Solar Panel Torque Tube Assembly for Onsite Distribution
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Solution Overview
Problem
The installation of solar farms faces challenges including material distribution, onsite assembly in difficult conditions, and environmental wear, which complicates resource management and efficiency.
Innovation Solution
A resource management system with a user interface and controller is used to navigate a worksite, assemble panels onto torque tubes via a panel assembly device, and transport assembled torque tubes using temporary brackets and specialized equipment, supported by a geographical map and location determiner for efficient distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If solar panels are assembled onsite at solar farms, then installation flexibility and adaptability to site conditions are improved, but assembly time and labor complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling torque tubes with multiple solar panels at a centralized location before transporting them to the installation site. This reduces onsite assembly time while maintaining installation flexibility, as the pre-assembled units can be quickly deployed and adjusted to fit specific site conditions.
Solution Approach 2:
The patent segments the solar array installation into modular torque tubes, each containing a specific number of panels (e.g., 20-50 panels per tube). This segmentation allows for efficient pre-assembly, simplified transportation, and flexible deployment at the solar farm site.
2Area of stationary object
If materials are distributed across large solar farm worksites, then installation coverage area is improved, but material management complexity and transportation time increase
Solution Approach 1:
The patent divides the solar farm installation into multiple torque tubes that can be independently managed and transported. Each torque tube serves as a discrete unit containing a specific number of panels, simplifying inventory tracking, transportation logistics, and on-site deployment across large areas.
Solution Approach 2:
The patent introduces torque tubes as intermediary structures that consolidate multiple solar panels into transportable units. These intermediaries simplify material management by serving as standardized containers that can be efficiently tracked, transported, and deployed across the solar farm worksite.
3Productivity
If solar panels are exposed to environmental factors during installation, then installation progress is improved, but material wear and damage risk increase
Solution Approach 1:
The patent applies preliminary action by completing the assembly of torque tubes with solar panels in a controlled environment before exposure to outdoor conditions. This minimizes the time panels are vulnerable to environmental factors such as weather, reducing wear and damage risk while maintaining installation progress.
Solution Approach 2:
The patent provides beforehand cushioning by designing torque tubes with protective features that shield solar panels from environmental damage during transportation and installation. The tube structure acts as a protective barrier against weather elements, reducing the risk of wear and damage.
Data Source
AI summary
A panel assembly device for assembly of solar panels onto a torque tube comprises a frame assembly configured to support the torque tube and solar panels. The frame assembly comprises a first portion including a torque tube alignment frame and a panel support member. The panel support member is configured to position a solar panel of the plurality of solar panels proximate the torque tube for securing of the solar panel to the torque tube. A second portion is positioned adjacent to the first portion and a third portion is positioned adjacent to the second portion. The third portion defines an egress configured to provide access to the torque tube for removal from the frame assembly. A conveyance is positioned on the frame assembly, the conveyance is operable to move at least one of the torque tube and the plurality of solar panels.