Solar module couplings for solar tracker
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and lengthy assembly time of solar tracker systems due to the numerous clamps and fasteners required to secure solar modules to support structures, which increases manufacturing costs and assembly time.
Innovation Solution
A coupling system for solar trackers featuring an elongate body with protuberances and a gap to receive a torque tube, along with through-holes for fasteners, allowing for efficient coupling to the torque tube using rivets, screws, or bolts, with the option to form bores on-site if pre-formed bores are not present.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous clamps and fasteners are used to secure solar modules to support structures, then the structural integrity and reliability are improved, but the manufacturing cost and assembly time increase significantly
Solution Approach 1:
The coupling integrates multiple fastening functions into a single unified component that simultaneously secures the torque tube and supports solar modules. The coupling body with integrated tabs, bores, and engagement features combines what would traditionally require separate clamps and multiple fasteners into one assembly operation, reducing assembly time while maintaining structural integrity through distributed fastener placement.
Solution Approach 2:
The coupling is designed with segmented functional zones: protuberances for torque tube engagement, tabs with bores for fastener attachment, and interfaces for solar module support. This segmentation allows each feature to perform its specific function efficiently, enabling reliable structural connection while simplifying the overall assembly process through modular functionality.
2Reliability
If numerous clamps and fasteners are used to secure solar modules to support structures, then the structural integrity and reliability are improved, but the manufacturing cost increases
Solution Approach 1:
The coupling consolidates multiple discrete fastening components into a single integrated part that can be manufactured as one piece or pre-assembled unit. This reduces the total number of parts that need to be procured, inventoried, and managed, thereby lowering manufacturing costs while maintaining the structural reliability achieved through multiple fastener attachment points.
Solution Approach 2:
The coupling serves multiple functions simultaneously: it acts as a structural connector to the torque tube, provides mounting points for solar modules, and distributes mechanical loads across multiple fasteners. This multi-functionality eliminates the need for separate components for each function, reducing overall system cost while ensuring structural integrity.
3Strength
If traditional coupling mechanisms are used, then adequate structural support is provided, but the assembly process becomes lengthy and costly
Solution Approach 1:
The coupling is designed with pre-positioned tabs, bores, and engagement features that are ready for fastener installation. The protuberances and gap geometry are pre-configured to receive the torque tube and position fasteners correctly, eliminating the need for alignment operations during assembly and enabling rapid installation while maintaining strong structural support.
Solution Approach 2:
The coupling integrates torque tube attachment and solar module support functions into a single component that can be installed in one location. This consolidation reduces the number of assembly steps and locations that need to be serviced, increasing assembly speed while providing adequate structural support through the integrated fastening system.
Data Source
AI summary
A coupling for use with a solar tracker includes an elongate body defining opposed top and bottom surfaces, the bottom surface defining a pair of protuberances disposed in spaced relation along a length of the elongate body and defining a gap therebetween, each of the pair of protuberances including a tab disposed thereon adjacent the gap, wherein the gap is configured to receive a torque tube such that an inner surface of the gap and the tabs of each of the pair of protuberances abut a portion of the torque tube, wherein each tab of the pair of protuberances includes a bore defined therethrough that is configured to receive a fastener to couple the elongate body to a torque tube.