Snap-On Mounting Bracket Assembly for Solar Tracker Rail Installation
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Solution Overview
Problem
Existing mounting bracket assemblies for solar modules are impractical for long module mounting rails, as they require threading over torque tubes during installation, which can lead to damage, and are not suitable for octagonal torque tubes, and do not facilitate easy attachment of frameless modules.
Innovation Solution
A clip-on or snap-on two-piece torque tube mounting bracket assembly with an upper clamp piece and a lower clamp piece, allowing attachment of mounting rails anywhere along the torque tube length, featuring an open bottom space that snaps onto the tube and includes angled reinforcement for secure attachment, and can provide a conductive ground path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If long mounting rails (2-3 meters) are threaded over torque tubes during installation, then mounting rails for frameless modules can be attached, but the rails hang from the torque tube and are likely to get damaged during assembly and tracker installation
Solution Approach 1:
The mounting bracket is divided into two separate pieces: an upper clamp piece that attaches to the torque tube and a lower clamp piece that attaches to the mounting rail. This segmentation allows the rail to remain on the ground during installation rather than being threaded over the torque tube, eliminating the damage risk while enabling frameless module mounting
2Ease of operation
If standard hardware with straight bolts is used for attachment, then simple installation is possible, but octagonal torque tubes are not readily suitable for attachment
Solution Approach 1:
The clamp pieces are designed with asymmetric features including an L-shaped configuration with a long leg and short leg, and angled reinforcement features at specific angles (e.g., 45 degrees). These asymmetric design elements enable the bracket to properly engage with and secure to octagonal torque tubes while maintaining ease of installation
3Ease of operation
If short module mounting clamps (0.3 meter) are used for framed modules, then they are easy to slide onto torque tubes and transport well, but they cannot support unframed glass modules that require longer structure
Solution Approach 1:
By segmenting the mounting system into a reusable upper clamp piece that attaches to the torque tube and a separate lower clamp piece that attaches to the mounting rail, the system maintains the ease of handling of short clamps while enabling support for long mounting rails required by unframed modules
Solution Approach 2:
The upper clamp piece is designed as a universal component that can be reused across multiple mounting locations along the torque tube. This multi-functional design allows the same clamp piece to support both framed and unframed modules, eliminating the need for different clamp sizes
Data Source
AI summary
A snap-on mounting bracket assembly suitable for connecting a mounting rail to a torque tube is provided. The mounting bracket assembly includes an upper clamp piece and a lower clamp piece. The upper clamp piece has a first member defining a tube insertion aperture and an open bottom space and includes an upper partial fastener. The lower clamp piece has a second member with a lower partial fastener configured to mate with the upper partial fastener such that the lower clamp piece is attachable to the upper clamp piece. In exemplary embodiments, the lower clamp piece further comprises two opposing support members configured to attach to the mounting rail. Solar tracker assemblies incorporating snap-on open mounting brackets are provided. Methods of mounting framed or unframed solar modules are also described. A mounting rail is attached to an upper clamp piece of a mounting assembly. Then the upper clamp piece is snapped onto a torque tube. A lower clamp piece of the mounting assembly is then attached to the upper clamp piece by mating a lower partial fastener of the lower clamp piece with an upper partial fastener of the upper clamp piece. When the upper and lower clamp pieces are attached, the open bottom space is closed and the mounting rail is secured to the torque tube.