Solar Module End Clamp Wedge Mechanism for Rail Mounting
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Solution Overview
Problem
Conventional solar module mounting systems face challenges in securely coupling adjacent modules side-by-side on a support structure, requiring improved methods to ensure proper positioning and secure attachment.
Innovation Solution
The proposed solution involves an end clamp system with a fastener, clamping plate, inner wedge, and block mechanism that applies horizontal and vertical forces to secure solar modules to a rail, providing a robust and efficient mounting method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coupling members are used to mount solar modules side-by-side, then the modules can be attached to the support structure, but it is challenging to ensure proper positioning of adjacent modules during assembly
Solution Approach 1:
The end clamp is pre-assembled with the coupling member and positioning features before installation. The block and wedge mechanism are pre-configured to automatically engage and position the solar module frame when the clamp is attached to the rail, eliminating the need for manual positioning adjustments during assembly.
Solution Approach 2:
The block acts as an intermediary element between the solar module frame and the coupling member. It transfers and distributes the clamping forces while maintaining precise positioning, allowing the frame to be securely held without direct complex interaction between the coupling member and frame edges.
2Reliability
If a robust clamping mechanism is implemented to securely mount solar modules, then the mounting stability is improved, but the device complexity increases
Solution Approach 1:
The clamping mechanism is segmented into distinct functional components: the end clamp body, the block for positioning, and the wedge for force application. Each component has a specific function and can be manufactured independently, simplifying the overall design while maintaining robust clamping capability.
Solution Approach 2:
The wedge mechanism is designed to automatically generate the necessary clamping force through its geometric shape. When the coupling member is tightened, the wedge self-generates increasing clamping force on the block, which in turn secures the solar module frame without requiring additional actuators or complex control systems.
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
This solution ensures secure and efficient mounting of solar modules by applying precise forces to engage the modules with the rail, enhancing stability and ease of installation while establishing an electrical grounding path.
Implementation Method 1
an inner wedge adapted to be disposed inside the rail and coupled to the interior bottom surface, a block disposed between and engaged with the clamping plate wedge and inner wedge, wherein the tail end of the fastener is engaged with the inner wedge to apply a first force in a first horizontal direction on the inner wedge, wherein the head end of the fastener is engaged with the clamping plate to apply a second force in a second horizontal direction on the clamping plate, and wherein the inner wedge and clamping plate wedge impart a vertical force onto the block in a vertical direction
Data Source
AI summary
A solar power system may include rails, solar modules, and a plurality of clamps to secure the solar modules to the rails. An end clamp may be partially disposed inside a rail at an end of the rail. The end clamp may secure a solar module to the rail by coupling to the frame of the solar module. The end clamp may include a fastener that may be tightened to engage the end clamp and secure the solar module by holding it on top of the rail. The end clamp may establish an electrical grounding connection between the frame of the solar module and the rail.