Frame enhancer
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Solution Overview
Problem
Solar panel systems face structural failure due to high loads from snow and wind, which can lead to power loss and potential damage, necessitating reinforcement of the support structures and connections.
Innovation Solution
A frame enhancer with extensions and notches that lock onto support arms and flanges, providing additional support and stability by sliding and clicking into place, allowing for increased load-bearing capacity and resistance to bending forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement is added to the support structure to withstand high loads from snow and wind, then the structural strength and reliability are improved, but the device complexity and weight increase
Solution Approach 1:
The frame enhancer is divided into multiple extensions (first extension, second extension, third extension) that can be separately configured to engage with different parts of the support structure. Each extension can independently provide reinforcement while maintaining overall structural integrity, allowing the system to achieve high strength without requiring a monolithic complex structure.
Solution Approach 2:
The frame enhancer is designed to nest within the existing support structure by receiving support arms within slots defined by the extensions. The enhancer body with its multiple extensions creates a nested configuration where the reinforcement structure fits within and around the existing flange and support arms, adding strength without significantly increasing external dimensions or complexity.
2Reliability
If the frame enhancer is designed with multiple extensions and notches to distribute loads effectively, then the reliability under high wind and snow conditions is improved, but the manufacturing complexity increases
Solution Approach 1:
The frame enhancer body is segmented into multiple extensions that can be manufactured as integrated features of a single casting or extrusion process. The slots, notches, and channels are designed as continuous features that can be formed during primary manufacturing operations, reducing the need for secondary operations while maintaining the load-distributing geometry required for high reliability.
Solution Approach 2:
The frame enhancer is designed with universal features that can accommodate different configurations of support arms and flanges. The slots and channels are dimensioned to provide universal engagement across varying support structure designs, allowing a single enhancer design to serve multiple applications and reduce manufacturing variety while maintaining reliable load distribution.
3Stability of the object's composition
If the extensions are designed to lock onto support arms with notches, then the stability and load-bearing capacity are improved, but the ease of installation decreases
Solution Approach 1:
The frame enhancer is designed with pre-formed slots and notches that are configured to automatically align with and engage the support arms during installation. The geometry of the extensions and locking features is predetermined to guide the assembly process, allowing the enhancer to be installed by simply positioning it over the support structure where the features self-align and lock into place, maintaining both stability and ease of installation.
4Force
If the frame enhancer uses multiple channels and legs to support the flange, then the load distribution is improved, but the device complexity increases
Solution Approach 1:
The frame enhancer combines multiple load-bearing functions into a single integrated body. The first extension with its channels and legs, the second extension, and the third extension are merged into one monolithic structure that simultaneously provides lateral support, vertical support, and load distribution through its integrated geometry, reducing the number of separate components needed while maintaining effective load distribution.
Data Source
AI summary
A frame enhancer may include a body, a first extension extending from the body and including a first notch, a second extension extending from the body, and a third extension extending from the body and including a second notch. The first extension and the second extension may define a first slot. The second extension and the third extension define a second slot. The first slot may be configured to receive a first side of a support arm, and the second slot may be configured to receive a second side of the support arm. The first notch may be configured to lock the first side of the support arm in the first slot, and the second notch may be configured to lock the second side of the support arm in the second slot. At least a portion of the first and third extensions may be configured to support a flange.