Process and joining device for mounting a solar collector
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Solution Overview
Problem
The manual assembly of solar collectors, comprising a solar absorber, transparent cover, frame, and optional rear wall, is inefficient and prone to errors, requiring improved methods and tools for precise alignment and secure mounting.
Innovation Solution
A method involving assembly mandrels for holding frame and absorber parts, with a joining device that includes suction grippers, adjustable mandrels, and sliding mechanisms for precise alignment and secure fitting, along with the application of sealants and thermal insulation, to facilitate efficient assembly and sealing of the solar collector components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used for solar collectors, then flexibility and adaptability are maintained, but assembly efficiency and precision deteriorate
Solution Approach 1:
The patent introduces assembly mandrels as intermediary tools that facilitate the connection between frame parts and solar absorber. These mandrels serve as temporary mediators during assembly, enabling precise alignment and secure positioning without requiring complex manual operations. The mandrels are inserted through frame openings and absorber openings to hold components in correct positions during the assembly process.
Solution Approach 2:
The frame is divided into multiple frame parts with frame openings, and the solar absorber has separate absorber openings. This segmentation allows for modular assembly where each component can be positioned and secured independently using assembly mandrels, improving assembly efficiency while maintaining precision through the structured segmentation of assembly steps.
2Manufacturing precision
If manual assembly is used, then equipment complexity is reduced, but assembly precision and alignment accuracy deteriorate
Solution Approach 1:
Assembly mandrels act as intermediary alignment tools that ensure precise positioning between frame parts and solar absorber. The mandrels provide fixed reference points and geometric constraints that guarantee accurate alignment without requiring complex measurement and adjustment equipment. The simplicity of the mandrel design maintains low device complexity while achieving high alignment accuracy.
Solution Approach 2:
The assembly mandrels are designed with predetermined geometric features and dimensions that pre-establish the correct alignment relationships between components. By preparing the mandrels in advance with precise dimensions and insertion features, the patent eliminates the need for complex real-time alignment adjustments during assembly, thereby improving manufacturing precision without proportionally increasing device complexity.
3Reliability
If components are assembled without secure holding, then assembly speed increases, but assembly reliability and structural stability deteriorate
Solution Approach 1:
The assembly mandrels serve as temporary holding intermediaries that securely position frame parts and solar absorber during assembly. These mandrels provide mechanical constraint and stability, ensuring reliable component positioning without requiring time-consuming manual adjustment or temporary fastening methods. The mandrels maintain assembly reliability while enabling efficient sequential assembly operations.
Solution Approach 2:
The mandrels are designed to automatically provide secure holding upon insertion, with geometric features that create immediate mechanical interlocking or frictional engagement. This preliminary securing action eliminates the need for additional time-consuming fastening steps while ensuring assembly reliability. The pre-designed mandrel geometry provides inherent holding capability that secures components reliably during the assembly 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
The method ensures accurate and secure assembly of solar collectors, reducing manual labor and errors, while enhancing thermal efficiency by minimizing heat loss through precise alignment and sealing of components.
Implementation Method 1
a first holding device (420) for holding the rear wall (500) in a position H1, the first holding device (420) having at least one switchable suction gripper for holding the rear wall (500) in place
Implementation Method 2
A thermal insulation element can also be provided in an intermediate space between the solar absorber and the rear wall
Data Source
Figure 1
Figure 2
Figure 3a~3d
AI summary
The invention relates to a method for mounting a solar collector (1), wherein the solar collector (1) comprises a solar absorber (300), a transparent cover (100), a frame (200), and optionally a back panel (500), the frame (200) comprising several frame parts (201, 202). The method according to the invention comprises the following steps: (a) optionally holding the optional back panel (500) in a position H1; (b) carried out on two first frame parts (201), each first frame part (201) having at least one frame opening (203), preferably two frame openings (203): inserting a mounting mandrel (410) into each frame opening (203) and holding the first frame parts (201) by means of the mounting mandrels (410).(c), carried out on the solar absorber (300), wherein the solar absorber (300) has at least two absorber openings (306), preferably four absorber openings (306): Inserting the same mounting mandrels (410) as in step (b) into the absorber openings (306) and holding the solar absorber (300) by means of the mounting mandrels (410) in a position H2, in particular parallel in front of the rear wall (500). (d), holding the cover (100) in a position H3 parallel in front of the solar absorber (300). (e), sliding the first frame parts (201) onto the solar absorber (300) and the cover (100) and optionally onto the rear wall (500).