PV Support Rail Fastening for Trapezoidal Sheet Ribs

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Solution Overview

Problem

Existing fastening methods for photovoltaic module support rails on trapezoidal sheets are labor-intensive, require individual manufacturing for different rib shapes, and involve complex screwing processes, making them inefficient and difficult to assemble.

Innovation Solution

A fastening system featuring a support rail with an undercut groove and a retaining element with an engaging extension that can be easily inserted into the groove, allowing for screw-free, stable, and assembly-friendly attachment to trapezoidal ribs, suitable for various rib shapes without adjustments, and utilizing self-cutting screws or elastic spacers for enhanced stability and sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional screwing processes are used to fasten support rails to trapezoidal ribs, then reliable connection is achieved, but assembly time and labor intensity increase significantly

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The retaining element is divided into distinct functional sections: a fastening section for attachment to the rib and an engaging extension for insertion into the groove. This segmentation allows each part to perform its specific function efficiently, enabling quick assembly without complex screwing operations while maintaining reliable connection through the coordinated action of both sections

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the traditional screwing mechanical system with a snap-fit engagement system. The engaging extension inserts into the undercut groove and locks automatically through elastic deformation and geometric interlocking, eliminating the need for screwdrivers, bolts, or threaded fasteners while reducing assembly time and labor intensity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If individual retaining elements are manufactured for different rib shapes, then adaptability is improved, but manufacturing complexity and costs increase

Engineering Contradiction:

Improveadaptability to different rib shapesVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The retaining element is designed as a universal component that can be used with different rib shapes and sizes. The fastening section can be attached to various rib configurations, and the engaging extension works with different groove dimensions, allowing a single design to serve multiple applications without requiring individual manufacturing for each rib type

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent allows for parameter adjustments within the retaining element design, such as varying the dimensions of the engaging extension or the fastening section, to accommodate different rib and groove specifications. This enables adaptability to different rib shapes through parameter modification rather than complete redesign, simplifying manufacturing while maintaining versatility

Inventive Principle:

Principle #35Parameter changes

3Strength

If complex multi-part clamping devices with threaded bolts are used, then secure fastening is achieved, but the number of parts and assembly steps increase

Engineering Contradiction:

Improvefastening strengthVSAvoidnumber of parts

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the fastening function and the retaining function into a single integrating retaining element. The fastening section provides secure attachment to the rib while the engaging extension provides retention in the groove, combining multiple functions into one component and eliminating the need for separate clamping devices, threaded bolts, and multi-part assemblies

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If screw-free fastening methods are used, then assembly speed is improved, but connection stability may be compromised

Engineering Contradiction:

Improveassembly speedVSAvoidconnection stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Instead of using threaded fasteners that screw into material, the patent inverts the approach by having the retaining element's engaging extension insert into a pre-formed groove and lock through elastic deformation. This inverted mechanical engagement provides stable connection through geometric interlocking and material elasticity rather than threading, maintaining reliability while enabling screw-free assembly

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS9525088B2Fastening of a support rail for a PV module to a trapezoidal sheet

Publication Date: 2016.12.20 SCHLETTER INTERNATIONAL BV

AI summary

A fastening of a support rail for a photovoltaic module to a trapezoidal rib of a trapezoidal sheet. The support rail comprises an undercut groove with a groove opening. The trapezoidal rib comprises an upper side and a slanted side. The support rail is positioned transversely to the trapezoidal rib. The fastening includes at least one retaining element comprising a fastening section fastened to the slanted side of the trapezoidal rib, and an engaging extension non-detachably arranged thereon. The engaging extension engages the undercut groove in an engaging position. The engaging extension is insertable through the groove opening into the undercut groove of the support rail in a loose position that is rotated relative to the engaging position. The support rail is held down against the upper side of the trapezoidal rib by the engaging extension. The at least one retaining element is arranged either left or right of the trapezoidal rib.