PV Leveling Foot Pivot-Fit Mounting for Tolerance Variation
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Solution Overview
Problem
Existing photovoltaic (PV) array mounting systems face challenges with dimensional variations among PV modules, leading to installation issues, unreliable electrical ground bonds, and unstable connections due to press-fit and hook-type connections, which increase costs and reduce efficiency.
Innovation Solution
A pivot-fit connection system using angled grooves and components like leveling feet and interlocks that allow for adjustment and secure mounting of PV modules, providing a sturdy and durable assembly while accommodating tolerance variations and ensuring reliable electrical grounding.
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 connection reliability and electrical ground bond consistency deteriorate
Solution Approach 1:
The patent changes the geometric parameters of the connection interface by introducing an angled groove (e.g., 15-45 degrees from horizontal) that transforms the insertion mechanism. This angular parameter change enables a pivot-fit motion that simultaneously achieves quick installation and reliable mechanical/electrical connection through bearing surfaces positioned at specific angles.
Solution Approach 2:
The patent employs curved or angled bearing surfaces within the groove geometry rather than flat press-fit interfaces. The angled groove creates a pivoting motion path that allows the module to rotate into place, transforming linear insertion into rotational engagement, which improves both installation speed and connection reliability.
2Device complexity
If PV modules are structurally connected in both north-south and east-west directions without rails, then system complexity is reduced, but tolerance accumulation causes installation impossibility
Solution Approach 1:
The patent introduces dynamic adjustment capability through the angled groove geometry that allows modules to pivot and self-align during installation. This dynamic mechanism absorbs dimensional variations and tolerance accumulations without requiring rigid precision, enabling successful installation despite manufacturing variations while maintaining a simple rail-free structure.
Solution Approach 2:
The connection system is segmented into distinct functional elements: the angled groove for mechanical engagement, bearing surfaces for load transfer, and electrical contact points for grounding. This segmentation allows each element to independently address specific requirements (mechanical strength, tolerance accommodation, electrical bonding) without compromising the others.
3Ease of operation
If the female receiving portion is made wider than the male connecting portion for quick connection, then ease of operation is improved, but connection stability deteriorates
Solution Approach 1:
The patent replaces the traditional wide female/receiving portion with an angled groove geometry that guides the module through a pivoting motion. The curved or angled bearing surfaces within the groove provide progressive engagement, allowing easy insertion through rotation while maintaining stable connection through distributed contact areas that resist loosening under load.
Data Source
AI summary
A system and apparatus 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 a leveling foot for engaging a PV module and supporting the PV module on a support structure. The leveling foot allow adjustment of the height of engaged PV modules relative to the support structure.