Flexible Solar Collector Clips for Fast Precise Array Alignment
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Solution Overview
Problem
The inefficiencies in the manufacturing process of solar arrays due to the need for precise angular alignment of solar collectors, which is currently achieved through shimming or additional hardware, result in increased complexity and cost, as well as reduced efficiency and longer assembly times.
Innovation Solution
A flexible attachment device, comprising a collector-engaging portion, a biasing portion, and frame-engaging portions with guide flanges, is used to attach solar collectors to a structural framework, allowing for precise alignment and flexible adjustment to accommodate manufacturing tolerances without the need for additional hardware or shimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solid or liquid shims are used to adjust alignment, then manufacturing precision is improved, but manufacturing time and productivity are reduced
Solution Approach 1:
The patent removes the shim component entirely from the assembly process. Instead of adding shims to adjust alignment, the connecting hardware itself is designed with built-in adjustment capability through its geometry and flexibility, allowing direct attachment without intermediate alignment components.
Solution Approach 2:
The patent combines the alignment adjustment function with the connecting hardware function. The single component performs both structural connection and angular adjustment, eliminating the need for separate shim components and reducing the number of assembly steps.
2Manufacturing precision
If additional connecting hardware is used to adjust collector angle, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The connecting hardware is designed as a multi-functional component that simultaneously provides structural support, angular adjustment, and mechanical connection. This universal design eliminates the need for multiple specialized components (shims, adjustment mechanisms, additional fasteners) and reduces overall system complexity.
Solution Approach 2:
The patent employs a flexible connecting hardware design that can bend or flex to accommodate angular variations. This flexibility allows the single component to adapt to different alignment requirements without requiring complex mechanical adjustment mechanisms or multiple rigid parts.
3Manufacturing precision
If traditional shimming process is used, then alignment precision is improved, but manufacturing time and cost increase
Solution Approach 1:
The connecting hardware is pre-designed with built-in alignment capabilities and geometric features that automatically compensate for tolerances during assembly. This preliminary design eliminates the need for time-consuming measurement, calculation, and application of shims during the assembly process.
Solution Approach 2:
The connecting hardware performs self-alignment through its geometric design and flexibility, automatically accommodating tolerance variations without requiring external adjustment tools or procedures. The component serves its own alignment function, eliminating the need for operator intervention in the shimming process.
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
This solution enables a more efficient and cost-effective manufacturing process by allowing for precise alignment of solar collectors with reduced complexity and assembly time, while maintaining the structural integrity and efficiency of the solar array.
Implementation Method 1
a biasing portion configured to allow the flexible attachment device to flex inward towards the solar collector during assembly
Data Source
AI summary
Methods and apparatuses described herein provide for the attachment of solar collectors to a structural framework in a solar array assembly. A flexible clip is attached to either end of each solar collector and utilized to attach the solar collector to the structural framework. The solar collectors are positioned to allow a member of the framework to engage a pair of flexible clips attached to adjacent solar collectors during assembly of the solar array. Each flexible clip may have multiple frame-engaging portions, each with a flange on one end to cause the flexible clip to deflect inward when engaged by the framework member during assembly and to guide each of the frame-engaging portions into contact with a surface of the framework member for attachment.


