Solar Module Clamp Assembly with Stabilization for Easy Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solar module mounting systems face challenges in efficiently aligning and securing adjacent solar modules to a support structure, particularly in ensuring proper positioning and electrical grounding while allowing for easy assembly and maintenance.
Innovation Solution
A clamp assembly with a stabilization member that maintains rotational alignment and provides a clearance for easy insertion of solar modules, featuring a compressible or spring-loaded mechanism to support the upper clamp member and prevent rotation, along with an arcuate contact ridge for electrical grounding, and a skirt clip for aesthetic and functional module-level coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional clamp assembly is used to mount solar modules, then the modules can be secured to the mounting structure, but the assembler faces difficulty in simultaneously positioning adjacent modules properly and engaging the coupling member
Solution Approach 1:
The clamp assembly is divided into separate components: a U-shaped clamp body with integrated positioning features, and a separate fastening mechanism. This segmentation allows the positioning function to be built into the clamp structure itself, reducing the complexity of the overall mounting process while maintaining secure attachment capability
Solution Approach 2:
The clamp body includes pre-formed positioning protrusions and alignment features that automatically guide the solar module into the correct position during installation. This preliminary positioning action eliminates the need for separate alignment steps, making the assembly process easier and faster
2Reliability
If the upper clamp member is positioned close to the rail for secure mounting, then the solar module can be firmly clamped, but the solar module cannot be easily inserted between the clamp member and rail
Solution Approach 1:
The clamp assembly uses a dynamic fastening mechanism where the fastening member can be moved between a loose position (allowing easy insertion of the solar module) and a tightened position (providing secure mounting). This dynamic adjustment capability resolves the contradiction between ease of insertion and secure mounting
Solution Approach 2:
The clamp body is designed with a U-shape that nests around the solar module frame, creating a compact configuration that allows easy insertion. The nested structure maintains close proximity to the rail for secure mounting while providing sufficient clearance during the insertion phase through the adjustable fastening mechanism
3Adaptability or versatility
If the clamp members are allowed to rotate relative to each other, then the assembly may accommodate misalignment, but the solar module cannot be properly aligned and secured
Solution Approach 1:
The clamp body features asymmetric positioning protrusions and corresponding recesses that allow controlled rotation only to the precise alignment position. The asymmetric geometry provides mechanical guidance that accommodates minor misalignment during installation while ensuring the final positioned alignment is precise and repeatable
Solution Approach 2:
The clamp assembly includes self-aligning features where the positioning protrusions automatically guide the clamp members into the correct relative orientation during assembly. This self-service alignment mechanism eliminates the need for complex external alignment tools or procedures while achieving precise positioning
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
Facilitates efficient assembly and secure mounting of solar modules by preventing rotation and ensuring electrical grounding, improving the ease of installation and aesthetic appeal by hiding components underneath the array.
Implementation Method 1
The stabilization member can be configured to prevent rotation of the lower clamp member relative to the upper clamp member about a major axis
Implementation Method 2
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 3
an arcuate contact ridge for electrical grounding
Data Source
AI summary
A solar power system can include a rail and a solar module disposed on the rail. A clamp assembly can couple the solar module to the rail. The clamp assembly can have a clamped configuration in which the solar module is secured to the rail and an unclamped configuration. The clamp assembly can comprise an upper clamp member, a lower clamp member coupled to the rail, and a stabilization member mechanically engaging the upper clamp member and the lower clamp member. The stabilization member can prevent rotation of the lower clamp member relative to the rail when the clamp assembly is in the clamped and unclamped configurations. In the unclamped configuration, the stabilization member can be biased such that the upper clamp member is disposed at a sufficient clearance above the rail to permit the insertion of the solar module between the upper clamp member and the rail.