Solar module mounting bracket assemblies
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Solution Overview
Problem
Solar mounting systems are costly due to expensive components and require skilled labor for installation and quality control, necessitating a more efficient and cost-effective solution for coupling solar modules to a framework.
Innovation Solution
A solar module mounting bracket assembly with a rail, movable braces, and truss arms that transition between collapsed and expanded configurations, allowing for easy packaging, shipping, and installation, with fasteners and coupling devices to securely attach solar modules to a torque tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid mounting systems are used, then structural strength is ensured, but packaging and shipping costs increase due to large volume requirements
Solution Approach 1:
The mounting system is divided into separate modular components: rails, braces with truss arms, and coupling devices. These segments can be packaged separately in compact forms and assembled on-site, reducing overall packaging volume while maintaining structural integrity when assembled
Solution Approach 2:
The braces incorporate movable truss arms that can transition between extended and retracted positions. During shipping, the truss arms are retracted to minimize volume; during installation, they extend to provide the necessary structural strength and support for solar modules
2Reliability
If complex mounting systems with multiple components are used, then installation strength and reliability are improved, but installation complexity and labor costs increase
Solution Approach 1:
Multiple functional elements are merged into integrated components. For example, the brace assembly combines the brace structure, truss arms, and coupling mechanisms into a single modular unit that maintains reliability while simplifying installation procedures through reduced part count and streamlined assembly steps
Solution Approach 2:
Components are designed with pre-configured features such as pre-positioned mounting holes, pre-assembled subcomponents, and intuitive alignment mechanisms. This preliminary preparation reduces on-site assembly complexity and enables faster installation while maintaining installation reliability
3Ease of manufacture
If standardized rigid mounting brackets are used, then manufacturing is simplified, but adaptability to different solar module configurations is reduced
Solution Approach 1:
The mounting system employs universal rails with standardized interfaces and adjustable coupling devices that can accommodate various solar module sizes and configurations. The braces and truss arms are designed with adjustable parameters allowing the same basic component design to serve multiple application scenarios, maintaining manufacturing simplicity while enhancing adaptability
Data Source
AI summary
A solar module mounting bracket assembly includes a rail configured to support a solar module thereon, and a pair of braces. The braces each have a first end portion movably coupled to the rail. The braces are movable relative to the rail between a collapsed configuration and an expanded configuration. In the expanded configuration, the braces cooperatively define a channel dimensioned for receipt of a frame member.