Systems and methods for threading a torque tube through U-bolt and module rail devices
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Solution Overview
Problem
The cost-effectiveness and efficiency of assembling large-scale solar panel systems are compromised due to the complexity and high cost of individually assembling and installing mounting equipment across vast areas, particularly in remote locations with inconsistent material sourcing and delivery challenges.
Innovation Solution
Implementing a centralized assembly factory with motorized guide elements to automate or partially automate the coupling of U-bolts and module rails to a torque tube, facilitating efficient threading and securing of solar panels within an assembly frame, which then allows for mass production and coordinated delivery of assembled solar tables to installation sites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If materials are delivered to deployment sites via access roads and assembled individually at each location, then installation flexibility is maintained, but installation cost and complexity increase significantly for large-scale systems
Solution Approach 1:
The patent applies preliminary action by pre-assembling solar tables in a centralized factory before delivery to deployment sites. Mounting equipment including U-bolts, module rails, and torque tubes are pre-installed on solar panels during manufacturing, creating pre-assembled units that reduce on-site assembly complexity while maintaining installation flexibility through coordinated delivery of multiple solar tables to the same location
2Ease of operation
If mounting equipment is individually assembled and installed at each solar table location, then on-site assembly simplicity is maintained, but overall installation cost increases for large-scale deployments
Solution Approach 1:
The patent implements preliminary action by performing mounting equipment assembly during solar panel manufacturing in centralized factories. U-bolts, module rails, and torque tubes are pre-installed on solar panels, transforming complex on-site assembly operations into simpler coordination and installation tasks at deployment sites, thereby improving installation efficiency without sacrificing operational simplicity
Solution Approach 2:
The patent introduces centralized assembly factories as intermediary facilities between manufacturing and deployment. These factories serve as intermediate processing centers where mounting equipment is assembled onto solar panels before delivery, acting as a mediator that separates complex assembly operations from on-site installation activities
3Device complexity
If a centralized assembly factory is implemented to pre-assemble solar tables, then installation cost and complexity are reduced, but assembly process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the solar table assembly process into distinct modular components: solar panels with pre-installed mounting equipment, torque tubes, U-bolts, and module rails. This modular segmentation allows standardized assembly procedures in centralized factories, reducing overall installation complexity while managing assembly process complexity through systematic component organization
Solution Approach 2:
The patent implements universality through standardized mounting equipment designs that can be applied across multiple solar tables. The same U-bolts, module rails, and torque tube configurations are used repeatedly in centralized assembly, creating universal assembly procedures that reduce complexity through standardization while enabling efficient mass production
Data Source
AI summary
A system and method for threading a torque tube through an opening within a U-bolt and module rail device is described. The system and method provide aligned horizontal movement of the torque tube across an assembly frame resulting in the torque tube being threaded through a plurality of U-bolt and module rail devices. After the threading process is complete, the threaded U-bolt and module rail devices are secured in place on the torque tube to allow coupling of solar panels to the module rails.