PV Mounting Bracket Assembly With Torsion Beam and Rib Reinforcement
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Solution Overview
Problem
Current photovoltaic (PV) mounting systems are heavy, complex, and costly due to the need for robust materials to support PV modules and withstand natural forces, and they require skilled labor for installation and quality control, with limited efficiency in using structural material and accommodating different module types.
Innovation Solution
A lightweight, flexible mounting bracket assembly made of injection-molded plastic, featuring a torsion beam design with metal sleeves and ribs for force distribution, tool-less fasteners, and conductive components for electrical communication, allowing for efficient material use and easier installation across various PV module types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy robust materials are used to support PV modules and withstand natural forces, then structural strength is improved, but weight and cost increase
Solution Approach 1:
The mounting bracket uses composite construction combining plastic material with integrated metal sleeves and ribs. The plastic provides corrosion resistance and lightweight properties, while the metal reinforcement elements provide structural strength at critical load-bearing areas, resolving the contradiction between weight and strength.
Solution Approach 2:
The bracket features localized reinforcement through integrated metal sleeves at mounting holes and ribs at stress concentration areas. Instead of using heavy material throughout the entire bracket, the design applies strong materials only where structurally necessary, reducing overall weight while maintaining required strength.
2Stability of the object's composition
If complex assemblies with large components are used to support heavy solar arrays, then structural stability is improved, but device complexity and cost increase
Solution Approach 1:
The mounting bracket integrates multiple functions into a single component: the main bracket body, mounting holes with metal sleeves, reinforcement ribs, and attachment features are all combined in one piece. This eliminates the need for separate reinforcement plates, multiple fastening components, and assembly steps, reducing complexity while maintaining stability.
Solution Approach 2:
The bracket design with standardized metal sleeves and rib structures can accommodate different PV module types and mounting configurations. The universal design approach allows the same bracket component to serve multiple functions and applications, reducing the variety of components needed in the overall mounting system.
3Adaptability or versatility
If traditional mounting systems are used to accommodate different PV module types, then adaptability is limited, but design simplicity is maintained
Solution Approach 1:
The mounting bracket incorporates universal features including standardized metal sleeves that accept various bolt sizes and configurations, and rib structures that can accommodate different module frame types (standard, custom, or unframed). This multi-functional design allows a single bracket type to mount diverse PV modules without requiring design changes.
Solution Approach 2:
The bracket design allows for flexible installation configurations and adjustments to accommodate different module types. The metal sleeves and rib structures can be positioned and configured during installation to match various module geometries, providing adaptability without requiring multiple pre-designed bracket variants.
4Manufacturing precision
If skilled operators perform quality control measures during installation, then installation quality is improved, but installation time and labor cost increase
Solution Approach 1:
The metal sleeves and rib features are pre-formed during bracket manufacturing with precise dimensions and tolerances. This preliminary action ensures that critical alignment and mounting features are already precision-engineered before field installation, reducing the need for time-consuming quality control checks and adjustments during installation.
Solution Approach 2:
The integrated metal sleeves and rib structures are self-aligning features that guide proper bracket installation. The design inherently provides alignment references and tolerance compensation, allowing installers to achieve correct positioning through the self-service nature of the features rather than requiring extensive measurement and quality control procedures.
Data Source
AI summary
A mounting bracket assembly comprising may include an upper region with flat portions on either end that interface with a photovoltaic (PV) module and a lower portion in between the flat portions, and a central portion at least partially surrounding a hole shaped to accommodate a torsion beam. The mounting bracket assembly may also include side portions extending from the ends of the upper region to below the hole shaped to accommodate the torsion beam, and a first outer lining along a periphery of the mounting bracket assembly. The mounting bracket assembly may also include a second outer lining along the hole shaped to accommodate the torsion beam, and multiple ribs extending between the first outer lining and the second outer lining.