Solar module mounting system
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Solution Overview
Problem
Solar mounting systems are costly due to expensive components and labor-intensive installation processes, requiring efficient packaging, shipping, and installation methods.
Innovation Solution
A solar module mounting bracket system with retainer assemblies, including through bolts, springs, mounting tabs, and nuts, integrated with torque tubes and mounting brackets, allowing for easy integration and secure positioning of solar modules on a rotating torque tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional solar mounting systems are used, then secure mounting of solar modules is achieved, but installation becomes laborious and time-consuming requiring skilled installers
Solution Approach 1:
The mounting system is divided into separate modular components: mounting brackets that attach to the torque tube, and retainer assemblies that secure the solar modules. These segments can be independently installed and positioned, allowing installers to work with smaller, more manageable parts rather than attempting to install large rigid structures, thereby reducing installation complexity while maintaining secure mounting.
Solution Approach 2:
The retainer assembly incorporates a movable retainer element that can be positioned in different states (open/closed, engaged/disengaged) to facilitate installation and removal of solar modules. This dynamic component allows the mounting system to transition between secure holding and easy release states, enabling non-skilled installers to quickly install and maintain modules without specialized tools or expertise.
2Reliability
If traditional solar mounting systems are used, then solar modules are securely fixed, but component cost and shipping cost increase due to weight and size
Solution Approach 1:
By segmenting the mounting system into smaller components (mounting brackets, retainer assemblies, individual fasteners), the system achieves secure module fixation while improving packaging efficiency. Smaller parts can be compactly packaged, reducing shipping volume and weight costs compared to traditional bulky mounting structures, while still providing reliable mechanical attachment when assembled.
Solution Approach 2:
The retainer assembly components are designed to nest within each other when not in use - the retainer element stores within the mounting bracket, and fasteners are contained within the assembly structure. This nesting arrangement minimizes the overall volume required for shipping and storage while maintaining the structural integrity and secure fixation capability when deployed.
3Reliability
If complex mounting systems are used, then secure positioning is achieved, but installation time and labor costs increase
Solution Approach 1:
The mounting brackets are pre-configured with attachment features for the torque tube, and the retainer assemblies are pre-assembled with their fastening components. This preliminary preparation allows installers to simply attach the pre-configured brackets to the torque tube and then secure the modules using the pre-assembled retainers, eliminating the need for complex field assembly operations and significantly increasing installation speed while maintaining accurate positioning.
Solution Approach 2:
The retainer assembly is designed as a self-contained unit that automatically secures the solar module when the retainer element is positioned in the engaged state. The system's own components work together to achieve secure positioning without requiring external tools, specialized skills, or complex adjustment procedures, thereby enabling rapid installation by non-skilled workers while ensuring accurate and reliable module 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
The system enables efficient and cost-effective installation of solar modules by simplifying the mounting process, reducing labor and material costs, while ensuring secure module positioning during rotation.
Implementation Method 1
a spring, a mounting tab, and nut
Implementation Method 2
a catch is positioned on the second mounting bracket such that it is received in the slot of a solar module from an interior direction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A solar module mounting bracket system including a plurality of solar modules including mounting slots formed in a sidewall of the solar module, a torque tube configured to support the solar modules such that they can be rotated, a plurality of mounting brackets configured for integration with the torque tube and to which the plurality of solar modules are mounted, at least one first retainer assembly connected to one of the plurality of mounting brackets, the first retainer assembly including a through bolt, a spring, a mounting tab, and nut. When a solar module is placed on the mounting bracket and supported by the torque tube the mounting tab retainer assembly is received in the mounting slot of the solar module.