Mounting bracket assembly
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Solution Overview
Problem
Current solar mounting systems are heavy, complex, and costly due to their large, heavy components, requiring significant materials and skilled labor for installation and quality control, and they struggle to accommodate standard, custom, and unframed photovoltaic modules efficiently.
Innovation Solution
A mounting bracket assembly with a flexible body, integral grounding device, and a configuration that uses a single bolt to securely connect PV modules to a torsion beam, featuring a threaded rod and clamping nut for easy installation and grounding, with adjustable clamps for varying torque and force distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mounting systems use large, heavy components to support PV modules, then the structural strength and stability are improved, but the overall weight and material usage increase significantly
Solution Approach 1:
The mounting system is divided into separate functional components: a rail segment that mounts to the structure, a bracket assembly that holds the PV module, and a separate grounding mechanism. This segmentation allows each component to be optimized independently, reducing overall material usage while maintaining structural strength.
Solution Approach 2:
The bracket assembly serves multiple functions simultaneously: it mechanically supports the PV module, provides electrical grounding through an integrated grounding device, and enables adjustable positioning. This multi-functionality eliminates the need for separate grounding components and adjustment mechanisms, reducing total material usage.
2Reliability
If traditional mounting systems use complex assemblies with multiple components, then the reliability and adaptability are improved, but the device complexity and installation time increase
Solution Approach 1:
The grounding device is integrated directly into the bracket assembly, combining mechanical support and electrical grounding functions into a single component. The bracket also incorporates adjustable positioning features, merging support and alignment functions. This reduces the number of separate components and simplifies installation.
Solution Approach 2:
The bracket assembly is pre-configured with the grounding device and adjustment mechanisms during manufacturing, so that during installation, the system is ready for immediate mounting and adjustment without requiring complex field assembly or additional grounding steps.
3Ease of manufacture
If traditional mounting systems use standardized components, then the manufacturing cost is reduced, but the adaptability to different PV module types (standard frames, custom frames, unframed) is limited
Solution Approach 1:
The bracket assembly incorporates adjustable positioning features that allow it to adapt to different PV module types (standard frames, custom frames, and unframed modules) by adjusting the bracket position and orientation, while still using standardized manufacturing processes for the bracket components themselves.
Solution Approach 2:
The bracket assembly is designed as a universal mounting solution that can accommodate various PV module types through its adjustable design, while the grounding device provides consistent electrical grounding across all module types, combining standardized manufacturing with versatile application.
Data Source
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AI summary
A mounting bracket assembly comprises a flexible body including at least one top member and a flexible angled bottom member connected to the top member. The flexible body defines a beam insertion aperture between the top member and the bottom member. The mounting bracket assembly further comprises at least one clamp attached to the top member. The mounting bracket assembly may further comprise a threaded rod running through the at least one top member and a clamping nut securing the threaded rod to the top member such that rotating the clamping nut compresses the top member and grounds an electricity generating device such as a photovoltaic module. The mounting bracket assembly may further comprise an integral grounding device disposed adjacent the top member to electrically ground the electricity generating device.