Solar panel top clamp assembly for roofs and the like
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Solar panel mounting devices face challenges in accommodating varying panel heights, as existing clamps are either height-specific or require separate mid-clamp and end-clamp assemblies, leading to instability when used incorrectly.
Innovation Solution
A novel over-the-panel clamp assembly that functions as both a mid-clamp and end-clamp, featuring obliquely extending legs and a rotating crossbar, allowing for height-adjustability and enhanced stability by creating two points of support, which balances rotational forces and accommodates different panel heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single clamp assembly is designed to function as both mid-clamp and end-clamp, then versatility and device complexity reduction are improved, but stability may worsen due to rotational forces
Solution Approach 1:
The clamp assembly is designed with a base featuring a slot and platform that can slide along the support section, and a panel clamp with oblique legs that can rotate. This universal design allows the same clamp to function effectively as both a mid-clamp (securing panels at array edges) and an end-clamp (securing panels at array ends), eliminating the need for separate clamp types and reducing overall system complexity
Solution Approach 2:
The panel clamp incorporates legs that can dynamically rotate about the support section as the clamp tightens. This rotational capability allows the clamp to adapt to different mounting positions and panel heights, maintaining stability in both mid-clamp and end-clamp configurations. The rotation mechanism transforms potential instability into a beneficial adaptive feature
2Adaptability or versatility
If height-adjustable clamps are used to accommodate varying panel heights, then adaptability is improved, but device complexity increases due to multiple clamp variants
Solution Approach 1:
The clamp assembly achieves height adjustability through parameter changes in its geometric configuration. The oblique legs are positioned at specific angles and can rotate to different positions, allowing the clamp to accommodate panel heights ranging from 30mm to 50mm. The slot length and platform position are designed to provide the necessary range of motion for height adjustment without requiring multiple discrete clamp variants
Solution Approach 2:
A single universal clamp design replaces multiple height-specific clamp variants. The combination of the slidable base and rotatable panel clamp creates a height-adjustable mechanism that works across the full range of solar panel heights, eliminating the need for manufacturers to produce and inventory multiple clamp types
3Adaptability or versatility
If end-clamps rotate away from the solar panel during tightening, then height adjustability is improved, but stability worsens when used as mid-clamps
Solution Approach 1:
The rotation of the panel clamp away from the solar panel during tightening is not prevented but rather utilized as a dynamic feature. As the clamp tightens, the legs rotate about the support section, and the platform slides along the slot. This dynamic motion allows the same mechanism to provide stable operation in both mid-clamp and end-clamp configurations, transforming what was previously a source of instability into a beneficial adaptive characteristic
Data Source
AI summary
Disclosed is a solar panel top clamp assembly for securing solar panels to a support section such as a rail or rail-less mounting structure. The solar panel top clamp assembly includes a panel clamp and a base. The panel clamp includes a crossbar and a pair of legs projecting obliquely downward from the crossbar and angled inward toward one another. The panel clamp is secured to a pedestal that projects upward from a platform. The platform is captively slidable within the support section. The pedestal and platform together form a portion of the base. Thanks in part to the unique structure of the panel clamp, the solar panel top clamp assembly can perform the function of both an end-clamp and a mid-clamp.