Torque Tube Coupler Nested Design for Unobstructed PV Module Mounting
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Solution Overview
Problem
Existing torque tube couplers for solar tracking systems often extend beyond the torque tubes, causing blockages and constraints in mounting and adjusting PV modules, necessitating a low-profile coupler that fits within the torque tube.
Innovation Solution
A torque tube coupler design featuring a central ring with radially extending fingers and an angled core, where the core's inward movement forces the fingers outward against the torque tube's inner surface, providing a secure and low-profile connection between torque tube segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional coupling devices are used to join torque tube segments, then the torque tubes can be connected together, but the coupling devices extend beyond the outside of the torque tubes causing blockages and constraints
Solution Approach 1:
The coupler body is inserted inside the torque tube segments, with the coupling mechanism nested within the tube structure. The set screws are accessed through openings in the torque tube wall, allowing the entire coupling mechanism to remain contained within the torque tube profile while still providing secure connection functionality.
2Reliability
If external coupling hardware is used, then torque tube segments can be joined securely, but PV modules cannot slide past the coupling location during installation
Solution Approach 1:
The coupling mechanism is extracted from the external environment and relocated entirely inside the torque tube structure. By removing the external hardware that previously protruded beyond the tube profile, the coupling device no longer interferes with PV module installation and positioning, while internal set screws maintain secure connection through openings in the torque tube wall.
3Strength
If traditional coupling hardware is used, then torque tube segments can be connected, but the hardware places constraints on where torque tubes can be mounted to support structures
Solution Approach 1:
The entire coupling mechanism including set screws and coupling body is nested within the torque tube profile. This allows torque tubes to be mounted at any location on support structures without external coupling hardware creating spatial constraints, while the internal set screws accessed through tube wall openings maintain secure structural connections.
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 solution allows for seamless integration of torque tube segments without external hardware interference, enabling flexible mounting and adjustment of PV modules while maintaining structural integrity and reducing installation complexities.
Implementation Method 1
tightening one or more of the set screws may force the first abutting surface away from the second abutting surface to press the outer body against an inner surface of a torque tube
Implementation Method 2
each finger of the first set of fingers is attached to the central ring at a middle end and is shaped to flex radially outward at a far end... when drawn inwards towards the central ring, the first set of fingers are caused to flex radially outwards away from the core
Data Source
AI summary
A first embodiment of a torque tube coupler may include an outer body that includes a first abutting surface and a second abutting surface adjacent to the first abutting surface. Set screws may be inserted into one or more channels of the first abutting surface. Tightening the set screws may force the abutting surfaces away from each other and the outer body to press against an inner surface of a torque tube. Another embodiment of the torque tube coupler may include a central ring sized based on a size of a torque tube. The torque tube coupler may also include a set of fingers that extend away from a first side of the central ring and are shaped to flex radially outward. The torque tube coupler may include a core disposed within the set of fingers that, when drawn towards the central ring, causes the fingers to flex radially outwards.