Photovoltaic Rail-to-Post Interlocking Mounts for Fast Roof Assembly
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Solution Overview
Problem
Traditional photovoltaic array mounting systems for flat roofs are complex, time-consuming to assemble, and difficult to adjust, often leading to roof leaks due to multiple connection points.
Innovation Solution
A simplified photovoltaic array mounting system with a minimal number of components, featuring interlocking grasps with interdigitated fingers and a fastening system that allows easy adjustment of the array's angle and reduces potential leaks by minimizing roof attachment points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional pipe frame designs are used for flat roof photovoltaic systems, then the structural stability is improved, but the assembly complexity and time increase significantly
Solution Approach 1:
The mounting system is divided into separate modular components: mounting posts that attach to the roof, mounting rails that support the photovoltaic modules, and connection mechanisms that join them. This segmentation allows each component to be independently installed and adjusted, reducing overall assembly complexity while maintaining structural stability.
Solution Approach 2:
The mounting posts serve multiple functions: they provide structural support, enable angle adjustment of the photovoltaic array, and allow for flexible positioning on the roof surface. This multi-functionality reduces the need for additional specialized components, thereby simplifying the overall system while maintaining stability.
2Strength
If traditional pipe frame designs with multiple parts are used, then the structural strength is improved, but the adjustability of the array angle deteriorates
Solution Approach 1:
The connection mechanism between mounting posts and rails incorporates adjustable elements that allow the array angle to be changed after installation. This dynamic capability enables optimization of the photovoltaic array orientation based on seasonal variations or specific installation requirements, while the overall structural strength is maintained through robust connection design.
3Strength
If multiple connection points through the roof are used in traditional designs, then the structural support is improved, but the risk of building leaks increases
Solution Approach 1:
The mounting posts are designed to be attached to the roof surface without requiring multiple penetration points. By extracting the need for multiple connection holes and using surface-mounted or minimally-invasive attachment methods, the system reduces leak risk while maintaining adequate structural support through proper distribution of loads.
4Reliability
If traditional elaborate pipe frame designs are used, then the structural reliability is improved, but the installation time and productivity decrease
Solution Approach 1:
The mounting components are designed to be pre-assembled or pre-positioned in key locations before final assembly. This preliminary action allows for faster installation on-site, as critical structural elements are already in place and ready for connection, thereby improving productivity without compromising structural reliability.
Data Source
AI summary
A system for connecting a photovoltaic mounting rail onto a mounting post using a connection system with a pair of interlocking grasps having interdigitated fingers that can be locked into the mounting rail when moved by a fastening system.