Aluminum Cable Saddle for Solar Tracker 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 moving components, and the need for frequent maintenance, particularly due to their installation methods and material degradation in harsh environmental conditions.

Innovation Solution

A wire positioning device with an open-access design featuring an aluminum structure, including a center leg, attachment support leg, attachment member, and cable support saddle, which allows for secure cable support, easy installation, and maintenance without locking, while preventing cable slippage and corrosion, and is designed to withstand extreme environmental conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional wire positioning devices are used with locking mechanisms, then cable support stability is improved, but installation complexity and maintenance time increase

Engineering Contradiction:

Improvecable support stabilityVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The wire positioning device is divided into separate functional components: a support leg for mounting, a saddle component for cable support, and an attachment mechanism. This segmentation allows each component to be optimized independently and facilitates easier installation and maintenance while maintaining overall stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using a locking mechanism that requires tightening and securing, the device uses a gravity-based retention system where the saddle component naturally holds the cable through its curved geometry and weight distribution. The center-of-gravity alignment creates a self-stabilizing structure that eliminates complex locking requirements.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If wire positioning devices are installed near moving solar tracker components, then cable support functionality is improved, but cable abrasion and pinch hazards increase

Engineering Contradiction:

Improvecable support functionalityVSAvoidcable abrasion

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The wire positioning device acts as an intermediary component between the solar panels and the support structure, positioning cables away from moving tracker components. The saddle component provides a protected cable routing path that prevents direct contact with pinch points and abrasive surfaces near rotating mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The device is designed to preemptively prevent cable damage by positioning cables in protected locations before they can contact moving components. The attachment point and saddle geometry are configured to maintain cable clearance from abrasive surfaces throughout the tracker's range of motion.

Inventive Principle:

Principle #9Preliminary anti-action

3Ease of manufacture

If wire positioning devices use conventional materials, then manufacturing cost is reduced, but durability in harsh environmental conditions deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoiddurability in harsh conditions

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The wire positioning device utilizes aluminum as the primary material, which provides an optimal balance of properties: it is lightweight for easy installation, sufficiently strong to support cable weights, highly resistant to corrosion from moisture and UV exposure, and maintains structural integrity across a wide temperature range. This material selection addresses harsh environmental conditions while remaining cost-effective.

Inventive Principle:

Principle #40Composite materials

4Manufacturing precision

If wire positioning devices require two-handed installation, then installation precision is improved, but installation speed decreases

Engineering Contradiction:

Improveinstallation precisionVSAvoidinstallation speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The wire positioning device incorporates a self-aligning design where the center-of-gravity alignment automatically orients the component correctly during single-handed installation. The attachment member and saddle geometry guide proper positioning without requiring two hands for stabilization, enabling rapid installation while maintaining precision through the device's inherent structural alignment features.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12110996B2Wire positioning device

Publication Date: 2024.10.08 AFFORDABLE WIRE MANAGEMENT LLC

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.