Torque Tube Saddle Mounts for Tool-Less Solar Module Assembly
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Solution Overview
Problem
Conventional sun-tracking solar power systems are costly due to the material and labor requirements for assembling torque tubes and associated hardware, which hinders the financial viability of solar power systems, especially when selling electricity to a regional grid power distribution system.
Innovation Solution
The implementation 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 while maintaining structural integrity during sun tracking motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional hardware and mounting procedures are used to connect solar modules to torque tubes, then structural integrity is maintained, but labor costs and assembly time increase substantially
Solution Approach 1:
The retention member is divided into distinct functional segments: a body portion that attaches to the torque tube, and protruding portions that engage with the solar module frame. This segmentation allows each component to be optimized independently and assembled through simple engagement rather than complex fastening procedures.
Solution Approach 2:
The retention member features self-aligning protruding portions with curved surfaces that automatically guide the solar module frame into proper engagement position. The complementary curved surfaces on both the retention member and frame create a self-positioning mechanism that eliminates the need for precise manual alignment or specialized assembly tools.
2Ease of manufacture
If tool-less connection mechanisms are used to connect solar modules to torque tubes, then labor costs are reduced, but connection strength may be compromised
Solution Approach 1:
Both the retention member and solar module frame feature complementary curved surfaces that create a snap-fit engagement. The curvature allows the components to elastically deform during assembly and then lock together with significant force, achieving strong connections without threaded fasteners or welding.
Solution Approach 2:
The connection mechanism transitions from a single-point contact to a distributed multi-point engagement along the curved surfaces. This dimensional distribution of contact points spreads the connection forces across multiple locations, increasing overall connection strength while maintaining the tool-less assembly advantage.
3Reliability
If complex hardware assemblies are used for mounting solar modules, then connection reliability is improved, but device complexity and cost increase
Solution Approach 1:
The retention member integrates multiple functions into a single component: attachment to the torque tube, positioning of the solar module, and securing through engagement with the frame. This consolidation eliminates the need for separate mounting brackets, fasteners, and alignment devices, reducing hardware complexity while maintaining reliability.
Solution Approach 2:
The retention member design with its body portion and multiple protruding portions can accommodate different solar module configurations and torque tube arrangements. The complementary curved engagement surfaces provide universal applicability across various installation scenarios, reducing the need for specialized hardware for different applications.
Data Source
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.