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Solution Overview
Problem
Existing solutions fail to securely fix photovoltaic module frames to supporting structures, particularly under stress conditions like wind forces, and maintain continuous electrical contact, especially when the structure is mobile and oriented according to sunlight.
Innovation Solution
A pin with a metal body featuring convex portions, inclined walls, protruding blades, and locking members is used to securely insert into a U-shaped rail, ensuring mechanical stability and continuous electrical contact through its design, which includes wings, shoulders, and blades that anchor the pin in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fasteners are used to attach the photovoltaic module frame to the rail, then the attachment is simple, but the assembly cannot resist significant stresses such as wind forces and module deflection stresses
Solution Approach 1:
The pin is divided into multiple functional segments: convex portions for mechanical interlocking with the rail, protruding blades for gripping the frame, locking members for preventing disengagement, and wings for additional anchoring. Each segment performs a specific function to collectively resist various stresses including wind forces and module deflection stresses.
Solution Approach 2:
The pin features asymmetric geometry with convex portions having inclined inner and outer walls forming ridges, protruding blades at specific positions, and locking members oriented in particular directions. This asymmetric design optimizes the mechanical interlocking and stress distribution, enabling the pin to effectively resist multi-directional forces while maintaining structural integrity.
2Strength
If the pin structure is made more complex to resist stresses, then the mechanical strength improves, but the ease of manufacture decreases
Solution Approach 1:
The pin utilizes controlled geometric parameters including the inclination angles of the inner and outer walls of the convex portions, the positioning and dimensions of the protruding blades, and the configuration of the locking members. By optimizing these parameters, the pin achieves high mechanical strength while remaining manufacturable through standard metal forming and cutting processes.
3Reliability
If the pin is designed to prevent detachment under stress, then the reliability improves, but the device complexity increases
Solution Approach 1:
The pin integrates multiple functions into a single unified component: mechanical interlocking through convex portions, electrical contact through the metallic body and protruding blades, and detachment prevention through locking members. This merging of functions into one piece reduces the number of separate components while maintaining high reliability for preventing frame detachment under various stress conditions.
4Reliability
If the pin uses multiple locking mechanisms to prevent disengagement, then the reliability under mobile conditions improves, but the manufacturing precision requirements increase
Solution Approach 1:
The pin employs optimized geometric parameters including the inclination angles of walls, the positioning of blades and locking members, and the dimensions of various features. These parameters are designed to provide sufficient tolerance margins that maintain reliable electrical contact and mechanical locking under mobile conditions while being achievable through standard manufacturing processes without requiring extreme precision.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2a~2b
AI summary
Pin (1) comprising a metal body (10) extending along a longitudinal axis (Ox) of insertion and having a first (103) and a second end (104) along the longitudinal axis (Ox), an upper face (101) and a lower face (102) opposite the upper face (101), the pin (1) comprising two convex portions (13) each having an inclined inner wall and an inclined outer wall, the inclined walls of each convex portion (13) forming a ridge and extending along the longitudinal axis (Ox), at least one ridge having on its lower face a projecting blade obtained by cutting and folding the metal body along the longitudinal axis (Ox); a concave portion connecting the inner walls of each convex portion (13) by a central surface (14); at least one locking member (12).