Solar Module Leveler With Top-Access Adjustment for Easy Replacement
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Solution Overview
Problem
Existing solar module mounting systems require excessive components and labor for installation and replacement, particularly on sloped roofs, as they necessitate disassembling adjacent modules to remove or replace a damaged module, and use tools that are difficult to align due to their design.
Innovation Solution
A height-adjustable roof anchor system with upwardly facing fasteners and a mechanism allowing solar modules to be removed without sliding adjacent modules, featuring a base with a hole and a height adjustment member with an annular groove for rotational adjustment, and a brace system that supports solar modules for easy disconnection and reinstallation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If solar modules are mounted using conventional rail systems, then the array can be installed on various roof types, but individual modules cannot be removed without disassembling adjacent modules
Solution Approach 1:
The mounting system is divided into independent module units, each with its own roof anchor and connection mechanism. This segmentation allows individual modules to be removed and replaced without affecting adjacent modules, as each module can be independently detached from the rail and roof anchor assembly.
Solution Approach 2:
The connection system incorporates dynamic elements including rotatable fasteners and adjustable height mechanisms that allow modules to be easily connected and disconnected. The rotatable fastener design enables tool access from above the module, facilitating dynamic assembly and disassembly operations without requiring module removal or complex tool manipulation.
2Strength
If a rotatable fastener with horizontal engagement face is used to connect modules, then modules can be securely joined, but tools must be aligned horizontally which is difficult when modules are surrounded by other modules
Solution Approach 1:
Instead of requiring horizontal tool alignment as in conventional systems, the fastener design inverts the tool engagement approach by providing an upwardly facing engagement surface. This allows tools to be inserted from above the module in a vertical orientation, which is much easier to align when working on installed arrays where horizontal access is constrained by surrounding modules.
Solution Approach 2:
The tool engagement interface is moved from a horizontal plane to a vertical plane. By orienting the fastener engagement face upwardly rather than horizontally, the system changes the dimensional orientation of tool access, allowing workers to approach from above rather than requiring precise horizontal alignment from the side.
3Reliability
If excessive components are used in the mounting system, then reliable anchoring to the roof is achieved, but installation and maintenance require excessive labor
Solution Approach 1:
The system merges multiple functions into integrated components. The roof anchor assembly combines the anchoring mechanism, height adjustment, and module connection features into a single integrated unit that attaches to the rail and secures the module. This consolidation reduces the number of separate components that must be handled and installed, improving productivity while maintaining reliable roof anchoring.
Solution Approach 2:
The mounting components are designed with multi-functionality to reduce overall system complexity. The rail serves both as a structural support element and as a guide for module positioning. The roof anchor provides both secure anchoring to the roof structure and a mechanism for height adjustment. These universal, multi-functional components reduce the total number of parts needed while maintaining system reliability.
Data Source
AI summary
A leveler for a solar module can include a base, a rotatable adjuster, and a follower. The rotatable adjuster can be mounted to the base with a swaging process, or other techniques. The follower can be embedded within a coupler configured to be connectable to solar modules. Turning the rotatable height adjuster changes the relative spacing between the solar module and the base.