Grounding Lug With Movable Clamping Pad For Solar PV Installation
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Solution Overview
Problem
Current grounding solutions for solar photovoltaic module frames, such as direct-bury lugs, are not ideal for running grounding conductors underneath photovoltaic modules due to their design, which limits installer flexibility and increases installation complexity.
Innovation Solution
A grounding lug with a conductive housing, clamping pad, and lay-in feature that allows for adjustable placement of the grounding wire before final installation, featuring an angled design for tool clearance and resilient clamping to prevent wire displacement, manufactured from stamped metal for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a direct-bury lay-in lug is used for grounding, then the grounding conductor can be installed, but the installer lacks flexibility to adjust wire position without disengagement and the design is not ideal for running grounding conductors underneath photovoltaic modules
Solution Approach 1:
The clamping pad is made movable relative to the housing, allowing it to transition between an unclamped position (providing lay-in feature for wire adjustment) and a clamped position (securing the wire). This dynamic mechanism enables installers to freely place and adjust grounding wires before final installation without disengagement, then securely clamp them in place.
2Reliability
If the grounding lug is inverted and installed on the underside of a solar photovoltaic module, then grounding can be achieved, but the wire falls out due to gravity without support
Solution Approach 1:
The lay-in feature allows the installer to preliminarily place the grounding wire in the grounding lug before final installation. The movable clamping pad can be positioned to support the wire against gravity in inverted installations, holding it in place during manipulation and placement. Only after proper positioning is achieved is the wire permanently clamped, ensuring both ease of placement and reliable grounding continuity.
3Ease of manufacture
If a traditional grounding lug design is used, then grounding is achieved, but tool clearance is insufficient for mounting hardware installation and wire clamping operation
Solution Approach 1:
The grounding lug employs an angled design where the clamping pad and housing are positioned at specific angles relative to each other. This asymmetric configuration creates sufficient clearance space for power tools to access mounting hardware installation areas and wire clamping operation zones, solving the tool clearance problem while maintaining a relatively simple overall structure.
4Reliability
If the clamping pad is tightly clamped during installation, then wire security is improved, but side loads cause housing sidewalls to spread and reduce holding force
Solution Approach 1:
Tabs protrude from the clamping pad and engage the housing sidewalls before and during the clamping action. These tabs apply preliminary counteracting force to prevent side loads from spreading the housing sidewalls. By engaging the sidewalls in advance, the tabs maintain structural integrity and preserve adequate holding force between the clamping pad and the wire throughout the clamping process.
Data Source
AI summary
A grounding lug for holding a grounding wire includes a housing defining an opening for receiving a wire and a clamping pad movable relative to the housing. The clamping pad is movable between an unclamped position in which the clamping pad defines a wire-receiving pocket in combination with the opening defined by the housing, and a clamped position in which the clamping pad clamps the wire to the housing. The grounding lug also includes a moving mechanism coupled to the housing and the clamping pad for moving the clamping pad between the unclamped and clamped positions.