Universal Solar Panel End Clamp for Hidden Rail Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional solar panel mounting systems on roofs are aesthetically unappealing due to visible attachment hardware, and existing end clamps require multiple sizes to accommodate various solar module heights, increasing costs and complexity.
Innovation Solution
A universal end clamp that applies torque to clamp the solar module's lower flange to the rail, using components like threaded bolts, T-slides, drive blocks, cams, coil springs, and offset drive brackets to generate a compressive clamping force, allowing the rail to be trimmed flush with the module edge and hidden from view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional T-shaped mounting brackets are used to attach solar panels to rails, then the solar panels can be securely mounted, but the attachment hardware becomes visible from the top, creating an aesthetic distraction
Solution Approach 1:
The mounting bracket is extracted from the visible top surface and repositioned to the underside of the solar panel. The clamp attaches to the lower flange of the module frame from below, securing the panel to the rail while remaining completely hidden from the top view, thus eliminating the aesthetic distraction while maintaining secure mounting
2Adaptability or versatility
If multiple sizes of end clamps are produced to accommodate various module frame heights, then different module manufacturers' products can be accommodated, but costs increase due to stocking multiple SKUs
Solution Approach 1:
The end clamp is designed with a universal adjustment mechanism that allows a single clamp size to accommodate various module frame heights. The clamp body can be adjusted along the rail to different positions, and the clamping force can be modified to suit different frame heights, enabling one clamp design to serve multiple functions across different module manufacturers' products
3Adaptability or versatility
If the rail extends beyond the edge of the solar module by about 1.5 inches, then traditional end clamps can accommodate various module heights, but the rail cannot be trimmed flush with the module edge
Solution Approach 1:
The end clamp incorporates dynamic adjustment capabilities that allow it to adapt to different module heights without requiring a fixed rail extension. The clamp can be positioned and adjusted along the rail to accommodate various frame heights, enabling the rail to be trimmed flush with the module edge while still providing secure attachment for different module sizes
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
The solution provides a clean, uncluttered appearance by hiding the hardware and offers a one-size-fits-all solution that reduces costs and complexity by accommodating various module heights with a single clamp design, ensuring secure and efficient mounting.
Implementation Method 1
means for applying a torque to a clamp body and generating a compressive clamping force
Implementation Method 2
generating a compressive clamping force between the body and a lower flange of a solar panel module frame
Implementation Method 3
coil springs, leaf springs
Implementation Method 4
coil springs, leaf springs
Data Source
AI summary
A universal end clamp and method for clamping a solar module to a rail are configured for applying a torque to a clamp body and generating a compressive clamping force between the body and a lower flange of a solar panel module frame so that the lower flange of the module frame is clamped to the rail. The clamp is disposed underneath the solar module, where it cannot be seen. The components of the assembly that can move include threaded bolts, front and rear T-slides, drive blocks, cams, coil springs, leaf springs, and offset drive brackets.