Clip-on mounting rails, mounting brackets, and methods of mounting solar modules
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Solution Overview
Problem
Existing mounting bracket assemblies for photovoltaic module installations are inefficient for long module mounting rails, as they require threading over torque tubes, which can lead to damage during assembly and installation, and are not suitable for octagonal torque tubes.
Innovation Solution
A clip-on or snap-on two-piece torque tube mounting bracket assembly with an upper clamp piece and a lower clamp piece, allowing attachment of module mounting rails anywhere along the torque tube length, featuring an open bottom space that can snap over the tube and provide a conductive ground path, suitable for octagonal shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long module mounting rails (2-3 meters) are threaded over the end of the torque tube for installation, then the rails can be attached to the torque tube, but the rails would hang from the torque tube and likely get damaged during assembly and tracker installation
Solution Approach 1:
The mounting bracket is divided into two separate pieces: an upper clamp piece that attaches to the torque tube and a lower clamp piece that attaches to the mounting rail. This segmentation allows the rail to remain horizontal during installation rather than hanging vertically, preventing damage while maintaining ease of installation.
Solution Approach 2:
The upper clamp piece is pre-installed on the torque tube at the desired position before the mounting rail is attached. This preliminary action allows the rail to be positioned horizontally and secured without being threaded over the tube end, eliminating the damage risk associated with vertical hanging during installation.
2Adaptability or versatility
If standard hardware with straight bolts is used to attach mounting rails to torque tubes, then attachment can be achieved, but it is not suitable for octagonal torque tube shapes
Solution Approach 1:
The clamp pieces are designed with asymmetric contact surfaces that conform to the octagonal geometry of the torque tube. The upper clamp piece includes angled reinforcement features and contact surfaces specifically shaped to match the flat sides and corners of the octagonal tube, providing secure attachment without requiring complex adaptive hardware.
Solution Approach 2:
The mounting bracket incorporates localized geometric features tailored to the octagonal shape, including angled reinforcement features and contact surfaces that match specific facets of the octagonal tube. This local adaptation ensures compatibility with octagonal geometry while keeping the overall design straightforward.
3Adaptability or versatility
If short module mounting clamps (0.3 meter) are used for framed modules, then they are easy to slide onto the torque tube and transport well, but they cannot support unframed glass modules which require longer structure
Solution Approach 1:
The mounting system is segmented into a compact upper clamp piece that attaches to the torque tube and a separate lower clamp piece that attaches to the mounting rail. This segmentation allows the clamp components to remain small and easy to handle during transport, while still supporting long mounting rails (2-3 meters) when assembled, enabling support for unframed modules without compromising ease of operation.
Data Source
Figure 1
Figure 2A~2D
Figure 3A~3E
AI summary
A snap-on mounting bracket assembly suitable for connecting a mounting rail to a torque tube is provided. The mounting bracket assembly includes an upper clamp piece and a lower clamp piece. The upper clamp piece has a first member defining a tube insertion aperture and an open bottom space and includes an upper partial fastener. The lower clamp piece has a second member with a lower partial fastener configured to mate with the upper partial fastener such that the lower clamp piece is attachable to the upper clamp piece. In exemplary embodiments, the lower clamp piece further comprises two opposing support members configured to attach to the mounting rail. Solar tracker assemblies incorporating snap-on open mounting brackets are provided. Methods of mounting framed or unframed solar modules are also described. A mounting rail is attached to an upper clamp piece of a mounting assembly. Then the upper clamp piece is snapped onto a torque tube. A lower clamp piece of the mounting assembly is then attached to the upper clamp piece by mating a lower partial fastener of the lower clamp piece with an upper partial fastener of the upper clamp piece. When the upper and lower clamp pieces are attached, the open bottom space is closed and the mounting rail is secured to the torque tube.