Torque Tube PV Module Interlock for Solar Tracking Assembly
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Solution Overview
Problem
Existing photovoltaic (PV) module mounting systems do not efficiently allow for the rotation of PV modules to track the motion of the sun, which limits their electrical efficiency.
Innovation Solution
An interlocking system that connects PV module frames to a torque tube using an interlock with couplings and a U-lock, allowing for easy rotation and alignment of PV modules, reducing the number of required parts and labor costs, and enabling auto-grounding between adjacent modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If PV modules are mounted on fixed mounting systems, then installation is simple, but the modules cannot rotate to track the sun, limiting electrical efficiency
Solution Approach 1:
The mounting system transitions from a fixed structure to a dynamic rotating structure. The torque tube enables the PV modules to rotate and track the sun's motion, transforming the static mounting system into a dynamic one that adapts to changing sunlight positions throughout the day, thereby improving electrical efficiency while maintaining ease of installation through the modular interlocking design
2Device complexity
If traditional mounting systems are used, then the structure is simple, but the number of parts and labor costs are high
Solution Approach 1:
The interlocking system merges multiple functions into a single integrated component. The interlock combines coupling mechanisms, grounding pathways, and module connection features into one unified device that simultaneously performs multiple functions: mechanically connecting modules, providing electrical grounding, and enabling rotational movement, thereby reducing the total number of parts and simplifying installation
Solution Approach 2:
The interlock is designed as a universal component that performs multiple functions: structural connection between modules, electrical grounding pathway, rotational joint, and alignment guide. This multi-functional design eliminates the need for separate components for each function, reducing both part count and installation complexity while maintaining structural integrity
3Reliability
If more parts are used for secure connection, then reliability increases, but device complexity and cost increase
Solution Approach 1:
Multiple connection functions are merged into the single interlock component. The interlock integrates mechanical coupling elements, grounding pathways, and rotational joints into one unified device, achieving reliable multi-functional connection without requiring multiple separate parts, thereby maintaining connection reliability while reducing device complexity
Data Source
AI summary
An interlocking system for connecting photovoltaic module frames to a torque tube, including: (a) an interlock dimensioned to be positioned between the sides of two adjacent photovoltaic module frames; (b) a pair of couplings or flanges, wherein the couplings or flanges connect the interlock to both of the adjacent photovoltaic module frames; and (c) a U-lock connected to the interlock, wherein the U-lock is dimensioned to be connected to a torque tube.