Solar Panel Foot Rail Assembly for Versatile Roof Mounting
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Solution Overview
Problem
Existing solar panel mounting systems require a multitude of specialized brackets and fastening means for different roof types and orientations, leading to increased production and storage costs, as well as environmental impact.
Innovation Solution
The introduction of foot members with a tongue mechanism that engages with a support rail, allowing for flexible positioning and secure fastening of solar panels across various applications, including sloping and flat roofs, without the need for numerous specialized parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple specialized brackets and fastening means are used for different roof types and orientations, then the solar panel mounting system can accommodate various applications, but the number of parts to be produced and stored increases
Solution Approach 1:
The support rail is designed with a universal slot system that can accommodate multiple types of foot members (first foot member for standard mounting, second foot member for angled mounting). The slot accepts different tongue configurations, allowing the same rail structure to serve flat roofs, sloping roofs, and various orientations without requiring specialized rails for each application.
Solution Approach 2:
The mounting system is divided into modular components: the support rail with slots, various foot members with tongues, and clamping brackets. This segmentation allows each component to be independently designed and combined in different configurations to suit specific roof types and orientations, reducing the need for completely different systems for each application.
2Ease of operation
If clamping devices are approximately positioned on rails before secure mounting, then the mounting process becomes faster and more convenient, but the clamping device may slide along the rail before being securely mounted
Solution Approach 1:
The tongue is preliminarily inserted into the slot before the foot member is fully secured to the rail. This preliminary action allows the installer to position the foot member at the desired location along the rail while the tongue engages with the slot to prevent sliding. Once positioned, the foot member is then securely fastened to the rail, maintaining both ease of positioning and stability.
3Adaptability or versatility
If unique fastening connections are used for each application (flat roof, sloping roof, rack), then each mounting scenario can be optimized, but production and storage costs increase
Solution Approach 1:
The support rail with standardized slots serves as a universal base structure that can be used across all application types (flat roofs, sloping roofs, racks). The adaptability to specific applications is achieved not through different rails, but through interchangeable foot members and clamping brackets that attach to the same rail system, thereby maintaining ease of manufacture while achieving application-specific optimization.
Solution Approach 2:
Different foot members provide localized adaptations: the first foot member with its tongue configuration optimizes for standard mounting scenarios, while the second foot member with its angled tongue optimizes for sloping roof applications. This allows each local component to be tailored to specific needs while the overall system architecture remains standardized and cost-effective.
Data Source
Figure 1~3
Figure 4a~5b
Figure 6a~6c
AI summary
First and second foot members (10, 20) and a system 1, arranged for fastening solar panels (100) to a substrate (150). The system (1) comprises a C-shaped support rail (80) which is arranged for fixed connection to a fixation bracket (60), first and second foot members (10, 20) which each are arranged with at least one flange (13, 23) for engagement with the rail (80) and at least two clamping brackets (50). Each clamping bracket (50) is arranged for clamping a solar panel (100) between the clamping bracket (50) and the first and/or the second foot member (10, 20).