Universal Solar Panel Clamp for Variable Mounting Hole Alignment
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Solution Overview
Problem
Existing solar panel mounting systems are custom-designed for specific panel sizes and manufacturers, requiring extensive on-site measurement and adjustment, and often do not utilize the manufacturers' mounting holes, leading to increased costs and potential warranty issues.
Innovation Solution
A universal solar panel mounting system featuring elongated slots and clamps that accommodate mounting holes located between 0.25″ to 2″ from the panel edge, allowing for adjustable tilt arms and A-shaped support members, enabling the use of different panel sizes and manufacturers without custom design requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-designed mounting systems are used for each solar panel manufacturer and size, then the mounting system can precisely fit specific panel configurations, but the device complexity and inventory control costs increase significantly
Solution Approach 1:
The mounting system uses a universal bracket design with adjustable components that can accommodate multiple solar panel sizes and mounting hole configurations. The bracket includes adjustable arms with multiple positioning holes and elongated mounting slots that can adapt to different hole locations, allowing a single bracket type to serve multiple panel manufacturers and models rather than requiring custom brackets for each panel type.
Solution Approach 2:
The mounting bracket incorporates adjustable and movable components including telescopic arms with adjustable lengths, rotating joints, and elongated mounting slots that allow positioning at various locations. This dynamic adjustability enables the same bracket design to fit different panel configurations without requiring multiple fixed-design brackets for each specific panel type.
2Ease of manufacture
If T-shaped clips are used to clip panels onto supporting rails, then the installation can proceed without utilizing manufacturers' mounting holes, but the clips require sliding onto rails from ends and cannot easily accommodate panel replacements
Solution Approach 1:
The mounting system segments the connection between panel and support structure into separate, independently adjustable components. The bracket consists of multiple segments including adjustable arms, mounting slots, and fastening points that can be independently positioned and adjusted. This segmentation allows individual panels to be accessed and replaced without requiring disassembly of the entire rail system, unlike T-shaped clips that must be slid onto ends of rails.
Solution Approach 2:
The universal bracket acts as an intermediary component between the solar panel and the supporting rail structure. Rather than directly clipping panels to rails, the bracket provides an intermediate mounting interface that utilizes the panel's existing mounting holes while connecting to the support structure. This intermediary design facilitates easier panel replacement compared to direct rail clipping systems.
3Reliability
If extensive on-site placement, measurement, and adjustment is required, then the mounting system can be precisely fitted to specific site conditions, but the installation time and labor costs increase
Solution Approach 1:
The universal mounting bracket is designed with pre-configured adjustable components and standardized dimensions that allow for rapid on-site adaptation to different panel sizes and site conditions. The bracket includes pre-positioned mounting slots, adjustable arms with multiple attachment points, and standardized connection interfaces that reduce the need for extensive on-site measurement and custom fabrication, thereby reducing installation time while maintaining reliability.
Data Source
AI summary
A mounting system for photovoltaic solar panels providing support for different sized panels, and/or panels having mounting holes located in different locations. A universal panel clamp includes at least one elongated hole or slot to attach to a mounting hole on a solar panel frame. A clamp is attached to an upper hole, and a second clamp is attached to a lower mounting hole. The upper clamps are attached to an upper lateral support member, and the lower clamps are attached to a lower lateral support member. This assembly may be supported by A-shaped support members having adjustable tilt arms, or posts with specially configured brackets.