Interlocking PV Module Frames for Tolerance-Adaptable Grounded Arrays
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Solution Overview
Problem
Existing photovoltaic (PV) module coupling systems face challenges in addressing dimensional variations due to manufacturing tolerances, providing a reliable electrical ground bond, and ensuring a strong, durable connection, which hinders quick and cost-effective assembly of PV arrays.
Innovation Solution
The system employs a pivot-fit connection using angled grooves and components like leveling feet and interlocks, allowing for adjustable positioning of PV modules to accommodate tolerance variations and providing a secure, electrical ground bond through cutting teeth, eliminating the need for cumbersome fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If press-fit and hook-type connections are used to reduce fastener usage, then installation time is reduced, but the connections cannot adequately account for dimensional variations due to manufacturing tolerances
Solution Approach 1:
The coupling system incorporates adjustable positioning mechanisms that allow the coupling to adapt dynamically to dimensional variations in PV modules. The coupling can be positioned at multiple locations along the module frame, enabling it to compensate for tolerance accumulations in both north-south and east-west directions without requiring heavy fasteners or complex deformation processes.
2Loss of time
If press-fit connections are used to reduce fastener usage, then installation time is reduced, but a reliable electrical ground bond cannot be provided without deforming standard PV module frame materials
Solution Approach 1:
The coupling acts as an intermediary component that provides the electrical ground bond function separately from the mechanical connection function. The coupling includes conductive elements that establish reliable electrical connections between adjacent PV modules without requiring deformation of the module frames, thereby maintaining both installation speed and electrical reliability.
3Ease of operation
If the female receiving portion is made wider than the male connecting portion to facilitate quick connection, then ease of operation is improved, but the connection becomes loose or unstable
Solution Approach 1:
The coupling system transitions from a static wide-female/narrow-male configuration to a dynamic adjustable configuration. The coupling can be positioned at multiple locations along the module frame, and the adjustable positioning allows the connection to maintain optimal engagement strength while still being easy to install. The coupling locks into place at the selected position, providing both ease of operation and strong connection.
4Reliability
If tight tolerance PV modules and couplings are produced to ensure precise alignment, then connection reliability is improved, but manufacturing costs increase
Solution Approach 1:
The coupling system changes the tolerance parameters from tight to loose by incorporating adjustable positioning capabilities. Instead of requiring tight tolerances in the PV modules themselves, the coupling absorbs the tolerance variations through its adjustable design, allowing standard tolerance PV modules to be used while maintaining reliable connections.
Data Source
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AI summary
A photovoltaic (PV) module framing and coupling system enables the attachment of PV modules to a roof or other mounting surface without requiring the use of separate structural support members which attach directly to and span between multiple PV modules in a formed PV array. The apparatus provides a parallel coupling for securely interlocking the outside surfaces of parallel frame members together in a side to side arrangement to form an array with improved structural load distribution. The coupling may attach to a slot in the frame at substantially any position along the length of the frame thereby enabling the interconnection of adjacent PV modules along both an x and y axis. The apparatus may further provide a rotating portion and locking portion, mounting brackets for direct connection to a mounting surface, grounding teeth, and a twist-lock engagement means for interlocking and aligning PV modules in the array.