Solar Tracker Clamp Assembly for Precise Torque Tube Alignment
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Solution Overview
Problem
Conventional solar tracking systems are inadequate in optimizing energy conversion from solar panels due to suboptimal sun angles, limiting their potential for energy capture.
Innovation Solution
A fully adjustable solar tracker system with a clamp assembly and torque tube configuration that allows for precise alignment of solar modules to maximize energy capture, featuring a cylindrical torque tube with notches and a clam shell clamp assembly to reduce load on the drive motor and prevent movement, and a swage fitting system for secure connection without welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional solar tracking mechanisms are used, then solar panels can be positioned to follow the sun, but the systems are inadequate in optimizing energy conversion due to suboptimal sun angles
Solution Approach 1:
The clamp assembly enables dynamic adjustment of the torque tube and solar panel array to various sun angles throughout the day and year. The mechanism allows continuous repositioning rather than fixed angles, optimizing energy capture at different times and seasons.
Solution Approach 2:
The system allows changing of positional parameters (angle, orientation) of the solar panels by adjusting the torque tube position through the clamp assembly, enabling adaptation to different sun positions and maximizing energy conversion efficiency.
2Productivity
If a clamp assembly with torque tube is used to allow precise alignment, then energy capture is maximized, but the device complexity increases
Solution Approach 1:
The clamp assembly is divided into separate functional components: the clamp body, the torque tube, the notches for positioning, and the swage fitting system. This segmentation allows each component to perform its specific function while simplifying manufacturing and assembly.
Solution Approach 2:
The torque tube acts as an intermediary element between the clamp assembly and the solar panel mounting structure. It provides a simple rotational interface that enables precise angular adjustment without requiring complex mechanisms.
3Strength
If welding is used for secure connection, then structural strength is improved, but installation costs and errors increase
Solution Approach 1:
The swage fitting system replaces welding (a thermal process) with a mechanical deformation process. The swage fitting is crimped onto the torque tube using mechanical force, creating a secure connection without heat, sparks, or complex welding procedures.
Solution Approach 2:
The swage fitting system is designed to be self-contained and tool-friendly, allowing installers to create secure connections using basic hand or power tools without requiring specialized welding equipment or expertise. The mechanical deformation of the fitting creates its own secure attachment.
4Productivity
If solar panels are fixed at suboptimal angles, then installation is simpler, but energy capture efficiency is reduced
Solution Approach 1:
The clamp assembly and torque tube create a dynamic mounting system that allows solar panels to be adjusted to optimal angles rather than being fixed at installation. This enables seasonal and daily optimization without requiring complex installation procedures.
Solution Approach 2:
The clamp assembly is pre-configured with notches and adjustment mechanisms that allow for quick angle selection and locking during installation, eliminating the need for complex angle calculations and adjustments after mounting.
Data Source
AI summary
In an example, the solar tracker has a clamp assembly configured to pivot a torque tube. In an example, the assembly has a support structure configured as a frame having configured by a first and second anchoring region. In an example, the support structure is configured from a thickness of metal material. In an example, the support structure is configured in an upright manner, and has a major plane region. In an example, the assembly has a pivot device configured on the support structure, a torque tube suspending on the pivot device and aligned within an opening of the support, and configured to be normal to the plane region. In an example, the torque tube is configured on the pivot device to move about an arc in a first direction or in a second direction such that the first direction is in a direction opposite to the second direction.