Tool-Less Solar Module Mounting with Serrated Clamps for Grounding
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Solution Overview
Problem
Existing solar module mounting systems are complex and costly, requiring specialized tools for installation and often lack flexibility in adjusting tilt angles and providing adequate grounding and bonding for electrical safety and reliability.
Innovation Solution
A solar module mounting system featuring tool-less attachment mechanisms with serrated surfaces and conductive materials for easy installation and removal, allowing for adjustable tilt angles and grounding, using support members and brackets with locking teeth for secure positioning and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mounting systems are used, then structural strength is achieved, but device complexity and installation cost increase
Solution Approach 1:
The mounting system is divided into modular components: support members with integrated attachment mechanisms, where each attachment mechanism is a self-contained unit comprising a clamp, serrated gripping surface, and mounting hole. This segmentation allows for standardized, interchangeable parts that reduce overall system complexity while maintaining structural integrity through distributed attachment points.
Solution Approach 2:
The support members serve multiple functions: they provide structural support for the solar modules, incorporate attachment mechanisms for securing modules, include grounding capabilities through conductive materials, and allow for tilt angle adjustment. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity while maintaining necessary structural strength.
2Reliability
If specialized tools are required for installation, then secure attachment is achieved, but ease of operation and installation speed decrease
Solution Approach 1:
The attachment mechanism incorporates a self-clamping design where the clamp automatically secures the solar module frame when positioned over the mounting hole. The serrated gripping surfaces provide self-locking friction that maintains secure attachment without requiring specialized tools or complex fastening operations, enabling installers to complete the attachment with simple manual actions.
3Manufacturing precision
If fixed tilt angles are used, then manufacturing precision is maintained, but adaptability to different installation conditions decreases
Solution Approach 1:
The support members incorporate adjustable tilt mechanisms that allow the mounted solar modules to be positioned at various angles relative to the mounting surface. The attachment mechanism maintains precise angular positioning through the serrated gripping surfaces and geometric constraints, while the overall system configuration can be adjusted to different tilt angles during installation to adapt to various roof pitches and optimal solar exposure requirements.
4Reliability
If grounding and bonding features are added, then safety and reliability improve, but device complexity increases
Solution Approach 1:
The grounding and bonding features are integrated directly into the support members and attachment mechanisms. Conductive materials are incorporated into the support member structure, and the attachment mechanism includes electrical contact paths that connect the solar module frames to the grounding system. This merging of electrical safety features with structural components eliminates the need for separate grounding wires and connection hardware, thereby improving electrical safety without significantly increasing overall device complexity.
Data Source
AI summary
Systems and methods for mounting one or more framed solar modules are disclosed. A solar module mounting system can include a plurality of support members configured to support one or more framed solar modules above a mounting surface, such as the ground or the roof of a building. The support members can include rails formed from a rigid material, such as steel. The solar module mounting system can also include a plurality of attachment mechanisms each configured to secure a portion of a framed solar module to a portion of a respective one of the support members.