Solar Mounting Assembly With Tolerance-Accommodating Coupling
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Solution Overview
Problem
Existing mounting assemblies for solar energy installations face challenges in aligning base elements precisely on sloping roof constructions due to dimensional tolerances, making it difficult to connect multiple base elements without applying excessive force.
Innovation Solution
The coupling member and coupling cavity contours feature a first and second arcuate part with different radii of curvature connected by an elongated part, providing additional tolerance and allowing for non-linear alignment of base elements, while maintaining a close-fitting connection for a reliable mounting basis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If base elements are connected precisely in line with circular coupling contours, then a reliable mounting basis is obtained, but great forces are exerted on the base elements when trying to join coupling elements simultaneously to multiple base elements
Solution Approach 1:
The coupling contour is segmented into two separate arcuate parts (first and second arcuate parts) instead of a single continuous circular contour. This segmentation allows the coupling element to engage base elements at different positions along the elongated part, distributing the connection forces and reducing the peak forces exerted on individual base elements during simultaneous coupling.
Solution Approach 2:
The coupling member and coupling cavity are designed with an elongated part that provides additional length in the coupling direction. This dimensional extension allows base elements to be positioned at different locations along the elongated axis, enabling flexible alignment that accommodates roof construction tolerances without requiring precise linear positioning, thereby reducing the forces needed for coupling.
2Ease of operation
If base elements are positioned to accommodate roof construction tolerances, then ease of installation is improved, but alignment precision between base elements deteriorates
Solution Approach 1:
The coupling contour is extended in one dimension by adding the elongated part, which provides additional length for the coupling member to engage with multiple base elements. This dimensional extension allows base elements to be positioned at different locations along the elongated axis, enabling flexible alignment that accommodates roof construction tolerances while maintaining reliable coupling.
Solution Approach 2:
The coupling contour parameters are changed from a simple circular shape to a more complex shape with two separated arcuate parts connected by an elongated part. This parameter change allows the coupling to accommodate variations in base element positioning while maintaining engagement, effectively decoupling the alignment precision requirement from the installation ease.
Data Source
Figure 1
Figure 2~4C
AI summary
A mounting assembly for attaching a device to an underlying construction comprises a base element (30) with attaching means (3) for attaching to the construction (21) and a coupling element (40) for connection to the base element. One of the base element and the coupling element comprises a coupling cavity (45) for receiving therein a coupling member (35) of another of the base element and the coupling element. Contours of the coupling member and the coupling cavity each comprise a first arcuate part (31,41) from a first centre (C1) and an opposite second arcuate part (32,42) from a second centre (C2), wherein the arcuate parts of each of the contours are mutually connected by a elongated part (33,43) and hook into each other.