Solar Module Carriers With Anti-Slip Frame Channels
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Solution Overview
Problem
The installation of solar modules is labor-intensive and poses safety risks due to the weight and awkward shape of the modules, requiring strong personnel and often violates OSHA guidelines for maintaining three points of contact while climbing a ladder.
Innovation Solution
A carrier device with a handle and attachment devices, including channels and anti-slip mechanisms, designed to securely engage with the solar module frame, providing ergonomic lifting and safe handling, and optionally incorporating a harness for user safety and wind abatement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If solar modules are handled manually without specialized equipment, then installation can proceed with simple tools, but labor intensity increases and safety risks arise due to module weight and awkward shape
Solution Approach 1:
The patent introduces a carrier device as an intermediary between the worker and the solar module. This carrier includes attachment devices that securely engage with the module frame, allowing workers to handle modules safely without direct manual contact. The carrier acts as a mediator that transfers the load from the worker to the module frame through properly designed engagement points.
Solution Approach 2:
The carrier device is segmented into multiple functional components: a body portion for structural support, attachment devices for securing to the module frame, and a handle for worker interaction. This segmentation allows each component to be optimized for its specific function, improving overall handling efficiency and safety.
2Ease of operation
If workers carry solar modules while climbing ladders, then installation can proceed, but OSHA guidelines for maintaining three points of contact are violated
Solution Approach 1:
The carrier device serves as an intermediary that frees the worker's hands from directly supporting the module weight. By securing the module to the carrier, the worker can climb ladders while maintaining three points of contact, as the carrier bears the module's weight rather than the worker's arms.
Solution Approach 2:
The patent replaces the mechanical system of direct manual carrying with a carrier-based suspension system. The attachment devices engage with the module frame to create a secure mechanical connection, allowing the module to be suspended from the carrier rather than held directly by the worker.
3Ease of manufacture
If attachment devices use simple channel structures, then manufacturing is easy, but module movement and slippage occur during handling
Solution Approach 1:
The attachment devices incorporate rubber elements at specific locations within the channel structure. These rubber elements provide localized friction and grip points that prevent module slippage, while the overall channel structure remains simple and easy to manufacture. The local quality enhancement is applied only where needed for secure engagement.
Solution Approach 2:
The attachment devices combine rigid channel structures (easy to manufacture) with rubber elements (provide grip and prevent slippage). This composite approach integrates materials with complementary properties: the rigid structure provides structural integrity and ease of manufacturing, while the rubber provides friction and secure engagement.
4Reliability
If carrier devices lack engagement feedback mechanisms, then device complexity is reduced, but workers cannot confirm proper module engagement
Solution Approach 1:
The engagement device incorporates a feedback mechanism that provides tactile or visual confirmation to the worker when the module is properly secured. This feedback allows the worker to verify correct engagement without adding significant complexity to the overall carrier device structure.
Data Source
AI summary
The present disclosure is directed to carrier device, and related systems. A device may include a handle and at least one attachment device coupled to the handle. The at least one attachment device may be configured to couple to a solar module, wherein each attachment device includes at least one of a channel for receiving a portion of a frame of the solar module.