T-Bolt Clamp Assembly for Faster, More Secure Solar Panel Mounting
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Solution Overview
Problem
Existing solar panel installation methods are inefficient and insecure, particularly in large solar farms, where fast and secure mounting of solar panels is necessary but not adequately addressed by current clamping systems.
Innovation Solution
A bolt and clamp assembly featuring a unique design with an externally threaded segment, a flange, and a T-bolt head, along with a radially extending clamp support surface, which includes serrated edges and an O-ring, allowing for quick and secure attachment of solar panels to mounting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional clamping systems are used for solar panel installation, then the installation process is simpler with fewer components, but the installation speed is slow and security is insufficient
Solution Approach 1:
The clamp is divided into multiple functional segments: a T-bolt with externally threaded segment for rapid insertion, a flange for positioning and support, and a head for final securing. This segmentation allows each component to perform its specific function efficiently, enabling fast installation while maintaining structural integrity
Solution Approach 2:
The externally threaded segment is pre-formed on the T-bolt, allowing the clamp to be quickly attached to the solar panel frame without requiring separate threading operations. The flange is pre-positioned to provide immediate support, enabling workers to rapidly secure multiple panels
2Reliability
If traditional bolts and clamps are used, then the components are simpler to manufacture, but the installation security and firm engagement are insufficient
Solution Approach 1:
The T-bolt features an asymmetric head geometry with a T-shaped cross-section that provides stable insertion through mounting holes while preventing rotation. The externally threaded segment has a specific pitch and profile optimized for engagement with the clamp, ensuring secure fastening without over-complexity in manufacturing
Solution Approach 2:
The head of the T-bolt incorporates radiused corners and curved surfaces that distribute stress evenly during installation and engagement. The externally threaded segment features rounded crests and roots that reduce stress concentration, enhancing reliability while maintaining manufacturability through standard machining processes
3Productivity
If rapid installation is prioritized, then productivity increases to 400 modules per worker per day, but the complexity of the fastening system increases
Solution Approach 1:
The T-bolt integrates multiple functions into a single component: the T-shaped head provides insertion and positioning, the externally threaded segment enables rapid attachment without separate threading tools, and the integration of these features allows one-handed operation, achieving 400 modules per worker per day while keeping the fastening system relatively simple
Solution Approach 2:
The externally threaded segment on the T-bolt is self-contained, eliminating the need for separate threading operations or additional fastening components. The clamp design allows automatic positioning through the flange, reducing the need for precise alignment and manual adjustment, thereby increasing installation speed without proportionally increasing system complexity
Data Source
AI summary
A bolt comprises a first shank segment axially comprising an externally threaded segment at a proximate axial end of the bolt. The bolt also includes a second shank segment, a flange extending perpendicularly a first distance from the first shank segment and axially located between a distal axial end of the first shank segment and a proximate axial end of the second shank segment, and a head axially adjacent to a distal axial end of the second shank segment, where the head is longer than the flange in a first direction perpendicular to the first shank segment but shorter than the flange in a second direction perpendicular to the first shank segment.