Purlin system for solar module attachment

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Solution Overview

Problem

Single-axis trackers face challenges in balancing the center of gravity and shading issues due to conventional purlin mounting methods on torque tubes, which are either top-heavy, bottom-heavy, or require costly specialty fabrication.

Innovation Solution

A purlin system with a first and second mating surface for frictional attachment to the sides of a torque tube, featuring a fastening clamp and downward sloping top surfaces to lower the center of gravity and eliminate the need for factory-attached tabs, allowing for easy disassembly and reconfiguration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If purlins are placed on top of torque tubes, then holding strength is improved, but center of gravity is raised making the system top-heavy

Engineering Contradiction:

Improveholding strengthVSAvoidcenter of gravity position

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent inverts the conventional mounting approach by attaching purlins to the sides of the torque tube rather than on top. This inversion lowers the center of gravity while maintaining structural strength through frictional attachment and fastening clamps, resolving the contradiction between holding strength and center of gravity position.

Inventive Principle:

Principle #13The other way round (Inversion)

2Weight of moving object

If purlins are placed on bottom of torque tubes, then center of gravity is lowered, but solar modules are shaded by the torque tube and the system becomes bottom-heavy

Engineering Contradiction:

Improvecenter of gravity positionVSAvoidshading of solar modules

Core Design Contradiction:

Weight of moving objectVSObject-affected harmful factors

Solution Approach 1:

Instead of placing purlins on the bottom (which causes shading), the patent attaches them to the sides of the torque tube. This side-mounted configuration eliminates shading of the solar modules while still achieving the desired lower center of gravity through frictional attachment and fastening clamps.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If factory-attached tabs are welded to torque tubes, then purlin attachment is enabled, but manufacturing cost increases due to specialty fabrication

Engineering Contradiction:

Improvepurlin attachment capabilityVSAvoidtorque tube cost

Core Design Contradiction:

Ease of manufactureVSWeight of stationary object

Solution Approach 1:

The patent extracts the attachment capability from the torque tube itself by using frictional attachment surfaces and fastening clamps instead of factory-welded tabs. This eliminates the need for specialty fabrication and additional components, reducing manufacturing costs while maintaining secure purlin attachment.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of operation

If straight purlins are used with frictional attachment, then ease of assembly is improved, but attachment security may be compromised

Engineering Contradiction:

Improveease of assemblyVSAvoidattachment security

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent merges frictional attachment with mechanical fastening clamps to create a secure connection system. The frictional surface enables easy alignment and assembly, while the fastening clamps provide reliable security, combining the benefits of both attachment methods without compromising either ease of assembly or attachment security.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The purlin system effectively balances the solar modules by lowering the center of gravity, reducing material costs, and enhancing structural strength-to-weight ratio, while avoiding shading and simplifying installation and maintenance.

Implementation Method 1

a first purlin (30) having a first mating surface configured for frictional attachment to a first side of a torque tube (2)

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11569780B2Purlin system for solar module attachment

Publication Date: 2023.01.31 SUN & STEEL SOLAR LLC

AI summary

One embodiment includes a device for solar tracker systems. The device includes a first purlin including a first mating surface configured for frictional attachment to a first side of a torque tube. The first purlin further including a first linear shaped top surface configured for mounting a first solar module. A second purlin includes a second mating surface configured for frictional attachment to a second side of the torque tube. The second purlin further including a second linear shaped top surface configured for mounting a second solar module. The first purlin and the second purlin connect to one another with a fastening clamp that is configured for holding the first purlin and the second purlin against the torque tube.