Tool-Free PV Module Clip for Fast Solar Panel Installation
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Solution Overview
Problem
Conventional fasteners for attaching PV modules to supportive structures in solar-tracking systems are inefficient, particularly in compact spaces, and increase installation costs as tool access diminishes with evolving PV systems.
Innovation Solution
A PV module clip with a toe portion and legs interconnected by a neck portion, allowing for tool-free installation by inserting through aligned holes and bending into a tensioned state to secure the PV module to the mounting assembly, utilizing stored strain energy for retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fasteners (bolts or rivets) are used to attach PV modules to torque tube assemblies, then the PV modules can be securely attached, but the installation process becomes complex and costly due to tool access requirements in compact spaces
Solution Approach 1:
The clip is designed to be self-installing without requiring external tools. The installer simply inserts the clip through aligned holes and bends the tail portion to engage with the mounting structure, allowing the clip to secure itself to the torque tube assembly. This eliminates the need for specialized fastening tools while maintaining secure attachment.
Solution Approach 2:
The clip is divided into distinct functional segments: a body portion that inserts through holes, a tail portion that bends to engage, and leg portions that secure to the mounting structure. This segmentation allows each part to perform its specific function independently, enabling tool-free installation while ensuring reliable attachment.
2Reliability
If conventional fasteners are used, then secure attachment is achieved, but installation time and costs increase due to diminishing tool access in evolving PV systems
Solution Approach 1:
The clip performs its own fastening operation without requiring external tools or multiple installation steps. The installer inserts the clip and bends the tail portion to engage with the mounting structure, completing the attachment in a single continuous motion. This self-service mechanism dramatically reduces installation time compared to conventional fasteners that require multiple tool operations.
Solution Approach 2:
The clip is pre-formed with bent leg portions and a tail portion designed to engage with the mounting structure. This preliminary shaping allows the clip to be inserted and activated in a single motion, eliminating the need for on-site bending or complex assembly operations that would consume installation time.
3Reliability
If conventional fasteners are used, then PV modules can be attached, but installation costs increase due to tool requirements and installation complexity
Solution Approach 1:
The clip eliminates the need for expensive specialized fastening tools and reduces installation labor complexity. By designing a self-installing clip that requires only basic bending tools already available on most job sites, the overall installation cost is reduced while maintaining secure attachment of PV modules to torque tube assemblies.
Solution Approach 2:
The clip appears to be designed as a low-cost, single-use fastening component. The simple wire construction and self-installing nature suggest it is intended to be an economical alternative to expensive, reusable conventional fasteners, particularly in applications where tool access is limited and installation speed is critical.
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
The PV module clip provides a low-cost, efficient solution for quickly attaching PV modules in compact spaces, reducing installation costs and enhancing the stability of solar-tracking systems without the need for tools.
Implementation Method 1
bending into a tensioned state to secure the PV module to the mounting assembly, utilizing stored strain energy for retention
Data Source
AI summary
A photovoltaic (PV) module clip, and methods of fastening a PV module to a structural member using the PV module clip, are described. In an example, a PV module clip includes a toe portion interconnected with several legs by a neck portion. The toe portion may be inserted through several aligned holes of a PV module frame and a mounting assembly strut to an underside of the strut. The neck portion may extend upward from the toe portion through the aligned holes to the legs above the strut. The legs may extend around a portion of the strut in a tensioned state, and engage with a retaining feature to hold the legs in the tensioned state. Accordingly, the legs may clamp the PV module to the mounting assembly.