Angled-Rail Solar Module Crate Transport for Transit Protection

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Solution Overview

Problem

The installation of large-scale solar systems faces challenges in securely moving and monitoring solar modules, which are prone to damage during transit and storage, and lacks efficient remote management of resources and personnel, leading to inefficiencies and ambiguity in liability for damage.

Innovation Solution

A solar module crate transport structure with angled bottom support rails and integrated monitoring features, including sensors, cameras, and wireless connectivity, to enhance secure movement and remote monitoring of solar modules, reducing damage and improving installation efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solar modules are transported using conventional flat transport structures, then the structure is simple and easy to manufacture, but the solar modules are prone to damage during transit and storage due to lack of secure positioning

Engineering Contradiction:

Improvesecurity of solar modules during transportVSAvoidcomplexity of transport structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The transport structure employs an angled bottom support rail configuration where the support rails are positioned at an angle rather than symmetrically flat, creating an asymmetric geometry that provides mechanical advantage for securing solar modules. This asymmetric design prevents modules from shifting during transport while maintaining structural simplicity

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The invention transitions from a conventional two-dimensional flat transport surface to a three-dimensional angled support structure. By introducing vertical and angular dimensions to the support rails, the system creates multiple planes of support that secure solar modules more effectively without significantly increasing overall structural complexity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Loss of information

If solar modules are monitored manually during transport and installation, then the monitoring system is simple, but the ability to remotely monitor resources and personnel across large distances is limited

Engineering Contradiction:

Improvevisibility of module status and locationVSAvoidcomplexity of monitoring system

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The monitoring system incorporates sensors that continuously detect the status, position, and environmental conditions of solar modules during transport and installation. This feedback is transmitted in real-time to remote monitoring stations, enabling continuous visibility of module status and location without requiring constant manual inspection

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The invention replaces manual mechanical monitoring methods with electronic sensing and wireless communication systems. Sensors, cameras, and GPS devices substitute for human observers, automatically collecting and transmitting data about module status, position, and conditions across large distances

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If solar modules are transported without damage prevention features, then the transport structure is simpler, but the modules are susceptible to damage from stress and torque pressure during movement

Engineering Contradiction:

Improveintegrity of solar modulesVSAvoidcomplexity of protective structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The transport structure incorporates cushioning and shock-absorbing elements positioned at critical contact points between the support rails and solar modules. These protective features are pre-installed to absorb stress and torque pressures that occur during movement, preventing damage before it happens

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The angled support rails are designed with specific geometric parameters and material properties that optimize the distribution of mechanical stresses. By carefully selecting rail angles, materials, and cross-sectional dimensions, the structure naturally reduces stress concentrations and torque pressures on solar modules during transport

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250335863A1Solar module crate transport and monitoring structure

Publication Date: 2025.10.30 TERABASE ENERGY INC

AI summary

A solar module crate transport is described that securely moves a solar module crate within a large-scale solar system. The solar module crate transport comprises an angled base, at least three vertical support structures, at least one vehicle receptacle and at least one monitoring device. The at least one monitoring device may provide a variety of monitoring functionality that allows remote monitoring of an installation location within the large-scale solar system. This monitoring allows visibility into resources, including solar modules, and personnel at an installation location within the large-scale solar system.