PV Module Pivot-Fit Frame for Fast Grounded Array Assembly
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Solution Overview
Problem
Current photovoltaic (PV) array mounting systems face challenges in efficiently addressing dimensional variations among PV modules, providing a reliable electrical ground bond, and ensuring a strong, durable connection, which hinders quick and cost-effective installation and increases system costs.
Innovation Solution
The implementation of a pivot-fit connection system using angled grooves and couplings, such as leveling feet and interlocks, that allow for adjustable positioning and secure engagement of PV modules, enabling easy assembly and accounting for tolerance variations while providing a reliable electrical ground bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If press-fit connections are used to reduce fastener usage, then installation time is reduced, but reliable electrical ground bond cannot be provided
Solution Approach 1:
The connection system is segmented into distinct functional components: the grounding element (metallic strip or wire) is separate from the structural connection elements (feet and interlocks). This segmentation allows the grounding function to be independently optimized and provided through multiple pathways without compromising structural integrity or installation speed.
Solution Approach 2:
A dedicated grounding element acts as an intermediary component that provides the electrical ground bond function. This intermediary is specifically designed for electrical connection and can be integrated into the pivot-fit system without affecting the mechanical connection performance or installation time.
2Loss of time
If hook-type connections are used for quick assembly, then installation time is reduced, but strong durable connection cannot be provided
Solution Approach 1:
The pivot-fit connection employs a dynamic insertion process where the coupling is inserted at an angle (e.g., 15-45 degrees) and then rotated to lock into place. This dynamic motion allows for quick installation while ensuring proper engagement and strong connection, eliminating the need for loose-fitting hook-type designs.
Solution Approach 2:
The coupling geometry is asymmetric with a tapered or angled insertion path that differs from the final locked position. This asymmetry enables easy insertion in one direction while providing mechanical locking in the final position, achieving both quick assembly and strong connection.
3Strength
If multiple small fasteners are used for secure connection, then connection strength is improved, but installation time increases
Solution Approach 1:
Multiple fastening functions are merged into a single pivot-fit coupling component. The coupling integrates structural connection, mechanical locking, and electrical grounding capabilities into one element, eliminating the need for multiple separate fasteners while maintaining connection strength and reducing installation time.
Solution Approach 2:
The pivot-fit coupling is designed as a universal component that performs multiple functions simultaneously: providing structural support, ensuring mechanical connection strength through angled engagement, enabling quick installation via simple rotation, and establishing electrical ground bonds through integrated grounding elements.
4Stability of the object's composition
If PV modules are connected in both north-south and east-west directions, then structural stability is improved, but tolerance variations compound and prevent complete installation
Solution Approach 1:
The pivot-fit coupling incorporates adjustable parameters including angular insertion range (15-45 degrees), rotational freedom, and positioning adjustments along the module edges. These parameter changes allow the system to accommodate dimensional variations in both north-south and east-west directions while maintaining structural stability through the angled locking mechanism.
Data Source
AI summary
A system and apparatus are disclosed including PV modules having a frame allowing quick and easy assembling of the PV modules into a PV array in a sturdy and durable manner. In examples of the present technology, the PV modules may have a grooved frame where the groove is provided at an angle with respect to a planar surface of the modules. Various couplings may engage within the groove to assemble the PV modules into the PV array with a pivot-fit connection. Further examples of the present technology operate with PV modules having frames without grooves, or with PV modules where the frame is omitted altogether.