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 and easy-to-install solutions for solar module mounting.
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 secure and efficient installation of solar modules on a rotating framework.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional mounting systems are used, then solar modules can be securely mounted, 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 torque tubes, retainer assemblies with spring-loaded clips, and solar modules with integrated mounting slots. This segmentation allows each component to be independently handled and assembled, enabling quick snap-fit installation without complex alignment procedures or specialized tools, thereby reducing both labor requirements and installation time
Solution Approach 2:
The retainer assemblies are pre-assembled with spring-loaded clips and mounting brackets are pre-configured with attachment mechanisms. The solar modules arrive with mounting slots pre-formed in their frames. This preliminary preparation of components eliminates the need for field assembly or complex fastening operations during installation, allowing installers to simply connect pre-prepared components together, significantly reducing installation time and skill requirements
2Reliability
If traditional mounting systems are used, then solar modules can be securely mounted, but component costs and shipping costs increase due to weight and size
Solution Approach 1:
The retainer assemblies utilize spring-loaded clips and thin metallic components instead of heavy rigid fasteners. The mounting brackets employ thin-walled structures with integrated attachment mechanisms. These flexible, thin-profile components maintain sufficient mechanical strength for secure mounting while dramatically reducing weight and material usage, leading to lower manufacturing costs and reduced shipping expenses
Solution Approach 2:
The mounting system merges multiple functions into integrated components: the mounting brackets combine structural support with attachment mechanisms, the retainer assemblies integrate spring loading with clipping functionality, and the solar module frames incorporate mounting slots directly into the structure. This consolidation eliminates the need for separate heavy fasteners and mounting hardware, reducing overall component weight and manufacturing complexity while maintaining secure mounting capability
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 reduces installation time and costs by providing a secure and efficient method for mounting solar modules on a rotating torque tube, enhancing the overall efficiency of solar power system setup.
Implementation Method 1
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
Implementation Method 2
a threaded U-bolt, wherein the first clamp assembly includes a bottom surface having a radius substantially similar to that of the torque tube
Data Source
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.