair of legs engages a module rail to selectively couple the module rail to the saddle.

Description

[0001] Cross-reference of related applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application Serial No. 63 / 453,462, filed March 20, 2023, the entire contents of which are incorporated herein by reference. This application also claims the benefit and priority of U.S. Provisional Patent Application Serial No. 63 / 468,412, filed May 23, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to solar power generation systems, and more particularly to clamps and clamping systems for securing solar modules to a support structure. Background Technology

[0004] Solar cells and solar panels are most efficient when oriented at a specific angle towards the sun, under conditions of abundant sunlight. Many solar panel systems are designed in conjunction with solar trackers that follow the sun's path across the sky from east to west to maximize the system's power generation capacity. The relatively low energy produced by a single solar cell requires the use of thousands of solar cells arranged in an array to generate enough energy to be used, for example, as part of an energy grid. Consequently, rather large solar trackers have been developed, spanning hundreds of feet in length and containing hundreds to thousands of individual solar modules mechanically connected to a supporting structure.

[0005] Connecting numerous solar modules to the support structure requires a large number of clamps or other mechanisms, each of which requires a large number of fasteners, thus increasing the cost of manufacturing each mechanism. It is understood that assembling each of these mechanisms and securely tightening each fastener takes considerable time, resulting in increased costs and longer assembly times. This disclosure seeks to address the shortcomings of existing tracker systems. Summary of the Invention

[0006] According to one aspect of this disclosure, a connection system for use with a solar tracker includes: a saddle defining a U-shaped profile extending between a first end portion and an opposing second end portion, the saddle defining a channel having an open upper portion and extending through each of the first and second end portions, the channel being configured to selectively receive a module rail of a solar module, wherein slots are defined through a first side surface adjacent to the first end portion and a second side surface; and a clip assembly slidably supported within the channel of the saddle, the clip assembly including clips having a generally U-shaped profile. The generally U-shaped profile is defined as a crown inserted between a pair of legs, each of the pair of legs extending from the crown and terminating at a corresponding hook, wherein an upturned tab is disposed on each of the pair of legs, wherein the clip assembly is configured to change from a first open position to a second closed position, in which the upturned tab of each of the pair of legs is received within the slot of the saddle, and the hook of each of the pair of legs is received within a corresponding slot formed in the module guide to selectively engage the module guide to the saddle.

[0007] In various respects, the crown of the clip assembly defines an arcuate profile that extends to the apex of the gap formed between the pair of legs.

[0008] In some respects, each hook of the pair of legs may define a channel configured to receive a portion of the module rail, wherein when the clamp assembly is placed in the second closed position, the channel advances the module rail toward the saddle and inhibits movement of the module rail relative to the saddle.

[0009] In other aspects, the saddle may include a cutout defined through the first and second side surfaces of the saddle and adjacent to the first end portion, the cutout extending in a direction transverse to a longitudinal axis defined through the first and second end portions and through the upper surface of the saddle, wherein the cutout allows the upper portions of the pair of legs of the clamp to open outward and extend over the respective first and second side surfaces of the saddle.

[0010] In some respects, the cutout of the saddle may extend a distance away from the upper surface, thereby allowing the tabs of each of the pair of legs of the clamp to extend over the respective first and second end surfaces of the saddle.

[0011] In various respects, the clip assembly may further include a pin operably coupled to the clip and slidably supported within the slot of the saddle, the pin defining a pair of opposing flanges that inhibit movement of the pin in a direction transverse to a longitudinal axis defined through the first and second end portions of the saddle.

[0012] In other respects, the clip may define a pair of lugs extending from each of the pair of legs in a direction away from the hook, each of the pair of lugs defining a hole for receiving the pin.

[0013] In all respects, when in the first open position, each of the pair of legs can be opened in an outward direction, wherein the distance between the upper portions of each of the pair of legs is greater than the length of the crown.

[0014] In some respects, when in the first open position, the first leg of the pair of legs may be parallel to the second leg of the pair of legs.

[0015] According to another aspect of the invention, a clip for use with a coupling assembly of a solar tracker includes: a crown defining an arcuate profile extending between a first end portion and an opposing second end portion; a pair of extendable legs defining a gap for receiving a module rail for a solar module, a first leg of the pair of extendable legs being disposed on the first end portion and a second leg of the pair of extendable legs being disposed on the second end portion, each leg of the pair of extendable legs extending from the crown and terminating at a hook extending into the gap, wherein each leg of the pair of extendable legs defines an upwardly flared tab extending away from the gap and toward the hook; and a pair of lugs, a first lug being disposed on the first leg of the pair of legs and a second lug being disposed on the second leg of the pair of extendable legs, wherein the first lug is parallel to the second lug.

[0016] In each respect, each hook of the pair of extended legs defines a channel for receiving a portion of the module rail.

[0017] In other respects, each of the pair of lugs may define a hole for receiving a pin.

[0018] In some respects, the clip may comprise a single piece of material, wherein the crown, the pair of openable legs, the pair of lugs, and the upturned tabs are integral with the single piece of material.

[0019] In all respects, the clip may be formed of an elastic material.

[0020] According to another aspect of this disclosure, a coupling system for use with a solar tracker includes: a saddle defining a U-shaped profile extending between a first end portion and an opposing second end portion, the inner surface of the saddle defining a channel having an open upper portion and extending through each of the first end portion and the second end portion, wherein the inner surface of the saddle defines a pair of recesses, wherein an internal dimension extending between the pair of recesses is greater than the internal dimension of the remainder of the channel, and a clip assembly slidably supported within the channel of the saddle, the clip assembly including clips having a generally U-shaped profile. The U-shaped profile defines a crown inserted between a pair of legs, wherein a portion of each of the pair of legs is selectively received within a corresponding recess in a pair of recesses, each of the pair of legs including an upward-folding tab, wherein the clamp assembly is configured to transition from a first open position to a second closed position, in the first open position, each upward-folding tab being received within a corresponding recess in a pair of recesses, and in the second closed position, each upward-folding tab being located within the remaining portion of the channel, the internal dimension of the remaining portion being smaller than the internal dimension extending between the pair of recesses.

[0021] In some aspects, the saddle may include a slot formed through a first side surface and a second side surface, the slot being configured to selectively receive the upturned tabs of the pair of legs when the clamp assembly is placed in the second closed position.

[0022] In all respects, each of the pair of legs of the clamp assembly may terminate at a hook that extends into the gap formed between the pair of legs.

[0023] In other respects, each hook of the pair of legs may define a channel for receiving a module rail for the solar module.

[0024] In some respects, the crown may be defined as an arched profile extending between the pair of legs.

[0025] In all respects, the pair of legs can open in a direction extending from the crown. Attached Figure Description

[0026] Various aspects and features of this disclosure are described below with reference to the figures, wherein:

[0027] Figure 1 This is a perspective view provided in this disclosure showing a connection assembly connected to a module guide rail and a torque tube;

[0028] Figure 2 yes Figure 1 A perspective view of the connecting assembly;

[0029] Figure 3 yes Figure 1 The illustration shows a side elevation view of the connection assembly that connects to the module guide rail and torque tube;

[0030] Figure 4 It is supply Figure 1 A perspective view of the clip assembly used with the connecting assembly;

[0031] Figure 5 yes Figure 3 The clip assembly is shown as an elevation view of the clip in its first open position;

[0032] Figure 6 yes Figure 5 The image shown is an elevation view of the clip in its second closed position;

[0033] Figure 7 yes Figure 1 A perspective view of the connecting assembly, showing Figure 4 The clip assembly is in the first open position and Figure 1 The modular guide rails advance partially within the connecting assembly;

[0034] Figure 8 yes Figure 1 A side view of the connecting assembly, showing Figure 4 The clip assembly is in the first open position and Figure 1 The modular guide rails advance partially within the connecting assembly;

[0035] Figure 9 yes Figure 1 A perspective view of the connecting assembly, showing Figure 4 The clip assembly is in the second closed position and Figure 1 The module guide rail is connected to the connecting assembly;

[0036] Figure 10 yes Figure 1 A side view of the connecting assembly, showing Figure 3 The clamp assembly is in the second closed state and Figure 1 The module guide rail is connected to the connecting assembly;

[0037] Figure 11 This is a perspective view of another embodiment of the connecting assembly provided in this disclosure.

[0038] Figures 12 to 15 The illustration illustrates another embodiment of the coupling assembly provided in this disclosure, wherein one or more clip assemblies are integrated with a saddle assembly. Figure 12This is a perspective view of an integrated saddle and clamp assembly connected to the torque tube via an overlap strap assembly and disconnected from the modular guide rail. Figure 13 It is a perspective view of an integrated saddle and clamp assembly that is connected to the torque tube via an overlap strap assembly and to the module rail via one or more integrated clamp assemblies at the integrated saddle and clamp assembly. Figure 14 Yes, this is a side view of the integrated saddle and clamp assembly, which is located in... Figure 13 The section is shown as being connected to the torque tube via an overlap strip assembly and to the module rail via one or more integrated clamp assemblies at the integrated saddle and clamp assembly. Figure 15 This is a perspective view of the independent integrated saddle and clamp assembly. Detailed Implementation

[0039] This disclosure relates to a coupling assembly for use with a solar tracker. The coupling assembly described herein reduces the number of fasteners required to connect a solar module to a torque tube and reduces the labor required to install and / or adjust the solar module on the torque tube. The coupling assembly includes a saddle, a pair of clip assemblies slidably supported by the saddle, and an overlap strap assembly rotatably supported by the pair of clip assemblies. The saddle is configured to be selectively coupled to the torque tube of the solar tracker via the overlap strap assembly and is configured to be selectively coupled to a module rail, such as the FSLR series-7 (S7) photovoltaic solar module of the solar tracker, via the pair of clip assemblies 50, to enable mounting of the solar module on the torque tube. Although generally described as being used with S7 module rails, it is contemplated that the coupling assembly can be used with any suitable solar module rail, such as the FSLR series-6, etc.

[0040] The saddle defines a generally U-shaped profile that defines a channel for receiving the module rails. The lower surface of the saddle defines a pair of protrusions spaced apart from each other. In this way, the pair of protrusions defines a gap for receiving the torque tube of the solar tracker. The saddle defines a pair of slots passing through opposing side surfaces and adjacent to corresponding protrusions of the pair of protrusions. The pair of slots are oriented in a vertical direction (e.g., transverse to a longitudinal axis defined through opposing first and second end portions of the saddle). The pair of slots are configured to receive corresponding pins of the clip assembly.

[0041] The clip assembly includes clips and pins operably coupled to the clips. The clips define a generally U-shaped profile with a crown inserted between a pair of extendable legs. Although generally described as open, it is contemplated that the pair of legs may define any suitable arrangement, including a parallel arrangement, without departing from the scope of this disclosure. The crown defines an arcuate profile extending between the pair of extendable legs, but please consider that the crown may define any suitable profile, such as a straight crown, a curved crown, a combination thereof, etc. Each of the pair of extendable legs terminates at a hook that extends toward the crown within a gap formed between the pair of extendable legs. Each hook is configured to be received in a corresponding slot formed within a module guide rail and defines a channel for selectively receiving a portion of the module guide rail. In this way, when the clip assembly is transitioned from a first open position to a second closed position, the hook is received in the corresponding slot of the module guide rail and advances the module guide rail toward the saddle to selectively engage the module guide rail to the saddle.

[0042] Each of the extended legs defines an upward-flaring flange, which is configured to be received within a corresponding slot in the saddle when the clip assembly is placed in the second closed position. It is understood that the upward-flaring flange abuts or otherwise contacts the outer perimeter of the slot to inhibit movement of the module guide in the vertical or longitudinal direction. It is foreseeable that an external force can be applied to the upward-flaring flange to release it from the slot in the saddle and to allow adjustment or removal of the module guide relative to the saddle. Lugs are disposed on each of the extended legs extending away from the hook. The lugs are arranged in parallel and define holes for receiving pins of the clip assembly to slidably engage the clip assembly to the saddle. It is foreseeable that the clips of the clip assembly can be formed from a single piece of sheet material or the like, and that each of the hook, upward-flaring tab, and lug can be formed from a single piece of sheet material using any suitable method, such as stamping, forming, folding, or a combination thereof. As can be understood and foreseen, without departing from the scope of this disclosure, the clip can be formed from any suitable number of components and can be formed using any suitable method.

[0043] A pin defines a generally linear center portion extending between a pair of radial flanges. The outer dimensions of the pair of radial flanges are larger than the outer dimensions of the linear center portion and larger than the inner dimensions of the saddle slot. In this way, the linear center portion is configured to be received within the bore of the lug of the clip and within the saddle slot, and the pair of radial flanges inhibit the pin from being removed from the saddle.

[0044] The overlap band assembly comprises a pair of overlap bands, a T-bolt, a cylindrical member, and a nut. Each pair of overlap bands defines a generally "L"-shaped profile extending between a pair of eyelets. A first eyelet is configured to receive a pin to rotatably support the overlap band on the saddle. A second eyelet of the first overlap band is configured to receive a portion of the T-bolt, and a second eyelet of the second overlap band is configured to receive the cylindrical member, which in turn includes a hole to slidably receive a portion of the T-bolt. The pair of overlap bands cooperate to define a gap for receiving a torque tube. The overlap band assembly is configured to transition from a first open position, in which the torque tube moves freely relative to the saddle, to a second closed position, in which the torque tube is clamped or otherwise connected to the saddle, by rotating the nut in a first direction to pull the second eyelets of the overlap bands toward each other. It is understood that rotating the nut in the first direction causes the first eyelet of each overlap band to pull or otherwise actuate the pin of the clamp assembly toward the torque tube. Continued rotation of the nut in the first direction causes the hooks of the clamp assembly's legs to be received within the slots of the module guide rail, pulling the module guide rail toward the saddle until the upward-facing tab is received within the slots of the saddle. Further rotation of the nut in the first direction will clamp or inhibit movement of the module guide rail and torque tube relative to the saddle.

[0045] Predictably, the saddle may define slits adjacent to each end portion and extending across the opposite side surfaces. The slits allow the upper portion of each leg of the clamp assembly (including the flip-up tab) to open outwards and extend across the opposite side surfaces of the saddle. The slits provide surfaces on which the flip-up tab may abut and cause the leg to compress or otherwise change from a first open position to a second closed position. In various embodiments, instead of slits, the saddle may include a pair of recesses defined on the inner surface of the channel. The internal dimension extending between the pair of recesses is larger than the internal dimension of the remaining portion of the channel, such that the upper portion of each leg of the clamp assembly (including the flip-up tab) is allowed to open outwards and be received within the recess. The pair of recesses define bosses that abut or otherwise contact the flip-up tabs, causing the leg to compress or otherwise change from a first open position to a second closed position. As can be understood, the pair of recesses protect the clamp assembly or otherwise prevent external objects from contacting and damaging the clamp assembly. These and other aspects of this disclosure will be described in detail below with reference to the drawings.

[0046] Please refer to the diagram. Figures 1 to 3The diagram illustrates the connection assembly generally identified by reference numeral 10. Connection assembly 10 includes a saddle 12, a pair of clip assemblies 50, and an overlap strap assembly 82. As will be described in further detail below, the saddle 12 is configured to selectively connect to the torque tube 100 of a solar tracker (not shown) via the overlap strap assembly 82, and is configured to selectively connect to a module rail 110 via the pair of clip assemblies 50, such as the FSLR series-7 (S7) photovoltaic solar module (not shown) of the solar tracker, to enable mounting of the solar module onto the torque tube 100. Although generally described as configured for use with S7 modules, it is contemplated that connection assembly 10 can be configured for use with any suitable solar module, such as the FSLR series-6 module, etc.

[0047] Continue to refer to Figures 1 to 3 The saddle 12 defines a generally saddle-shaped configuration that defines a longitudinal axis AA extending between a first end portion 14 and an opposing second end portion 16. Predictably, depending on the design requirements of the coupling assembly 10, the saddle 12 may comprise any suitable length (e.g., a dimension extending along the longitudinal axis AA between the first end portion 14 and the second end portion 16). The saddle 12 includes a first side surface 18 extending between each of the first end portion 14 and the second end portion 16 and an opposing second side surface 20, and a lower surface 22 extending between the first end portion 14 and the second end portion 16 and each of the first side surface 18 and the second side surface 20. A pair of protrusions 24 are disposed on the lower surface 22, extending in a downward direction (e.g., in the same direction as facing the lower surface 22). The pair of protrusions 24 are spaced apart from each other along the longitudinal axis AA and define a gap 26 therebetween, the gap 26 being configured to receive a portion of the torque tube 100 therein. In this way, when connected to the connecting assembly 10, the torque tube 100 extends transversely to the longitudinal axis AA.

[0048] The saddle 12 includes an inner surface 28 that defines a cavity 30 therein and extends toward a lower surface 22. The cavity 30 includes an internal shape that is generally complementary to the profile of the lower surface 22. In this way, the inner surface 28 defines a generally flat surface 32 adjacent to each of the first end portion 14 and the second end portion 16, the generally flat surface 32 being configured to support or otherwise abut a portion of the module rail 110 of the solar module when the module rail 110 is seated within a portion of the cavity 30. Figure 9 and 10The saddle 12 includes a pair of cutouts or protrusions 34 defined by a first side surface 18 and a second side surface 20 adjacent to each of the first end portion 14 and the second end portion 16 of the saddle 12. The pair of cutouts 34 are configured to provide clearance for or allow the legs of the clamp assembly 50 to be placed in a first open position (e.g., protruding over or opening over each of the first side surface 18 and the second side surface 20). Figure 8 The upper portion of each of the first side surface 18 and the second side surface 20 defines a corresponding everted flange 36. The everted flange 36 extends transversely to the longitudinal axis AA and in a direction away from the first side surface 18 and the second side surface 20 (e.g., away from the cavity 30). Each of the everted flanges 36 defines a generally flat top surface 38, which is configured to abut or otherwise support the solar module when the module rail 110 of the solar module is coupled to the coupling assembly 10. In various embodiments, one or both of the everted flanges 36 may include a folded tab or lug 40 extending toward the lower surface 22 and spaced apart from the respective first side surface 18 and the second side surface 20. Although the illustrations generally depict the everted flange 36 extending to a portion of its length (e.g., along the longitudinal axis AA), it is contemplated that, without departing from the scope of this disclosure, one or both of the downward-facing tabs 40 may extend the everted flange 36 to any length, which may be different lengths, or may be positioned at different locations along the longitudinal axis AA. It will be understood that the downward-facing tabs 40 increase the stiffness of the saddle 12 or otherwise increase its bending resistance.

[0049] Continue to refer to Figures 1 to 3The saddle 12 includes a pair of slots 42 extending through both the first side surface 18 and the second side surface 20 and disposed adjacent to each of the pair of cutouts 34. Although generally illustrated as disposed over a pair of protrusions 24, please consider that the pair of slots 42 may be disposed at any location along the length of the pair of cutouts 34 (e.g., along the longitudinal axis AA). In a non-limiting embodiment, the pair of slots 42 are disposed 200 mm apart from each other. Each of the slots 42 extends in a direction transverse to the longitudinal axis AA (e.g., in a direction from the lower surface 22 toward the top surface 38 of the everted flange) and is configured to slidably retain a corresponding pin of a pair of pins 76 of the clip assembly 50. Although generally described as oriented in a direction perpendicular or transverse to the longitudinal axis AA, please consider that one or both of the slots 42 may extend in any suitable direction, such as diagonal, horizontal, etc., without departing from the scope of this disclosure. As can be understood and foreseen, without departing from the scope of this disclosure, the saddle 12 may include any number of slots 42 disposed through the first side surface 18 and the second side surface 20.

[0050] continue Figures 1 to 3 And refer to other sources. Figures 4 to 6 The clip assembly 50 includes a clip 52 and a pin 76 rotatably connected to the clip 52. The clip 52 is configured from a first open configuration ( Figure 5 ) to switch to the second closing or clamping configuration ( Figure 6 ), and defines a generally U-shaped profile with a crown 54 inserted between a pair of legs 56. When placed in the first open configuration ( Figure 5 As it extends between the first end portion 58 and the opposing second end portion 60, the crown 54 defines a generally arcuate profile. In this way, the central portion of the crown 54 defines a vertex 62, which, as will be understood, causes the crown 54 to act as a biasing element, as will be described in further detail below. The S7 PV module rail 110 consists of a sheet metal frame with multiple holes and slots. The mounting feature of the S7 module rail 110 is a snap-fit ​​or quick-lock engagement between the module rail 110 and the tracker rail without the use of any conventional or permanent fastening methods. Through slots 112 are provided at distances of 200 mm and 500 mm from the center portion of the module rail 110. It is foreseeable that, for mounting purposes, two slots 110 or all four slots 110 may be used per rail.

[0051] The first leg of a pair of legs 56 is attached to a first end portion 58 of the crown 54, and the second leg of the pair of legs 56 is attached to a second end portion 60 of the crown 54. In this way, the pair of legs 56 are arranged in a mirror configuration around the apex 62 of the crown 54. Each leg of the pair of legs 56 is substantially similar to each other, and therefore, for the sake of brevity, only one leg 56 will be described in detail herein. The leg 56 is attached to and extends from the first end portion 58 of the crown 54, terminating at a hook-shaped or J-shaped configuration 64. In this way, the hook 64 bends and extends rearward toward the crown 54, which defines a channel 66 for receiving a portion of the module guide rail 110, as will be described in further detail below. When the clamp 52 is placed in the first open position, the legs 56 open outward (e.g., away from the apex 62 of the crown 54) and define a generally orthogonal angle relative to the first end portion 58 of the crown 54, but it is conceivable that the legs 56 may define any suitable angle relative to the crown 54. It is understood that by opening outward, the hook portion 64 of each of the pairs of legs 56 is further away from each other than a portion of the adjacent crown 54 of each of the pairs of legs 56, which allows a portion of the module guide rail 110 to advance within the gap 68 defined between the pairs of legs 56. Figure 7 and 8 ).

[0052] The leg 56 defines a tab 70 extending horizontally in a direction toward the hook 64 and away from the apex 62 of the crown 54. The tab 70 is positioned on the leg 56 in a location where, in a first open position, the tab is located above a portion of the boss 34 of the saddle, and in various embodiments, the tab abuts said portion, and in a second closed or clamped position, the tab is received within a corresponding slot in a pair of slots 42 to lock or otherwise inhibit movement of the clamp assembly 50 relative to the saddle 12, as will be described in further detail below. The leg 56 includes a lug 72 extending from a first end portion 58 of the crown 54 in a direction away from the hook 64. When the clamp assembly 50 is in the first open position, the lug 72 is oriented vertically, wherein the corresponding lugs 72 of the pair of legs 56 are parallel to each other. Lug 72 includes a hole 74 defined therethrough for receiving a pin 76, which connects the clip 52 and the overlap strap assembly 82 to the saddle 12 via a corresponding slot in a pair of slots 42.

[0053] It is foreseeable that clip 52 can be formed from any suitable elastic material, such as metal, polymer, composite, etc. In a non-limiting embodiment, clip 52 is formed from an elastic sheet material, such as galvanized steel. Compared to clips formed from multiple materials joined together using fasteners, welding, adhesives, etc., clip 52 is formed from a single material that is processed or otherwise shaped to reduce the amount of material and processes required to form clip 52. As will be understood, clip 52 can be formed using any suitable number of components and by any suitable method without departing from the scope of the materials of this invention.

[0054] Pin 76 defines a generally barbell-shaped configuration having a linear center portion 78 inserted between a pair of flanges 80. The linear center portion 78 includes external dimensions configured to receive within corresponding slots in the bore 74 of the lug 72 and a pair of slots 42 of the saddle 12 to slidably support pin 76. Each of the pair of flanges 80 includes external dimensions larger than the external dimensions of the linear center portion 78 and larger than the internal dimensions of the slots 42 to hold pin 76 within the slot 42.

[0055] Refer again Figures 1 to 3 And refer to other sources. Figure 9 The overlap strip assembly 82 includes a pair of overlap strips 84, a T-bolt 86, a cylindrical member 88, and a nut 90. Each of the pair of overlap strips 84 is substantially similar to each other, and therefore, for the sake of brevity, only the overlap strip 84 will be described in detail herein. The overlap strip 84 defines the first end portion 92 ( Figure 3 The first end portion 92 and the opposite second end portion 94 extend in a generally "L"-shaped profile. Each of the first end portion 92 and the second end portion 94 defines an eye or ring 96 for receiving one of the pin 76 adjacent to the first end portion 92 and the T-bolt 86 or the cylindrical part 88 adjacent to the second end portion 94. Figure 3 and 4 As can be understood, a ring 96 adjacent to the first end portion 92 is rotatably supported on a pin 76 to allow a pair of overlapping straps 84 to rotate relative to the saddle 12, thereby accommodating the movement or insertion of the torque tube 14 between the pair of overlapping straps 84. In this way, the first end portion 92 of the overlapping strap 84 is received in the orifice 98 ( Figure 3Inside the saddle 12, a corresponding protrusion of one of a pair of protrusions 24 defines the orifice 98. A cylindrical tube 88 slidably receives a portion of a T-bolt 86 passing through it, and the T-bolt 86 threadedly engages a nut 90. In this way, rotation of the nut 90 in a first direction causes the second end portions 94 of each of a pair of overlapping straps 84 to pull toward each other to clamp or otherwise secure the torque tube 14 to the saddle 12. Rotation of the nut 90 in the opposite second direction allows the second end portions 94 of the pair of overlapping straps 84 to expand, or otherwise allow the torque tube 14 to move relative to the saddle 12. Although generally described using T-bolts 88 and nuts 90, it is contemplated that any suitable assembly capable of clamping or otherwise securing the torque tube 14 to the saddle 12 may be used without departing from the scope of this disclosure.

[0056] refer to Figures 7 to 10 During operation, both the clamp assembly 50 and the overlap strap assembly 82 are placed in the first open position. Figure 7 and 8 This causes the pair of legs 56 of the clamp 52 to open outwards. In this first position, the pair of tabs 70 of the clamp 52 are positioned above the boss 34 of the saddle. The module guide rail 110 advances toward the saddle 12 and is received within the gap 68 defined by the pair of legs 56 of the clamp 52 until a portion of the module guide rail 110 abuts the apex 62 of the top 54. Figure 8 Further advancement of the module guide rail 110 toward the saddle 12 will push the clamp assembly 50 toward the saddle 12 and cause a pair of tabs 70 to abut the inner surface 28 of the saddle 12, thereby causing the hook 64 to be received in a corresponding slot 112 formed in the module guide rail 110. Further advancement of the module guide rail 110 toward the saddle 12 causes the tabs 70 to be received in corresponding slots in a pair of slots 42 of the saddle 12 to lock the module guide rail 110 to the saddle 12. Figure 9 and 10As can be understood, portions of the modular guide rail 110 are received within corresponding channels 66 of a pair of legs 56 to engage or otherwise secure the support rail to the saddle. In this way, the hooks 64 of the clamp assembly 50 cooperate with the tabs 70 to inhibit vertical or torsional movement of the modular guide rail 110 relative to the saddle 12. As the modular guide rail 110 is engaged to the saddle 12, the nut 90 of the overlap strap assembly 82 rotates in a first direction such that a pair of overlap straps 84 pull toward each other. Continued rotation of the nut 90 in the first direction causes the pair of overlap straps 84 to compress or otherwise clamp the torque tube 14, and causes the pair of overlap straps 84 to pull a pair of pins 76, and thus pull the clamp assembly 50 toward the torque tube 14 to further secure the modular guide rail 110 to the saddle 12, while also securing the torque tube 14 to the saddle 12 and inhibiting movement of both the modular guide rail 110 and the torque tube 14 relative to the saddle 12. Predictably, without requiring external force on the modular guide rail 110, once the modular guide rail 110 is received within the gap 68 formed between a pair of legs 56 of the clamp assembly 50, the nut 90 of the overlapping strap assembly 82 can rotate in the first direction, causing the pair of legs 84 to pull the pair of pins 76, and thus the clamp 52, toward the saddle 12. It is understood that continued rotation of the nut 90 in the first direction causes the modular guide rail 110 and the torque tube 14 to be simultaneously secured to the saddle 12.

[0057] Although generally described as initially placed in a first open position, it is foreseeable that the clamp assembly 50 can initially be placed in a second closed position. In this way, as the modular guide rail 110 advances toward the saddle 12, portions of the modular guide rail 110 abut or otherwise contact the hooks 64 of a pair of legs 56 of the clamp assembly 50. Further advance of the modular guide rail 110 toward the saddle 12 causes the pair of legs 56 to open outwards, allowing the modular guide rail 110 to be received within the gap 68 formed between the pair of legs 56. At this point, the modular guide rail 110 and the torque tube 14 can be secured to the saddle 12 following the procedure described above.

[0058] It is foreseeable that external force can be used to compress the tabs 70 so that the support rail can be removed from the saddle 12. In this way, external force is applied to each of the tabs 70 (incrementally or sequentially) to disengage the tab 70 from the slot 42 while advancing the module rail 110 in a direction away from the saddle 12. As the tabs 70 are pressed down and thus disengaged from the slot 42, the clamp assembly 50 and the module rail 110 are allowed to be pushed away from the saddle 12 and the module rail 110 is released from the clamp assembly 50. It is foreseeable that this process can be used to completely remove the module rail 110 or to allow adjustment of the position of the module rail 110 relative to the saddle 12.

[0059] Go to Figure 11Another embodiment of the coupling assembly is illustrated and is generally identified by reference numeral 200. Coupling assembly 200 is substantially the same as coupling assembly 10, and therefore, for the sake of brevity, only the differences between them are described in detail herein. The saddle 212 of coupling assembly 200 does not include a pair of cutouts 34, but instead includes a first side surface 218 and a second side surface 220 extending to the first end portion 214 and the second end portion 216. A first pair of recesses 260 are formed adjacent to the first end portion 214, and a second pair of recesses 270 are formed adjacent to the second end portion 216. The first pair of recesses 260 and the second pair of recesses 270 are substantially similar to each other, and therefore, for the sake of brevity, only the first pair of recesses 260 are described in detail herein.

[0060] The first pair of recesses 260 define generally U-shaped recesses formed within the inner surface 228 and extending apart from each other, such that the distance between each recess in the first pair of recesses 260 is greater than the dimension between the inner surfaces of each of the adjacent first side surface 218 and second side surface 220. Each recess in the first pair of recesses 260 extends through the upper surface 238 and toward the protrusion 224, terminating at a boss 262 where the recesses in the first pair of recesses 260 transition to the inner surface 228. As can be understood, the first pair of recesses 260 provides clearance for a pair of legs 56 of the clip assembly 50 to be placed in a first open or spread position. The boss 262 provides a surface abutting the tabs 70 of the clip assembly 50 to initially hold the clip assembly 50 in the first open position. The coupling assembly 200 operates in a substantially similar manner to the coupling assembly 10, and therefore, for the sake of brevity, the operation of the coupling assembly 200 will not be described in detail herein.

[0061] Figures 12 to 15 The illustration illustrates another embodiment of the coupling assembly 300 provided in this disclosure. The coupling assembly 300 may be similar to or the same as the coupling assembly 10 disclosed elsewhere herein, unless otherwise disclosed herein. Specifically, the coupling assembly 300 includes one or more clip assemblies 350 integrated with the saddle assembly 312. Figure 12 This is a perspective view of the integrated saddle and clamp assembly 312, which is connected to the torque tube 100 and disconnected from the module guide rail 110 via the overlap strap assembly 82. Figure 13 It is a perspective view of the integrated saddle and clamp assembly 312, which is connected to the torque tube 100 via the overlap strap assembly 82 and to the module guide rail 110 via one or more integrated clamp assemblies 350 at the integrated saddle and clamp assembly 312. Figure 14 yes Figure 13The side view of the integrated saddle and clamp assembly 312 shown here, which is connected to the torque tube 100 via the overlap strap assembly 82 and to the module guide rail 110 via one or more integral clamp assemblies 350 at the integrated saddle and clamp assembly 312. Figure 15 This is a perspective view of the independent integrated saddle and clamp assembly 312.

[0062] The connecting assembly 300 may include an integrated saddle and clamp assembly 312 and an overlap strap assembly 82. One or more clamp assemblies 350 may be integrally formed with the body of the saddle assembly to form a single-workpiece integrated saddle and clamp assembly 312 (e.g., such that one or more clamp assemblies 350 integrally formed with the body of the saddle assembly are movable relative to the saddle portion of the integrated saddle and clamp assembly 312). The overlap strap assembly 82 may be coupled to the integrated saddle and clamp assembly 312. For example, as illustrated in the embodiment of the integrated saddle and clip assembly 312, the overlap strap assembly 82 can be connected to a pair of clip assemblies 350 portions of the integrated saddle and clip assembly 312 (e.g., as illustrated, such that the overlap strap assembly 82 has one end of the overlap strap 84 connected to a first clip assembly 350a at the integrated saddle and clip assembly 312, and the opposite end of the overlap strap 84 connected to a second clip assembly 350b at the integrated saddle and clip assembly 312). Further details will be provided elsewhere herein. The saddle portion of the integrated saddle and clip assembly 312 can be configured to be selectively coupled to the torque tube 100 of the solar tracker (not shown) via the overlap strap assembly 82, and one or more clip assemblies 350 (e.g., a pair of clip assemblies 350) portions of the integrated saddle and clip assembly 312 can be configured to be selectively coupled to the module rail 110, such as the FSLR series-7 (S7) of the photovoltaic solar module (not shown) of the solar tracker, so that the solar module can be mounted on the torque tube 100 (e.g., via coupling one or more solar modules to the module rail 110).

[0063] exist Figure 15The main body of the saddle portion of the integrated saddle and clip assembly 312 can be seen. The saddle portion of the integrated saddle and clip assembly 312 may include an inner surface 28 that defines a cavity 30 therein and extends toward the lower surface 22. The cavity 30 may have an internal shape that is generally complementary to the profile of the lower surface 22. In this way, the inner surface 28 may define a generally flat surface 32 adjacent to each of the first end portion 14 and the second end portion 16, said generally flat surface 32 being configured to support or otherwise abut a portion of the module rail 110 of the solar module when the module rail 110 is seated within a portion of the cavity 30. The saddle portion of the integrated saddle and clip assembly 312 may include a pair of cutouts or protrusions 34 defined through a first side surface 18 and a second side surface 20 adjacent to each of the first end portion 14 and the second end portion 16. The pair of cutouts 34 may be located adjacent to the position of a pair of clip assemblies 350 on the body of the integrated saddle and clip assembly 312. The pair of cutouts 34 may be configured to provide relative movement functionality of the pair of clip assemblies 350 relative to the saddle portion. For example, the cutouts 34 may be configured to allow the clip assemblies to bend or rotate relative to the flat surface 32 of the saddle portion.

[0064] The integrated saddle and clip assembly 312 may include one or more pairs of slots 42 extending through both the first side surface 18 and the second side surface 20. A pair of slots 42 may be defined at each of a pair of clip assemblies 350, and the pair of slots 42 may be positioned adjacent to each of a pair of cutouts 34. In a non-limiting embodiment, the pair of slots 42 are positioned 200 mm apart from each other in a direction along the longitudinal axis of the integrated saddle and clip assembly 312 (e.g., spaced 200 mm apart along the longitudinal length across the side surfaces 18 or 20). Each of the pair of slots 42 can be configured to slidably hold a corresponding pin of the clip assembly 50 such that the pin can extend through one slot 42 on one side of the clip assembly 350, through the overlap band 84 located between opposite sides of the clip assembly 350, and into the other slot 42 located on the opposite side of the clip assembly 350, such that the pin can be used to engage the overlap band 84 to the clip assembly 350. As will be understood, it is foreseeable that, without departing from the scope of this disclosure, the saddle may include any number of slots 42 disposed through the first side surface 18 and the second side surface 20.

[0065] The clip assembly 350 may include a pin (e.g., pin 76 as shown elsewhere herein) and a clip 352. The clip 352 may be configured from a first open configuration (e.g., Figure 12 ) to switch to a second closing or clamping configuration (e.g., Figure 13 , 14The crown 354, which is inserted between a pair of legs 356, can be defined in a generally U-shaped profile. When placed in a first open configuration, the crown 354 can define a generally arcuate profile as it extends between the first end portion and the opposite second end portion. In this way, the central portion of the crown 354 can define a vertex 62, which, when present, can cause the crown 354 to act as a biasing element. Each clip 352 may include, for example, an overlapping band slot 353 located between a pair of legs 356 (e.g., at the crown 354 between a pair of legs 356). The mounting features of the S7 module rail 110 can be a snap-fit ​​or quick-fit between the module rail 110 and the tracker rail without using any conventional or permanent fastening methods.

[0066] A first leg of a pair of legs 356 may be coupled to a first end portion of the crown 354, and a second leg of the pair of legs 356 may be coupled to an opposite second end portion of the crown 354. In this way, the pair of legs 356 may be arranged in a mirror configuration around the crown 354. Each leg 356 may extend outward from the crown 354 and terminate at a hook-shaped or J-shaped structure 364. In this way, the hook 364 may bend and extend rearward toward the crown 354 to define a channel 66 for receiving a portion of the module guide 110, as disclosed elsewhere herein. When the clip 352 is placed in a first open position, the legs 356 may open outward (e.g., away from the crown 354). As can be understood, by opening outwards, the hook portion 364 of each of the pair of legs 356 can be further away from each other than the portion of the adjacent crown portion 54 of each of the pair of legs 356, which allows a portion of the module guide rail 110 to advance between the gaps defined between the pair of legs 356.

[0067] Clip 352 may be formed from any suitable elastic material, such as metal, polymer, composite, etc. In a non-limiting embodiment, clip 52 is formed from the same material as the saddle assembly of the integrated saddle and clip assembly 312, such that the saddle portion and clip 352 portion of the integrated saddle and clip assembly 312 are formed as a single piece of material. For example, overlap strap assembly 82 may be similar to or identical to overlap strap assembly 82 disclosed elsewhere herein, such that overlap strap assembly 82 may include overlap strap 84. For example, here, the overlap band 84 may be a single overlap band assembly 84 configured to extend from one side of the integrated saddle and clip assembly 312 (e.g., from an overlap band slot 353 at a clip assembly 352a at one end portion of the integrated saddle and clip assembly 312), around the torque tube 100, and to the other side of the integrated saddle and clip assembly 312 (e.g., to an overlap band slot 353 at another clip assembly 352b at the opposite end portion of the integrated saddle and clip assembly 312).

[0068] For example, during operation, one or more clip assemblies 350 and overlap strap assemblies 82 can be placed in a first open position (e.g., Figure 12 This arrangement causes the pair of legs 356 of the clip 352 to be in a first orientation relative to the flat surface 32 at the saddle portion of the integrated saddle and clip assembly 312 (e.g., the pair of legs are outwardly spread and / or oriented at a first tilt angle relative to the flat surface 32). The modular guide rail 110 can advance toward the saddle portion (e.g., toward the flat surface 32) and is received within the gap defined between the pair of legs 356 of the clip 352 until a portion of the modular guide rail 110 abuts the crown 354. Continued advance of the modular guide rail 110 toward the saddle portion can be used to advance the clip assembly 350 toward the saddle portion (e.g., toward the flat surface 32) and cause the hook 364 to be received within a corresponding slot 112 formed in the modular guide rail 110. As may be understood, portions of the modular guide rail 110 can be received within corresponding channels of a pair of legs 356 to engage or otherwise secure the support rail to the saddle portion of the integrated saddle and clamp assembly 312. In this way, the hooks 364 of the clamp assembly 350 can cooperate to inhibit vertical or torsional movement of the modular guide rail 110 relative to the saddle portion of the integrated saddle and clamp assembly 312. As the modular guide rail 110 is engaged to the saddle portion, the overlap strap assembly 82 can be actuated to secure the overlap strap assembly 82 around the torque tube 100, thereby further securing the modular guide rail 110 to the saddle portion of the integrated saddle and clamp assembly 312, while also securing the torque tube 100 to the integrated saddle and clamp assembly 312, and helping to inhibit movement of both the modular guide rail 110 and the torque tube 100 relative to the saddle portion of the integrated saddle and clamp assembly 312 (e.g., relative to the flat surface 32).

[0069] Although several embodiments of the present disclosure have been shown in the views, this is not intended to limit the disclosure thereto, as the disclosure is intended to be as broad as possible within the scope permitted by the said field, and the specification should be understood in the same manner. Therefore, the above description should not be construed as limiting, but merely as examples of particular embodiments.

Claims

1. A connection system for use with a solar tracker, comprising: A saddle, defined by a U-shaped profile extending between a first end portion and an opposing second end portion, the saddle defining a channel having an open upper portion and extending through each of the first and second end portions, the channel being configured to selectively receive module rails for solar modules, wherein slots are defined through a first side surface adjacent to the first end portion and a second side surface; and A clip assembly slidably supported within the channel of the saddle, the clip assembly comprising a clip having a generally U-shaped profile defining a crown inserted between a pair of legs, each of the pair of legs extending from the crown and terminating at a corresponding hook, wherein an upturned tab is disposed on each of the pair of legs, wherein the clip assembly is configured to transition from a first open position to a second closed position, in which the upturned tab of each of the pair of legs is received within the slot of the saddle, and the hook of each of the pair of legs is received within a corresponding slot formed in the module guide to selectively engage the module guide to the saddle.

2. The coupling system of claim 1, wherein the crown of the clamp assembly defines an arcuate profile that extends to a apex in the gap formed between the pair of legs.

3. The coupling system of claim 1, wherein each hook of the pair of legs defines a channel configured to receive a portion of the module rail, wherein when the clamp assembly is placed in the second closed position, the channel advances the module rail toward the saddle and inhibits movement of the module rail relative to the saddle.

4. The coupling system of claim 1, wherein the saddle includes a cutout defined through the first side surface and the second side surface of the saddle and adjacent to the first end portion, the cutout extending in a direction transverse to a longitudinal axis defined through the first end portion and the second end portion and through the upper surface of the saddle, wherein the cutout allows the upper portions of the pair of legs of the clamp to open outward and extend over the respective first side surface and the second side surface of the saddle.

5. The coupling system of claim 4, wherein the cutout of the saddle extends a distance away from the upper surface, thereby allowing the tabs of each corresponding leg of the pair of legs of the clamp to extend over the corresponding first end surface and second end surface of the saddle.

6. The coupling system of claim 1, wherein the clip assembly further includes a pin operably coupled to the clip and slidably supported within the slot of the saddle, the pin defining a pair of opposing flanges that inhibit movement of the pin in a direction transverse to a longitudinal axis defined through the first end portion and the second end portion of the saddle.

7. The coupling system of claim 6, wherein the clip defines a pair of lugs extending from each of the pair of legs in a direction away from the hook, each of the pair of lugs defining a hole for receiving the pin.

8. The connection system of claim 1, wherein when in the first open position, each of the pair of legs is opened in an outward direction, wherein the distance between the upper portions of each of the pair of legs is greater than the length of the crown.

9. The connection system of claim 1, wherein when in the first open position, the first leg of the pair of legs is parallel to the second leg of the pair of legs.

10. A clip for use with a coupling assembly of a solar tracker, comprising: The crown is defined by an arched profile extending between the first end portion and the opposite second end portion; A pair of extendable legs defining a gap for receiving a module rail for a solar module, a first leg of the pair of extendable legs being disposed on a first end portion and a second leg of the pair of extendable legs being disposed on a second end portion, each leg of the pair of extendable legs extending from the crown and terminating at a hook extending into the gap, wherein each leg of the pair of extendable legs defines an upwardly flared tab extending away from the gap and toward the hook. and A pair of lugs, wherein a first lug is disposed on a first leg of the pair of extended legs, and a second lug is disposed on a second leg of the pair of extended legs, wherein the first lug is parallel to the second lug.

11. The clip of claim 10, wherein each hook of the pair of extended legs defines a channel for receiving a portion of a module rail for a solar module.

12. The clip of claim 10, wherein each of the pair of lugs defines a hole for receiving a pin.

13. The clip of claim 10, wherein the clip comprises a single piece of material, wherein the crown, the pair of openable legs, the pair of lugs and the upturned tab are integral with the single piece of material.

14. The clip of claim 10, wherein the clip is formed of an elastic material.

15. A connection system for use with a solar tracker, comprising: A saddle, defined by a U-shaped profile extending between a first end portion and an opposing second end portion, the inner surface of the saddle defining a channel having an open upper portion and extending through each of the first and second end portions, wherein the inner surface of the saddle defines a pair of recesses, wherein an internal dimension extending between the pair of recesses is greater than the internal dimension of the remaining portion of the channel; and A clip assembly slidably supported within the channel of the saddle, the clip assembly comprising clips having a generally U-shaped profile defining a crown inserted between a pair of legs, wherein a portion of each of the pair of legs is selectively received within a corresponding recess in a pair of recesses, each of the pair of legs comprising an upward-folding tab, wherein the clip assembly is configured to transition from a first open position to a second closed position, in the first open position, each upward-folding tab being received within a corresponding recess in the pair of recesses, and in the second closed position, each upward-folding tab being located within the remaining portion of the channel, the internal dimensions of the remaining portion being smaller than the internal dimensions extending between the pair of recesses.

16. The coupling system of claim 15, wherein the saddle includes a slot formed through a first side surface and a second side surface, the slot being configured to selectively receive the upturned tabs of the pair of legs when the clamp assembly is placed in the second closed position.

17. The coupling assembly of claim 15, wherein each of the pair of legs of the clamp assembly terminates at a hook extending into a gap formed between the pair of legs.

18. The coupling assembly of claim 17, wherein each hook of the pair of legs defines a channel for receiving a portion of a module rail for a solar module.

19. The connecting assembly of claim 15, wherein the crown defines an arcuate profile extending between the pair of legs.

20. The connecting assembly of claim 15, wherein the pair of legs are spread out in a direction extending from the crown.

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