Photovoltaic Mounting Channels With Pre-Installed Clips
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Solution Overview
Problem
The installation of photovoltaic array mounting structures is time-consuming and labor-intensive, with high labor costs and safety concerns, and current techniques often fail to ensure proper construction and quality assurance.
Innovation Solution
A novel photovoltaic mounting structure featuring 'top hat' channels with locator teeth and pre-installed mounting clips that allow easy insertion and secure retention of photovoltaic modules, reducing installation effort and ensuring proper alignment and stability through a frame design with lengthwise beams and ground posts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mounting structures are used, then structural stability is achieved, but installation time and labor intensity increase significantly
Solution Approach 1:
The mounting clips are pre-installed on the channels before the photovoltaic modules arrive at the site. This preliminary preparation eliminates the need for on-site clip installation, significantly reducing installation time and labor requirements while maintaining structural stability
Solution Approach 2:
The mounting structure is divided into modular components: channels with pre-installed clips, lengthwise beams, and support structures. This segmentation allows for easier transportation, assembly, and disassembly, improving installation productivity without compromising overall structural integrity
2Manufacturing precision
If manual installation techniques are used, then flexibility is maintained, but quality assurance and safety concerns arise
Solution Approach 1:
The mounting clips are designed to self-align and self-retain the photovoltaic modules in place. The clips automatically grip the module edges when inserted between the channels, eliminating the need for complex alignment procedures and reducing installation difficulty while ensuring consistent positioning precision
Solution Approach 2:
The mounting clips serve as intermediary components between the channels and photovoltaic modules. These clips simplify the connection process by providing a standardized interface that guides module placement and ensures proper alignment, reducing both installation difficulty and positioning errors
3Reliability
If retention teeth are added to channels, then module retention is improved, but friction during insertion increases
Solution Approach 1:
The retention teeth are strategically positioned only in specific locations on the channel flanges where they are needed for module retention. The majority of the channel surface remains smooth to minimize friction during insertion, while localized teeth provide secure holding positions once the module is in place
Data Source
AI summary
A photovoltaic mounting structure includes a frame for holding a photovoltaic array including a plurality of widthwise channels so as to permit photovoltaic modules to be easily slid between pairs of the channels, the photovoltaic modules resting upon flanges of the channels. In various embodiments, domed protrusions are disposed on lateral sides of the channel to prevent kinking of the modules and reduce friction, retention teeth are formed on upper surfaces of the flanges to position the modules; locator teeth are formed on lower surfaces of the flanges to guide the channels to predetermined spacing; and pre-installed mounting clips are attached to a top surface of the channel. The mounting clips each include an anti-rotation tab oriented downwardly and partially disposed in a corresponding hole in a top surface of the channel so as to prevent rotation of the mounting clip when a bolt of the mounting clip is rotated.