Mounting bracket extension
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Solution Overview
Problem
Current solar mounting systems for photovoltaic (PV) modules are heavy, complex, and costly due to the need for large, heavy components to support PV arrays and withstand natural forces, requiring significant material and skilled labor for installation, and are not adaptable to standard, custom, or unframed modules.
Innovation Solution
A flexible mounting bracket assembly with extension panels that securely attach PV modules to a torsion beam using a single bolt, allowing for efficient use of structural material, easier installation, and compatibility with various module types by extending the contact point and surface area, thereby reducing material stress and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large, heavy components are used to support PV arrays and withstand natural forces, then the structural strength and stability are improved, but the overall weight and material usage increase significantly
Solution Approach 1:
The mounting system is divided into separate functional components: a clamp assembly for clamping the PV module, an extension panel for positioning and support, and a torsion beam for mounting. This segmentation allows each component to be optimized independently, using material only where structurally necessary rather than requiring large heavy components throughout the entire assembly.
Solution Approach 2:
The extension panel provides localized structural support at specific points where needed - extending the contact point and surface area at the rear of the PV module to distribute forces evenly. This local reinforcement eliminates the need for heavy overall structure while maintaining strength at critical load-bearing locations.
2Strength
If complex mounting assemblies are used to support heavy PV modules, then the load-bearing capacity is improved, but the device complexity and installation difficulty increase
Solution Approach 1:
The clamp assembly and extension panel are designed to work together as an integrated unit that attaches to the PV module frame. The clamp secures the module while the extension panel simultaneously provides rear support and positioning, combining multiple functions into a single assembly that reduces overall system complexity.
Solution Approach 2:
The extension panel serves multiple functions: it extends the contact point for rear support, provides a mounting surface for attaching the PV module to the torsion beam, distributes structural forces, and accommodates various module types including standard, custom, and unframed modules. This multi-functionality reduces the number of separate components needed.
3Reliability
If traditional mounting systems are used for standard PV modules, then the mounting security is improved, but the adaptability to custom and unframed modules is reduced
Solution Approach 1:
The extension panel is designed with a universal mounting interface that can accommodate various PV module types. The panel extends to provide support for unframed modules, can interface with custom frame configurations, and works with standard modules through the clamp assembly, making the same basic design adaptable to diverse module designs.
Solution Approach 2:
The mounting system incorporates adjustable elements that allow the clamp and extension panel configuration to be adapted to different module types. The system can be adjusted to secure unframed modules, custom-framed modules, or standard modules while maintaining reliable mounting for each type.
4Reliability
If multiple bolts and complex fastening mechanisms are used to attach PV modules, then the attachment security is improved, but the installation time and labor requirements increase
Solution Approach 1:
The clamp assembly and extension panel are designed to be attached together and to the PV module in a simplified sequence. The extension panel provides structural support that works in conjunction with the clamp, allowing both components to be secured efficiently while maintaining secure attachment through coordinated fastening rather than multiple separate fastening operations.
Data Source
AI summary
An extension panel may include a mating surface shaped to interface with a back surface of a clamp that includes a mounting hole corresponding to a bolt slot in the back surface of the clamp to accommodate a single bolt passing through the extension panel and the clamp. The extension panel may also include a pair of flanges projecting outward from the mating surface and positioned to be on either side of the clamp. The extension panel may also include a flat top surface generally parallel and aligned linearly with another flat top surface of a flexible member. The extension flat top surface may be sized to be approximately a same width as the flexible member at a first end of the extension flat top surface proximate the mating surface and may flare out as the extension flat top surface extends away from the flexible member.