Torque tube interface with two-part bearing sleeve

Abstract

A two-part bearing sleeve (202) for use within a torque tube (108) interface may include a first assembly (206) defining a first portion (210a) of a bore configured to receive a first portion of a swivel bearing; a second assembly (208) defining a second portion (210b) of the bore, configured to receive a second portion of the swivel bearing; and a connection interface (215a, 215b) between the first component (206) and the second component (208), where the connection interface (215a, 215b) is located below a center point of the aperture defined by the first component (206) and the second component (208) when the first component (206) and the second component (208) are in an attached configuration. The two-part bearing housing (202) may include one or more ridges (222a-q), gussets (230a-d), and / or flanges (420a-d) to increase the structural integrity and stiffness of the bearing housing (202).

Description

[0001] Inventors: Nathan Schuknecht and Kevin Krautbauer Technical Field

[0002] The present disclosure relates to a torque tube interface and, more particularly, to a two-part bearing sleeve for mounting a photovoltaic (PV) module to a support structure. Background Art

[0003] Each PV module in a solar panel system can be attached to a support structure or pile. The PV modules can be mounted in rows on a solar tracker that directs the orientation of the PV modules so that the angle of the PV modules relative to the support structure changes throughout the day. Changing the angle of the PV modules relative to the support structure enables the PV modules to track the position of the sun and maximize efficiency. Typically, a large number of PV modules are mounted to a single torque tube, which is secured to one or more piles or other support structures via one or more torque tube interfaces. The torque tube interface typically includes a bearing and a bearing sleeve. The bearing is typically configured to rotate with the torque tube within the bearing sleeve.

[0004] While changing the angle of a PV module to track the position of the sun can increase the efficiency of the PV module, it can also create interference points between the PV module and the flanges on the torque tube interface used to mount the PV module to the support structure. For example, when the module is extended on the torque tube interface, the mounting flanges on the torque tube interface may prevent the PV module from being positioned at an angle that most efficiently captures sunlight in the morning or evening or when the PV module is closest to a vertical position.

[0005] In addition, due to various contributing factors, including the weight of the PV modules mounted on a single torque tube, seismic activity, and environmental conditions (such as wind), a large amount of stress can be exerted on the torque tube interface. Such stress can lead to failure, breakage, and the need to repair or replace one or both of the bearings and bearing sleeves in the torque tube interface. Typically, the bearings and bearing sleeves are unitary structures that cannot be separated into multiple parts. In order to install or remove these unitary torque tube interfaces, the bearings and bearing sleeves must be passed through one end of the torque tube.

[0006] Bearings and bearing sleeves having a unitary structural design can result in significant inefficiencies and costs. For example, replacing a damaged torque tube interface in the middle of a row of PV modules on a torque tube would require removing all of the PV modules and torque tube interfaces between the damaged torque tube interface and one end of the torque tube so that a new bearing and / or bearing sleeve can be passed through the torque tube and back into position with the replaced torque tube interface. Unitary bearing and bearing sleeve structures also result in inefficiencies and increased costs during the initial installation of a solar panel system because the unitary structure may require coupling of the PV modules to the unitary structure during the installation process.

[0007] Therefore, there is a need for a torque tube interface that does not interfere with the PV modules when they are positioned at an angle that most effectively captures sunlight in the morning or evening, or when the PV modules are positioned closest to vertical. There is also a need to increase the structural rigidity and strength of the torque tube interface. Finally, there is a need for a design of torque tube interfaces that will allow them to be installed to and removed from the torque tube without having to penetrate one end of the torque tube.

[0008] The subject matter claimed in this disclosure is not limited to embodiments that solve any disadvantages or that operate only in environments such as described above. Rather, this background is merely provided to illustrate one example technology area where some embodiments described in this disclosure may be practiced. Summary of the invention

[0009] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0010] Exemplary embodiments of the present disclosure address problems encountered in conventional solar panel tracking systems, including problems associated with interference points between a PV module and a portion of a bearing sleeve, such as a mounting flange, which can prevent the PV module from being positioned at a particular angle. The embodiments disclosed herein address this problem by providing a two-part bearing sleeve that includes an upper component and a lower component that define an aperture in which a bearing is positioned. The mounting flanges of the upper and lower components of the two-part bearing sleeve can be lowered so that the plane in which these mounting flanges engage is lower than the center point of the aperture defined by the upper and lower bearing sleeve components. In some embodiments, the plane in which the interface is located can be lower than the bearing aperture defined by the first component and the second component so that it does not intersect the bearing aperture.

[0011] Additionally, the interface between the two-part bearing sleeve and the support structure can also be located on a plane below the center point of the hole defined by the upper and lower bearing sleeve assemblies. In some embodiments, the plane where the interface is located can be lower than the bearing hole so that it also does not intersect the bearing hole. By lowering the level of these interfaces, sufficient space can be created for the PV modules to rotate to an angle that most effectively captures sunlight in the morning and evening when the PV modules are most nearly vertically positioned.

[0012] Exemplary embodiments of the present disclosure also address issues related to failure and breakage of bearing sleeves, which may be caused by the amount of stress concentrated on these structures. Reducing the level of the mounting flanges of the upper and lower components in a two-part bearing sleeve can increase the loads and stresses on the bearing sleeve. Embodiments disclosed herein address this issue by using one or more features that increase the structural integrity of the bearing sleeve. For example, embodiments of the bearing sleeve described herein may include one or more structural ridges, gussets, or hems. These features can provide additional strength and rigidity for the bearing sleeve to avoid damage and failure caused by stresses caused by the location of the mounting flanges, the weight of the components, seismic activity, weather events, and other environmental conditions.

[0013] Exemplary embodiments of the present disclosure also address issues associated with inefficiencies associated with bearings and bearing housings having an integral structural design. Embodiments disclosed herein address this issue by providing a two-part bearing housing including an upper assembly and a lower assembly, and a two-part bearing also including an upper assembly and a lower assembly. By disassembling these structures into multiple parts, they can be removed from the torque tube and repaired or installed without having to thread these structures to one end of the torque tube.

[0014] Specifically, in one embodiment, a two-part bearing sleeve for mounting a photovoltaic (PV) module to a support structure in a solar tracking system is provided, comprising: a first component defining a first portion of a hole, configured to accommodate a first portion of a rotating bearing; a second component defining a second portion of the hole, configured to accommodate a second portion of the rotating bearing; and a connection interface between the first component and the second component, wherein when the first component and the second component are in an attached configuration, the connection interface is located on a plane below a center point of the hole defined by the first component and the second component.

[0015] In some embodiments, the first component may include a first mounting flange, the second component may include a second mounting flange, and the connection interface may be located between a bottom surface of the first mounting flange and a top surface of the second mounting flange. In these embodiments, the first mounting flange and the second mounting flange may extend laterally away from the hole defined by the first component and the second component. In these embodiments, the first mounting flange may include a first hole, the second mounting flange may include a second hole, and the first hole may be aligned with the second hole when the first component and the second component are in an attached configuration. In these embodiments, the first mounting flange may include a first structural ridge, and the second mounting flange may include a second structural ridge. In these embodiments, the size and shape of the first structural ridge and the second structural ridge may be such that when the first component and the second component are in an attached configuration, the first structural ridge and the second structural ridge may be aligned to allow a flush interface to be formed between the bottom surface of the first mounting flange and the top surface of the second mounting flange.

[0016] In some embodiments, a portion of the first component defining the aperture may include a structural ridge. In these embodiments, a portion of the second component defining the aperture may include a structural ridge.

[0017] In some embodiments, at least a portion of the edge of the first component may include a hem, the shape of the hem providing additional structural rigidity to the first component. In these embodiments, at least a portion of the edge of the second component may include a hem, the shape of the hem providing additional structural rigidity to the second component.

[0018] In some embodiments, the two-part bearing sleeve can be configured to be fixed to the bracket at a connection interface between the two-part bearing sleeve and the bracket, and the connection interface between the bearing sleeve and the bracket can be located on a plane that does not intersect the hole defined by the first component and the second component.

[0019] In some embodiments, the first component may include a first mounting flange, the second component may include a second mounting flange, and at least one of the first component and the second component may include a gusset, the shape of the gusset providing additional structural rigidity to the two-part bearing sleeve. In these embodiments, the first component may include a first gusset, and the second component may include a second gusset. In these embodiments, the size and shape of the first gusset and the second gusset may be such that when the first component and the second component are in an attached configuration, the first gusset and the second gusset may be aligned to allow a flush interface to be formed between the first component and the second component.

[0020] In some embodiments, the connection interface may be located on a plane that does not intersect the aperture defined by the first component and the second component.

[0021] The objects and advantages of the embodiments will be realized and achieved at least by the elements, features and combinations particularly pointed out in the claims.The foregoing summary and the following detailed description are exemplary and illustrative rather than restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The exemplary embodiments will be described and explained with additional specificity and detail through the accompanying drawings, in which:

[0023] Figure 1 An exemplary system for mounting PV modules is shown;

[0024] Figures 2A-2F Shows Figure 1 Various views of the torque tube interface shown;

[0025] Figure 3A-3B shows a side view of a torque tube interface secured to a support structure with PV modules positioned at different angular orientations;

[0026] Figures 4A-4C Various views of a torque tube interface having one or more flanges are shown;

[0027] Figure 5 shows a torque tube interface with structural elements providing additional support and stiffness; and

[0028] Figure 6 A two-part bearing sleeve configured to accommodate a spherical slew bearing is shown. DETAILED DESCRIPTION

[0029] Embodiments of the present disclosure will be explained with reference to the accompanying drawings. It should be understood that the accompanying drawings are diagrammatic and schematic representations of these exemplary embodiments and are not restrictive and are not necessarily drawn to scale. In the accompanying drawings, unless otherwise specified, features with the same reference numerals represent the same structure and function.

[0030] Figure 1An exemplary system 100 for mounting a PV module is shown. System 100 includes a support structure or pile 102, a bracket 104, a torque tube interface 200, a torque tube 108, a PV module 110, and a module bracket 111. Bracket 104 may be secured to pile 102 by one or more mounting slots 112a that allow bracket 104 to be movable up and down relative to the position of torque tube interface 200 and pile 102. Similarly, the top of bracket 104 may also include mounting slots 112b extending in one direction, while corresponding mounting slots ( Figure 2A , 2b, 2E, and 2F) may extend in substantially opposite directions to allow for greater flexibility in positioning the torque tube interface 200 relative to the post 102. In some embodiments, the post 102 may also include a mounting slot that corresponds to the mounting slot 112a to provide a similar type of adjustability.

[0031] The torque tube interface 200 may include a bearing housing 202 and a swivel bearing 204. In some embodiments, the swivel bearing 204 may be operably coupled to the bearing housing 202 in a manner that allows the swivel bearing 204 to have some rotational freedom within the bearing housing 202. As provided in more detail below, the amount of such rotational freedom may be limited by a mechanism such as a stop 234. Other embodiments of the torque tube interface may have no stop, thereby enabling the swivel bearing 204 to rotate a full 360 degrees within the bearing housing 202.

[0032] In some embodiments, the lateral movement of the swivel bearing 204 within the bearing sleeve 202 can be sufficiently limited. The bearing sleeve 202 can be made of any suitable material, including but not limited to plastic or metal, such as aluminum and steel. In some embodiments, pre-treated metal sheets, such as galvanized steel sheets, can be used, which can allow for a stronger assembly and / or greater flexibility in manufacturing and cost savings in manufacturing. Additionally or alternatively, such materials can allow a low friction coating to be applied to the steel prior to the forming process, thereby reducing costs.

[0033] The rotational bearing 204 may be fixedly coupled to the torque tube 108. Allowing the bearing 204 to rotate within the bearing housing 202 also allows rotational movement of the torque tube 108 relative to the pile 102. Allowing the torque tube 108 to rotate within the bearing housing 202 allows the PV module 110 to rotate with the torque tube 108 to track the position of the sun as it moves across the sky. The PV module 110 may also be fixedly coupled to the torque tube 108 via a module bracket 111. In some embodiments, multiple PV modules may be fixedly coupled to the torque tube 108 in the manner shown in the system 100.

[0034] While changing the angle of the PV module to track the position of the sun can increase the efficiency of the PV module, this can also create interference points between the PV module and the bearing sleeve when the module is extended on the bearing sleeve. As described in more detail below, the bearing sleeve 202 includes features that avoid interference with the PV module 110 so that when the PV module 110 is positioned closest to vertical, there is sufficient space for the PV module 110 to rotate to an angle that most effectively captures sunlight in the morning and evening. In addition, the bearing sleeve 202 also includes structural features that increase its stiffness and strength. Finally, the bearing sleeve 202 and the bearing 204 can be separated into multiple parts to facilitate installation and removal from the torque tube 108.

[0035] Without departing from the scope of the present disclosure, modifications, additions, or omissions may be made to the system 100. For example, the designation of different elements in the described manner is intended to help explain the concepts described herein and is not restrictive. In addition, the system 100 may include any number of other elements, or may be implemented in other systems or environments other than those described. For example, in some embodiments, the torque tube interface may include only a bearing sleeve without a separate rotating bearing. In these embodiments, the torque tube may rotate directly within the bearing sleeve. The bearing sleeve may include a lubricant coating to facilitate rotation through the torque tube. Alternatively, the torque tube interface may include a bearing that is maintained in a fixed position relative to the bearing sleeve. In this embodiment, the torque tube may be configured to rotate within the bearing.

[0036] Figures 2A-2F The present invention shows one or more embodiments of the present invention. Figure 1 Different views of the torque tube interface 200 are shown. Specifically, Figure 2A An isometric view of the torque tube interface 200 is shown. Figure 2B An exploded view of the torque tube interface 200 is shown, Figure 2C A front view of the torque tube interface 200 is shown. Figure 2D A side view of the torque tube interface 200 is shown. Figure 2E A top view of the torque tube interface 200 is shown, and Figure 2F A bottom view of the torque tube interface 200 is shown.

[0037] from Figures 2A-2F As can be seen in the figure, the bearing housing 202 of the torque tube interface 200 is a two-part housing including an upper component 206 and a lower component 208. The upper component 206 and the lower component 208 can be selectively attached (such as Figure 2A , 2C , 2D and 2E) and separation (as shown in Figure 2B). Having the upper assembly 206 and the lower assembly 208 that are selectively removable allows the bearing sleeve 202 to be removed from the torque tube at any point on the torque tube. Therefore, the bearing sleeve 202 does not need to be installed through one end of the torque tube (which is the case for many bearing sleeves that cannot be disassembled into multiple parts). For example, the bearing sleeve 202 also does not need to be installed through one end of the torque tube to be removed, replaced, or repaired.

[0038] The bearing sleeve may define all or a portion of a bore in which the bearing may be secured or received. For example, the upper component 206 of the bearing sleeve 202 includes a first bore defining portion 210a. The lower component 208 of the bearing sleeve 202 includes a second bore defining portion 210b. When the upper component 206 and the lower component 208 are in an attached configuration, the first bore defining portion 210a and the second bore defining portion 210b define a bore 212 that secures the swivel bearing 204 within the bearing sleeve 202, as described herein. The bore 212 has a center point 219 (e.g., centered at the center of the bore 212) that is located in the middle of the bore 212. Figure 2C The center point 219 is also located on the rotation axis of the rotary bearing 204 , and the rotary bearing 204 rotates in the bearing sleeve 202 .

[0039] In some embodiments, the rotation bearing 204 can also be selectively disassembled into two or more parts, so that like the two-part bearing sleeve 202, it can also be removed from the torque tube at any point on the torque tube. For example, the attachment tab 205 on the rotation bearing 204 can be cut or removed to disassemble the rotation bearing 204 into two separate parts. The rotation bearing 204 can be operably coupled to the bearing sleeve 202 so that it can rotate with the torque tube within the bearing sleeve 202.

[0040] The bearing sleeve can include one or more mounting flanges. For example, the bearing sleeve 202 of the torque tube interface 200 includes four mounting flanges. Specifically, the upper assembly 206 includes a first mounting flange 214a and a second mounting flange 214b. The lower assembly 208 includes a third mounting flange 214c and a fourth mounting flange 214d. The mounting flanges 214a, 214b, 214c, and 214d can extend laterally away from the first hole defining portion 210a and the second hole defining portion 210b. For example, in Figure 2E In the top view of the torque tube interface 200 shown, the mounting flanges 214a and 214b (and the mounting flanges 214c and 214d located below the mounting flanges 214a and 214b) extend laterally in opposite directions away from the hole formed by the first hole defining portion 210a and the second hole defining portion 210b. Providing the mounting flanges 214a, 214b, 214c and 214d in this configuration can facilitate coupling the bearing sleeve to one or more mounting brackets, such as Figure 1The mounting bracket 104 in the embodiment of the present invention can be used because there is enough space directly above the mounting flanges 214a, 214b, 214c and 214d to insert the screws or bolts into the mounting bracket below.

[0041] When the upper assembly 206 and the lower assembly 208 are in the attached configuration, the connection interface 215a can exist between the lower surface 216a of the mounting flange 214a and the upper surface 218a of the mounting flange 214c. Similarly, the connection interface 215b can exist between the lower surface 216b of the mounting flange 214b and the upper surface 218b of the mounting flange 214d.

[0042] The connection interface between the upper component and the lower component in a two-part bearing sleeve can be located on one or more planes. In some embodiments, there are two or more connection interfaces between the upper component and the lower component, which can be located on the same plane, or on different planes. In some embodiments, the upper component and the lower component of the two-part bearing sleeve can include only a single connection interface. For example, this may be the case for a two-part bearing sleeve that has only one mounting flange on the upper component and only one mounting flange on the lower component.

[0043] With respect to the two-part bearing sleeve 202, the connection interfaces 215a and 215b are located on a single plane 220 (as shown in FIGS. 2A and 2C). The plane 220 is located below the center point 219 of the bore 212. In fact, the plane 220 does not intersect the bore 212 or the slew bearing 204 at all. Therefore, the plane 220 is also located below any torque tube secured within the slew bearing 204.

[0044] Lowering the level of the connection interface between the upper and lower components in a two-part bearing housing and / or the connection interface between the bearing housing and the support structure can provide additional space for the PV module, which is connected to the bearing housing via a torque tube and bearings, to rotate. This is particularly important if the PV module is part of a solar tracker system configured to track the position of the sun in the sky.

[0045] For example, Figure 3A and 3BA side view of a torque tube interface 300 as part of a solar tracking system is shown. The torque tube interface 300 is fixed to a support structure 302 by a bracket 304. The torque tube interface 300 includes a bearing sleeve 306 and a rotation bearing 308. The module bracket 311 fixedly couples the PV module 316 to the torque tube 314. Similar to the torque tube interface 200, the bearing sleeve 306 of the torque tube interface 300 can be a two-part bearing sleeve having an upper component and a lower component. The bearing sleeve 306 includes a pair of mounting flanges 310a and 310b on the upper component and a pair of corresponding mounting flanges 310c and 310d on the lower component. The connection interface between the mounting flanges 310a and 310c can be located on a plane 318. The connection interface between the mounting flanges 310b and 310d can also be located on a plane 318. Additional connection interfaces 320 can also exist between the mounting flanges 310c and 310d and the bracket 304 fixed to the support structure 302. The torque tube 314 is secured within the swivel bearing 308 .

[0046] The bearing housing 306 forms a hole in which the swivel bearing 308 and the torque tube 314 are positioned. A center point 319 is located in the middle of the hole in which the swivel bearing 308 and the torque tube 314 are positioned. The center point 319 is also located on the axis of rotation of the swivel bearing 308 and the torque tube 314.

[0047] exist Figure 3A , the torque tube 314 has been rotated with the rotary bearing 308 within the bearing housing 306 such that the PV module 316 is oriented at an angle of approximately +52° relative to the horizontal plane (0°). Figure 3B , the torque tube 314 has been rotated with the rotation bearing 308 within the bearing housing 306 such that the PV module 316 is oriented at an angle of approximately -52° relative to the horizontal plane (0°). From these angular orientations, it can be seen that the mounting flanges 310a, 310b, 310c, and 310d do not interfere with or obstruct the PV module 316. Although + / - 52° is Figure 3A , but other ranges of rotational travel are possible depending on the configuration of the components.

[0048] In some embodiments, to prevent potential obstruction of the PV module by the mounting flange, the connection interface between the upper and lower components of the two-part bearing sleeve and / or the connection interface between the bearing sleeve and the support structure (or bracket of the support structure) can be located on one or more planes that are lower than the center point of the hole defined by the bearing sleeve, or the rotation axis of the rotary bearing and / or torque tube. Figure 3A and 3B308, the plane 318 at which the connection interface between the upper and lower components of the bearing sleeve 306 lies is below the center point 319 and the axis of rotation of the torque tube 314 and the swivel bearing 308. Similarly, the plane 320 at which the connection interface between the bearing sleeve 306 and the bracket 304 lies is also below the center point 319 and the axis of rotation of the torque tube 314 and the swivel bearing 308. None of these planes intersect the aperture defined by the bearing sleeve, the swivel bearing 308, or the torque tube 314.

[0049] Depending on the desired angular orientation of the PV module, the mounting flanges may be located at any distance from center point 319. For example, the mounting flanges may be spaced sufficiently below center point 319 to allow the PV module to be oriented at angles of ±55°, ±60°, or greater relative to horizontal (0°).

[0050] return Figures 2A-2F , the upper assembly 206 and the lower assembly 208 may include one or more structural ridges 222a-222q. These structural ridges may provide increased structural rigidity and strength to prevent the bearing sleeve 202 from deforming and / or damaging when subjected to loads from a rotating torque tube, when there are high winds, or other high stress conditions on the bearing sleeve 202. For example, these structural ridges 222a-222q better maintain the circular profile of the bearing sleeve 202 than a bearing sleeve without structural ridges.

[0051] In some embodiments, the first hole defining portion 210a may include structural ridges 222a, 222b, 222c, and 222d. The structural ridges 222a, 222b, 222c, and 222d may extend parallel to each other and to the edge of the first hole defining portion 210a. The structural ridges 222a, 222b, 222c, and 222d may extend over most of the span of the first hole defining portion 210a. In some embodiments, the structural ridges 222a, 222b, 222c, and 222d may extend substantially parallel to each other in the longitudinal direction. For example, if the first hole defining portion 210a is flattened into the same plane as the mounting flanges 214a and 214b, each structural ridge 222a, 222b, 222c, and 222d may extend substantially parallel to each other.

[0052] In some embodiments, one or more of the structural ridges 222a, 222b, 222c, and 222d may laterally overlap adjacent structural ridges. For example, the structural ridge 222c laterally overlaps a portion, but not all, of the adjacent structural ridges 222a and 222b.

[0053] In some embodiments, the second hole defining portion 210b may include structural ridges 222e, 222f, and 222g. The structural ridges 222e, 222f, and 222g may extend parallel to each other and to the edge of the second hole defining portion 210b. The structural ridges 222e, 222f, and 222g may extend over most of the span of the second hole defining portion 210b. In some embodiments, the structural ridges 222e, 222f, and 222g may extend approximately parallel to each other in the longitudinal direction. For example, if the second hole defining portion 210b is flattened into the same plane as the mounting flanges 214c and 214d, each structural ridge 222e, 222f, and 222g may extend approximately parallel to each other. In some embodiments, one or more of the structural ridges 222e, 222f, and 222g may overlap adjacent structural ridges laterally.

[0054] In some embodiments, mounting flanges 214a, 214b, 214c, and 214d may also include structural ridges. For example, first mounting flange 214a may include structural ridges 222h and 222i. Second mounting flange 214b may include structural ridges 222j and 222k. Third mounting flange 214c may include structural ridges 222m and 222n. Fourth mounting flange 214d may include structural ridges 222p and 222q.

[0055] The structural ridges 222h, 222i, 222j, 222k, 222m, 222n, 222p, and 222q can have a size and shape such that when the upper component 206 and the lower component 208 are in the attached configuration, the structural ridges 222h, 222j, and 222k on the upper component 206 are aligned with the corresponding structural ridges 222m, 222n, 222p, and 222q on the lower component 208 to allow a flush interface between the upper component 206 and the lower component 208. Specifically, the structural ridge 222m can have a shape that engages with (or fits inside of) the structural ridge 222h. The structural ridge 222n can have a shape that engages with (or fits inside of) the structural ridge 222i. The structural ridge 222p can have a shape that engages with (or fits inside of) the structural ridge 222j. Structural ridge 222q may have a shape that engages with (or fits within) structural ridge 222k. In addition to providing increased structural rigidity, structural ridges 222h, 222i, 222j, 222k, 222m, 222n, 222p, and 222q may provide a guide to quickly align upper and lower assemblies 206, 208 during installation.

[0056] In some embodiments, all of the structural ridges 222 can have similar cross-sectional dimensions (e.g., the ridges have approximately the same height relative to the surrounding surface). For example, the structural ridges 222 can each include a comparable or similar height relative to the planar surface surrounding the ridge. In other embodiments, the structural ridges can have different cross-sectional dimensions, shapes, and sizes. For example, in some embodiments, the structural ridges can be non-parallel to each other. Furthermore, any number of structural ridges can be included on the bearing sleeve.

[0057] In some embodiments, the upper assembly 206 and the lower assembly 208 of the two-part bearing sleeve 202 may include transition portions between the mounting flanges and the hole defining portions. Specifically, the upper assembly 206 may include a first transition portion 226a between the first mounting flange 214a and the first hole defining portion 210a. The upper assembly 206 may include a second transition portion 226b between the second mounting flange 214b and the first hole defining portion 210a. The lower assembly 208 may include a third transition portion 226c between the third mounting flange 214c and the second hole defining portion 210b. The lower assembly 208 may include a fourth transition portion 226d between the fourth mounting flange 214d and the second hole defining portion 210b.

[0058] In some embodiments, gussets 230a, 230b, 230c, and 230d may be included at transition portions 226a, 226b, 226c, and 226d, respectively, to further provide additional structural support and / or rigidity to the two-part bearing sleeve 202. Gussets 230a, 230b, 230c, and 230d may be used as brackets at the corners of transition portions 226a, 226b, 226c, and 226d. Gussets 230a, 230b, 230c, and 230d may be connected to the mounting flange and the hole defining portion via an angled or other non-90° interface.

[0059] The gussets 230a, 230b, 230c, and 230d can have a size and shape so that when the upper assembly 206 and the lower assembly 208 are in an attached configuration, the gussets 230a and 230b on the upper assembly 206 are aligned with the corresponding gussets 230c and 230d on the lower assembly 208 to allow a flush interface between the upper assembly 206 and the lower assembly 208. Specifically, the gusset 230c can have a shape that engages with (or fits inside) the gusset 230a. The gusset 230d can have a shape that engages with (or fits inside) the gusset 230b. In addition to providing increased structural rigidity, the gussets 230a, 230b, 230c, and 230d can provide a guide to quickly align the upper assembly 206 and the lower assembly 208 during installation. In some embodiments, the bearing housing can include one or more gussets on one or both sides of the lower assembly instead of the upper assembly. Alternatively, the bearing housing may include one or more gussets on one or both sides of the upper assembly rather than the lower assembly.

[0060] In some embodiments, a stopper 234 may be included within the swivel bearing 204, which may be used to limit the degree of rotation of a torque tube fixedly coupled to the swivel bearing 204. In these embodiments, the hole defining portion 210a may include a slot 236 to accommodate the stopper 234. The stopper 234 may be fixedly coupled to the torque tube and serve as a limiter of the rotation limit of the torque tube within the two-part bearing sleeve 202. In some embodiments, the stopper 234 and the slot 236 may be configured to prevent rotation through the torque tube that would cause interference between the PV module and one or more mounting flanges 214a, 214b, 214c, and 214d. In other embodiments, the swivel bearing may not have a stopper that limits the degree of rotation of the torque tube.

[0061] In some embodiments, the upper assembly 206 and the lower assembly 208 can be selectively attached to each other. Any suitable mechanism can be used to selectively attach the upper assembly 206 and the lower assembly 208 together. For example, in the two-part bearing sleeve 202, bolts 240a and 240b and nuts 242a and 242b are used to attach the upper assembly 206 and the lower assembly 208.

[0062] In some embodiments, the mounting flanges 214a-214d may include one or more holes for mounting the two-part bearing sleeve 202 to a support structure via the bracket 104, such as Figure 1Specifically, mounting flange 210a may include hole 250a, mounting flange 210b may include hole 250b, mounting flange 210c may include hole 250c, and mounting flange 210d may include hole 250d. In some embodiments, these holes may be elongated slots that, when mounted to a bracket (such as Figure 1 The slot allows for positional flexibility when mounting bracket 104 in the housing. Figure 2A , 2E As can be seen in FIGS. 2A and 2F , when the upper assembly 206 and the lower assembly 208 are in the attached configuration, the holes 250a are aligned with the holes 250c, and the holes 250b are aligned with the holes 250d.

[0063] In some embodiments, fasteners (e.g., bolts or screws) can extend through holes 250a-250d to physically secure bearing sleeve 202 to the support structure. In some embodiments, one or more of holes 250a-250d can include slots that can facilitate use of bearing sleeve 202 with support structures of different sizes and / or configurations, and / or allow adjustment of bearing sleeve 202 if the support structure is not perfectly aligned.

[0064] By using a two-part bearing sleeve 202, if the bearing sleeve 202 and / or the swivel bearing 204 need to be damaged, maintained, or replaced, embodiments of the present disclosure may allow access to these components without having to completely disassemble the PV module from the entire length of the torque tube and remove each successive bearing sleeve along the length of the torque tube until the problematic bearing sleeve is reached. This is particularly problematic for those components toward the middle of the torque tube. Rather than disassembling the entire assembly to get to the problematic bearing sleeve, the upper assembly 206 may be removed, allowing access to the stop 234, the swivel bearing 204, and / or complete removal of the bearing sleeve 202. Furthermore, even for situations where only a subset of the bearing sleeves are removed to reach an intermediate coupler along the length of the torque tube, embodiments of the present disclosure may still reduce the effort, expense, and difficulty of removing even a subset of the bearing sleeves along the length of the torque tube.

[0065] Figures 4A-4C Various views of a torque tube interface 400 are shown. Similar to torque tube interfaces 200 and 300, torque tube interface 400 includes a two-part bearing sleeve 402 configured to hold a rotating bearing 404. The two-part bearing sleeve 402 includes an upper component 406 and a lower component 408. The upper component 406 of the bearing sleeve 402 includes a first bore defining portion 410a. The lower component 408 of the bearing sleeve 402 includes a second bore defining portion 410b. The two-part bearing sleeve 402 also includes mounting flanges 412a, 412b, 412c, and 412d.

[0066] Additional structural support and / or rigidity are provided to the two-part bearing sleeve 402 by hemming 420a, 420b, 420c and 420d. For example, hemming 420a and 420d can be formed along the outer edge of the upper component 406. Any hemming type can be used. In some embodiments, flat hemming, open hemming, rolled hemming, teardrop hemming, rope hemming or other types of hemming can be used. For example, in some embodiments, the hemming can include an angled bend at the edge of the material, such as a bend of about 90 °. Hemming 420b and 420c can be formed along a slot 424 that accommodates a stopper 426, which limits the rotation of the swivel bearing 404. Similar hemming can be formed in the edge of the lower component 408.

[0067] The hem may extend in the longitudinal direction along all or part of the first hole defining portion 410a and mounting flanges 412a and 412b of the upper component 406. The hem may extend in the longitudinal direction along all or part of the second hole defining portion 410b and mounting flanges 412c and 412d of the lower component 408. The hems 420b and 420c are formed at the edges of the slot 424. For example, Figure 4C A cross-sectional view of the top of the first hole defining portion 410a is shown.In addition to the flanges 420a, 420b, 420c, and 420d, a first structural ridge 422a and a second structural ridge 422b are formed to provide additional structural support and rigidity.

[0068] Figure 5 A perspective view of a torque tube interface 500 is shown, which includes a two-part bearing sleeve 502 and a rotation bearing 504. The upper component of the two-part bearing sleeve 502 includes a gusset 506. However, the lower component of the two-part bearing sleeve 502 lacks the gusset. The two-part bearing sleeve 502 also includes flanges 510a and 510b formed on the edges of the slot in which the limiter 512 rotates.

[0069] Figure 6 A perspective view of a two-part bearing sleeve 600 is shown. The two-part bearing sleeve 600 includes an upper component and a lower component that define a hole for a swivel bearing (not shown). The hole formed by the two-part bearing sleeve 600 is spherical to accommodate a spherical swivel bearing. The use of a spherical swivel bearing can provide greater tolerance for uneven ground or misalignment between the ground and the torque tube. The use of a spherical swivel bearing can also provide greater flexibility in the installation tolerance of the pile and accommodate unstable or heaving-prone ground where the height or position of the pile can change over time.

[0070] For the variations shown herein, it is apparent that any of the features included herein are optional and may be combined in any manner. For example, the presence or absence of any structural ridges, the presence or absence of any gussets, the presence or absence of hems, the presence or absence of slots for stops, etc., are all contemplated in any combination in the present disclosure. For example, in some embodiments, the bearing sleeve may include gussets and hems, but no structural ridges. In another embodiment, gussets, etc., may be used alone.

Claims

1. A two-part bearing sleeve for mounting a photovoltaic (PV) module to a support structure in a solar tracking system, comprising: a first component defining a first portion of a bore configured to receive a first portion of a swivel bearing; a second component defining a second portion of the bore configured to receive a second portion of the slew bearing; and A connection interface between the first component and the second component, wherein the connection interface is located in a plane below a center point of the hole defined by the first component and the second component when the first component and the second component are in an attached configuration.

2. A two-part bearing sleeve according to claim 1, wherein: The first component includes a first mounting flange, The second component includes a second mounting flange, and The connection interface is located between a bottom surface of the first mounting flange and a top surface of the second mounting flange.

3. A two-part bearing sleeve according to claim 2, wherein: The first mounting flange and the second mounting flange extend laterally away from the aperture defined by the first component and the second component.

4. A two-part bearing sleeve according to claim 3, wherein: The first mounting flange includes a first hole, The second mounting flange includes a second hole, and The first hole is aligned with the second hole when the first component and the second component are in an attached configuration.

5. A two-part bearing sleeve according to claim 4, wherein: The first mounting flange includes a first structural ridge, and The second mounting flange includes a second structural ridge.

6. A two-part bearing sleeve according to claim 5, wherein: The first and second structural ridges are sized and shaped such that when the first and second components are in an attached configuration, the first and second structural ridges are aligned to allow a flush interface to be formed between a bottom surface of the first mounting flange and a top surface of the second mounting flange.

7. The two-part bearing sleeve according to claim 1, wherein: A portion of the first component defining the aperture includes a structural ridge.

8. A two-part bearing sleeve according to claim 7, wherein: A portion of the second component defining the aperture includes a structural ridge.

9. The two-part bearing sleeve according to claim 1, wherein: At least a portion of the edge of the first component includes a hem, the shape of the hem providing additional structural rigidity to the first component.

10. A two-part bearing sleeve according to claim 9, wherein: At least a portion of the edge of the second component includes a hem, the shape of the hem providing additional structural rigidity to the second component.

11. The two-part bearing sleeve according to claim 1, wherein: The two-part bearing sleeve is configured to be fixed to the bracket at a connection interface between the two-part bearing sleeve and the bracket, and The connection interface between the bearing sleeve and the bracket is located on a plane that does not intersect the hole defined by the first component and the second component.

12. The two-part bearing sleeve according to claim 1, wherein: The first component includes a first mounting flange, The second component includes a second mounting flange, and At least one of the first component and the second component includes a gusset, the shape of the gusset providing additional structural rigidity to the two-part bearing sleeve.

13. A two-part bearing sleeve according to claim 12, wherein: The first component includes a first gusset plate, and the second component includes a second gusset plate.

14. A two-part bearing sleeve according to claim 13, wherein: The first gusset plate and the second gusset plate are sized and shaped such that when the first component and the second component are in an attached configuration, the first gusset plate and the second gusset plate are aligned to allow a flush interface between the first component and the second component.

15. The two-part bearing sleeve according to claim 1, wherein: The connection interface is located on a plane that does not intersect the aperture defined by the first component and the second component.

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