Solar panel mounting system and method
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Solution Overview
Problem
The existing solar panel installation process is inefficient, requiring multiple installers, leading to wasted time and safety issues due to loose hardware, exposed cables, and rodent damage, which can cause electrical hazards and system failures.
Innovation Solution
A solar panel mounting system with a modular peripheral frame and pre-installed captive T-bolt assemblies that allow for rapid installation with one installer, internal cable routing, and a snap-in rodent-proof conduit cover to secure cables, eliminating the need for manual handling of hardware and reducing exposure to rodents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional loose mounting hardware is used to secure solar panels to rails, then the panels can be mounted, but the hardware becomes loose and dislodged during installation requiring multiple installers and creating safety hazards
Solution Approach 1:
The T-bolt assemblies are pre-installed and pre-positioned on the solar panel frame before the panel is lifted onto the roof. This preliminary action ensures the hardware is securely attached to the panel and cannot become loose or dislodged during installation, eliminating the need for multiple installers to handle loose hardware and removing safety hazards associated with falling objects
Solution Approach 2:
The pre-installed captive T-bolt assemblies enable a single installer to secure the solar panel to the rails independently. The panel's own hardware serves the function of securing it during installation, eliminating the need for additional installers to manage loose mounting components
2Reliability
If traditional installation process is used with multiple installers, then panels can be secured, but installation time increases and efficiency decreases
Solution Approach 1:
By pre-installing the T-bolt assemblies on the panel frame before roof installation, the complex process of coordinating multiple installers to handle loose hardware is eliminated. A single installer can efficiently secure the panel by simply tightening the pre-positioned bolts, significantly reducing installation time and improving productivity
Solution Approach 2:
The mounting system is segmented into pre-assembled components (T-bolts attached to panel frame) that can be independently installed. This segmentation allows the panel to be self-sufficient during installation, requiring only one installer and reducing overall installation time
3Ease of manufacture
If cables are routed externally beneath panels, then cable connections can be made, but cables become exposed to rodent damage and electrical hazards
Solution Approach 1:
The cable management system uses a nested structure where the conduit is embedded within the solar panel frame, and cables are routed through the conduit. This nested arrangement protects cables from rodent damage by placing them inside the protected conduit structure that is integrated into the panel frame, eliminating external cable exposure
4Ease of manufacture
If loose mounting hardware is used, then panels can be assembled, but hardware is lost in shrubbery or lawns and can damage property or injure people
Solution Approach 1:
The solar panel's own pre-installed T-bolt assemblies serve as the mounting hardware, eliminating the need for separate loose hardware components. Since the bolts are permanently attached to the panel frame, they travel with the panel and cannot be lost or cause damage to property or people during installation
Data Source
AI summary
A solar panel mounting system for forming a solar array includes longitudinal support rails mounted to a support structure such as a roof. A first solar panel disposed on the rails has a peripheral frame including a locking frame member with deformable clamping portion configured for slideably receiving a peripheral frame portion of an adjacent second solar panel. A pair of captive T-bolt sets passing through the clamping portion include T-bolts having locking heads and nuts frictionally engaged with the T-bolts to rotate the T-bolts. The heads are each inserted and rotationally locked into fastening channels of respective support rails. The second solar panel is inserted into the first panel clamping portion and the nuts are fully tightened producing a clamping action which locks the first and second panels together. Power/control cables may be routed inside covered cable compartments on rears of the panels for protection against rodent damage.