Solar Module Connection Device Segmentation and Nesting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical connection devices for solar modules, such as those using omega clamps, are complex to produce, difficult to dimensionally reduce, and have poor quality verification, making them inefficient and costly.
Innovation Solution
A connection device with a compact contacting system featuring a movable contacting device on a contact rail that acts as both a conductor and clamping mechanism, utilizing diodes and resilient arms for reliable and efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If omega clamps are used for electrical contacting, then reliable electrical connection is achieved, but device complexity and production complexity increase
Solution Approach 1:
The contacting device is divided into separate functional components: a contact rail for current transfer and a separate contacting device with resilient arm for clamping. This segmentation allows each component to be optimized independently, reducing overall complexity while maintaining reliable electrical connection.
Solution Approach 2:
The contact rail serves multiple functions: it acts as both a conductor for current transfer and as part of the clamping mechanism structure. The resilient arm provides both the clamping force and ensures electrical contact, combining multiple functions into single components to reduce overall device complexity.
2Reliability
If omega clamps are used for electrical contacting, then reliable electrical connection is achieved, but manufacturing cost and production complexity increase
Solution Approach 1:
By separating the contacting device into modular components (contact rail, resilient arm, clamping element), each part can be manufactured independently using simpler, more cost-effective processes, then assembled through straightforward attachment mechanisms.
Solution Approach 2:
The design uses resilient arms with specific elastic properties that can be achieved through standard material selection and simple geometric parameters, allowing for cost-effective manufacturing while maintaining reliable contact pressure and electrical connection.
3Reliability
If conventional contacting devices are used, then electrical connection is achieved, but dimensional reduction of solar box is difficult
Solution Approach 1:
The contacting device components are nested within the housing structure, with the contact rail integrated into the housing and the resilient arm positioned within the available space. This nesting approach maximizes space utilization and enables compact dimensional reduction of the solar box.
Solution Approach 2:
The resilient arm provides dynamic clamping action that adapts to the available space, allowing the contacting device to function reliably in compact configurations. The elastic properties enable the device to accommodate varying dimensional constraints while maintaining effective electrical contact.
4Reliability
If conventional contacting methods are used, then electrical connection is achieved, but quality verification is difficult
Solution Approach 1:
The resilient arm's elastic deformation provides inherent feedback on contact pressure and connection quality. By monitoring the position or force characteristics of the resilient arm, the quality of electrical contacting can be easily verified during and after assembly.
Solution Approach 2:
The contacting device structure itself provides verification capabilities through the visible and measurable state of the resilient arm and clamping elements. The design allows quality verification to be performed through simple observation or measurement of component positions without requiring complex testing equipment.
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
Enables simple and cost-effective production of a compact connection device with reliable electrical contacting, reducing the complexity of assembly and verification processes.
Implementation Method 1
the resilient arm is in abutment against the contact rail, the foil conductor being clamped between a contacting portion of the resilient arm or clamping means and the contact rail
Data Source
AI summary
The invention relates to a connection device for a solar module, comprising a housing, at least one contact rail which is arranged in the housing, and at least one contacting device for contacting an electrical conductor, the contacting device being able to be fitted to the contact rail and being able to be moved at least between an initial position (AS) and an end position (ES).