PV Module Clamp Assembly for Faster Rail Mounting
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Solution Overview
Problem
Existing photovoltaic module securing systems are inefficient and time-consuming to assemble, often requiring numerous parts and complex arrangements, which can be cumbersome in physically demanding conditions.
Innovation Solution
A stanchion clamp assembly with a first and second clamp portion mounted on a bolt, allowing for secure attachment of PV modules by rotating the bolt to draw the clamp portions together, featuring a spring to maintain distance and a spacer for tolerance, with a stanchion providing structural support and attachment to rails or structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing photovoltaic module securing systems are used, then the modules can be secured to structures, but the assembly process becomes time-consuming and complex due to numerous parts and complex arrangements
Solution Approach 1:
The patent combines multiple securing functions into a single integrated clamp assembly. The clamp assembly includes a clamp body with first and second clamp portions, a bolt, a spring, and a spacer all integrated together. This merging of parts reduces the total number of components needed and simplifies the assembly process while maintaining secure attachment of PV modules to rail structures.
Solution Approach 2:
The clamp assembly is designed to perform multiple functions: the clamp portions secure the PV module frame, the bolt provides adjustable fastening, the spring maintains tension and compensation for tolerances, and the spacer ensures proper positioning. This multi-functional design eliminates the need for separate components for each function, thereby reducing part count and assembly complexity.
2Ease of operation
If existing photovoltaic module securing systems are used, then the modules can be secured to structures, but the assembly process becomes physically demanding and hazardous due to complex arrangements
Solution Approach 1:
The clamp assembly is segmented into distinct functional components (clamp portions, bolt, spring, spacer) that are designed to work together in a simplified sequence. The clamp portions can be positioned on the rail and module frame, followed by insertion of the bolt, spring, and spacer in a straightforward order. This segmentation with clear functional separation makes the assembly process more intuitive and easier to perform safely.
Solution Approach 2:
The spring component provides automatic tensioning and compensation for manufacturing tolerances without requiring additional adjustment steps. Once the bolt is inserted and tightened, the spring automatically maintains the proper tension between clamp portions, eliminating the need for complex adjustment mechanisms or multiple fastening steps, thereby simplifying the assembly process.
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
Facilitates quick and efficient assembly of PV modules, reducing installation time and enhancing safety by minimizing the number of parts and simplifying the assembly process.
Implementation Method 1
a spring (210) disposed on the bolt (120) such that the spring (210) abuts a surface of the first clamp portion (124) and maintains a distance between the first clamp portion (124) and the second clamp portion (126)
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.