Solar panel rail
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Solution Overview
Problem
Current solar mounting systems require extensive labor and hardware for installation due to the need for numerous fasteners and complex assembly processes, increasing costs and installation time, especially in large commercial installations.
Innovation Solution
A solar mounting rail with integrated indexing flanges and tabs that allows for easy attachment to a torque tube using a single carriage bolt, eliminating the need for separate indexing features and fasteners, and enabling rapid installation of solar modules with automatic alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional solar mounting systems use multiple fasteners and separate indexing features, then structural integrity is maintained, but installation time and labor costs increase significantly
Solution Approach 1:
The patent combines multiple functions into a single integrated rail component that simultaneously provides structural support, indexing features, and fastening capabilities. The rail incorporates integrated indexing flanges and tabs that eliminate the need for separate indexing components, while the carriage bolt assembly replaces multiple fasteners with a single fastening mechanism, thereby reducing installation time without compromising structural integrity
Solution Approach 2:
The solar mounting rail is designed as a multi-functional component that performs multiple roles: it provides structural support, enables precise indexing and alignment of solar modules, and facilitates rapid fastening. The integrated design allows the same component to achieve indexing, positioning, and securing functions that traditionally required separate parts, thus reducing the number of installation steps
2Manufacturing precision
If conventional systems use numerous separate fasteners and indexing components, then precise alignment is achieved, but the number of parts and hardware requirements increase
Solution Approach 1:
The patent integrates indexing flanges and alignment tabs directly into the rail structure, eliminating the need for separate indexing components and alignment features. This consolidation maintains precise alignment capabilities while significantly reducing the total number of parts and hardware items required for the solar mounting system
Solution Approach 2:
The mounting rail serves as a universal component that incorporates multiple functions: structural support, precise indexing through integrated flanges, alignment through tabs, and fastening through the carriage bolt assembly. This multi-functionality reduces the quantity of separate parts needed while maintaining manufacturing precision
3Reliability
If conventional mounting systems use complex assembly procedures with multiple steps, then reliable connections are established, but labor costs and installation complexity increase
Solution Approach 1:
The patent merges multiple assembly operations into a single streamlined process. The pre-assembled carriage bolt with washer and nut is inserted through the rail and module frame in one motion, simultaneously achieving attachment and securing. The integrated indexing flanges and tabs automatically align components during this single operation, eliminating the need for separate alignment and fastening steps
Data Source
AI summary
A solar panel rail for mounting a photovoltaic module frame thereto is provided and has a rail body configured to for attachment of a rail bracket, an indexing flange located on the rail body and configured to box and maintain a module frame position along a short-side direction of the module frame, a tab located on the rail body and configured to hold the module in place along a long-side direction of the module frame, wherein the indexing flange and tab are configured to provide a predetermined locked in installation position of the module frame during installation thereof.