Solar array support structure, mounting rail and method of installation thereof
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Solution Overview
Problem
Prior art solar array support structures require additional costly angle iron components to attach mounting rails to horizontal rails, increasing construction and material costs.
Innovation Solution
A mounting rail design with a main body, solar panel mounting portion, and flanges with U-bolt holes that allow direct attachment to horizontal rails without additional angle irons, using a U-shaped connection mechanism and U-bolts for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If angle iron components are used to attach mounting rails to horizontal rails, then structural integrity is maintained, but material costs and construction costs increase significantly
Solution Approach 1:
The mounting rail is merged with the angle iron function by integrating the attachment mechanism directly into the mounting rail body. The mounting rail includes built-in attachment mechanisms (such as brackets or integrated connection elements) that perform both the mounting function and the structural support function that previously required separate angle iron components, thereby eliminating the need for additional angle iron while maintaining structural integrity
Solution Approach 2:
The mounting rail is designed to perform multiple functions: it provides structural support, serves as a mounting surface for solar panels, and includes integrated attachment mechanisms for connecting to horizontal rails. This multi-functional design eliminates the need for separate angle iron components, reducing material costs while maintaining the required structural integrity
2Reliability
If angle iron components are used to attach mounting rails to horizontal rails, then secure attachment is achieved, but device complexity increases
Solution Approach 1:
The mounting rail integrates the attachment mechanism directly into its structure, combining what were previously separate components (mounting rail, angle iron, and fasteners) into a single unified component. This reduces the total number of parts and simplifies the assembly process while maintaining secure attachment through the integrated connection design
Solution Approach 2:
The angle iron component is extracted from the system by integrating its attachment function directly into the mounting rail. The mounting rail includes built-in attachment mechanisms that perform the function of the removed angle iron, thereby reducing device complexity and the number of components while maintaining secure attachment
Data Source
AI summary
Disclosed herein is a mounting rail for a solar array support structure that includes a main body having a top and a bottom, the main body extending from a first end to a second end. The mounting rail further includes a solar panel mounting portion extending along the top of the main body, the solar panel mounting portion configured to secure the solar panel to the mounting rail. The mounting rail further includes a first flange extending from the bottom of the first vertical element, the first flange including a first pair of holes configured to receive two ends of a U-bolt, the first pair of holes spaced apart substantially equal to a width of the horizontal rail. A method of installing a solar array support structure using the mounting rail is further disclosed.