End Clamp With Dual-Axis Force Application for PV Module Alignment
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Solution Overview
Problem
Conventional end clamps for PV modules can only apply a normal force parallel to the turnbuckle's longitudinal axis, requiring manual precise orientation of the PV module before tightening, and cannot apply a lateral force to secure the module against adjacent clamps.
Innovation Solution
The end clamp features a clamp strap with a fixing element that engages with a counter fixing element on the console element via a positive mechanical or frictional connection, allowing a pitching moment to be applied when tightened, enabling a clamping force parallel to the turnbuckle's axis and a lateral thrust to secure the PV module, while adjustable design accommodates different module heights and includes a grounding element for electrostatic discharge prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional end clamps are used with only a normal force application, then the structure is simple, but the PV module cannot be precisely aligned and secured against adjacent clamps
Solution Approach 1:
The clamp strap is divided into two independent arms: a first clamp strap arm and a second clamp strap arm. Each arm can apply force independently - the first arm applies normal force parallel to the turnbuckle axis, while the second arm applies lateral force perpendicular to the first arm. This segmentation allows precise alignment and securing without increasing overall device complexity.
Solution Approach 2:
The clamp strap transitions from applying force in only one dimension (normal force parallel to turnbuckle axis) to applying forces in two dimensions by adding the second clamp strap arm that applies lateral force perpendicular to the first arm. This dimensional expansion enables both precise alignment and secure fixation against adjacent clamps.
2Force
If only a normal force is applied parallel to the turnbuckle axis, then the clamp structure is simple, but lateral securing force cannot be applied
Solution Approach 1:
The clamp strap is segmented into two functional arms: the first clamp strap arm for normal force application parallel to the turnbuckle axis, and the second clamp strap arm for lateral force application perpendicular to the first arm. This segmentation enables independent force application in different directions without requiring a completely redesigned clamp structure.
Solution Approach 2:
The force application is extended from one dimension (parallel to turnbuckle axis) to two dimensions by adding the second clamp strap arm that applies lateral force perpendicular to the first arm. This allows the clamp to secure PV modules against adjacent clamps while maintaining structural simplicity.
3Ease of operation
If the clamp strap is rigidly fixed to prevent all movement, then positioning is precise, but assembly becomes difficult and adjustment is lost
Solution Approach 1:
The connection between the clamp strap and console element transitions from a static rigid connection to a dynamic adjustable connection. The clamp strap can slide along the console element during assembly and tightening, allowing easy positioning and adjustment. Once the second clamp strap arm engages the frame, the positioning is secured with precision, combining ease of operation with manufacturing precision.
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
This design ensures secure fixation of PV modules with both normal and lateral forces, allowing for precise alignment and grounding, and accommodates varying module heights with adjustable elements, enhancing the stability and electrical safety of the module installation.
Implementation Method 1
the fixing element can be fixed to a counter fixing element which has a complementary shape in a positive and/or frictional manner in the contact surface of the console element
Implementation Method 2
A turnbuckle engages between the clamp strap and the console. The clamp strap can be tensioned against the console by tightening the turnbuckle
Implementation Method 3
a clamping surface is provided at the clamp strap, the clamping surface coming into contact with a corresponding surface of the frame of the PV module
Data Source
AI summary
An end clamp (01) for fixing a framed PV module (02) on a support profile (03), includes a console element (05) fixed to the support profile (03), and including a clamp strap (04) for holding down the frame (08) of the PV module (02), the clamp strap (04) having at least one clamping surface (07) in contact with the frame (08) of the PV module (02) in a clamping manner. The clamp strap (04) has a supporting surface (17) which contacts a side of a contact surface (20) of the console element (05) while supporting the clamp strap (04). A turnbuckle (06) engages between the clamp strap (04) and the console element (05) for tightening the clamp strap (04) against the console element (05) to hold down the frame (08) of the PV module (02). An least one fixing element (18) is provided at the supporting surface (17) of the clamp strap (04). The fixing element (18) is fixed to a counter fixing element (21) having a complementary shape in a positive and/or frictional manner in the contact surface (20) of the console element (05). An approximation of the supporting surface (17) of the clamp strap (04) towards the support profile (03) is excluded by positive mechanical engagement and/or frictional connection between the fixing element (18) and the counter fixing element (21).