Aluminum Wire Positioning Saddle for Solar Cable Abrasion Prevention
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Solution Overview
Problem
Existing wire positioning devices for solar panel and harness string cables in utility-scale solar power plants face issues such as cable abrasion, pinch hazards from rotating components, and the need for frequent maintenance, which can lead to electrical shock hazards and inefficiencies in installation and removal processes.
Innovation Solution
A wire positioning device with an open-access design featuring an aluminum construction, an attachment member with an open hook, and a cable support saddle that allows for single-handed installation and maintenance, preventing cable slippage and supporting cables in a way that withstands environmental stress and rotation, while preventing galvanic corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables are secured on or near rotating components of solar trackers, then cable support is achieved, but cable abrasion and pinch hazards occur leading to electrical shock risks
Solution Approach 1:
The wire positioning device serves as an intermediary component between the solar panel support structure and the cables. It provides a dedicated cable support saddle that positions cables away from rotating tracker components, eliminating direct contact and abrasion hazards while maintaining secure cable support throughout tracker rotation
Solution Approach 2:
The device segments the support function by separating the attachment to the support structure from the cable support function. The attachment member secures the device to the support structure while the cable support saddle independently manages cable positioning, allowing the cables to be supported without contacting rotating components
2Ease of operation
If traditional wire positioning devices are used, then cable support is provided, but installation and removal require multiple hands and frequent maintenance
Solution Approach 1:
The open hook attachment member is designed to be self-installing by snapping into slots on the support structure without requiring tools or multiple hands. The cable support saddle features an open design that allows cables to be easily inserted and secured, enabling single-handed installation and maintenance operations
Solution Approach 2:
The attachment member is pre-configured with an open hook shape that aligns with the slots on the support structure, allowing for quick snap-in installation. The cable support saddle is pre-formed with an open top design, enabling cables to be readily inserted without complex assembly steps
3Duration of action of stationary object
If aluminum wire positioning device is used, then resistance to UV and extreme temperatures is achieved, but galvanic corrosion may occur with dissimilar metals
Solution Approach 1:
The device is constructed entirely from aluminum material, creating a homogeneous structure that eliminates galvanic corrosion risks between dissimilar metals. The uniform aluminum construction maintains resistance to UV radiation and extreme temperatures while preventing electrochemical reactions that would occur with mixed metal components
Data Source
AI summary
An aluminum wire positioning device system for solar panel cabling and harness string cabling is provided that includes a support structure, a cable, and a wire positioning device. The wire positioning device includes a center leg, an attachment support leg, an attachment member configured to couple the wire positioning device to the solar panel frame or solar panel support structure at an attachment point, a saddle support leg, and a cable support saddle configured to support the at least one cable. The attachment member is arranged at an angle relative to the cable support saddle about the center leg, and a center-of-gravity of the wire positioning device is aligned with the attachment point, the center leg, and the saddle support leg.