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 and movable braces that transition between collapsed and expanded configurations, allowing for easy packaging, shipping, and installation, featuring truss arms and fastener assemblies for secure attachment to a torque tube, reducing overall footprint and installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional solar mounting systems use fixed, rigid bracket assemblies, then structural stability is maintained, but packaging and shipping costs increase due to larger footprint and installation complexity increases
Solution Approach 1:
The bracket assembly is divided into separable components including the rail, braces, truss arms, and fastener assemblies that can be independently packaged and transported. This segmentation allows each component to be optimized for compact shipping while maintaining structural integrity when assembled on-site.
Solution Approach 2:
The braces are designed with movable joints that allow them to transition between collapsed and expanded configurations. This dynamic capability enables the bracket assembly to be compact during transport and then deployed to its full structural form during installation, reducing packaging footprint while maintaining structural stability.
2Reliability
If solar mounting systems use complex assembly structures, then attachment security is improved, but installation time and skilled labor requirements increase
Solution Approach 1:
The fastener assemblies are pre-configured with washers and fasteners attached to the truss arms before shipping. This preliminary preparation eliminates the need for separate fastener installation steps during assembly, reducing installation time while maintaining secure attachment through the pre-positioned fastening components.
Solution Approach 2:
The bracket assembly incorporates self-aligning features and intuitive connection points that allow installers to easily identify and connect components without requiring specialized training or complex alignment procedures. The movable braces automatically position themselves during assembly, reducing the skill level required for installation.
3Ease of manufacture
If the bracket assembly uses fixed, non-collapsible structures, then manufacturing simplicity is maintained, but shipping costs and storage requirements increase
Solution Approach 1:
The braces incorporate movable joints that enable them to collapse parallel to the rail during shipping and expand perpendicular to the rail during operation. This dynamic transformation allows the same component to occupy minimal space during transport while providing full structural support during installation, effectively reducing shipping volume by approximately half compared to fixed structures.
Solution Approach 2:
The truss arms and braces are designed to nest together in a compact configuration during shipping, with smaller components fitting within or alongside larger ones. This nesting arrangement maximizes space utilization during transport while allowing easy separation and assembly of individual components during installation.
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.