Quick-Attach Clamp Assembly for Solar Cable Routing
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Solution Overview
Problem
Existing photovoltaic system installations face challenges in efficiently routing, securing, and connecting electrical cables to support structures, particularly at column supports, torque tubes, and mounting brackets.
Innovation Solution
The described clamp assemblies, comprising a clamp with a hinge mechanism, locking mechanisms, and a mounting member, along with a bracket and interlock mechanism, provide a secure and adjustable means to attach elongate members like electrical cables to support structures, allowing for easy routing and securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional band clamps or polygonal mounting brackets are used to secure solar panels to torque tubes, then the solar panels can be mounted and cables can be routed, but the installation process requires disassembly and reassembly to add cable mounting brackets, and additional cable ties or tape are needed to secure cables
Solution Approach 1:
The patent combines the solar panel mounting clamp and cable mounting bracket into a single integrated assembly. The clamp includes a mounting surface with a mounting hole that can directly receive and secure cables, eliminating the need for separate cable mounting brackets and reducing the number of components required.
Solution Approach 2:
The clamp assembly serves multiple functions: it secures the solar panel to the torque tube, provides a mounting surface for cable attachment, and includes integrated cable securing features. This multi-functional design eliminates the need for separate cable ties or tape to secure cables.
2Adaptability or versatility
If cable mounting brackets are added to band clamps, then cables can be routed and secured, but the brackets must be disassembled and reassembled, which increases installation time and complexity
Solution Approach 1:
The clamp and cable mounting bracket are merged into a single pre-assembled unit. The mounting surface is integrated into the clamp structure, allowing cables to be mounted directly without requiring disassembly and reassembly of separate brackets.
Solution Approach 2:
The cable mounting bracket is pre-assembled with the clamp during manufacturing, creating a ready-to-install unit. This preliminary action eliminates the need for field assembly operations, reducing installation time and complexity.
3Reliability
If traditional mounting methods are used, then solar panels can be secured to torque tubes, but additional cable ties or tape are required to secure electrical cables, increasing the number of components and installation steps
Solution Approach 1:
The clamp assembly integrates cable securing features directly into the mounting structure. The mounting surface includes a mounting hole and positioning features that work with mounting hardware to securely attach cables, eliminating the need for separate cable ties or tape.
Solution Approach 2:
The clamp serves as both the solar panel mounting device and the cable mounting structure. The integrated design provides secure cable attachment capabilities while reducing the total number of components needed in the system.
Data Source
AI summary
This document describes clamp assemblies, techniques for manufacturing clamp assemblies, and techniques for using clamp assemblies. In aspects, a disclosed clamp assembly is configured for securing an elongate member to a support structure and includes a clamp, a bracket, and an interlock mechanism. The clamp includes a first clamp member and a second clamp member, the clamp defining a passageway configured to enclose at least a portion of the elongate member. The clamp also includes a mounting member that includes a mounting insert channel configured to receive a clamp mounting attachment. The bracket includes a base that includes the clamp mounting attachment. The base further includes a support structure connector that is configured for releasably attaching the bracket to the support structure. The interlock mechanism is configured for releasably connecting the mounting member of the clamp and the base of the bracket together.