Pivot-Fit PV Module Coupling for Tolerance-Resistant Grounding
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Solution Overview
Problem
Existing photovoltaic (PV) array mounting systems face challenges in efficiently addressing dimensional variations among PV modules, providing reliable electrical ground bonds, and achieving strong, durable connections, which hinders quick and cost-effective installation and increases system costs.
Innovation Solution
The implementation of a pivot-fit connection system using angled grooves and couplings that allow for adjustable positioning of PV modules, incorporating leveling feet and interlocks with angled keys and tongues to secure modules while accommodating tolerance variations and ensuring a stable electrical ground bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If press-fit connections are used to reduce fastener usage, then installation time is reduced, but the connection reliability deteriorates due to inability to accommodate dimensional variations and provide reliable electrical ground bond
Solution Approach 1:
The coupling system incorporates adjustable positioning mechanisms that allow the coupling to dynamically adapt to dimensional variations in PV modules. The coupling can be positioned at multiple locations along the module frame, enabling installation without requiring precise dimensional tolerances while maintaining secure mechanical and electrical connections.
Solution Approach 2:
The system changes the electrical contact parameter by using conductive adhesives or conductive materials in the sealing between the coupling and PV module frame. This provides both mechanical bonding and reliable electrical ground bond simultaneously, eliminating the need for separate fasteners and electrical connections.
2Ease of operation
If hook-type connections are used to simplify assembly, then ease of operation is improved, but connection strength deteriorates due to loose-fitting design
Solution Approach 1:
The coupling uses composite construction combining rigid structural components for mechanical strength with flexible sealing elements and conductive materials. This composite design maintains ease of assembly while providing strong mechanical connection and reliable electrical bonding that hook-type connections cannot achieve.
3Strength
If multiple small fasteners are used to ensure strong connections, then connection strength is improved, but device complexity and installation time increase
Solution Approach 1:
The coupling merges multiple functions into a single integrated component: mechanical attachment, electrical grounding, and environmental sealing. This eliminates the need for multiple separate fasteners and electrical connectors, reducing device complexity while maintaining strong connections.
Solution Approach 2:
The coupling is designed as a universal component that performs multiple functions simultaneously: providing mechanical attachment to the PV module frame, establishing electrical ground bond through conductive sealing, and offering environmental protection. This multi-functionality replaces multiple specialized fasteners with a single versatile coupling.
Data Source
AI summary
A system and method are disclosed for quickly and easily assembling PV modules into a PV array in a sturdy and durable manner. In examples of the present technology, the system includes various couplings having a first engaging portion adapted to engage a first PV module and a second engaging portion adapted to engage a second PV module. At least one of the engaging portions allows variable positioning of the engaged PV module along the engaging portion.