Mounting system and a method for mounting photovoltaic modules

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Solution Overview

Problem

Conventional photovoltaic module mounting systems face challenges such as the need for manual handling and additional personnel to secure modules, instability during windy conditions, and difficulties in replacing or post-processing modules due to clamps and clearance requirements, as well as material and alignment issues.

Innovation Solution

A mounting system with a steel frame and mounting elements featuring hook-like engagement portions and screw connections that allow secure interlocking and fixation from the rear side, eliminating the need for manual handling and reducing module-to-module clearance, using steel components to prevent corrosion and enhance stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional clamps are used to fixate photovoltaic modules, then the modules can be secured to mounting rails, but the modules require significant clearance (20-30 mm) between them to accommodate the clamp body thickness

Engineering Contradiction:

Improvesecure connectionVSAvoidmodule-to-module clearance

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The mounting element is divided into two functional portions: a first portion that hooks into the frame opening to provide interlocking connection, and a second portion that enables secure fixation to the mounting rail. This segmentation allows each portion to be optimized independently, eliminating the need for thick clamp bodies and reducing clearance requirements between modules.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of clamping the module frame from the front side (light incidence side), the mounting system hooks into openings or protrusions at the lateral or bottom sides of the frame and fixes from the rear side. This inversion of the mounting approach eliminates the need for front-side clamp bodies, significantly reducing the required module-to-module clearance.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If clamps are used to hold the frame from the front side, then the modules can be secured, but additional personnel are needed to manually hold the modules during installation

Engineering Contradiction:

Improvesecure connectionVSAvoidmanual handling requirement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The mounting element's first portion automatically hooks into the opening or protrusion of the frame, providing self-aligning interlocking connection without requiring manual positioning or holding of the module. The hook-like engagement portion captures the frame feature, allowing the module to be secured without additional personnel for manual support.

Inventive Principle:

Principle #25Self-service

3Productivity

If conventional mounting systems are used, then modules can be installed on rails, but replacing or post-processing modules becomes cumbersome due to the need to detach clamps and handle multiple modules

Engineering Contradiction:

Improveinstallation efficiencyVSAvoidmodule replacement difficulty

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The mounting system creates independent connections between each mounting element and its corresponding module frame. This segmentation allows individual modules to be detached by removing only their specific mounting elements, without needing to detach clamps that secure multiple modules simultaneously, greatly simplifying module replacement and post-processing operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting element acts as an intermediary component that connects the module frame to the mounting rail through distinct connection points. This intermediary structure allows individual module detachment while maintaining the stability of neighboring modules, as each module has its own dedicated mounting elements that can be independently removed.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Device complexity

If aluminum extruded rails without grooves are used, then the mounting system can be simpler, but the rails become expensive

Engineering Contradiction:

Improvemounting system simplicityVSAvoidrail manufacturing cost

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The mounting element's second portion is designed to enable direct secure fixation to plain mounting rails without requiring pre-formed grooves or special features on the rail. The mounting element itself provides the necessary connection geometry, eliminating the need for expensive grooved aluminum extrusions and allowing the use of simpler, more cost-effective rail designs.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11309830B2Mounting system and a method for mounting photovoltaic modules

Publication Date: 2022.04.19 HANWHA Q CELLS GMBH

AI summary

A mounting system for mounting a photovoltaic module onto at least one mounting rail. The mounting system comprises a frame for the photovoltaic module with at least one opening or protrusion at a lateral side or a bottom side of the frame, the bottom side being opposite to light incidence side of the photovoltaic module. The mounting system further comprises a plurality of mounting elements, each comprising a first portion and a second portion for securing the frame to the at least one mounting rail, the first portion defining a hook-like engagement portion to hook into the opening or the protrusion or the bottom side of the frame to provide an interlocking connection, the second portion enabling a secure fixation to the at least one mounting rail.