PV Module Pivot-Fit Frame for Tolerance-Ready Grounded Assembly
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Solution Overview
Problem
Existing photovoltaic (PV) module coupling systems face challenges in addressing dimensional variations due to manufacturing tolerances, providing a reliable electrical ground bond, and ensuring a strong, durable connection, which hinders quick and cost-effective assembly of PV arrays.
Innovation Solution
A system utilizing a grooved frame with angled grooves for pivot-fit connections, allowing for adjustment to account for tolerance variations and incorporating leveling feet and interlocks with key and tongue mechanisms for secure and grounded module assembly.
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 the connections cannot adequately account for dimensional variations due to manufacturing tolerances
Solution Approach 1:
The connection geometry is changed by introducing an angled groove (e.g., 15 degrees from vertical) instead of a straight vertical groove. This angular parameter change allows the coupling to self-adjust and accommodate dimensional variations in the PV module frames while maintaining a secure press-fit connection, thus resolving the contradiction between installation speed and tolerance accommodation.
2Reliability
If press-fit connections are made with sufficient force to deform materials for reliable ground bond, then ground bond reliability is improved, but heavy-duty tools are required eliminating cost and time savings
Solution Approach 1:
The groove is designed with curved, angled surfaces rather than straight vertical walls. This curvature allows the coupling to be inserted at an angle and then rotated into final position, using the rotation motion to progressively deform the materials and create a reliable ground bond without requiring excessive force or heavy-duty tools.
Solution Approach 2:
The connection process is made dynamic by allowing the coupling to be inserted at an angle and then rotated into its final position. This dynamic insertion and rotation process distributes the deformation force over time and motion, enabling reliable material deformation and ground bond creation without requiring heavy-duty static pressing tools.
3Ease of operation
If the female receiving portion is made wider than the male connecting portion for quick connection, then ease of connection is improved, but the connection becomes loose and unstable under mechanical stress
Solution Approach 1:
The coupling transitions from a loose angular insertion position to a tight final position through rotation. The angled groove allows easy initial insertion, but the rotation motion transforms this loose connection into a secure, tight fit where the coupling is firmly held by the angled surfaces, thus achieving both ease of connection and connection strength.
Solution Approach 2:
The angled groove geometry is designed so that the loose angular insertion is actually a preliminary action that facilitates the final tight connection. The easy angular insertion gets the coupling into position, and then simple rotation completes the secure connection, making the preliminary loose state a useful intermediate step rather than a defect.
4Strength
If multiple small fasteners are used to ensure strong connection, then connection strength is improved, but installation time increases and part count increases
Solution Approach 1:
Multiple separate fastening functions are merged into a single integrated coupling component. The coupling simultaneously provides structural connection, electrical ground bond, and tolerance accommodation through its angled groove design, eliminating the need for multiple separate fasteners and reducing installation time while maintaining connection strength.
Solution Approach 2:
The coupling is designed as a multi-functional component that performs multiple functions: it provides mechanical connection strength through the angled press-fit, establishes electrical ground bond through the deformed material contact, and accommodates dimensional variations through the angular geometry. This universality replaces multiple specialized fasteners with a single component.
Data Source
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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.