Abstract: A photovoltaic (PV) panel distribution device may include a housing assembly, an elevating system, or a movement mechanism. The housing assembly may store a PV panel in a predetermined orientation within a volume defined by the housing assembly. The elevating system may engage the PV panel to move the PV panel in a direction within the volume so as to position the PV panel in an initial removal position relative to the volume. The movement mechanism may apply a force on the PV panel in the initial removal position to move the PV panel to a final removal position to permit a user to retrieve the PV panel from the final removal position.

Abstract: A mounting bracket assembly comprising may include an upper region with flat portions on either end that interface with a photovoltaic (PV) module and a lower portion in between the flat portions, and a central portion at least partially surrounding a hole shaped to accommodate a torsion beam. The mounting bracket assembly may also include side portions extending from the ends of the upper region to below the hole shaped to accommodate the torsion beam, and a first outer lining along a periphery of the mounting bracket assembly. The mounting bracket assembly may also include a second outer lining along the hole shaped to accommodate the torsion beam, and multiple ribs extending between the first outer lining and the second outer lining.

Abstract: Systems and methods for using high-impact fasteners to couple components of a solar power system together to prevent these components from any movement or slippage relative to each other. A strap may be secured over a top surface of the high-impact fasteners and around the components to prevent a disengagement of the high-impact fastener from the components and a separation of the components.

Abstract: A method of forming a module clamp of a photovoltaic module support structure may include cutting a folding pattern into a sheet of metal. The folding pattern may include one or more width-wise slits relative to the sheet of metal, one or more length-wise slits relative to the sheet of metal, and a hole. The method may include stamping one or more first features onto the sheet of metal to form a stamped sheet and folding the stamped sheet along the one or more width-wise slits and the one or more length-wise slits to form a preliminary module clamp. The method may include stamping one or more second features onto the preliminary module clamp to form the module clamp.

Abstract: A bifurcated bearing housing for use within a torque tube interface may include a first component defining a first portion of an aperture configured to house a first portion of a rotating bearing, a second component defining a second portion of the aperture configured to house a second portion of the rotating bearing, and a connection interface between the first and second components, wherein, when the first and second components are in an attached configuration, the connection interface lies below a centerpoint of the aperture defined by the first and second components. The bifurcated bearing housing may include one or more of ridges, gussets, and/or hems to increase the structural integrity and rigidity of the bearing housing.

Abstract: A deflection pad may include a body. The body may include a recess to accommodate a fastener configured to attach the deflection pad to a support structure. The base of the deflection pad may include a bottom surface configured to engage a surface of the support structure. The deflection pad may be included in a system that includes a torsion beam and one or more support racks to which multiple PV modules may be attached, where the support are racks attached to the torsion beam. One or more deflection pads may be positioned between the PV modules and the support rack so as to cushion impact.

Abstract: A photovoltaic module mounting system may include a module clamp that includes a central section that includes two first walls connected at the top of each first wall by a first connecting surface. The central section may have a first cross-sectional height corresponding to a height of each of the first walls and a first width corresponding to a distance between the two first walls. The module clamp may have ends that include two second walls connected at the top of each second wall by a second connecting surface in which each of the ends has a second cross-sectional height that is shorter than the first cross-sectional height and a second width that is wider than the first width. The central section may be connected to each of the ends such that the first connecting surface and the second connecting surface are bridged and form a bowtie shape.

Abstract: A bifurcated bearing housing for use within a torque tube interface may include a first component defining a first portion of an aperture configured to house a first portion of a rotating bearing, a second component defining a second portion of the aperture configured to house a second portion of the rotating bearing, and a connection interface between the first and second components, wherein, when the first and second components are in an attached configuration, the connection interface lies below a centerpoint of the aperture defined by the first and second components. The bifurcated bearing housing may include one or more of ridges, gussets, and/or hems to increase the structural integrity and rigidity of the bearing housing.

Abstract: A method may include positioning one or more PV module mounting devices along a length of a structural component. The method may include specifying one or more parameters related to fastening the PV module mounting devices to the structural component, the one or more parameters indicating a spacing between the PV module mounting devices. The method may include fastening, by an automated attachment equipment, the PV module mounting devices to the structural component based on the specified parameters and moving the PV module mounting devices fastened to the structural component to an assembly platform.

Abstract: Torque limiters prevent the transmission of excessive torque between moving components of one or more gears in a tracker drive assembly. When an amount of torque between these moving components exceeds a threshold, the torque limiter may slip, thus allowing the components to move relative to each other. Embodiments disclosed herein may include a drive motor configured to rotate a drive shaft, at least one gear configured to translate rotation of the drive shaft into rotation of a PV module mounting structure, and a torque limiter interposed between an interior surface of a first component of the at least one gear and an exterior surface of a second component of the at least one gear to allow the first component to slip relative to the second component when an amount of torque between the first and second components exceeds a threshold.

Abstract: A mounting assembly may include an arced connecting member that includes a first drive chain along a bottom surface of the arced connecting member, a second drive chain positioned adjacent to the first drive chain, and a third drive chain in a gap between the first and the second drive chains. The mounting assembly may include an intermittent-motion drive system that has a drive wheel with a nub extending from a lateral surface of the drive wheel, the nub being shaped to interface with notches included along the third drive chain. The intermittent-motion drive system may include a first and a second protrusion shaped to interface with surfaces of the first and second drive chains, respectively. Rotation of a drive axle extending through the drive wheel may affect rotation of the drive wheel, rotational movement of the nub extending from the drive wheel, and movement of the arced connecting member.

Abstract: A method may include positioning one or more PV module mounting devices along a length of a structural component. The method may include specifying one or more parameters related to fastening the PV module mounting devices to the structural component, the one or more parameters indicating a spacing between the PV module mounting devices. The method may include fastening, by an automated attachment equipment, the PV module mounting devices to the structural component based on the specified parameters and moving the PV module mounting devices fastened to the structural component to an assembly platform.

Abstract: An extension panel may include a mating surface shaped to interface with a back surface of a clamp that includes a mounting hole corresponding to a bolt slot in the back surface of the clamp to accommodate a single bolt passing through the extension panel and the clamp. The extension panel may also include a pair of flanges projecting outward from the mating surface and positioned to be on either side of the clamp. The extension panel may also include a flat top surface generally parallel and aligned linearly with another flat top surface of a flexible member. The extension flat top surface may be sized to be approximately a same width as the flexible member at a first end of the extension flat top surface proximate the mating surface and may flare out as the extension flat top surface extends away from the flexible member.

Abstract: A mounting assembly may include an arced connecting member that includes a first drive chain along a bottom surface of the arced connecting member, a second drive chain positioned adjacent to the first drive chain, and a third drive chain in a gap between the first and the second drive chains. The mounting assembly may include an intermittent-motion drive system that has a drive wheel with a nub extending from a lateral surface of the drive wheel, the nub being shaped to interface with notches included along the third drive chain. The intermittent-motion drive system may include a first and a second protrusion shaped to interface with surfaces of the first and second drive chains, respectively. Rotation of a drive axle extending through the drive wheel may affect rotation of the drive wheel, rotational movement of the nub extending from the drive wheel, and movement of the arced connecting member.

Abstract: A deflection pad may include a body. The body may include a recess to accommodate a fastener configured to attach the deflection pad to a support structure. The base of the deflection pad may include a bottom surface configured to engage a surface of the support structure. The deflection pad may be included in a system that includes a torsion beam and one or more support racks to which multiple PV modules may be attached, where the support are racks attached to the torsion beam. One or more deflection pads may be positioned between the PV modules and the support rack so as to cushion impact.

Abstract: An extension panel may include a mating surface shaped to interface with a back surface of a clamp that includes a mounting hole corresponding to a bolt slot in the back surface of the clamp to accommodate a single bolt passing through the extension panel and the clamp. The extension panel may also include a pair of flanges projecting outward from the mating surface and positioned to be on either side of the clamp. The extension panel may also include a flat top surface generally parallel and aligned linearly with another flat top surface of a flexible member. The extension flat top surface may be sized to be approximately a same width as the flexible member at a first end of the extension flat top surface proximate the mating surface and may flare out as the extension flat top surface extends away from the flexible member.

Abstract: A deflection pad may include a body including two peaks, and a recess in the body between the two peaks, the recess may be sized to accommodate a fastener such that when deployed, the fastener is below a height of the two peaks within the recess. The deflection pad may include arms projecting in a direction generally opposite the two peaks, the arms biased inward towards the recess. The deflection pad may be included in a system that includes a torsion beam and one or more support racks to which multiple PV modules may be attached, where the support are racks attached to the torsion beam. One or more deflection pads may be positioned on the support racks to be below the PV modules.

Abstract: A method may include positioning one or more PV module mounting devices along a length of a structural component. The method may include specifying one or more parameters related to fastening the PV module mounting devices to the structural component, the one or more parameters indicating a spacing between the PV module mounting devices. The method may include fastening, by an automated attachment equipment, the PV module mounting devices to the structural component based on the specified parameters and moving the PV module mounting devices fastened to the structural component to an assembly platform.