PV Module Clamping Assembly for Below-Purlin Carport Installation
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Solution Overview
Problem
Existing systems lack an efficient and simple method for assembling solar photovoltaic module arrays on carport purlins, as installers need to work from below the modules, which complicates the process of securing successive modules onto the purlins.
Innovation Solution
A clamping assembly that secures the corners of four photovoltaic modules to a beam or purlin, featuring a rotating connector with arms that lock into side grooves and a fastener for adjustable securement, allowing for easy installation and operation from below, and enabling mid-module removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If installers work from above the modules on traditional roofs, then installation is straightforward, but carport installations require working from below which complicates the process
Solution Approach 1:
The clamping assembly is designed to be installed and operated from below the photovoltaic modules, inverting the traditional approach where installers work from above. The rotating connectors and fasteners are positioned to allow installation personnel to access and operate the system from the ground level, eliminating the need to work on rooftops or elevated structures.
Solution Approach 2:
The clamping assembly acts as an intermediary mechanism that bridges the gap between the purlin structure and the photovoltaic modules. It provides a mechanical interface that allows securement from below, with the rotating connectors and fasteners serving as mediating elements that translate ground-level operations into secure module attachment.
2Productivity
If traditional fastening methods are used for each module individually, then securement is achieved, but the assembly process is time-consuming and inefficient
Solution Approach 1:
The clamping assembly merges multiple fastening functions into a single integrated unit. One clamping assembly can simultaneously secure multiple photovoltaic modules (typically four modules at their corners) to the purlin structure, eliminating the need for separate fastening operations for each module and significantly reducing assembly time.
Solution Approach 2:
The clamping assembly is designed as a multi-functional device that performs multiple operations: it attaches modules to the purlin, secures adjacent modules together through rotating connectors, and provides adjustable fastening through the fastener mechanism. This universal design allows one assembly to handle the securement of an entire module intersection.
3Adaptability or versatility
If fixed-size clamping assemblies are used, then manufacturing is simple, but they cannot accommodate different beam shapes and sizes
Solution Approach 1:
The clamping assembly incorporates dynamic, adjustable components rather than fixed rigid structures. The fastener mechanism allows the gap between the upper and lower body portions to be adjusted to accommodate different beam dimensions and shapes. The rotating connectors can also be positioned and oriented to match various module configurations, providing adaptability without requiring multiple custom-designed assemblies.
Data Source
AI summary
A clamping system for securing the corners of four photovoltaic modules to a carport purlin, the clamping system having upper and lower body portions with an adjustable set screw between, the gap dimensioned to receive the purlin therein and the set screw rotatable to secure the purlin to the upper body portion. The system also having a pair of PV module connectors at opposite ends of the clamping assembly, each PV module connector adapted to secure a pair of PV modules to the purlin.