Solar Rail End Clamp With Wedge Positioning and Grounding
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Solution Overview
Problem
Existing solar photovoltaic systems face challenges in efficiently mounting solar modules side-by-side on support structures, requiring improved coupling methods to ensure proper positioning and secure attachment.
Innovation Solution
The use of an end clamp system with a fastener, clamping plate, inner wedge, and block mechanism that applies horizontal and vertical forces to secure solar modules to rails, providing a stable and adjustable mounting solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coupling members are used to mount solar modules side-by-side, then the modules can be attached to the mounting structure, but it is challenging to ensure proper positioning of adjacent modules during assembly
Solution Approach 1:
The end clamp is pre-positioned at the end of the rail before the solar module is installed. This preliminary positioning action ensures that the module will be correctly aligned when attached, eliminating the need for difficult post-positioning adjustments during assembly.
Solution Approach 2:
The invention replaces the conventional coupling member with an end clamp that utilizes a wedge mechanism. When the clamp is secured to the rail, the wedge geometry automatically generates horizontal and vertical forces that precisely position the module, substituting complex mechanical alignment procedures with a self-positioning mechanical system.
2Reliability
If a secure mounting system is implemented to ensure stable attachment, then the solar modules are firmly attached to the support structure, but the system complexity increases
Solution Approach 1:
The end clamp is divided into distinct functional components: a clamping portion that attaches to the rail, a wedge mechanism that generates positioning forces, and a securing mechanism. This segmentation allows each component to perform its specific function efficiently while keeping the overall system understandable and maintainable.
Solution Approach 2:
The wedge acts as an intermediary element between the clamping portion and the solar module. It converts the simple act of securing the clamp to the rail into complex horizontal and vertical positioning forces, mediating between the mounting structure and the module to achieve stable attachment without requiring a complex overall system.
3Strength
If a fastening mechanism is used to secure the clamping plate, then the solar module is firmly attached to the rail, but the installation process becomes more time-consuming
Solution Approach 1:
The wedge mechanism provides self-service by automatically generating the necessary horizontal and vertical positioning forces simply by being secured to the rail. This eliminates the need for additional adjustment steps or multiple fasteners, reducing installation time while maintaining strong attachment.
Solution Approach 2:
The fastening mechanism changes the physical state of the wedge and clamping plate from a loose configuration to a tightly secured configuration. This parameter change (from unsecured to secured) automatically triggers the force generation mechanism, providing strong attachment without requiring time-consuming manual adjustment of multiple parameters.
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 secure and efficient mounting of solar modules on support structures, ensuring proper alignment and stability while allowing for easy installation and drainage, thereby enhancing the overall efficiency and durability of solar power systems.
Implementation Method 1
an inner wedge adapted to be disposed inside the rail and coupled to the interior bottom surface, a block disposed between and engaged with the clamping plate wedge and inner wedge
Data Source
AI summary
A solar power system may include rails, solar modules, and a plurality of clamps to secure the solar modules to the rails. An end clamp may be partially disposed inside a rail at an end of the rail. The end clamp may secure a solar module to the rail by coupling to the frame of the solar module. The end clamp may include a fastener that may be tightened to engage the end clamp and secure the solar module by holding it on top of the rail. The end clamp may establish an electrical grounding connection between the frames of the solar module and the rail.