Solar Module End Clamp Assembly for Anti-Rotation Alignment
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Solution Overview
Problem
Existing solar module mounting systems face challenges in efficiently aligning and securing adjacent solar modules to a support structure, particularly in maintaining rotational alignment and ensuring proper electrical grounding, while also hiding mounting components for aesthetic purposes.
Innovation Solution
The proposed solution involves a clamp assembly with a stabilization member that prevents rotation between upper and lower clamp members, allowing for easy alignment and secure mounting of solar modules, and includes a rail with ribs for improved electrical grounding, along with skirt clips to conceal mounting structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clamp assembly is used to mount solar modules to a rail, then the solar modules can be securely mounted, but the clamp assembly components may rotate relative to each other causing misalignment
Solution Approach 1:
The stabilization member is pre-configured with a relaxed state that automatically prevents rotation between clamp members when assembled, eliminating the need for post-installation alignment adjustments and ensuring precise alignment from the outset
Solution Approach 2:
The stabilization member acts as an intermediary component between the upper and lower clamp members, mechanically preventing rotation and maintaining proper alignment without interfering with the clamping function
2Strength
If the upper clamp member is positioned close to the rail for secure clamping, then mounting strength is improved, but solar modules cannot be easily inserted or aligned
Solution Approach 1:
The stabilization member dynamically adjusts its state during installation: in the relaxed state it maintains clearance for easy module insertion, and when compressed during clamping it provides the necessary holding force to secure the module firmly to the rail
Solution Approach 2:
The clearance is preliminarily established by the relaxed stabilization member before the clamping action occurs, allowing solar modules to be easily inserted and aligned, after which the clamping force is applied to secure the connection
3Ease of manufacture
If mounting components are visible on the support structure, then the mounting function is clear, but the aesthetic appearance is compromised
Solution Approach 1:
The stabilization member is extracted or concealed within the space between the rail and the solar module, removing the visually problematic rotating components from view while maintaining their essential alignment and stabilization functions
Solution Approach 2:
The stabilization member is nested within the clamp assembly structure, positioned in a way that is functionally integrated but visually concealed, allowing the mounting components to be hidden from view while maintaining their operational effectiveness
4Ease of operation
If the clamp assembly allows rotation between components, then ease of assembly is improved, but rotational misalignment occurs
Solution Approach 1:
The anti-rotation feature is preliminarily built into the stabilization member's relaxed state, so that when the clamp assembly is simply assembled without complex alignment procedures, the components are automatically prevented from rotating relative to each other
Solution Approach 2:
The stabilization member provides self-aligning functionality through its relaxed state configuration, automatically preventing rotation between clamp members during assembly without requiring the assembler to perform additional alignment operations
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 enhances the efficiency of solar module alignment and mounting, improves electrical grounding, and maintains a visually appealing installation by hiding mounting components, thereby addressing the challenges of alignment, grounding, and aesthetics in solar module arrays.
Implementation Method 1
The stabilization member in the relaxed state can be biased to support at least the weight of the upper clamp member to prevent translation of the upper clamp member towards the lower clamp member along the major axis
Implementation Method 2
When the lower clamp member is clamped against the rail, the first rib and the arcuate contact ridge engage to form an electrical pathway between the lower clamp member and the rail
Data Source
AI summary
A solar power system can include an array of solar modules. The system can include a rail and a solar module positioned at an outer end of the array. The solar module can have a frame around a periphery of the solar module. The frame can include a flange along an edge of the solar module that is disposed at the outer end of the array. The flange can project inwardly from the frame underneath the solar module. A clamp assembly can be disposed underneath the solar module and can mechanically secure the solar module to the rail. The clamp assembly can include a clamp body and a base. The clamp body and the base can cooperate to clamp the flange between the clamp body and the rail.