Tool-Less Solar Module Mounting Hardware Using Spring Retention
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Solution Overview
Problem
Conventional hardware for mounting solar modules in sun tracking systems is costly and labor-intensive, requiring significant resources for assembly, which hampers the financial viability of solar power systems.
Innovation Solution
The use of tool-less connections, such as snap fit or interference type mechanisms, for connecting solar modules to torque tubes, simplifying the mounting process and reducing labor costs by enabling tool-free assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hardware and mounting procedures are used to connect solar modules to torque tubes, then reliable connection is achieved, but labor costs and assembly time increase significantly
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (bolts, nuts, washers, clamps) with a spring-based elastic retention mechanism. The spring member engages with the torque tube and solar module frame through elastic deformation, creating a secure connection without requiring complex mechanical fasteners or multiple components. This substitution dramatically simplifies the assembly process while maintaining connection reliability.
Solution Approach 2:
The spring member is designed to automatically engage and retain the solar module on the torque tube through its elastic properties. The mechanism self-adjusts to accommodate dimensional variations in the torque tube and module frame, requiring no additional adjustment tools or procedures. The spring's inherent elasticity provides automatic tensioning and retention, eliminating the need for manual fastening operations.
2Reliability
If conventional hardware is used for mounting solar modules, then secure connection is achieved, but material costs and manufacturing complexity increase
Solution Approach 1:
The mounting system is segmented into three simple functional components: the spring member (providing retention force), the torque tube (providing structural support), and the module frame (providing attachment interface). This segmentation eliminates the need for complex multi-component hardware assemblies, reducing both material costs and manufacturing complexity while maintaining mounting security.
Solution Approach 2:
The patent utilizes the elastic parameter of the spring member to create a compliant mounting system. By changing from rigid mechanical fasteners to an elastic retention mechanism, the system can accommodate dimensional variations and thermal expansion/contraction, providing secure connection with simpler hardware. The spring's elastic modulus and geometry are optimized to provide appropriate retention force.
Data Source
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AI summary
A solar energy collection system can include improved mounting hardware for reducing hardware costs and labor required for assembly. For example, mounting hardware can include surfaces for supporting part or all of the weight of a solar module as it is brought into contact with mounting hardware and then moved into a final engaged position. In some systems, a torque tube can include saddle mount assemblies that allow a solar module to be partially engaged and a registered with the saddle mount while being pivoted into a final locked engagement. Some systems can include arrangements sufficient to support the full weight of a solar module in a disengaged position, and as it is moved into a final engaged position. Some systems can include a configuration of apertures and interference or snap-fit features for providing tool-less connections, thereby simplifying the assembly process.