Solar Module Leveler for Independent Panel Replacement
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Solution Overview
Problem
Existing solar module mounting systems require excessive components and labor for installation and maintenance, particularly when replacing damaged modules, as they often necessitate disassembling the entire array to access and remove modules, and tools with specialized fasteners are needed for alignment, complicating the process.
Innovation Solution
A height-adjustable roof anchor system with a base and upwardly extending height adjustment member, allowing solar modules to be removed without sliding adjacent modules, and a brace system that supports frames with shorter lengths to facilitate easy module replacement and adjustment, enabling vertical adjustments and upward engagement for secure anchoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If solar modules are mounted using conventional rail systems, then modules can be secured to the roof, but replacing damaged modules requires disassembling the entire array and sliding adjacent modules off rails
Solution Approach 1:
The mounting system is divided into independent module-level components (levelers and anchors) rather than continuous rails. Each solar module can be independently mounted and removed with its own levelers, allowing damaged modules to be replaced without affecting adjacent modules or requiring disassembly of the entire array.
Solution Approach 2:
The levelers are designed to be removable from the roof anchors, allowing the solar module and its associated levelers to be easily extracted from the mounting system. This extraction capability enables individual module replacement without requiring removal of other modules or complex disassembly procedures.
2Reliability
If specialized fasteners with horizontal engagement faces are used, then modules can be securely connected, but alignment becomes difficult and requires special tools
Solution Approach 1:
Instead of requiring the fastener engagement face to be horizontal (perpendicular to the module), the design inverts the engagement orientation so that the fastener engagement face is vertical and parallel to the module. This allows alignment to occur in the vertical direction, which is more accessible and easier to align during installation and maintenance operations.
Solution Approach 2:
The leveler acts as an intermediary component between the roof anchor and the solar module frame. It provides a standardized interface with vertical engagement faces that simplify alignment, while also accommodating the structural requirements for secure connection. The leveler mediates between the fixed roof anchor and the modular solar panel, enabling easy alignment and reliable connection.
3Reliability
If excessive components are used in mounting systems, then secure anchoring is achieved, but installation and maintenance require excessive labor
Solution Approach 1:
The leveler combines multiple functions into a single component: it provides structural support for the solar module, enables connection to the roof anchor, allows for height adjustment, and facilitates easy removal and replacement. By merging these functions into one integrated component, the system achieves reliable anchoring while minimizing the number of separate parts and simplifying installation and maintenance operations.
Solution Approach 2:
The leveler is designed as a universal component that can be used with any solar module and any roof type (flat or angled). It provides multiple functions including mounting, leveling, height adjustment, and easy removal. This multi-functionality reduces the need for specialized components for different scenarios, thereby reducing overall system complexity and improving installation efficiency.
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.