Solar Tracker Rail Coupling Clip for Fastener-Free Module Mounting
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Solution Overview
Problem
The high cost and lengthy assembly time of solar tracker systems due to the large number of clamps and fasteners required to secure solar modules to support structures, which increases manufacturing costs and assembly time.
Innovation Solution
A coupling system using snap-fit or quick-fit mechanisms, such as clips with wedges and hard stops, that allow solar modules to be securely attached to tracker rails without conventional fasteners, utilizing slots and integrated wedges for positive engagement and secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fasteners and clamps are used to secure solar modules to support structures, then structural integrity is maintained, but assembly time and manufacturing costs increase significantly
Solution Approach 1:
The patent integrates the clamp body and engagement features into a single unified component that attaches directly to the support structure. The solar module frame itself is designed with integrated attachment features that combine multiple functions (structural support, module positioning, and fastening) into one element, eliminating the need for separate clamps and fasteners for each module.
Solution Approach 2:
The support structure is designed with universal attachment features that can secure multiple solar modules simultaneously. The integrated clamp system serves multiple functions: providing structural support, securing modules to the tracker rail, and enabling quick attachment/detachment without requiring different fastening mechanisms for different modules.
2Reliability
If numerous clamps and fasteners are used to secure each solar module, then secure attachment is achieved, but manufacturing costs increase
Solution Approach 1:
The patent integrates the clamp body and engagement features into a single unified component that attaches directly to the support structure. The solar module frame itself is designed with integrated attachment features that combine multiple functions (structural support, module positioning, and fastening) into one element, eliminating the need for separate clamps and fasteners for each module.
Solution Approach 2:
The patent extracts the fastening function from separate fasteners and integrates it directly into the module frame and support structure. By taking out the need for discrete fastening components and embedding the attachment mechanism into the structural elements themselves, the system reduces component count and manufacturing complexity while maintaining secure attachment.
3Strength
If traditional fastening mechanisms are used for each solar module, then secure coupling is achieved, but assembly time increases enormously
Solution Approach 1:
The solar modules are manufactured with pre-integrated attachment features built into the frame during the manufacturing process. The support structure is pre-configured with corresponding engagement features. This preliminary integration of fastening capabilities into the structural elements eliminates the need for time-consuming assembly of separate fasteners during installation.
Solution Approach 2:
The patent integrates the clamp body and engagement features into a single unified component that attaches directly to the support structure. The solar module frame itself is designed with integrated attachment features that combine multiple functions (structural support, module positioning, and fastening) into one element, eliminating the need for separate clamps and fasteners for each module.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces assembly time and manufacturing costs by eliminating the need for conventional fasteners and enabling faster, more efficient attachment of solar modules to tracker rails, while maintaining structural integrity and load-bearing capacity.
Implementation Method 1
A coupling system using snap-fit or quick-fit mechanisms, such as clips with wedges and hard stops
Implementation Method 2
clips with wedges and hard stops, that allow solar modules to be securely attached to tracker rails
Data Source
AI summary
A coupling system for use with a solar tracker includes a support rail including a pair of opposed flanges disposed in spaced relation to one another and defining a channel therebetween, each of the pair of opposed flanges including a respective slot defined therethrough, and a coupling clip configured to be received within each of the slots and a portion of a module rail received within the channel of the support rail, wherein the coupling clip includes a resilient finger disposed on a distal end portion configured to engage a portion of the pair of opposed flanges to inhibit proximal movement of the coupling clip and a one protrusion disposed on a proximal portion thereof configured to engage a portion of an opposite flange of the pair of opposed flanges to inhibit distal movement of the coupling clip to couple the module rail to the support rail.