Solar Cable Tray Bracket for Thermal Expansion and Grounding
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Solution Overview
Problem
Large solar collector systems face challenges in reducing component costs and simplifying the cable support tray design while accommodating thermal expansion and maintaining safe electrical grounding.
Innovation Solution
A cable management system using a vertically-oriented pile with a mounting bracket and cable tray made from galvanized sheet steel, featuring a design that allows for cantilevered deflection to accommodate thermal expansion and provides a continuous electrical grounding path without sliding connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional ladder-like cable support tray is used, then the structural strength is sufficient, but the component cost is high and the design is complex
Solution Approach 1:
The patent changes the structural parameters of the cable support tray by transitioning from a traditional ladder-like design with multiple rungs and cross-bracing to a simplified U-shaped channel design. This parameter change maintains sufficient structural strength for supporting cables while dramatically reducing manufacturing complexity and component cost. The U-shaped channel can be formed from a single piece of metal through bending operations, eliminating the need for multiple separate components and complex assembly procedures.
2Reliability
If a fixed cable support tray design is used, then the electrical grounding is stable, but thermal expansion cannot be accommodated
Solution Approach 1:
The patent introduces dynamic characteristics to the cable support tray system by incorporating sliding mechanisms that allow the tray to move relative to its mounting structure. This dynamic design enables the tray to accommodate thermal expansion and contraction of the cables and tray itself while maintaining continuous electrical grounding through conductive sliding contacts. The sliding mechanism transforms the static fixed design into a dynamic system that adapts to thermal variations.
Solution Approach 2:
The patent uses sliding contacts or intermediate elements as mediators between the cable support tray and the mounting structure. These intermediary components facilitate both mechanical movement to accommodate thermal expansion and continuous electrical contact for grounding. The sliding contact acts as a bridge that allows relative motion while maintaining electrical connectivity, resolving the contradiction between stability and adaptability.
3Ease of manufacture
If simplified cable support trays are used, then manufacturing cost is reduced, but the ability to support heavy loads and thermal expansion is compromised
Solution Approach 1:
The patent enhances the load-bearing capacity of the simplified U-shaped cable support tray by utilizing three-dimensional structural features. The U-shaped channel provides inherent structural strength through its geometric form, which resists bending and deformation under heavy cable loads. Additionally, the tray is mounted at multiple points along its length and secured to the mounting structure at various heights, distributing loads across multiple support points and enhancing overall load-bearing capacity despite the simplified tray design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces component costs, simplifies the installation process, and ensures safe and code-compliant electrical grounding while supporting heavy loads and thermal expansion, enhancing the overall efficiency and reliability of solar energy collection systems.
Implementation Method 1
providing for cantilevered deflection in response to thermal expansion
Implementation Method 2
provides a continuous electrical grounding path without sliding connections
Data Source
AI summary
A cable tray and support system facilitates cable management in a solar energy collector system at reduced cost relative to previous cable tray and support systems. The cable tray and support system comprises cables trays, mounting brackets, and vertically-oriented piles. The mounting brackets are coupled to the cables trays and vertically-oriented piles. The mounting brackets include one or more stress relief features (e.g., notches) to allow the mounting bracket to provide cantilevered deflection in response to thermal expansion or contraction-of the cable tray. The cable tray and support system also provides a ground path from a cable tray, to the mounting bracket, to the pile, and then to the ground to dissipate transient voltages in the solar energy collection system.