PV Mounting Bracket Assembly With Integral Grounding and Single-Bolt Clamping
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Solution Overview
Problem
Current solar mounting systems are heavy, complex, and costly due to their large, heavy components, requiring significant materials and skilled labor for installation, and often fail to efficiently accommodate standard, custom, and unframed photovoltaic modules, especially in harsh environments with high loads and corrosive conditions.
Innovation Solution
A flexible mounting bracket assembly with a torsion beam and integral grounding device that securely connects photovoltaic modules using a single bolt, allowing for efficient material use, easier installation, and corrosion resistance, featuring a flexible body with a beam insertion aperture and clamping mechanism that adjusts to various module types and environmental loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional heavy mounting systems are used to support PV modules and withstand natural forces, then structural strength and stability are improved, but system weight and material usage increase significantly
Solution Approach 1:
The patent employs thin-walled hollow torsion beams instead of traditional heavy solid structural members. These hollow beams provide the necessary structural strength to support PV modules and withstand natural forces while significantly reducing material usage and system weight. The hollow cross-section efficiently resists bending and torsional loads.
Solution Approach 2:
The patent changes the structural parameter from solid to hollow cross-section in the mounting beams. This parameter change maintains structural integrity while reducing weight and material consumption. The hollow beams are designed with optimized wall thickness and cross-sectional dimensions to achieve the required strength-to-weight ratio.
2Adaptability or versatility
If traditional mounting systems with multiple components are used to accommodate different PV module types, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent designs a universal mounting bracket assembly that can accommodate multiple PV module types including standard framed modules, custom framed modules, and unframed modules. The bracket system uses standardized hollow beam connections and adjustable clamping mechanisms that work across different module configurations, eliminating the need for multiple specialized mounting systems.
Solution Approach 2:
The mounting system incorporates adjustable and flexible components that can adapt to different module dimensions and frame types. The hollow beams can be positioned and secured at various configurations, and the clamping mechanisms can be adjusted to fit different module sizes, providing dynamic adaptability without increasing overall system complexity.
3Reliability
If traditional mounting systems with multiple fasteners and components are used to secure PV modules, then connection reliability is improved, but installation time and labor requirements increase
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated hollow beam structure. The hollow beams serve as both the structural support element and the primary fastening component, eliminating the need for separate mounting brackets, multiple bolts, and complex assembly procedures. PV modules are secured by directly attaching them to the hollow beams using simplified connection methods.
Solution Approach 2:
The mounting system is segmented into modular hollow beam units that can be independently installed and connected. This segmentation allows for quick assembly where each hollow beam unit can be independently positioned and secured, reducing overall installation time while maintaining connection reliability through standardized connection interfaces.
4Object-affected harmful factors
If traditional mounting systems are used in harsh corrosive environments, then protection against environmental loads is improved, but material usage and cost increase
Solution Approach 1:
The patent employs hollow beams that can be constructed from corrosion-resistant materials or composite structures. The hollow cross-section provides inherent corrosion protection by reducing the total material surface area exposed to harsh environments. The beams can be made from stainless steel, aluminum, or other corrosion-resistant materials with optimized wall thickness to achieve the required durability without excessive material usage.
Data Source
AI summary
A mounting bracket assembly is provided in which a mounting bracket includes a first attachable bracket piece and a second attachable bracket piece, a first fastener, a second fastener, and a third fastener. Each attachable bracket piece has a top member and a bottom member connected to the top member at an angle. The first clamp is attached to the top member of the first attachable bracket piece by the first fastener. The second clamp is attached to the top member of the second attachable bracket piece by a second fastener. The third fastener secures the bottom member of the first attachable bracket piece to the bottom member of the second attachable bracket piece. The mounting bracket defines a beam insertion aperture between the top members and the bottom members. The mounting bracket assembly may include a first integral grounding device located adjacent the top member of the first attachable bracket piece or adjacent the top member of the second attachable bracket piece. The first integral grounding device is configured to electrically bond a frame of an electricity generating device to the mounting bracket assembly. The mounting bracket assembly may further include a second integral grounding device configured to electrically bond a torque tube to the mounting bracket assembly.