Support Profile Adapter With Symmetric Clamps for Load Alignment
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Solution Overview
Problem
Existing solar module attachment systems face issues with uneven force distribution under wind and snow loads, material deformation, and increased assembly costs due to asymmetrical connections and limited flexibility in adjusting the profile rail's alignment and height.
Innovation Solution
A U-shaped adapter with internal fastening clamps and a central mounting head allows for central accommodation of carrier profiles, enabling easy loading and secure attachment without direct screwing, with adjustable features for height and alignment, and a design that prevents slipping and tilting, facilitating rapid, reliable, and cost-effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an asymmetrical connection with a flag perpendicular to the profile rail is used, then the connection can be created with simple components, but uneven force distribution and material-tiring torsional forces occur under wind and snow loads
Solution Approach 1:
The patent applies asymmetry in reverse by creating a symmetrical connection structure. The adapter features two identical legs extending in opposite directions, both equipped with fastening clamps, creating a balanced symmetrical design that distributes forces evenly across the profile rail, eliminating the torsional forces caused by asymmetrical connections.
Solution Approach 2:
The connection system is segmented into distinct functional components: the adapter body, two separate fastening clamps, and mounting brackets. This segmentation allows each component to be optimized independently and facilitates even force distribution through the modular structure, with each clamp handling forces on its respective side.
2Productivity
If direct screwing of profile rails to the holder is used, then the assembly process is simple, but adjustment of vertical distance and lateral alignment is impossible
Solution Approach 1:
The adapter incorporates adjustable features that allow dynamic modification of the connection geometry. The mounting brackets can be positioned at different locations on the adapter body, and the fastening clamps can be adjusted along the legs, enabling both vertical distance adjustment and lateral alignment correction while maintaining a simple assembly process.
Solution Approach 2:
The adapter acts as an intermediary component between the holder and the profile rail. This intermediate element provides the necessary adjustment capabilities without complicating the overall assembly process, as the adjustments are built into the adapter's design rather than requiring complex alignment procedures during installation.
3Manufacturing precision
If multiple adjustment steps are required during assembly, then precise alignment can be achieved, but assembly time increases and error rate increases
Solution Approach 1:
The adapter is pre-designed with integrated adjustment features and pre-assembled mounting brackets in various positions. This preliminary preparation allows installers to achieve precise alignment in a single step by simply selecting the appropriate bracket position and inserting the profile rail, rather than requiring multiple iterative adjustment steps during assembly.
4Adaptability or versatility
If plastically deformable materials are used for the holder, then the connection can accommodate misalignments, but the selection of carrier profile and mounting material is restricted and material weakening occurs
Solution Approach 1:
Instead of relying on plastic deformation of materials, the adapter uses adjustable geometric parameters such as bracket positions and clamp locations to accommodate misalignments. This approach maintains material strength and allows free selection of carrier profile and mounting materials, as the adaptability is achieved through design flexibility rather than material deformability.
Data Source
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AI summary
The invention relates to an adapter (1) for support profiles (A), in particular of support arrangements for solar modules, characterized by an assembly head (2) for receiving a support profile (A) comprising at least two opposing legs (4a, 4b) connected by at least one web (3), and at least two mounting clamps (5a, 5b) for the support profile (A) operationally connected to the assembly head (2).