PV Module Coupling With Grounding Teeth for Tolerance Take-Up
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing photovoltaic (PV) module coupling systems face challenges in addressing dimensional variations due to manufacturing tolerances, providing a reliable electrical ground bond, and ensuring a strong, durable connection, which hinders efficient and cost-effective installation of PV arrays.
Innovation Solution
The system employs a groove configuration on the PV module frame with sloped surfaces and a pivot-fit connection mechanism, allowing for easy alignment and secure locking of modules while providing an electrical ground bond through cutting teeth, thereby accommodating dimensional variations and ensuring stability under mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If press-fit and hook-type connections are used to reduce fastener usage, then installation time is reduced, but the system cannot adequately account for dimensional variations due to manufacturing tolerances
Solution Approach 1:
The coupling member incorporates a tolerance compensation mechanism that adjusts the connection parameters to accommodate dimensional variations in PV modules. The adjustable positioning features allow the coupling to adapt to ±0.10" variations in module dimensions without requiring tight manufacturing tolerances, thus maintaining quick installation while handling precision variations.
Solution Approach 2:
The coupling member includes movable and adjustable components that can dynamically adapt to dimensional variations. The adjustable positioning features allow the connection to self-adjust during installation, compensating for tolerance accumulations in both north-south and east-west directions while maintaining a stable final connection.
2Loss of time
If press-fit connections are used to reduce fastener usage, then installation time is reduced, but a reliable electrical ground bond cannot be provided without deforming materials
Solution Approach 1:
The coupling member introduces an intermediary grounding mechanism that establishes electrical connection without requiring deformation of PV module frames. The coupling includes dedicated grounding contacts and conductive paths that mediate the electrical bond between adjacent modules, eliminating the need for forceful material deformation while ensuring reliable ground bonding.
Solution Approach 2:
The system replaces the mechanical deformation approach (pressing frames together to create ground bonds) with an electrical contact-based grounding system. The coupling member incorporates conductive elements and grounding contacts that establish electrical connections through controlled contact surfaces, substituting mechanical force with electrical conduction principles.
3Ease of operation
If the female receiving portion is made wider than the male connecting portion to facilitate quick connection, then ease of operation is improved, but the connection becomes loose or unstable
Solution Approach 1:
The coupling member incorporates sloped surfaces and angled engagement features that guide the male connecting portion into the female receiving portion. The sloped surfaces provide self-aligning action during insertion, ensuring proper positioning while maintaining connection integrity. The angled geometry allows easy insertion while preventing lateral movement that would cause loosening.
Solution Approach 2:
The coupling design employs asymmetric geometry where the male and female portions have complementary but non-symmetric shapes. The male portion includes engagement features that fit into corresponding recesses in the female portion, creating a keyed connection that prevents rotation and lateral movement while maintaining ease of insertion through the asymmetric guiding surfaces.
4Manufacturing precision
If rail-based systems are used to solve tolerance take-up, then dimensional variations are accommodated, but device complexity increases
Solution Approach 1:
The invention extracts the tolerance compensation function from the rail system and integrates it directly into the coupling member. By incorporating adjustable positioning features and tolerance compensation mechanisms within the coupling itself, the system eliminates the need for separate rails while maintaining the ability to accommodate dimensional variations in PV modules.
Solution Approach 2:
The coupling member is designed as a multi-functional component that simultaneously provides mechanical connection, electrical grounding, and tolerance compensation. By integrating multiple functions into a single component, the system achieves the tolerance take-up capability of rail systems without the added complexity of separate rail structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables rapid and durable assembly of PV arrays by accommodating tolerance variations, ensuring a strong and reliable connection, and providing a consistent ground bond, thus reducing installation time and costs.
Implementation Method 1
providing an electrical ground bond through cutting teeth
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
A photovoltaic (PV) module framing and coupling system enables the attachment of PV modules to a roof or other mounting surface without requiring the use of separate structural support members which attach directly to and span between multiple PV modules in a formed PV array. The apparatus provides a parallel coupling for securely interlocking the outside surfaces of parallel frame members together in a side to side arrangement to form an array with improved structural load distribution. The coupling may attach to a slot in the frame at substantially any position along the length of the frame thereby enabling the interconnection of adjacent PV modules along both an x and y axis. The apparatus may further provide a rotating portion and locking portion, mounting brackets for direct connection to a mounting surface, grounding teeth, and a twist-lock engagement means for interlocking and aligning PV modules in the array.