PV Module Clamp Assembly for Faster Secure Rooftop Mounting
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Solution Overview
Problem
Existing photovoltaic module mounting systems are inefficient and time-consuming to assemble, particularly in physically demanding or hazardous conditions, due to complex arrangements and numerous parts.
Innovation Solution
A stanchion clamp assembly that securely attaches photovoltaic modules using a bolt-driven mechanism with spring-loaded clamp portions and a stanchion design, allowing for quick assembly and adaptation to various module sizes and structures, including rail mounting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing mounting systems use complex arrangements and numerous parts to secure PV modules, then the securing reliability is improved, but the assembly time increases and worker safety deteriorates due to prolonged exposure to hazardous conditions
Solution Approach 1:
The clamp assembly is divided into distinct functional segments: a stanchion portion for structural support, a clamp portion for securing the PV module, and a fastening mechanism. This segmentation allows each component to be optimized independently while simplifying the overall assembly process and reducing the number of parts needed.
Solution Approach 2:
The patent combines multiple functions into integrated components. The stanchion and clamp portions are merged into a single assembly that can be quickly installed, and the fastening mechanism integrates the clamping and securing functions into one operation, reducing assembly time while maintaining reliability.
2Reliability
If existing mounting systems use complex arrangements and numerous parts, then the securing reliability is improved, but the device complexity increases making assembly more difficult
Solution Approach 1:
By segmenting the clamp assembly into functional portions (stanchion, clamp, fastening mechanism), the patent reduces overall system complexity while maintaining securing reliability. Each segment performs a specific function, making the system easier to understand and assemble.
Solution Approach 2:
The clamp assembly is designed as a universal mounting system that can secure PV modules of various sizes and types. The integrated design provides multi-functionality, eliminating the need for multiple specialized components and reducing system complexity.
3Reliability
If workers spend more time assembling mounting systems in hazardous conditions, then the securing reliability is improved through careful installation, but worker safety deteriorates
Solution Approach 1:
The clamp assembly is designed to be pre-configured and ready for installation, with components that align and assemble in a predetermined sequence. This preliminary design reduces the time workers spend in hazardous conditions while ensuring proper installation quality through the built-in alignment features.
Solution Approach 2:
The simplified clamp assembly design allows workers to quickly complete the installation process, minimizing exposure to hazardous rooftop conditions. The reduced assembly time enables workers to complete installations faster while maintaining reliability through the robust integrated design.
Data Source
AI summary
A clamp assembly configured to clamp a frame of a photovoltaic (PV) module, the clamp assembly including a first clamp portion shaped to receive an outside surface of the frame and a second clamp portion shaped to secure a flange of the frame between the second clamp portion and a portion of the first clamp portion, wherein the first clamp portion and the second clamp portion are mounted on a bolt. The clamp assembly further includes a stanchion having a first side and a second side, the first side and the second side including apertures through which the bolt is inserted.