Single-Piece Hinged Clamp for Faster Solar Track Mounting
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Solution Overview
Problem
The installation of solar power generation systems is delayed due to the complexity of existing mounting assemblies, which require handling multiple components during the installation process.
Innovation Solution
A single-piece hinged-clamp assembly with a flexible hinge, tapered flanges, and notches, along with a spring mechanism, that simplifies the clamping process by reducing the number of parts to handle and provides a snapping indication of secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple separate components (threaded fastener, nut, two opposing members) are used to provide clamping force, then the clamping function is achieved, but the number of parts to handle increases and installation time increases
Solution Approach 1:
The patent combines multiple separate clamping components (threaded fastener, nut, and opposing members) into a single integrated clamp assembly. The clamp includes a body with first and second arms that can be positioned on opposite sides of a workpiece, with a fastening mechanism that secures both arms to the workpiece simultaneously, eliminating the need to handle multiple separate parts during installation.
Solution Approach 2:
The single clamp assembly performs multiple functions that previously required separate components: it provides clamping force through its arms, secures the workpiece through the fastening mechanism, and maintains alignment through its integrated structure. This multi-functional design reduces the number of parts an installer must handle while achieving all necessary clamping functions.
2Productivity
If multiple separate components are used during installation, then the clamping function is achieved, but installation time increases due to the need to fit multiple parts together
Solution Approach 1:
By integrating the fastening mechanism and clamping arms into a single clamp assembly, the patent eliminates the time required to assemble multiple separate components during installation. The installer handles one pre-assembled unit rather than multiple parts, significantly reducing installation time and improving productivity.
3Loss of time
If a single-piece hinged-clamp with spring mechanism is used, then installation time is reduced and clamping indication is provided, but the device structure becomes more complex
Solution Approach 1:
The patent incorporates a spring mechanism within the clamp assembly that provides dynamic functionality. The spring enables the clamp to automatically adjust and maintain clamping force, and provides tactile feedback to the installer when proper clamping is achieved. This dynamic element adds complexity to the internal structure but simplifies the installation process.
Solution Approach 2:
The spring mechanism in the clamp assembly provides self-service functionality by automatically indicating when proper clamping force is applied. The spring's mechanical response gives immediate feedback to the installer, eliminating the need for additional tools or measurement devices to verify correct installation, thereby reducing installation time despite the added structural complexity.
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 hinged-clamp assembly reduces installation time by allowing for a more streamlined process with fewer parts to manage and provides a clear indication of successful clamping, thereby speeding up the installation of solar panel systems.
Implementation Method 1
The use of this clamp assembly may improve installation time by reducing the number of parts with which the installer needs to handle and providing the installer a snapping feature to provide him/her an affirmative indication of that two structural members have been clamped together.
Implementation Method 2
a spring mechanism, that simplifies the clamping process by reducing the number of parts to handle and provides a snapping indication of secure engagement
Data Source
AI summary
Single-piece hinged-clamps employed used in assemblies used to mount solar power modules to surface installation are disclosed. In some embodiments, a clamp with a right portion with a right notch having a right platform, a left portion with a left notch having a left platform, and a base portion with a flexible hinge is disclosed. The left portion also includes a threaded aperture extending downwardly from the left platform. In some embodiments, a method of securing a component with the clamp is disclosed in which a right member of a component is inserted into a right notch of a clamp, an applied force imparts movement of a left notch away from the right notch, and a buildup of potential energy in the flexible hinge during the application of the force moves the left notch in the opposite direction to engage the left member of the component.