Sliding PV Module Couplings for Faster Mounting Alignment
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Solution Overview
Problem
Assembling photovoltaic arrays is a time-consuming process due to the need for precise location of mounting components, which increases system costs and requires additional components and potential roof repairs when exact locations are not correctly determined.
Innovation Solution
The use of short extruded base members and slidable coupling assemblies that can be locked into position, allowing for flexible installation and reducing the need for precise pre-determination of mounting locations, thereby simplifying the assembly process and minimizing the requirement for additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise location of mounting components is required, then module positioning accuracy is improved, but assembly time and complexity increase
Solution Approach 1:
The coupling assembly incorporates a slidable mechanism that allows dynamic adjustment of position along the base member during installation. The coupling can be positioned at any location along the base member's length and then locked in place, transforming a static precise-positioning requirement into a dynamic adjustment process that reduces planning time while maintaining final positioning accuracy.
Solution Approach 2:
The mounting system divides the positioning function into two independent components: the base member provides the mounting foundation at approximate locations, while the coupling assembly provides the precise positioning and locking mechanism. This segmentation allows the base members to be installed quickly at approximate locations without requiring precise positioning, while the couplings can be adjusted to achieve exact module alignment.
2Manufacturing precision
If precise pre-determination of mounting locations is performed, then module positioning accuracy is improved, but device complexity and number of components increase
Solution Approach 1:
The coupling assembly serves multiple functions: it attaches modules to the base member, provides adjustable positioning along the base member, and locks into place to maintain final position. This multi-functional design eliminates the need for separate positioning devices, adjustment mechanisms, and locking components that would otherwise be required, reducing overall system complexity while maintaining mounting precision.
3Ease of operation
If flexible placement of base members is allowed, then ease of installation is improved, but positioning accuracy may worsen
Solution Approach 1:
The coupling assembly's slidable mechanism enables dynamic positioning that compensates for variations in base member placement. Installers can quickly position base members at approximate locations without precise measurement, then slide the couplings to exact positions along the base members, maintaining both ease of installation and final positioning accuracy.
Data Source
AI summary
Photovoltaic mounting systems and coupling assemblies for mounting photovoltaic modules are provided. The mounting systems may include short extruded base members that are mounted onto the supporting surface at approximate locations on the supporting surface, and coupling assemblies that may slide along the length of the base members during installation and be locked at particular positions on the length of the base members. The coupling assemblies may be coupled to connectors that in turn couple to two photovoltaic modules. In operation, the installer may first determine approximate locations on which to mount the base members and mount all required base members, and then, place the coupling assemblies at desired locations, lock the coupling assemblies at the desired locations, position the photovoltaic modules in the connectors of the coupling assemblies, and move to the next set of coupling assemblies.