Low-profile backrail module clamp
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Solution Overview
Problem
Existing module clamps for solar panel systems face challenges in efficiently aligning with module rails and distributing force, leading to potential misalignment and increased wear on support structure components, which can reduce the longevity and increase replacement costs of solar panel tracking systems.
Innovation Solution
A low-profile backrail module clamp is designed with a folding pattern of width-wise and length-wise slits and stamped features, allowing for efficient formation through a stamping process, incorporating jog features and protruding elements to improve alignment and reduce force on the support structure, facilitating secure locking of module rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional module clamps are used, then the structure is simple to manufacture, but the alignment with module rails is poor and force distribution is inefficient
Solution Approach 1:
The clamp body is divided into multiple functional segments including a seating portion with lateral walls, a base surface, and integrated locking features. The folding pattern creates distinct zones for alignment, securing, and force distribution, allowing each segment to perform its specific function optimally while maintaining overall manufacturing efficiency through stamping processes
Solution Approach 2:
Different regions of the clamp are designed with locally optimized properties: the lateral walls include alignment features and slots for precise positioning, the base surface provides friction reduction for smooth module insertion, and the locking features concentrate force at specific points. This local differentiation improves alignment and force distribution without requiring complete redesign of the entire clamp structure
2Reliability
If module clamps with basic design are used, then the production cost is low, but the wear on support structure components increases
Solution Approach 1:
The clamp design incorporates friction reduction features on the base surface and force distribution elements that proactively protect the support structure from excessive wear and stress concentrations. These features are built into the clamp structure before installation, preventing damage to torque tubes and other components during operation and extending system longevity
Solution Approach 2:
The locking features are designed to dynamically adapt to the module rail position, with movable components that engage and lock securely. The folding pattern allows the clamp to flex and conform during installation, then maintain a stable locked position, providing both ease of manufacture through stamping and improved reliability through adaptive locking
3Productivity
If conventional clamps are used, then the installation process is simple, but misalignment and replacement costs increase
Solution Approach 1:
Alignment features such as slots and lateral wall configurations are pre-formed during the stamping manufacturing process. The folding pattern is predetermined to create built-in alignment guides that automatically position the clamp correctly on the module rail during installation, eliminating the need for complex adjustment procedures and reducing misalignment errors
Solution Approach 2:
The clamp design incorporates self-aligning features where the geometry of the lateral walls, base surface, and locking mechanisms automatically guide the clamp into proper alignment with the module rail during installation. The structure serves its own alignment function without requiring external alignment tools or complex adjustment procedures, maintaining simple installation while improving alignment precision
Data Source
AI summary
A method of forming a module clamp of a photovoltaic module support structure may include cutting a folding pattern into a sheet of metal. The folding pattern may include one or more width-wise slits relative to the sheet of metal, one or more length-wise slits relative to the sheet of metal, and a hole. The method may include stamping one or more first features onto the sheet of metal to form a stamped sheet and folding the stamped sheet along the one or more width-wise slits and the one or more length-wise slits to form a preliminary module clamp. The method may include stamping one or more second features onto the preliminary module clamp to form the module clamp.