Bidirectional Wire Grounding Assembly for PV Modules
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Solution Overview
Problem
There is a need for a reliable wire grounding assembly that can efficiently establish a ground path between a photovoltaic module and its anodized aluminum frame, as existing solutions are not suitable for this specific application.
Innovation Solution
A unitary bidirectional connector with a radially oriented torque-receiving portion, featuring aligned threaded shafts for ground wire and frame penetration, along with a nut and free-spinning washer for secure installation, allowing efficient grounding of photovoltaic modules with non-conductive frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire grounding assembly is used to ground a PV module with an anodized aluminum frame, then the grounding reliability is improved, but the installation complexity increases due to the non-conductive frame surface
Solution Approach 1:
The connector is divided into two separate threaded shafts (first threaded shaft and second threaded shaft) that can be independently installed. The first threaded shaft installs through the non-conductive frame surface while the second threaded shaft installs through the conductive ground path, allowing each segment to address specific installation challenges and simplify the overall process
Solution Approach 2:
The non-conductive frame surface acts as an intermediary barrier that the first threaded shaft must penetrate to reach the conductive path. The shaft's design includes features specifically for penetrating this intermediate layer while maintaining electrical contact, transforming the installation challenge into a manageable process
2Strength
If sufficient torque is applied to penetrate the non-conductive frame surface, then the grounding connection strength is improved, but the risk of damaging the frame increases
Solution Approach 1:
The first threaded shaft features a localized penetrating tip with specific geometric properties designed to concentrate force only at the contact point with the non-conductive frame surface. This allows high localized stress for penetration while distributing the overall load to prevent spreading damage across the frame structure
Solution Approach 2:
The shaft material properties and geometric parameters are specifically selected to enable controlled penetration. The shaft undergoes a transition from a non-penetrating state to a penetrating state through controlled torque application, with the material and geometry designed to stop penetration automatically when the conductive path is reached, preventing over-penetration and frame damage
3Productivity
If a unitary bidirectional connector with aligned threaded shafts is used, then the installation efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
Two separate connector components are merged into a single unitary bidirectional connector with two threaded shafts that share a common axis and torque-receiving portion. This integration allows both shafts to be installed simultaneously using a single installation tool, doubling the installation efficiency while the unitary construction simplifies manufacturing compared to assembling multiple separate components
Solution Approach 2:
The unitary bidirectional connector serves multiple functions: it provides two grounding paths simultaneously, accepts a single torque-receiving portion for installation, and maintains alignment of both threaded shafts through its symmetric design. This multi-functionality reduces the number of installation steps and tools required while the standardized geometry facilitates manufacturing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and reliable grounding of photovoltaic modules, ensuring safety by reducing shock and fire hazards, and meeting electrical standards for secureness and pull-out tests, while being easy to install with minimal components and tools.
Implementation Method 1
a torque-receiving portion that is radially oriented about a major axis of the unitary bidirectional connector... upon application of sufficient torque to the torque-receiving portion
Implementation Method 2
the attached free-spinning washer having a serrated surface configured to penetrate a second non-conductive surface of the frame
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A wire grounding assembly (10) including a unitary bidirectional connector (20) having a first threaded shaft (30), a second threaded shaft (50), and a torque-receiving portion (70) that is radially oriented about major axis of the unitary bidirectional connector (20) and that has a first radial surface and an opposing second radial surface (90). The first threaded shaft (30) and the second threaded shaft (50) project, respectively, from the first radial surface and the second radial surface (90), and are aligned such that their respective major axes coincide with the major axis. The first threaded shaft (30) has an axial ground wire slot (60) configured to receive a ground wire therein, and the second threaded shaft (50) has a base (170). The unitary bidirectional connector (20) has an annular sharp projection (160) that projects beyond the plane of the second radial surface (90), encircling the base (170), and is configured to penetrate a non-conductive surface of a ground upon application of sufficient torque to the torque-receiving portion (70).