Solar Panel Clamp Plate with Integrated Hooks for Tool-Free Mounting
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Solution Overview
Problem
Conventional solar array mounting systems require multiple tools and multiple users to connect photovoltaic panel modules to a mounting frame, increasing complexity and installation time.
Innovation Solution
A clamping system with a clamp plate and hooks that connects solar panel modules to a mounting frame using a rail structure and clamp fasteners, allowing for tool-free or single-user installation by securing the module with a clamp plate and hooks that fit onto a mounting rail.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional mounting systems use separate fasteners and tools to connect solar panels to mounting frames, then secure connection is achieved, but device complexity and installation time increase
Solution Approach 1:
The clamp integrates multiple functions into a single device: the clamp body (106) incorporates both the mounting interface for the mounting frame and the panel clamping mechanism with hooks (190). This merging eliminates the need for separate fasteners and reduces the number of components, directly reducing device complexity while maintaining secure connection through the integrated design.
Solution Approach 2:
The clamp plate serves multiple functions: it attaches to the mounting frame via the rail structure, secures the solar panel through hooks, and provides a unified interface for both mounting operations. This multi-functionality reduces the overall system complexity by eliminating separate fastening components while ensuring reliable connection.
2Productivity
If conventional mounting systems require multiple tools and users, then secure installation is achieved, but installation time and labor complexity increase
Solution Approach 1:
The clamp is pre-assembled with the mounting frame connection structure and panel hooks integrated into a single unit. This preliminary assembly allows the installer to simply attach the pre-configured clamp to both the frame and panel without requiring multiple tools or coordination between multiple users, thereby increasing installation speed and ease of operation.
Solution Approach 2:
The clamp design enables a single user to perform the entire mounting operation independently. The integrated structure with pre-positioned hooks and mounting interfaces allows one person to secure the panel without needing assistance from multiple users or specialized tools, improving both productivity and ease of operation.
3Ease of manufacture
If conventional mounting systems use multiple separate parts, then secure attachment is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The clamp integrates the mounting frame attachment structure, panel hooks, and fastening mechanism into a single manufactured component (clamp body 106). This merging reduces the total number of parts that need to be manufactured, stored, and assembled, directly lowering manufacturing costs and simplifying the overall device while maintaining secure attachment capability.
Data Source
AI summary
Mounting systems for securing a solar array to a mounting frame and clamping systems thereof are disclosed. The clamping systems may include one or more hooks for connecting a solar panel module to mounting frame. The hooks may be disposed on one or more wings of a clamp plate that extend from a rail structure of the clamp plate. The rail structure may form a rail chamber which receives a mounting rail.