Modular PV Panel Retention Assembly for Reduced Racking Complexity
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Solution Overview
Problem
Conventional systems for mounting photovoltaic panels on structures, such as metal roofs, are costly due to the need for numerous parts and complex assemblies, increasing manufacturing and installation costs and time.
Innovation Solution
A modular retention system using a solar cap with integral flange extensions for spacing and stabilization, and a support bracket with a base platform and L-shape configuration to eliminate the need for expensive racking frames, incorporating a clamp assembly with improved holding force and adjustable features for secure and level mounting of PV panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting assemblies with numerous parts are used, then the PV panel can be securely mounted, but the manufacturing cost and installation cost increase
Solution Approach 1:
The patent combines multiple functions into a single integrated mounting assembly. The clamp assembly integrates the clamp body, clamp arm, and fastening mechanism into one unit that attaches to the standing seam. The support bracket combines the mounting function with the leveling function in a single L-shaped component, eliminating the need for separate leveling devices and reducing the total number of parts required for secure PV panel installation.
Solution Approach 2:
The mounting assembly is designed to perform multiple functions simultaneously. The clamp assembly not only secures the PV panel to the standing seam but also provides electrical grounding through its conductive structure. The support bracket serves both as a mounting support and as a leveling device with adjustable feet, eliminating the need for separate grounding and leveling components.
2Reliability
If conventional mounting assemblies with numerous parts are used, then the PV panel can be securely mounted, but the installation time increases
Solution Approach 1:
The mounting system is divided into modular components that can be independently assembled and installed. The clamp assembly, support bracket, and leveling feet are separate modules that can be pre-assembled and then quickly installed on-site. This segmentation allows for faster installation compared to conventional systems that require assembling many small parts during installation.
Solution Approach 2:
The mounting components are designed to be pre-assembled or pre-configured before installation. The clamp assembly can be pre-assembled with the fastening mechanism, and the support bracket can be pre-configured with adjustable feet. This preliminary preparation reduces the complexity and time required for on-site assembly and installation.
3Reliability
If conventional racking frames and systems are used, then the PV panel array can be supported, but the manufacturing cost and installation expense increase
Solution Approach 1:
The patent extracts and eliminates the complex racking frame system from the mounting assembly. Instead of using a complete racking frame structure, the invention uses a simplified clamp assembly that attaches directly to the standing seam and a support bracket that provides localized support. This extraction of the essential support function while removing unnecessary complexity significantly reduces the number of components required.
Solution Approach 2:
The mounting assembly uses simple, inexpensive components that can be easily replaced if needed. The clamp assembly and support bracket are designed as straightforward mechanical components without complex moving parts, making them cheaper and simpler than conventional racking systems while providing adequate support for the PV panel array.
Data Source
AI summary
The invention relates to retention systems and, more particularly, for a modular retention apparatus, system and method for securing and leveling a photovoltaic (PV) panel and other objects on a wall, rooftop and other structure to secure and ground electrically. The photovoltaic panel retention assembly utilizes a solar cap with one or more integral elongated flange extensions of a predetermined dimension to provide spacing between PV solar panels and/or to stabilize the solar cap from tipping under installation forces and load in use. The flanges extend through a support bracket configured with a base portion to support adjacent PV panels in a PV panel array and a base platform portion. The solar cap comprises integral teeth on a surface of the solar cap spaced apart from the flanged projections to locate the teeth adjacent a frame of the PV panel for electrical grounding thereof.