Cable routing systems

Abstract

A device for cable routing may include a second leg connected to the first leg at an angle to form a center bend. A device may include a securement leg extending from the first leg, wherein the securement leg includes a deformable portion. A device may include a saddle leg extending from the second leg, wherein the saddle leg forms a saddle configured to support a cable; and an end portion positioned on the saddle leg, the end portion configured to selectively connect to the saddle leg, encapsulating a cable within the saddle.

Description

CABLE ROUTING SYSTEMSCROSS-REFERENCE

[0001] The present application claims priority under 35 U.S.C. § 119(e) to U.S. Application No. 63 / 552,478, filed on February 12, 2024, and entitled “CABLE ROUTING SYSTEMS,’' which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] The present application generally relates to systems and methods for routing and securing cables found on utility -scale solar generation plants.BACKGROUND

[0003] Energy production and transmission infrastructures, such as photovoltaic (PV) solar energy production, utilize a variety of cable types to convey electrical current and / or signal data from source facilities to consumer locations. In large-scale solar power plants, cables (e.g., solar panel lead wires and string harness cables) transmit electrical current and signal data from solar panels to other production and / or transmission equipment within the plant. These cables are typically supported and arranged above ground, either directly on the solar panel framing or on the steel structure securing the solar panels.

[0004] In many installations, solar panels are mounted on single-axis solar trackers, which rotate the panels from east to w est throughout the day to optimize energy' capture. The dynamic motion of these trackers presents challenges for cable management, as cables must accommodate continuous movement without experiencing pinching, abrasion, or excessive mechanical stress. Improper routing can lead to insulation wear, electrical faults, and safety hazards such as electrical shock or fire risks.

[0005] Moreover, the compatibility of cable routing solutions with specific tracker types and module configurations is a critical design consideration. Different tracker architectures have varying degrees of tilt, rotation angles, and structural constraints that influence how cables can be safely routed. Additionally, the use of bifacial modules introduces another layer of complexity7, as improperly routed cables can create unwanted shading on the backside of the panels, reducing energy yield.

[0006] Accordingly, improved wire positioning devices and engineering routing techniques are needed to ensure cable longevity7, electrical safety7, and optimized energy7production. These improved solutions need to accommodate tracker movement while preventing mechanical strain on cables and minimizing shading impacts, particularly in bifacial module applications.SUMMARY

[0007] In some aspects, the techniques described herein relate to a wire positioning device for cable routing, including: a first leg; a second leg connected to the first leg at an angle to form a center bend; a securement leg extending from the first leg, wherein the securement leg includes a deformable portion; a saddle leg extending from the second leg, wherein the saddle leg forms a saddle configured to support a cable; and an end portion positioned on the saddle leg, the end portion configured to selectively connect to the saddle leg, encapsulating a cable within the saddle.

[0008] In some aspects, the techniques described herein relate to a wire positioning device, wherein the end portion is a hook configured to partially wrap around a portion of the saddle leg.

[0009] In some aspects, the techniques described herein relate to a wire positioning device, wherein the first leg, second leg, and center bend form a triangular gap underneath the first leg and the second leg.

[0010] In some aspects, the techniques described herein relate to a wire positioning device, wherein the triangular gap corresponds to a detent positioned on a support structure that the wire positioning device is supported on.

[0011] In some aspects, the techniques described herein relate to a wire positioning device, wherein an extension leg extends between the first leg and the securement leg.

[0012] In some aspects, the techniques described herein relate to a wire positioning device, wherein an extension leg extends between the second leg and the saddle leg.

[0013] In some aspects, the techniques described herein relate to a wire positioning device, wherein the first leg, second leg, securement leg, and a portion of the saddle leg are positioned within a singular plane.

[0014] In some aspects, the techniques described herein relate to a wire positioning device, wherein the securement leg is configured to pass through an aperture of a support structure that the wire positioning device is supported on

[0015] In some aspects, the techniques described herein relate to a cable routing system, including: a support structure; a torque tube moveably positioned on the support structure; a bracket positioned on the torque tube, the bracket including a detent and an aperture; a first wire positioning device positioned on the bracket above the torque tube, the first wire positioning device including: a center bend formed from a first leg and a second leg, the center bend configured to the abut the detent of the bracket; a securement leg extending from the first leg, wherein the securement leg includes a deformable portion configured to pass through the aperture of the bracket; and a saddle leg extending from the second leg. wherein the saddle leg forms a saddle configured to support a first cable; and a second wire positioning device positioned on the bracket below the torque tube, the second wire positioning device including: a center leg; a first suspension leg positioned on a first side of the center leg, the first suspension legincluding a first end portion; a second suspension leg positioned on a second side of the center leg, opposite the first side, the second suspension leg including a second end portion; a cable saddle configured to support a second cable, the cable saddle formed from the center leg, the first suspension leg, and the second suspension leg; wherein the second wire positioning device connects to the bracket via the first end portion and the second end portion.

[0016] In some aspects, the techniques described herein relate to a cable routing system, wherein a third end portion is positioned on the saddle leg of the first wire positioning device, the third end portion configured to selectively connect to the saddle leg, encapsulating the first cable within the saddle.

[0017] In some aspects, the techniques described herein relate to a cable routing system, wherein the third end portion is a hook configured to partially wrap around a portion of the saddle leg.

[0018] In some aspects, the techniques described herein relate to a cable routing system, wherein a bolt is connected to the bracket underneath the torque tube, and the first end portion and the second end portion connect to the bracket via the bolt.

[0019] In some aspects, the techniques described herein relate to a cable routing system, wherein the first end portion and the second end portion are hooks configured to partially wrap around the bolt.

[0020] In some aspects, the techniques described herein relate to a cable routing system, wherein the second wire positioning device and the bolt encapsulate the second cable.

[0021] In some aspects, the techniques described herein relate to a cable routing system, wherein the first wire positioning device is vertically aligned with the second wire positioning device.

[0022] In some aspects, the techniques described herein relate to a cable routing system, wherein the first leg, second leg, securement leg, and a portion of the saddle leg of the first wire positioning device are positioned within a singular plane.

[0023] In some aspects, the techniques described herein relate to a cable routing system, wherein the deformable portion of the securement leg is deformed subsequent to passing through the aperture of the bracket to secure the first wire positioning device to the bracket.

[0024] In some aspects, the techniques described herein relate to a cable routing system, wherein the deformable portion of the securement leg is deformed along a plane aligned with the first leg, second leg, and a portion of the saddle leg.

[0025] In some aspects, the techniques described herein relate to a cable routing system, wherein the detent of the bracket is triangular-shaped.

[0026] In some aspects, the techniques described herein relate to a cable routing system, wherein the center bend, the first leg, and the second leg form a triangular gap corresponding to the detent.

[0027] In some aspects, the techniques described herein relate to a cable routing system, including: a support structure; a bearing positioned on the support structure; a torque tube positioned within the bearing and configured to rotate relative to the support structure, the torque tube extending axially outward from the support structure; a first bracket positioned on the torque tube and configured to support a first solar panel thereon; a first wire positioning device positioned on the first bracket and radially offset from the torque tube and the bearing, the first wire positioning device configured to support a cable within a first saddle of the first wire positioning device such that the cable is radially offset from the support structure, bearing, and torque tube when positioned within the first saddle; a second bracket positioned on the torque tube andaxially offset from the first bracket, the second bracket configured to support a second solar panel thereon; and a second wire positioning device positioned on the second bracket below the torque tube, the second w ire positioning device configured to support the cable w ithin a second saddle of the second w ire positioning device such that the cable is below the torque tube when positioned within the second saddle.

[0028] In some aspects, the techniques described herein relate to a cable routing system, wherein the first wire positioning device is positioned between the bearing and the second wire positioning device.

[0029] In some aspects, the techniques described herein relate to a cable routing system, wherein the cable is spaced from the bearing during rotation of the torque tube relative to the support structure.

[0030] In some aspects, the techniques described herein relate to a cable routing system, wherein the first wire positioning device is positioned vertically above the second ware positioning device.

[0031] In some aspects, the techniques described herein relate to a cable routing system, further including a third ware positioning device positioned on a third bracket and radially offset from the torque tube and the bearing, the third wire positioning device configured to support the cable within a third saddle of the third wire positioning device such that the cable is radially offset from the support structure, bearing, and torque tube wiien positioned within the third saddle.

[0032] In some aspects, the techniques described herein relate to a cable routing system, wherein the first wire positioning device is positioned on a first side of the support structure, and the third wire positioning device is positioned on a second side of the support structure, opposite the first side.

[0033] In some aspects, the techniques described herein relate to a cable routing system, further including a fourth w ire positioning device positioned on a fourth bracket below' the torque tube, the fourth wire positioning device configured to support the cable within a fourth saddle of the second w ire positioning device such that the cable is below' the torque tube when positioned w ithin the fourth saddle.

[0034] In some aspects, the techniques described herein relate to a cable routing system, w herein the fourth w ire positioning device is positioned axially outw ard of the third wire positioning device and the support structure. 29.

[0035] The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below'. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.DESCRIPTION OF DRAWINGS

[0036] These and other features will be more readily understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0037] FIG. l is a perspective view of an exemplary aspect of a wire positioning device for cable routing;

[0038] FIG. 2 is a side view of the wire positioning device of FIG. 1;

[0039] FIG. 3 is a side view of the wire positioning device of FIG. 1 with cables inserted therein;

[0040] FIG. 4 is a front perspective view of a bracket assembly including the wire positioning device of FIG. 1;

[0041] FIG. 5 is a top perspective view of the bracket assembly of FIG. 4;

[0042] FIG. 6 is a front perspective view of the bracket assembly of FIG. 4;

[0043] FIG. 7 is a perspective view of a solar assembly including the wire positioning device of FIG. 1;

[0044] FIG. 8 is a detailed perspective view of the solar assembly of FIG. 7;

[0045] FIG. 9 is a perspective view of an exemplary7aspect of a wire positioning device for cable routing;

[0046] FIG. 10 is a side view of the wire positioning device of FIG. 9;

[0047] FIG. 11 is a perspective view of a bracket assembly including the wire positioning device of FIG. 9;

[0048] FIG. 12 is a perspective view of the bracket assembly of FIG. 11;

[0049] FIG. 13 is a perspective view7of a solar assembly including the wire positioning devices of FIG. 1 and FIG. 9;

[0050] FIG. 14 is a detailed perspective view of the solar assembly of FIG. 12;

[0051] FIG. 15 is a perspective view7of a solar assembly7including the wire positioning devices of FIG. 1 and FIG. 9;

[0052] FIG. 16A is a perspective view of an exemplary aspect of a wire positioning device for cable routing;

[0053] FIG. 16B is a side view7of the wire positioning device of FIG. 16A;

[0054] FIG. 16C is a front view of the wire positioning device of FIG. 16 A;

[0055] FIG. 17 is a perspective view of a solar assembly including the wire positioning device of FIG. 16A;

[0056] FIG. 18 is a detailed perspective view of the solar assembly of FIG. 17;

[0057] FIG. 19 is a perspective view of an exemplary- aspect of a wire positioning device for cable routing;

[0058] FIG. 20 is a perspective view of a solar assembly including the wire positioning device of FIG. 19;

[0059] FIG. 21 is a detailed perspective view of the solar assembly of FIG. 19;

[0060] FIG. 22 is a perspective view of an exemplary aspect of a wire positioning device for cable routing;

[0061] FIG. 23 is a perspective view of a solar assembly including the wire positioning device of FIG. 22;

[0062] FIG. 24 is a detailed perspective view of the solar assembly of FIG. 22;

[0063] FIG. 25 is a perspective view of an exemplary aspect of a wire positioning device for cable routing;

[0064] FIG. 26 is a perspective view of an exemplary aspect of a wire positioning device for cable routing;

[0065] FIG. 27 is a perspective view of a solar assembly including the wire positioning device of FIG. 26;

[0066] FIG. 28 is a perspective view of a solar assembly including the wire positioning device of FIG. 26;

[0067] FIG. 29 is a perspective view of a solar assembly including the wire positioning device of FIG. 26;

[0068] FIG. 30 is a perspective view of an exemplary aspect of a wire positioning device for cable routing;

[0069] FIG. 31 is a perspective view of a solar assembly including the wire positioning device of FIG. 30;

[0070] FIG. 32 is a perspective view of a solar assembly of FIG. 31;

[0071] FIG. 33 is a perspective view of a solar assembly of FIG. 31; and

[0072] FIG. 34 is a perspective view of a cable routing system and solar panel assembly.

[0073] It is noted that the drawings are not necessarily to scale. The drawings are intended to depict only typical aspects of the subject matter disclosed herein, and therefore should not be considered as limiting the scope of the disclosure.DETAILED DESCRIPTION

[0074] Certain exemplary embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the devices and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention.

[0075] Solar panel cabling and harness string cabling, such as those used in utility scale solar power generation and transmission systems, can be deployed and managed using a wire positioning device. Typically, these cables are not buried underground as the solar panels are installed at least three feet above the ground, so to route the cabling from the solar panel to an underground trench is costly and time consuming for the installer. In addition, the wires typically require a larger diameter when installed below ground. The wire positioning devices described herein can support the cables, such as harness cables, in an organized and serviceable manner. When these cables are secured with zip ties or cables ties, the cables are not secured in an organized and serviceable manner.

[0076] A wire positioning device can couple to a structure or to a frame. When these cables are directly secured to the structure, there is risk that the cables chafe, abrade, and pinch on the moving and rotating components of the structure, the primary component that could pinch the cabling would be the Solar Tracker Bearing and Torque Tube (a single-axis Tracker has a component call the Torque Tube in which the Solar Panels attach to, this Torque Tube rests on top of bearings which can rotate, if cabling is secured close to the Torque Tube and near the bearing, cabling can get caught between these components as the Torque Tube rotates). In addition, other components such as Actuators and Dampers can also be potential pinch points for cabling. There are numerous Thin Sheet Steel components in which the cable could abrade on such as: Pile, Bearing Housing, Solar Panel Mounting Rail, Actuator Mounting Brackets, Slew Drive Motor Mounting Brackets, Damper Mounting Brackets, Controller Mounting Brackets. As described above, panels can rotate, creating a potential electrical shock safety hazard and can also lead to energy production issues. As shown in Figure 6, when the wire position device is coupled to the Frame, the cable is supported at a safe distance away from the moving and rotating components of a structure.

[0077] Over the life of utility-scale solar power plants, solar panels, trackers, and cabling occasionally need servicing and may be temporary un-installed or removed. With wire positioning devices that lock close, such as zip ties and cables ties, the wire positioning device must be cut down and destroyed before the cabling can be removed from the device. The open-saddle of the wire-position device allows for maintenance and removal of the cable without the need to cut-down or destroy the wire position device. Furthermore, due to the open latching hook of the device, the device can be removed from the solar panel without the need to cut down or destroy the wire positioning device.

[0078] Utility-scale solar power plants are typically located in environmental conditions of extreme heat or extreme cold. Some wire positioning devices, such as plastic zip ties or cables ties, or vinyl-coated products, will degrade in a UV environment, and will become brittle in extreme cold environments. Some implementations of the wire positioning device described herein be made from ultraviolet (UV) and cold-environment resistance material, such as aluminum, galvanized steel, stainless steel, and copper. The device can also be made from UV- resistance and brittle-resistance thermoplastic materials.

[0079] For wire positioning devices such as zip ties or cables ties, these devices cannot support cables until the device is locked into position. In other words, the cabling and the device must be installed at the same time, and thus require at least two hands to install the cable tie and cable. Specifically, the installer has to hold the cable tie in position, such that it does not slip out of the solar panel frame, then must lift the cable up and secure the zip tie around the cable, then lock the zip tie in place. Some implementations of the wire positioning device described herein can be configured such that the open access wire position device can first be latched onto the solar panel with a single hand, then cables can be lifted and placed into the cable saddle with a single hand, allowing for a seamless, single-hand installation operation.

[0080] For locking positioning devices, such as zip ties or cables ties, all the cables must be installed at a single time and cables cannot be added or removed from the locking wire-position device without cutting down and destroying the wire positioning device, and then installing a new device. Some implementations of the wire positioning device described herein can be configured such that the open-access wire-position device allows for cables to installed and removed at varying times without the need of removing or destroying the wire-positioning device.

[0081] Some implementations of the wire positioning devices described herein includes an open-access design for large scale deployment in energy generation and transmission infrastructures, such as solar panel and solar energy' generation infrastructures, which are advantageous to the existing wire positioning devices. “Open- Access” can be defined herein as a device that has an open hook and an open saddle and does not lock closed. In other words, open-access devices can allow for maintaining and accessing the solar panel cabling and harness string cabling without modifying the wire position devices. Furthermore open-access devices can allow maintaining and removing the wire positioning device from the solar panel frame or support structure without modify ing it.

[0082] Some implementations of wire positioning devices described herein can include features to maintain the structural integrity of the cable material when exposed to high UV light or extreme cold environmental conditions. The wire positioning device can support the cables in an organized and serviceable manner that allows for easy arrangement of the cables. Two positive solar harness conductors can be arranged on the left most portion of the cable saddle and two negative solar harness conductors can be arranged on the right most portion of the cable saddle. In some implementations, the cabling is pulled tight, along with the wire positioning device, causing tensile / axial stress to be applied to the device at the location where it attaches to the solar panel frame. When the device is made from low tensile-strength materials, such as thin steel wire, or the thermoplastic materials that zip ties are made from, the device can deform or fracture and break, potentially causing cables to fall and become damaged or create an unsafe environment. Some implementations of the wire positioning device disclosed herein has suitable tensile strength to withstand even the worst-case axial stress conditions.

[0083] In addition, thermoplastic materials are much softer than the aluminum material of the solar panel frame, so as the zip tie rotates back and forth in the solar panel frame hole, (rotation occurs due to the solar panel rotating on the single-axis tracker, or dynamic events, such as wind or seismic, can cause the zip tie to rotate back and forth in the hole) the thermoplastic material can abrade and rub away over time. Over the life of the solar power plant, the zip tie can be completely cut in half from this rubbing action and fail. In addition, some wire position devices can be made of steel, whereas the solar panel frame can be made of aluminum, where this interaction between the two dissimilar metals can cause galvanic corrosion over the life the power plant, potentially causing both the wire position device and the solar panel frame to fail. In addition, the steel material has a higher hardness than the solar panel frame material, which is aluminum. Therefore, over time the steel material can rub away the solar panel frame material, potentially weakening the strength of the solar panel frame. In an aspect, the wire positioning device can be made from the same material as the solar panel frame, such as aluminum, so there is no potential of risk of galvanic corrosion over the life of the power plant. The aluminum material is more resistant to atmospheric corrosion than steel, zinc coatings, or copper, so the aluminum solar wire positioning device will corrode less than wire positioning devices made from other materials, which is advantageous to solar power generation plant owners and operators since the aluminum solar wire positioning device will last longer than other materials.

[0084] Some aspects of the wire positioning devices described herein can be installed directly onto a bundle of cabling. When the wire positioning device is coupled with the solar cabling and installed close to another wire positioning device, the wire positioning device is configured to act as a "stopper." preventing the solar cables from sliding or moving in the other wire positioning device. This also allows for the adjustment of asolar cable's tension and sag on either side of the cable hanger, which is advantageous for some installation methodologies to prevent excessive cable slack from sliding in the wire positioning device.

[0085] Accordingly, some implementations of the current subject matter include an approach to positioning solar panel cables and solar harness cables within an aluminum wire positioning device which supports and organizes the cables in a serviceable manner. By using an attachment member with an open hook design and an open cable support saddle design, some implementations of wire positioning devices described herein can allow for maintaining and accessing the cables arranged therein, while also allowing for easy installation of the wire positioning devices on a solar panel support structure or solar panel frame, which is advantageous to the installer since it will increase installation speed over traditional cable support methods. This is also advantageous to the operator and maintainer of the solar power generation plant as the cables and solar panels can be serviced faster over traditional cable support methods.

[0086] FIGS. 1-8 illustrate an exemplary aspect of a wire positioning device 100. The wire positioning device 100 can generally include a securement leg 102, a center bend 104, a and a cable saddle 111. The center bend 104 can include angled legs 105, 107 positioned on either side of the center bend 104. The angled legs 105, 107 extend downward from the center bend 104, creating a space underneath the legs 105, 107 and center bend 104. In an aspect, the angled legs 105, 107 form an angle within the range of 60 degrees to 150 degrees. The angled leg 105 connects to a leg 103. that extends axially outward from the center bend 104. and connects the angled leg 105 to the securement leg 102. The angled leg 107 connects to a leg 109. that extends axially outward from the center bend 104, and connects the angled leg 107 to a saddle leg 108.In an aspect, the saddle leg 108 is perpendicular to the leg 109.

[0087] Positioned at the end of the saddle leg 108 is a bottom leg 110. In an aspect, the bottom leg 110 is perpendicular to the saddle leg 108. Extending upward from the bottom leg 110 is a saddle leg 113. In an aspect, the saddle leg 113 can be positioned parallel or at an angle relative to the saddle leg 108. A saddle leg 115 extends from the saddle leg 113, and includes an end portion 112. In an aspect, the end portion 112 is in the form of a hook configured to w rap around the saddle leg 108. As show n in FIG. 2, the end portion 112 is not connected to the saddle leg 108 directly, allowing for cables and wires to be passed into the saddle 111, formed by the saddle legs 108, 113, 115, and the bottom leg 110. After the wires and cable have been positioned in the saddle 111, the end portion 112 is connected to the saddle leg 108, fully encapsulating the wires and cables within the saddle 111, as shown in FIG. 3. The connection between the saddle leg 108 and the end portion 112 prevents cables from unintentionally being removed from the saddle 111 during both installation and operation.

[0088] FIGS. 4-8 illustrate the wire positioning device 100 secured to a bracket 120 of a support structure. In an aspect, the support structure and bracket 120 are portions of a solar panel support structure. The bracket 120 is secured to a torque tube 130 via a bracket 121. A detent 122 is positioned on a top surface of the bracket 120 and corresponds to the center bend 104. As shown in FIG. 5, the center bend 104 has a similar cross-sectional shape to the detent 122, which the center bend 104 abuts against. This interaction of the center bend 104 and the detent 122 secures the wire positioning device 102 to the to the bracket 120 and prevents unintentional movement of the wire positioning device 100 relative to the bracket 120. Additionally, an aperture 126 is positioned within the top surface of the bracket 120. As the center bend 104 is aligned with the detent, the securement leg 102 passes through the aperture 126. At this time in an installation process, the securement leg 102 is perpendicular to the leg 103.Additionally, as shown in FIG. 6, cables 132 are spaced from the torque tube 130 and bracket 120 when positioned in the saddle 111, which prevents abrading of the cable 132 as the torque tube 130 and bracket 120 rotate due to a solar tracking system to align the solar panels with the sun to maximize energy generation.

[0089] As shown in FIG. 6, once the securement leg 102 is passed through the aperture 126 and the center bend 104 is abutting the detent 122, the securement leg 102 can be deformed by bending at least a portion of the securement leg 102 such that the securement leg 102 is no longer parallel with then leg 103. In combination with the detent 122 and center bend 104, the deformation of the securement leg 102 prevents unintentional removal of the wire positioning device 100 from the bracket 120.

[0090] FIGS. 9-12 illustrate and exemplary aspect of a wire positioning device 300. The wire positioning device 300 can include a left end portion 302, a left suspension leg 304, a center leg 306, a right suspension leg 308, and a right end portion 310. The left suspension leg 304 can be arranged on one end of the center leg 306. The left end portion 302 can be arranged on and perpendicular to the left suspension leg 304 opposite the center leg 306. In an aspect, the left end portion 302 can include a portion 303 positioned parallel to the left suspension leg 304. In an aspect, the portion 303 can be deformed relative to the left suspension leg 304 in order to encapsulate and / or secure a cable within the gap formed by the right suspension leg, right end portion, and portion 311.

[0091] The right suspension leg 308 can be arranged on the other end of and perpendicular to the center leg 306. The right end portion 310 can be arranged on the right suspension leg 308 opposite the center leg 306. In an aspect, the right end portion310 can include a portion 311 positioned parallel to the right suspension leg 308. In an aspect, the portion 311 can be deformed relative to the right suspension leg 308 in orderto encapsulate and / or secure a cable within the gap formed by the right suspension leg, right end portion, and portion 311. In some implementations, the left end portion 302 and the right end portion 310 can be used to suspend the wire positioning device 300 from a messenger cable or a wire. In some implementations, the center leg 306 can securely fasten cables or a plurality' of cables to the wire positioning device 300. In some implementations, the wire positioning device 300 is sized so it fits snugly within a steel clamp attached to a tracker, such that the wire positioning device 300 does not slide or rotation during movement of the tracker.

[0092] As shown in FIGS. 11-12, the wire positioning device 300 can be positioned on a bolt 334. The bolt 334 passes through a bracket 332, which is connected to a torque tube 330. In an aspect, with the wire positioning device 300 positioned on the bolt 334, the end portions 302 and 310 can be deformed to secure the wire positioning device 300 to the bolt 334. By' securing the wire positioning device 300 to the bolt 334, cables 336 positioned within the saddle 313 of the wire positioning device 300 are encapsulated and secured to prevent unintentional removal of the cables 336 from the saddle 313.

[0093] FIGS 13-15 illustrate an assembly 350 including wire positioning devices 100 and 300 used in combination. The wire positioning devices 100 support a cable 338 adjacent to the torque tube 330, and underneath solar panels 340. The wire positioning devices 300 support the cable 336 underneath the torque tube 330. By using both the wire positioning device 100, 300, the cables 336. 338 can be positioned on the assembly 150 without undue abrasion occurring between the cables 336, 338 and the torque tube 330 or solar panels 340. As shown in FIG. 15, the wire positioning device 300 can also be used to transition cables 336 from underneath the solar panels 340 to a messenger cable 382, which includes hangers 384 positioned along the messenger cable 382.

[0094] FIGS. 16A-18 depict an exemplary aspect of a wire positioning device 300. As shown in FIGS. 16A-18, the wire positioning device 400 generally includes a center leg 404, an attachment member 402, a bottom member 406, a saddle leg 408, and an end portion 410. The attachment member 402 can be arranged on one end of the center leg 404. The bottom member 406 can be arranged on the other end of the center leg 404. The end portion can be arranged on the bottom member 406 opposite the center leg 404. In an aspect, the bottom member 406 can support a cable. In an aspect, the attachment member 402 can suspend the wire positioning device 400 on a messenger wire or a cable. In some implementations, the end portion 410 can hook onto the center leg 404 to securely7fasten the cables. In an aspect, any portion of the wire positioning device 400 can be deformable relative to any other portion of the wire positioning device 400. This ensures proper securement of cables and wire within and about the wire positioning device 400. FIGS. 17-18 illustrate the wire positioning device 400 secured to a torque tube 422 via a strap 426. The wire positioning devices 400 are secured underneath the torque tube 422, and support a cable 424 underneath the torque tube 422 to prevent abrasion of the cable 424.

[0095] FIGS. 19-21 illustrate an exemplary implementation of a wire positioning device 450. The wire positioning device 450 is substantially similar to the wire positioning devices described herein. Therefore, similar components will not be described in detail. The wire positioning device 450 includes a securement leg 452. a center leg 454. a saddle 456. and an end portion 458. In an aspect, the securement leg 452 includes a deformable end section to secure the wire positioning device 450 to a frame component 460, as shown in FIG. 21. Additionally, in an aspect, the end portion 458 can connect to the center leg 454 to encapsulate any cables positioned within the saddle 456. as shown in FIG. 21.

[0096] FIG. 22 depict aspects of a wire positioning device 500. As shown in FIG. 22, the wire positioning device 500 generally includes a center leg 504, an attachment member 502, and end portion 503, a bottom member 506, and an end portion 508. The attachment member 502 can be arranged on one end of the center leg 504. The bottom member 506 can be arranged on the other end of the center leg 504. The end portion 508 can be arranged on the other end of the bottom member 506 opposite the center leg 504. In an implementation, the bottom member 506 can support a cable. In an implementation, the attachment member 502 can suspend the wire positioning device 500 on a frame member 510, as shown in FIGS. 23-24.

[0097] FIG. 25 depict aspects of a wire positioning device 600. The wire positioning device 600 is substantially similar to the wire positioning devices described herein. Therefore, similar components will not be described in detail. As shown in FIG. 25, the wire positioning device 600 generally includes a center leg 604, an attachment member 602, an extension leg 603, a saddle leg 605, a bottom member 606, and an end portion 608. The attachment member 602 can be arranged on one end of the extension leg 604. The bottom member 606 can be arranged on the saddle leg 605. A cable saddle 607 is formed by the saddle leg 605, the bottom leg 606, and the end portion 608. The end portion 608 can be arranged on the other end of the bottom member 606 opposite the saddle leg 605. In an implementation, the bottom member 606 can support a cable within the saddle 607.

[0098] In order to clear large gaps between solar panels, certain cable hangers and wire positioning devices are used in order to extend across the gap to ensure supported cables are not loosened and then caught or abraded by moving support structures. FIGS. 26-29 illustrate and exemplary implementation of a wire positioning device 700. The wire positioning device 700 generally includes a center portion 702, an end portion 704, andan end portion 706. The end portions 704, 706 are positioned on opposite ends of the center portion 702. Additionally, in an aspect, the end portions 704, 706 are deformable relative to the center portion in order to secure the wire positioning device 700 to a support structure. As shown in FIGS. 27-29, the end portion 706 is positioned within an aperture 714 of a frame 712. Additionally, the end portion 704 is secured within an aperture 716 of a frame member 710. With both end portions 704, 706 positioned within their respective apertures, the end portion 706 can be deformed into a hook shape to secure the wire positioning device 700 to both frame members 710, 712. A cable 722, extending between two junction boxes 720 ortwo adjacent solar panels, can be wrapped around the center portion 702 at least once to prevent the cable 722 from sagging and abrading or being caught in the solar tracking mechanisms which the frame 710, 712 are mounted to.

[0099] FIGS. 30-33 illustrate an exemplary implementation of a wire positioning device 800. The wire positioning device 800 is substantially similar to the wire positioning devices described herein. Therefore, similar components will not be described in detail. As shown in FIG. 30, the wire positioning device 800 generally includes a securement leg 802, an extension leg 803, a center leg 804, a plurality of saddle legs 806, and an end portion 808. In an aspect, the securement leg 802 includes a deformable end portion configured to be deformed after insertion of the wire positioning device 800 within an aperture 812 of a frame 810, as shown in FIGS. 31- 32. A cable saddle 807 is formed by the saddle legs 806, and is configured to support cables 820 within the saddle 807.

[0100] FIG. 34 illustrates an assembly 900 including wire positioning devices700 and 800. The assembly 900 includes solar panels 902, frame member 904, cables906, frame member 908, torque tube 910, support structure 912, junction box 914,connector 916, and cable 918. As disclosed above, the wire positioning device 700 spans a gap between two solar panel 902. The cable 722 is supported by the wire positioning device 700 to prevent sagging and contact with the torque tube 910. The wire positioning device 800 are connected to the frame member 904, 908, and support the cable 906. In an aspect, the cable 906 extends across the same gap between solar panels 902, and is spaced from the wire positioning device 700.

[0101] In an exemplar}' implementation, any of the disclosed w ire positioning devices disclosed herein can be used in combination with any other wire positioning devices. For example, the wire positioning device 300 can be used on a run of solar panels positioned on torque tube to position a cable underneath the toque tube to minimize or eliminate abrasion to the cable due to movement of the solar panels, and any shadow which may be cast by the cable. Additionally, the wire positioning device 100 can be used at sections of the run of solar panels where a bearing or motor is arranged on a support structure. The cable within the wire positioning device 300 can be routed to wire positioning devices 100 positioned on brackets on either side of the support structure in order to axially offset the cable from the bearing and support structure to further prevent abrasion of the cable due to the moving parts of the bearing and any associate mechanism, such as a motor or gears. Once the cable is cleared of the beanng, the cable to then be routed to subsequent wire positioning devices 100 as the cable continues down the length of the torque tube.

[0102] In the descriptions above and in the claims, phrases such as “at least one of’ or “one or more of may occur followed by a conjunctive list of elements or features. The term “and / or” may also occur in a list of two or more elements or features.Unless otherwise implicitly or explicitly contradicted by the context in which it is used, such a phrase is intended to mean any of the listed elements or features individually orany of the recited elements or features in combination with any of the other recited elements or features. In an aspect, the phrases “at least one of A and B;” “one or more of A and B;” and “A and / or B” are each intended to mean “A alone, B alone, or A and B together.” A similar interpretation is also intended for lists including three or more items. In an aspect, the phrases “at least one of A, B, and C;” “one or more of A, B, and C;” and “A, B, and / or C” are each intended to mean “A alone, B alone, C alone, A and B together, A and C together, B and C together, or A and B and C together.” In addition, use of the term “based on,” above and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible.

[0103] Certain exemplary implementations have been described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the systems, devices, and methods disclosed herein. One or more examples of these implementations have been illustrated in the accompanying drawings. Those skilled in the art will understand that the systems, devices, and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary implementations and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary implementation may be combined with the features of other implementations. Such modifications and variations are intended to be included within the scope of the present invention. Further, in the present disclosure, like-named components of the implementations generally have similar features, and thus within a particular implementation each feature of each like-named component is not necessarily fully elaborated upon.

[0104] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that couldpermissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[0105] One skilled in the art will appreciate further features and advantages of the invention based on the above-described implementations. Accordingly, the present application is not to be limited by what has been particularly shown and described, except as indicated by the appended claims. All publications and references cited herein are expressly incorporated by reference in their entirety.

[0106] The subject matter described herein can be embodied in systems, apparatus, methods, and / or articles depending on the desired configuration. The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been descnbed in detail above, other modifications or additions are possible. In particular, further features and / or variations can be provided in addition to those set forth herein. In an aspect, the implementations described above can be directed to various combinations and subcombinations of the disclosed features and / or combinations and subcombinations of several further features disclosed above. In addition, the logic flows depicted in the accompanying figures and / or described herein do not necessarily require the particular order shown, or sequential order, toachieve desirable results. Other implementations may be within the scope of the following claims.

Claims

WHAT IS CLAIMED IS:

1. A wire positioning device for cable routing, comprising: a first leg; a second leg connected to the first leg at an angle to form a center bend; a securement leg extending from the first leg, wherein the securement leg includes a deformable portion; a saddle leg extending from the second leg, wherein the saddle leg forms a saddle configured to support a cable; and an end portion positioned on the saddle leg, the end portion configured to selectively connect to the saddle leg, encapsulating a cable within the saddle.

2. The wire positioning device of claim 1, wherein the end portion is a hook configured to partially wrap around a portion of the saddle leg.

3. The wire positioning device of claim 1, wherein the first leg, second leg, and center bend form a triangular gap underneath the first leg and the second leg.

4. The wire positioning device of claim 3, wherein the triangular gap corresponds to a detent positioned on a support structure that the wire positioning device is supported on.

5. The wire positioning device of claim 1, wherein an extension leg extends between the first leg and the securement leg.

6. The wire positioning device of claim 1, wherein an extension leg extends between the second leg and the saddle leg.

7. The wire positioning device of claim 1, wherein the first leg, second leg, securement leg, and a portion of the saddle leg are positioned within a singular plane.

8. The wire positioning device of claim 1, wherein the securement leg is configured to pass through an aperture of a support structure that the wire positioning device is supported on9. A cable routing system, comprising: a support structure; a torque tube moveably positioned on the support structure; a bracket positioned on the torque tube, the bracket including a detent and an aperture; a first wire positioning device positioned on the bracket above the torque tube, the first wire positioning device comprising: a center bend formed from a first leg and a second leg, the center bend configured to the abut the detent of the bracket; a securement leg extending from the first leg, wherein the securement leg includes a deformable portion configured to pass through the aperture of the bracket; and a saddle leg extending from the second leg, wherein the saddle leg forms a saddle configured to support a first cable; and a second wire positioning device positioned on the bracket below the torque tube, the second wire positioning device comprising: a center leg; a first suspension leg positioned on a first side of the center leg, the first suspension leg comprising a first end portion; a second suspension leg positioned on a second side of the center leg, opposite the first side, the second suspension leg comprising a second end portion; a cable saddle configured to support a second cable, the cable saddle formed from the center leg, the first suspension leg, and the second suspension leg; wherein the second wire positioning device connects to the bracket via the first end portion and the second end portion.

10. The cable routing system of claim 9. wherein a third end portion is positioned on the saddle leg of the first wire positioning device, the third end portion configured to selectively connect to the saddle leg, encapsulating the first cable within the saddle.

11. The cable routing system of claim 10, wherein the third end portion is a hook configured to partially wrap around a portion of the saddle leg.

12. The cable routing system of claim 9, wherein a bolt is connected to the bracket underneath the torque tube, and the first end portion and the second end portion connect to the bracket via the bolt.

13. The cable routing system of claim 12, wherein the first end portion and the second end portion are hooks configured to partially wrap around the bolt.

14. The cable routing system of claim 1313, wherein the second wire positioning device and the bolt encapsulate the second cable.

15. The cable routing system of claim 913, wherein the first wire positioning device is vertically aligned with the second wire positioning device.

16. The cable routing system of claim 9, wherein the first leg, second leg, securement leg, and a portion of the saddle leg of the first wire positioning device are positioned within a singular plane.

17. The cable routing system of claim 9, wherein the deformable portion of the securement leg is deformed subsequent to passing through the aperture of the bracket to secure the first wire positioning device to the bracket.

18. The cable routing system of claim 17, wherein the deformable portion of the securement leg is deformed along a plane aligned with the first leg, second leg. and a portion of the saddle leg.

19. The cable routing system of claim 9, wherein the detent of the bracket is triangular-shaped.

20. The cable routing system of claim 19, wherein the center bend, the first leg, and the second leg form a triangular gap corresponding to the detent.

21. A cable routing system, comprising: a support structure; a bearing positioned on the support structure;a torque tube positioned within the bearing and configured to rotate relative to the support structure, the torque tube extending axially outward from the support structure; a first bracket positioned on the torque tube and configured to support a first solar panel thereon; a first wire positioning device positioned on the first bracket and radially offset from the torque tube and the bearing, the first wire positioning device configured to support a cable within a first saddle of the first wire positioning device such that the cable is radially offset from the support structure, bearing, and torque tube when positioned within the first saddle; a second bracket positioned on the torque tube and axially offset from the first bracket, the second bracket configured to support a second solar panel thereon; and a second wire positioning device positioned on the second bracket below the torque tube, the second wire positioning device configured to support the cable within a second saddle of the second wire positioning device such that the cable is below the torque tube when positioned within the second saddle.

22. The cable routing system of claim 21, wherein the first wire positioning device is positioned between the bearing and the second wire positioning device.

23. The cable routing system of claim 21, wherein the cable is spaced from the bearing during rotation of the torque tube relative to the support structure.

24. The cable routing system of claim 21, wherein the first wire positioning device is positioned vertically above the second wire positioning device.

25. The cable routing system of claim 21, further comprising a third wire positioning device positioned on a third bracket and radially offset from the torque tube and the bearing, the third wire positioning device configured to support the cable within a third saddle of the third wire positioning device such that the cable is radially offset from the support structure, bearing, and torque tube when positioned within the third saddle.

26. The cable routing system of claim 2513, wherein the first wire positioning device is positioned on a first side of the support structure, and the third wirepositioning device is positioned on a second side of the support structure, opposite the first side.

27. The cable routing system of claim 2613, further comprising a fourth wire positioning device positioned on a fourth bracket below the torque tube, the fourth wire positioning device configured to support the cable within a fourth saddle of the second wire positioning device such that the cable is below the torque tube when positioned within the fourth saddle.

28. The cable routing system of claim 27, wherein the fourth wire positioning device is positioned axially outward of the third wire positioning device and the support structure.

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