Solar panel rail
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Solution Overview
Problem
Large commercial 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.
Innovation Solution
A solar mounting rail with integrated indexing flanges and tabs that allows for easy installation by securing solar modules in both north/south and east/west directions using preassembled brackets and a single carriage bolt, eliminating the need for separate indexing features and fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional solar mounting assemblies are used with 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 separate components (bracket, indexing flange, and fastener) into a single integrated solar mounting assembly. The indexing flange is built into the bracket structure, and a single fastener secures both the bracket to the rail and the indexing function, eliminating the need for separate indexing features and reducing the number of installation steps
Solution Approach 2:
The single fastener in the invention serves multiple functions simultaneously: it secures the bracket to the solar panel rail, provides indexing alignment, and maintains structural integrity. This multi-functional design replaces the conventional separate fasteners and indexing features, reducing installation complexity while maintaining reliability
2Manufacturing precision
If multiple separate fasteners and indexing features are used, then module alignment precision is improved, but device complexity and number of parts increase
Solution Approach 1:
The indexing flange is integrated directly into the bracket structure, combining the alignment function with the mounting function. This eliminates separate indexing features and reduces the total number of parts while maintaining precise module alignment through the built-in flange geometry
3Ease of operation
If preassembled brackets with integrated features are used, then ease of installation is improved, but manufacturing complexity may increase
Solution Approach 1:
The bracket and indexing flange are preassembled into an integrated unit before delivery to the installation site. This preliminary assembly simplifies the installation process by reducing the number of steps required on-site, while the manufacturing complexity is shifted to the factory setting where automated assembly can be more efficiently implemented
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.