Lever-Actuated Panel Clamp for Tool-Free Solar Installation
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Solution Overview
Problem
Existing solar panel fastening systems require two types of clamps (intermediate and end clamps), are cumbersome to install due to the need for additional tools, and offer limited flexibility in adjusting panel positions due to invasive or predetermined connections.
Innovation Solution
A panel clamp with a lever mechanism that allows for tool-free installation, enabling the clamp to function as both an intermediate and end clamp, featuring a solar panel engaging element, a rail engaging element, and a fastening tool, which uses a lever mechanism to securely fasten the solar panel to the mounting rail without damaging it, and can be easily adjusted in position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two different types of clamps (intermediate and end clamps) are used, then the fastening function is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The panel clamp is designed with a universal structure that can function as both an intermediate clamp and an end clamp. The clamp body includes a solar panel engaging element with a body and flange, a rail engaging element with a body and connector portion, and a fastening tool with a lever mechanism. This single design can be used in both intermediate positions (between two solar panels) and end positions (at the end of a row), eliminating the need for separate intermediate and end clamp types.
2Strength
If additional tools or equipment are required for fastening, then the fastening strength is improved, but the ease of operation deteriorates
Solution Approach 1:
The fastening tool is designed to be self-contained and self-operating. The tool includes a handle that acts as a lever mechanism, with a fulcrum positioned on the clamp body. By simply operating the handle, the user activates the lever mechanism that generates relative movement between the solar panel engaging element and the rail engaging element, fastening the clamp without requiring any additional external tools or equipment.
3Strength
If invasive connections are used to fasten the clamp to the mounting rail, then the connection strength is improved, but the adaptability deteriorates
Solution Approach 1:
The connection between the panel clamp and the mounting rail is designed to be dynamic and adjustable rather than fixed and invasive. The rail engaging element can be positioned at different locations along the mounting rail, and the lever mechanism allows for easy installation and removal without drilling holes or making permanent modifications to the rail. This enables flexible positioning and adjustment of solar panels while maintaining a strong connection during operation.
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 simplifies the installation process by eliminating the need for additional tools, enhances flexibility in panel positioning, and reduces manufacturing costs by allowing a single type of clamp to serve multiple functions, while maintaining secure and durable fastening.
Implementation Method 1
the fastening tool uses a lever mechanism to generate a relative movement between the solar panel engaging element and the rail engaging element, thereby fastening the solar panel engaging element to the rail engaging element
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3C
AI summary
There is provided a panel clamp (20) for fastening a solar panel to a mounting rail in a solar panel installation. The panel clamp comprises a solar panel engaging element (22), a rail engaging element (24), and a fastening tool (26). The fastening tool is operably engaged to both the solar panel engaging element (22) and the rail engaging element (24) and arranged to provide generate a relative movement between the elements to clamp the solar panel. The fastening tool uses a lever mechanism to generate the relative movement.