Panel mounting components

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Solution Overview

Problem

Conventional single axis trackers for solar panels require multiple parts to perform distinct functions, leading to increased complexity, labor, and variability in grounding and torsional strength, while also being costly and prone to slipping due to the need for additional materials and tooling.

Innovation Solution

A system utilizing a round torque tube with a raised weld seam that serves as both a mechanical stop and electrical grounding path, combined with a solar panel mounting rail featuring a semi-circular cutout to fit over the seam, providing friction and a no-slip design without additional tabs or tracks, and using standard off-the-shelf tubing for cost-effectiveness and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple parts are used to perform distinct functions in conventional single axis trackers, then grounding and torsional strength can be achieved, but device complexity and installation labor increase

Engineering Contradiction:

Improvegrounding and torsional strengthVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions (grounding, mechanical support, torsional strength, and no-slip mechanism) into a single integrated torque tube assembly. The torque tube includes both the structural tube and the grounding path as one unified component, eliminating the need for separate grounding wires and mechanical stops that were required in conventional designs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The torque tube is designed as a multi-functional component that simultaneously provides structural support, electrical grounding, and prevents slipping through its raised weld seam feature. This single component performs what previously required multiple separate parts, reducing overall system complexity while maintaining all necessary functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If additional materials and tooling are used in conventional designs, then grounding and mechanical functions can be achieved, but installation costs and labor requirements increase

Engineering Contradiction:

Improvegrounding and mechanical functionVSAvoidinstallation cost and labor

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The torque tube integrates the grounding path and mechanical features into one component, eliminating the need for separate grounding wires, mechanical stops, and additional tooling. This reduction in part count directly lowers material costs and simplifies installation procedures.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The raised weld seam on the torque tube automatically provides both the mechanical stop feature and the grounding path without requiring additional components or complex installation steps. The design uses the weld seam itself to serve multiple functions, reducing the need for extra materials and simplifying the installation process.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If conventional tracking mechanisms are used, then panel rotation can be achieved, but slipping occurs due to insufficient friction and additional materials are required

Engineering Contradiction:

Improvepanel rotationVSAvoidslipping prevention

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The torque tube features an asymmetric raised weld seam that creates a unique mechanical interface with the mounting rail. This asymmetric feature provides a positive mechanical stop that prevents slipping while allowing controlled rotation, eliminating the need for additional friction-based mechanisms or extra materials.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The circular cross-section of the torque tube combined with the raised weld seam creates a curved mechanical interface that provides both rotational freedom and slip prevention. The rounded shape allows smooth rotation while the raised seam feature maintains consistent contact and friction to prevent unwanted slipping.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

This configuration reduces material and installation costs, enhances reliability, and simplifies assembly by using standard round tubing, while maintaining torsional strength and ensuring electrical grounding, allowing for easy disassembly and reconfiguration of solar panels.

Implementation Method 1

providing friction and a no-slip design

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS10845092B2Panel mounting components

Publication Date: 2020.11.24 DALLY ROBERT B

AI summary

A system includes a first torque tube with a weld seam. A mounting rail includes a cutout portion with a weld seam alignment slot. The first torque tube is configured for placement in the cutout portion. The weld seam of the first torque tube is configured for placement within the weld seam alignment slot.