Modified clamp
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Solution Overview
Problem
Conventional solar mounting systems are heavy and costly due to the use of glass-encased photovoltaic modules, requiring significant material and labor for installation and quality control, which increases the complexity and expense of solar power systems.
Innovation Solution
A lightweight mounting bracket assembly with a flexible body and a configuration that facilitates secure connection between a photovoltaic module and a torsion beam using a single bolt, minimizing material usage and simplifying installation and quality control processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional glass-encased photovoltaic modules and heavy mounting components are used, then structural strength and stability are improved, but system weight and cost increase significantly
Solution Approach 1:
The mounting system is divided into separate functional components: a lightweight bracket assembly for supporting PV modules and a separate torsion beam for structural strength. This segmentation allows each component to be optimized independently - the bracket can be minimal and light while the torsion beam provides the necessary structural support.
Solution Approach 2:
The bracket assembly nests onto the torsion beam, with the bracket's U-shaped channel receiving the torsion beam. This nested configuration allows the lightweight bracket to leverage the structural strength of the torsion beam without requiring the bracket itself to be heavy and rigid throughout.
2Reliability
If traditional mounting systems with multiple components are used, then secure connection is achieved, but device complexity and installation time increase
Solution Approach 1:
The bracket assembly combines multiple functions into a single integrated component: it provides PV module support, interfaces with the torsion beam, and includes built-in alignment features. This merging eliminates the need for separate alignment tools and multiple assembly steps, reducing complexity while maintaining connection reliability.
Solution Approach 2:
The bracket assembly serves multiple functions simultaneously: it supports PV modules, connects to the torsion beam, provides alignment through its U-shaped channel geometry, and enables quick installation. This multi-functionality reduces the number of separate components needed and simplifies the overall system.
3Reliability
If conventional mounting brackets are used, then PV modules can be secured, but material usage and installation cost increase
Solution Approach 1:
The design extracts only the essential structural elements needed for securing PV modules - the U-shaped channel and mounting holes - rather than using a solid, heavy bracket. This extraction of essential functions allows for minimal material usage while maintaining securing capability.
Solution Approach 2:
The bracket uses thin-walled tubular structures rather than solid material, providing the necessary strength and securing capability with minimal material. The tubular geometry of the U-shaped channel provides structural efficiency with reduced material consumption.
Data Source
AI summary
A mounting system may include a frame associated with a power-generating device, the frame including an opening. The mounting system may include a bracket mounting assembly. The bracket mounting assembly may include a top member having a first surface, a clamp, and a single bolt passing through both the top member and the clamp such that the clamp moves along an interface between the first and a second surfaces as the single bolt is tightened. The clamp may include the second surface corresponding to the first surface, an arm projecting away from the top member, and a flange at least proximate a top of the arm. The flange may include an ear at the top of the arm and a tab on a bottom side of the ear projecting back towards the top member, the tab positioned to interface with the opening on the frame.