Torque tube coupler

Abstract

A torque tube coupler may include a sleeve. The sleeve may include an outer surface, a first opening, and a second opening. The outer surface may be configured to physically engage a portion of the inner surface of the first torque tube section and a portion of the inner surface of the second torque tube section. The first opening may be configured to be positioned proximate a first countersunk opening of the first torque tube section. The second opening may be configured to be positioned proximate a second countersunk opening of the second torque tube section. The first opening and the second opening may be configured to receive a fastener via the first countersunk opening and the second countersunk opening to couple the first torque tube section and the second torque tube section to the sleeve, thereby forming a torque tube including a flush outer surface.

Description

[0001] Inventors: N. Schuknecht, R. Jinx, G. Horst Cross-reference to related applications

[0002] This application claims the benefit and priority of U.S. Patent Application Serial No. 18 / 801,094, filed August 12, 2024, which claims the benefit of U.S. Patent Application Serial No. 63 / 519,397, filed August 14, 2023, the disclosure of which is incorporated herein by reference. Technical Field

[0003] The embodiments discussed in this disclosure relate to solar energy devices, and more specifically, to torque tube couplers for solar energy devices. Background Technology

[0004] Solar installations, including solar farms, photovoltaic (PV) plants, solar tracking systems, fixed solar systems, and other PV systems, typically consist of numerous PV modules that collect sunlight and generate energy. Multiple PV modules are usually coupled to a single torque tube. The torque tubes and PV modules can be arranged in rows at the location where the solar installation is installed. The length of the torque tubes in each of these rows can be significant. Due to the length of these rows, multiple torque tube segments are typically coupled together using torque tube couplers to form a torque tube.

[0005] Some torque tube couplers physically engage with the outer surface of a torque tube segment to couple to that segment. However, because these torque tube couplers physically engage with the outer surface of the torque tube segment to which they are connected, they lead to inefficiencies in the design and / or manufacture of solar installations. This is because the torque tube couplers restrict the coupling locations of the PV modules, support structures, and other components of the solar installation. For example, restricting the coupling locations of the PV modules and support structures may limit the possible locations of support columns in the solar installation, the possible length of the torque tube segment, or both. Therefore, there is a need for a torque tube coupler that does not restrict the coupling locations on the torque tube and avoids inefficiencies.

[0006] The subject matter claimed in this disclosure is not limited to embodiments that address any shortcomings or operate only in environments such as those described above. Rather, this background is provided merely to illustrate an example technical field in which some of the embodiments described in this disclosure can be practiced. Summary of the Invention

[0007] The present invention is provided to present, in a simplified form, the selection of concepts further described below in the detailed embodiments. The present invention is not intended to identify key or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter.

[0008] The exemplary embodiments of this disclosure address problems experienced in solar energy installations, including issues related to torque tube couplers that restrict the location where PV modules can be coupled to a torque tube. Specifically, the disclosed embodiments provide a torque tube coupler mounted within an internal volume of a torque tube segment. The torque tube coupler includes an opening for receiving a fastener via a countersunk opening on the torque tube segment. The fastener couples the torque tube segment to the torque tube coupler to form a torque tube. The fastener may include a countersunk fastener that intersects with the countersunk opening of the torque tube segment such that the fastener and the outer surface of the torque tube segment form a flush outer surface. Therefore, the torque tube coupler couples to the torque tube segment without physically engaging with the outer surface of the torque tube segment. Furthermore, because the torque tube coupler is disposed within an internal volume of the torque tube segment, it does not restrict the location where PV modules can be coupled to the torque tube. Therefore, the torque tube coupler does not restrict the location where the torque tube interface can be coupled to the torque tube, which does not restrict the location where a support post can be located.

[0009] For example, in one embodiment, the torque tube coupler may include a sleeve having an outer surface configured to physically engage with a portion of the inner surface of a first torque tube segment and a portion of the inner surface of a second torque tube segment. The coupler may further include: a first opening configured to be positioned proximate to a first countersunk opening of the first torque tube segment; and a second opening configured to be positioned proximate to a second countersunk opening of the second torque tube segment. The first and second openings may be configured to receive fasteners via the first and second countersunk openings to couple the first and second torque tube segments to the sleeve to form a torque tube having a flush outer surface.

[0010] In some embodiments, the sleeve may further include a third opening located within a sleeve surface section different from the sleeve surface section including the first opening. The third opening may be configured to be positioned adjacent to a third countersunk opening of the first torque tube section. In this embodiment, the sleeve may further include a fourth opening located within a sleeve surface section different from the sleeve surface section including the first opening. The fourth opening may be configured to be positioned adjacent to a fourth countersunk opening of the second torque tube section. The third and fourth openings may be configured to receive additional fasteners via the third and fourth countersunk openings to further couple the first and second torque tube sections to the sleeve. Furthermore, in these embodiments, the third opening may be located within a sleeve surface section opposite to the sleeve surface section including the first opening, and the fourth opening may be located within a sleeve surface section opposite to the sleeve surface section including the second opening.

[0011] In some embodiments, the first opening and the second opening may include threaded portions configured to mate with a fastener to attach the fastener to the sleeve.

[0012] In some embodiments, the torque tube coupler may further include: a first nut coupled to an inner surface of the sleeve near a first opening; and a second nut coupled to an inner surface of the sleeve near a second opening. The first and second nuts may be configured to receive and abut a fastener via the first and second openings to attach the fastener to the sleeve.

[0013] In some embodiments, the first opening and the second opening may be configured to receive a fastener, such that rotating the fastener pulls a portion of the sleeve toward the inner surface of the first torque tube segment and the inner surface of the second torque tube segment.

[0014] In some embodiments, the first opening and the second opening may be located on the same surface of the sleeve.

[0015] In some embodiments, the sleeve may be sized to fit within a portion of the inner volume of the first torque tube segment and a portion of the inner volume of the second torque tube segment, such that a portion of the outer surface of the sleeve physically engages with a portion of the inner surface of the first torque tube segment and a portion of the inner surface of the second torque tube segment.

[0016] In some embodiments, the first opening, the second opening, the first countersunk opening, and the second countersunk opening can be positioned such that when the first torque tube segment and the second torque tube segment are coupled to the sleeve, the first torque tube segment and the second torque tube segment are in contact with each other.

[0017] In some embodiments, the sleeve may further include a collar, the size and shape of which are such that the outer surface of the collar forms a flush outer surface with the outer surface of the torque tube section.

[0018] In another embodiment, a system may include a first torque tube segment including a first countersunk opening, a first inner surface, and a first internal volume. The system may also include a second torque tube segment including a second countersunk opening, a second inner surface, and a second internal volume. The system may also include a plurality of fasteners. The system may further include a sleeve including an outer surface configured to physically engage with a portion of the inner surface of the first torque tube segment and a portion of the inner surface of a second torque tube segment. The coupler may further include: a first opening configured to be positioned proximate to the first countersunk opening of the first torque tube segment; and a second opening configured to be positioned proximate to the second countersunk opening of the second torque tube segment. The first and second openings may be configured to receive fasteners via the first and second countersunk openings to couple the first and second torque tube segments to the sleeve to form a torque tube having a flush outer surface.

[0019] In another embodiment, the torque tube segment may include a swaged end with an outer surface configured to physically engage a portion of the inner surface of a different torque tube segment. The torque tube segment may also include a first opening configured to be positioned adjacent to a second opening of a different torque tube segment. The torque tube segment may also include a third opening configured to be positioned adjacent to a fourth opening of a different torque tube segment. The first and third openings may be configured to receive fasteners via the second and third openings to couple the torque tube segment and different torque tube segments together, thereby forming a torque tube including a flush outer surface.

[0020] The objects and advantages of the embodiments will be realized and achieved, at least by means of the elements, features, and combinations particularly pointed out in the claims. The foregoing overview and the following detailed description are exemplary and illustrative, not restrictive. Attached Figure Description

[0021] Example embodiments will be described and explained with additional specificity and detail using the accompanying drawings, wherein:

[0022] Figure 1 An exemplary solar tracking system is shown, which includes an exemplary embodiment of a torque tube coupler connecting a torque tube segment;

[0023] Figure 2A It shows Figure 1 Top perspective view of the partially exploded torque tube coupler and torque tube segment;

[0024] Figure 2B It shows Figure 1 A partially exploded bottom perspective view of the torque tube coupler and torque tube segment;

[0025] Figure 2C It shows Figure 1 Top perspective view of the decomposed torque tube coupler and another part of the torque tube segment;

[0026] Figure 2D It shows Figure 1 A cross-sectional view of an example torque tube coupler and torque tube segment;

[0027] Figure 3 A cross-sectional view of a torque tube segment and an exemplary torque tube coupler is shown, the exemplary torque tube coupler including a nut coupled to the inner surface of a sleeve of the torque tube coupler;

[0028] Figure 4 It shows Figure 1 A perspective view of the torque tube coupler and torque tube segment in the installed state;

[0029] Figure 5An exemplary torque tube segment including a forged end and a perspective view of an exemplary torque tube segment are shown; and

[0030] Figure 6 An example of a sleeve including a collar is shown;

[0031] All are based on at least one embodiment described in this disclosure. Detailed Implementation

[0032] The embodiments disclosed herein will be explained with reference to the accompanying drawings. It should be understood that the drawings are illustrative and schematic representations of these exemplary embodiments and are not restrictive, nor are they necessarily drawn to scale. In the drawings, features having the same reference numerals indicate the same structure and function, unless otherwise stated.

[0033] refer to Figure 1 This illustrates an example of a type of system environment in which aspects of this disclosure can be used. Figure 1 The illustration shows an embodiment of a solar tracking system 100. Although illustrated and described with respect to a solar tracking system 100, it will be understood that the embodiments described herein can be implemented in a solar tracking system, a fixed solar system, or any other suitable solar system. In the example shown, a single row 111 includes three exemplary PV modules 112a-c and two torque tube segments 102a-b. The torque tube segments 102a-b can be coupled together via a torque tube coupler 127 to form a torque tube 125 extending the length of row 111.

[0034] The torque tube interface 109 operably connects the torque tube 125, including torque tube segments 102a-b, to the support column 106 via mounting brackets 108a-b. The torque tube interface 109 allows the torque tube 125 to rotate, typically orienting the PV modules 112a-c towards the sun or perpendicular to the east-west portion of the solar irradiance, which can promote an increase in power generation caused by the PV modules 112a-c. Alternatively, in a fixed solar system, the torque tube interface 109 can connect the torque tube segments 102a-b to the support column 106 such that the torque tube 125 is stationary (e.g., in a fixed position) to maintain the orientation of the PV modules 112a-c. Furthermore, the mounting brackets 108a-b can be used to secure the torque tube interface 109 to the support column 106.

[0035] Figure 1 The torque tube coupler 127 is positioned within portions of the torque tube sections 102a-b. Fasteners 126a-d (126b and 126d are in...) Figures 2A-2D(As shown in the diagram) Torque tube segments 102a-b are secured to torque tube coupler 127. Specifically, fasteners 126a-d are used with countersunk openings 142a-d of torque tube segments 102a-b (142b and 142d are in...). Figure 2B (as shown in the diagram) and the sleeve of the torque tube coupler 127 (such as in...) Figures 2A-2D As shown in Figure 229), a mating joint is used to secure torque tube segments 102a-b to the sleeve of torque tube coupler 127. Fasteners 126a-d can secure torque tube segments 102a-b to torque tube coupler 127 to form torque tube 125.

[0036] The torque tube coupler 127 can be coupled to the torque tube segments 102a-b, so that the torque tube segments 102a-b form a joint 120. For example... Figure 1 As shown, the torque tube coupler 127 allows the torque tube segments 102a-b to be adjacent to each other, such that the outer surfaces 122a-b of the torque tube segments 102a-b and the fasteners 126a-d form a flush outer surface 124.

[0037] As in Figure 1 As can be seen, the torque tube coupler 127 is at least partially enclosed within the torque tube segments 102a-b and does not extend beyond the outer surfaces 122a-b of the torque tube segments 102a-b. This allows the PV modules 112a-c, the torque tube interface 109, or any other suitable solar device components to be coupled anywhere along the length of the torque tube 125. Therefore, the torque tube coupler 127 can reduce or eliminate inefficiencies in the solar tracking system 100 by preventing restrictions on the locations where the PV modules 112a-c can be coupled to the torque tube 125. Furthermore, the torque tube coupler 127 does not restrict the locations where the torque tube interface 109 can be coupled to the torque tube 125, which does not restrict the locations where the support column 106 can be positioned.

[0038] Figure 1 Row 111 shown includes three PV modules 112a-c and two torque segments 102a-b. This row can include any suitable number of PV modules and / or torque segments. For example, row 111 can include one, two, three, four, or more PV modules. As another example, row 111 can include two, three, four, five, or more torque segments. In the example shown, torque segments 102a-b have an octagonal shape. However, torque segments 102a-b can include any suitable shape. For example, the shape of torque segments 102a-b can include a square, pentagonal, hexagonal, heptagonal, nonagonal, circular, or any other shape.

[0039] Further reference Figure 1 and Figures 2A-2DThe torque tube segments 102a-b are coupled together using a torque tube coupler 127 to form a torque tube 125. In the illustrated example, the torque tube coupler 127 includes a sleeve 229 and fasteners 126a-d. The sleeve 229 may include a first region 240a corresponding to the first torque tube segment 102a and a second region 240b corresponding to the second torque tube segment 102b.

[0040] The sleeve 229 is sized to fit within a portion of the internal volume 232a-b of the torque tube sections 102a-b. Specifically, the first region 240a can be fitted within a portion of the internal volume 232a of the first torque tube section 102a. Furthermore, the second region 240b can be fitted within a portion of the internal volume 232b of the second torque tube section 102b. Compared to the outer periphery of the torque tube sections 102a-b, the outer periphery of the sleeve 229 can be smaller, allowing the internal volume 232a-b of the torque tube sections 102a-b to receive the region 240a-b of the torque tube coupler 127.

[0041] The sleeve 229 can be sized such that at least a portion of the outer surface 234 of the sleeve 229 physically engages with a portion of the inner surface 230a-b of the torque tube section 102a-b. At least a portion of the surface section 246a-h of the outer surface 234 of the sleeve 229 physically engages with the inner surface 230a-b of the torque tube section 102a-b. For example, as... Figures 2A-2D As shown, the second surface segment 246b, the third surface segment 246c, the fourth surface segment 246d, the sixth surface segment 246f, the seventh surface segment 246g, and / or the eighth surface segment 246h physically engage with the inner surfaces 230a-b of the torque tube segments 102a-b. Furthermore, during installation, fasteners 126a-b can pull the first surface segment 246a and the fifth surface segment 246e of the sleeve 229 toward the countersunk opening 142a-d, causing the first surface segment 246a and / or the fifth surface segment 246e to physically engage with a portion of the countersunk opening 142a-d of the torque tube segments 102a-b.

[0042] The sleeve 229 can be sized to accommodate the countersunk openings 142a-d of the torque tube sections 102a-b, allowing the sleeve 229 to fit between the countersunk openings 142a-d. Alternatively, the sleeve 229 can be sized and / or formed such that a gap is formed between the sleeve 229 and the inner surfaces 230a-b of the torque tube sections 102a-b to accommodate the countersunk openings 142a-b. For example, the height of the sleeve 229 can be less than the width of the sleeve 229, allowing the sleeve 229 to fit between the countersunk openings 142a-d while still contacting at least a portion of the inner surfaces 230a-b of the torque tube sections 102a-b on the sides. In other words, the lengths of the second surface segment 246b, the fourth surface segment 246d, the sixth surface segment s246f, and the eighth surface segment 246h can be smaller than the lengths of the third surface segment 246c and the seventh surface segment 246g to accommodate the countersunk openings 142a-d extending from the inner surfaces 230a-b of the torque tube segments 102a-b. Furthermore, the lengths of the first surface segment 246a and the fifth surface segment 246e can be greater than the lengths of the third surface segment 246c and the seventh surface segment 246g to accommodate the smaller lengths of the second surface segment 246b, the fourth surface segment 246d, the sixth surface segment s246f, and the eighth surface segment 246h. As another example, in an embodiment where the torque tube segments 102a-b include a circular shape, the sleeve 229 may include an elliptical shape, such that a gap is formed between the sleeve 229 and the inner surfaces 230a-b of the torque tube segments 102a-b, which are only close to the countersunk recesses 142a-d.

[0043] Furthermore, sleeve 229 includes openings 228a-d configured to receive fasteners 126a-d. When sleeve 229 is disposed within the internal volumes 232a-b of torque tube sections 102a-b, openings 228a-d can be configured to be positioned adjacent to corresponding countersunk openings 142a-d. For example, when a first region 240a of sleeve 229 is disposed within a portion of the internal volume 232a of the first torque tube section 102a, the first opening 228a and the second opening 228b can be configured to be positioned adjacent to the first countersunk opening 142a and the second countersunk opening 142b, respectively. As another example, when a second region 240b of sleeve 229 is disposed within a portion of the internal volume 232b of the second torque tube section 102b, the third opening 228c and the fourth opening 228d can be configured to be positioned adjacent to the third countersunk opening 142c and the fourth countersunk opening 142d, respectively. In the illustrated embodiment, openings 228a-d of sleeve 229 are shown as countersunk openings. However, it will be understood that openings 228a-d can be through holes or any other suitable flush holes. Regarding Figure 3 Examples of openings 228a-d, including those with through holes positioned near the nut, are discussed in more detail.

[0044] The first opening 228a and the third opening 228c are located within the first surface section 246a of the sleeve 229. Furthermore, the second opening 228b and the fourth opening 228d are located within the fifth surface section 246e of the sleeve 229. The first surface section 246a can be positioned relative to the first surface section 246a on the sleeve 229.

[0045] Openings 228a-d can receive fasteners 126a-d via corresponding countersunk openings 142a-d. For example, the first opening 228a can receive the first fastener 126a via the first countersunk opening 142a, the second opening 228b can receive the second fastener 126b via the second countersunk opening 142b, the third opening 228c can receive the third fastener 126c via the third countersunk opening 142c, and the fourth opening 228d can receive the fourth fastener 126d via the fourth countersunk opening 142d.

[0046] Openings 228a-d can receive fasteners 126a-d via corresponding countersunk openings 142a-d to couple sleeve 229 to torque sections 102a-b. For example, a first opening 228a can receive a first fastener 126a via a first countersunk opening 142a, and a second opening 228b can receive a second fastener 126b via a second countersunk opening 142b to couple sleeve 229 to the first torque section 102a. As another example, a third opening 228c can receive a third fastener 126c via a third countersunk opening 142c, and a fourth opening 228d can receive a fourth fastener 126d via a fourth countersunk opening 142d to couple sleeve 229 to the second torque section 102b. Fasteners 126a-d may include heads 244a-d, which are shaped and sized to fit within countersunk openings 142a-d.

[0047] In some embodiments, openings 228a-d can be compressed by forming holes in sleeve 229 and pulling material close to the holes toward the internal volume 236 of sleeve 229. In these and other embodiments, openings 228a-d may include threaded or tapped portions (not shown) configured to mate with fasteners 126a-d. For example, the threaded or tapped portions of openings 228a-d may mate with the threaded portions of fasteners 126a-d. The threaded or tapped portions of openings 228a-d may mate with the threaded portions of fasteners 126a-d to attach fasteners 126a-d to sleeve 229 and couple torque segments 102a-b to sleeve 229. In some embodiments, countersunk openings 142a-d may form smooth, tapered openings.

[0048] Openings 228a-d can mate with fasteners 126a-d, allowing rotation of fasteners 126a-d to alter the amount of draw of a portion of sleeve 229 toward the inner surface 230a-b of torque tube sections 102a-b. For example, clockwise rotation of fasteners 126a-d increases the amount of draw of the first surface section 246a and the fifth surface section 246e toward the inner surface 230a-b of torque tube sections 102a-b. As another example, counterclockwise rotation of fasteners 126a-d decreases the amount of draw of the first surface section 246a and the fifth surface section 246e toward the inner surface 230a-b of torque tube sections 102a-b.

[0049] In some embodiments, the length of fasteners 126a-d may be dimensioned such that fasteners 126a-d are rotated until the head 244a-d is flush with the outer surface 122a-b of the torque tube segment 102a-b, indicating that appropriate torque has been applied to fasteners 126a-d. In these and other embodiments, fasteners 126a-d may be configured to be twisted to a threshold. This threshold may be equal to or between ten ft-lbs and one hundred and seventy-five ft-lbs. In some embodiments, the length of fasteners 126a-d may be dimensioned such that a portion of one or more fasteners 126a-d extends beyond the opening 228a-d within the internal volume 236 of sleeve 229. In other embodiments, the length of fasteners 126a-d may be dimensioned such that a portion of one or more fasteners 126a-d is flush with the opening 228a-d. In some embodiments, rivets may be used instead of fasteners, and rivets may be configured to apply appropriate pretension that applies axial tension during installation.

[0050] Sleeve 229 may include a single metal sheet 248 cut, stamped, or otherwise removed from a single sheet of pre-galvanized metal. The single metal sheet 248 may be cut from the single sheet of pre-galvanized metal such that the galvanizing process extends through the entire depth of the single metal sheet 248. Alternatively, the single metal sheet 248 may be galvanized post-formation. For example, the single metal sheet 248 may undergo a hot-dip galvanizing process post-formation. The single metal sheet 248 may include pre-galvanized metal of a thickness that allows for tapping of the first and second openings during the manufacture of the torque tube coupler.

[0051] In the example shown, torque tube section 102a-b has an octagonal shape. However, torque tube section 102a-b can include any suitable shape. For example, the shape of torque tube section 102a-b can include a square shape, a pentagonal shape, a hexagonal shape, a heptagonal shape, a nonagonal shape, a circular shape, or any other shape.

[0052] Sleeve 229 may include a shape corresponding to the shape of torque tube sections 102a-b. For example, as shown, sleeve 229 has an octagonal shape corresponding to the octagonal shape of torque tube sections 102a-b. However, sleeve 229 may include any suitable shape, such as a square shape, pentagonal shape, hexagonal shape, heptagonal shape, nonagonal shape, circular shape, or any other shape corresponding to the shape of torque tube sections 102a-b. For example, torque tube sections 102a-b may include a square shape, and sleeve 229 may include a rectangular shape. As another example, torque tube sections 102a-b may include a circular shape, and sleeve 229 may include an elliptical shape.

[0053] The openings 228a-d can be sized, shaped, and / or positioned within the sleeve 229 such that, when the sleeve 229 is positioned within the internal volume 232a-b of the torque tube sections 102a-b, one or more of the openings 228a-d are positioned adjacent to the corresponding countersunk openings 142a-d. The sleeve 229 can be positioned within the internal volume 232a-b of the torque tube sections 102a-b such that the openings 228a-d are aligned (e.g., coaxial) with the corresponding countersunk openings 142a-d. For example, as... Figure 3 As shown, the first countersunk opening 142a can be coaxial with the first opening 228a along axis 350. As another example, such as... Figure 3 As shown, the second countersunk opening 142b can be coaxial with the second opening 228b along axis 350. Although in Figure 3 Not shown, but along axis 350, the third countersunk opening 142c can also be coaxial with the third opening 228c and the fourth countersunk opening 142d can also be coaxial with the fourth opening 228d.

[0054] In some embodiments, fasteners 126a-b may include 3 / 8-inch bolts, half-inch bolts, 5 / 8-inch bolts, or some combination thereof. In some embodiments, fasteners 126a-d may include lengths such that a single fastener can extend across the internal volume 236 of the sleeve 229 and engage with countersunk openings 142a-d and / or openings 228a-d on opposite sides of the sleeve 229 and / or torque tube segments 102a-b. For example, a first fastener 126a may include lengths such that the first fastener 126a engages with the first countersunk opening 142a and the first opening 228a; extends across the internal volume 236 of the sleeve 229; and engages with the second opening 228b and the second countersunk opening 142b.

[0055] refer to Figure 3The torque tube coupler 127 may include a plurality of nuts 307a-b located within the internal volume 236 of the sleeve 229 near openings 228a-b. Nuts 307a-b may be coupled to the inner surface 338 of the sleeve 229. Nuts 307a-b may receive fasteners 126a-b via countersunk openings 142a-b and openings 228a-b. Nuts 307a-b may abut against fasteners 126a-b such that rotating fasteners 126a-b alters the amount of pull of nuts 307a-b toward the inner surface 338 of the sleeve 229. Furthermore, altering the amount of pull of nuts 307a-b toward the inner surface 338 of the sleeve 229 alters the amount of pull of a portion of the sleeve 229 toward the inner surface 230a-b of the torque tube section 102a-b. Nuts 307a-b may include rivet nuts, weld nuts, clamping nuts, piercing nuts, nylock nuts, nuts mating with locking half nuts, capped nuts, or combinations thereof. In some embodiments, nuts 307a-b may be glued, brazed, or otherwise attached to the inner surface 338 of sleeve 229. Figure 3 In this example, only two nuts 207a-b are shown. The torque tube coupler 127 may include washers (not shown) positioned between the nuts 307a-b and the inner surface 338 of the sleeve 229. The washers may include retaining washers, star washers, spring washers, beveled spring washers, serrated washers, or combinations thereof. The torque tube coupler 127 may include any suitable number of nuts. In some embodiments, the number of nuts in the torque tube coupler 127 may correspond to the number of openings 228a-d. For example, the torque tube coupler 127 may include four nuts, with a single nut adjacent to each opening 228a-d. Alternatively, the number of nuts may correspond only to a portion of the number of openings 228a-d.

[0056] Further reference Figure 1-2D and Figure 4 An example of a torque tube 125 in an installed state is shown. In the installed state, torque tube segments 102a-b form a joint 120. In some embodiments, for example... Figure 4 As shown, torque tube coupler 127 can be coupled to torque tube segments 102a-b such that torque tube segments 102a-b are in contact with each other (e.g., adjacent) and the width of the joint 120 is equal to zero millimeters (mm). In other embodiments, torque tube coupler 127 can be coupled to torque tube segments 102a-b such that the width of the joint 120 is greater than zero millimeters.

[0057] The torque tube coupler 127 can be coupled to the torque tube segments 102a-b, such that the outer surfaces 122a-b of the torque tube segments 102a-b form a flush outer surface 124. Furthermore, the heads 244a-d of the fasteners 126a-d can be positioned within the countersunk openings 142a-d during installation, such that the heads 244a-d of the fasteners 244a-d are flush with the outer surfaces 122a-b of the torque tube segments 102a-b. The outer surfaces 122a-b of the torque tube segments 102a-b and the heads 244a-d of the fasteners 126a-d can form a flush outer surface 124.

[0058] refer to Figure 5 Exemplary torque tube segments 560 and 562, including a forged end 564, are shown. Torque tube segment 560 can be coupled to torque tube segment 562 via forged end 564 and fasteners 578a-d to form a torque tube. Torque tube segments 560 and 562 can be similar to... Figure 1-4 The torque tube sections 102a-b and sleeve 229 operate. However, the torque tube section 560 may include a single metal sheet that undergoes a forging process to form a forged end 564 for coupling the torque tube section 560 to the torque tube section 562. Furthermore, the forged end 564 may be coupled to the torque tube section 562 such that the outer surfaces 582a-b of the torque tube sections 560 and 562 form flush outer surfaces.

[0059] During the forging process, a single metal sheet can be deformed to form the forging end 564. Furthermore, during the forging process, openings 568a-d can be cut and / or formed in the forging end 564.

[0060] The dimensions of the forged end 564 can be configured to fit within a portion of the internal volume 580 of the torque tube section 562. The perimeter of the forged end 564 can be smaller than the perimeter of the torque tube section 562, such that the internal volume 580 of the torque tube section 562 receives the forged end 564. Furthermore, the dimensions of the forged end 564 can be configured such that at least a portion of the outer surface 576 of the forged end 564 physically engages with at least a portion of the inner surface 574 of the torque tube section 562.

[0061] The torque section 560 may include a transition region 570 that connects the forged end 564 to the riser region 586. The riser region 586 may include a perimeter greater than the perimeter of the forged end 564. Similarly, the riser region 586 may include a perimeter corresponding to the perimeter of the torque section 562 to form a flush outer surface. The transition region 570 may include an inclined surface or other transition surface that transitions between the different perimeter dimensions of the forged end 564 and the riser region 586.

[0062] The transition region 570 may abut the end of the torque tube section 562 to prevent the forged end 564 from over-inserting into the internal volume 580 of the torque tube section 562. Furthermore, the raised region 586 may abut the end of the torque tube section 562 to align the openings 568a-d of the forged end 564 with respect to the openings 572a-d of the torque tube section 562. For example, the transition region 570 may be positioned to prevent the forged end 564 from over-inserting into the internal volume 580 of the torque tube section 562, thus preventing the openings 568a-d from extending beyond the openings 572a-d of the torque tube section 562.

[0063] When the forging end 564 is disposed within the internal volume 580 of the torque tube section 562, the openings 568a-d of the forging end 564 can be configured to be positioned close to the corresponding openings 572a-d of the torque tube section 562. For example, when the forging end 564 is disposed within a portion of the internal volume 580 of the torque tube section 562, openings 568a and 568b can be configured to be positioned close to openings 572a and 572b, respectively. As another example, when the forging end 564 is disposed within a portion of the internal volume 580 of the torque tube section 562, openings 568c and 568d can be configured to be positioned close to openings 572c and 572d, respectively. Opening 572b is not in... Figure 5 As shown in the figure, it is positioned relative to opening 572d.

[0064] In the illustrated embodiment, the openings 568a-d of the forging end 564 are shown as through holes; however, it will be understood that the openings 568a-d may be countersunk openings or any other suitable holes.

[0065] Openings 568a-d can receive fasteners 578a-d via corresponding openings 572a-d in the torque conduit segment 562 to couple the forging end 564 to the torque conduit segment 562. Fasteners 578a-d may include blind fasteners or any other type of fastener configured to connect to the forging end 564 and the torque conduit segment 562, and not enter the internal volume 590 of the forging end 564 due to the length of the torque conduit segment 562. For example, when the forging end 564 is disposed within the internal volume 580 of the torque conduit segment 562, the length of the torque conduit segment 562 can prevent access to the fastener within the internal volume 590 of the forging end 564.

[0066] During installation, fasteners 578a-d can pull the corresponding portions of the forged end 564 toward the inner surface 574 of the torque tube section 562, so that at least a portion of the outer surface 576 of the forged end 564 is physically engaged with at least a portion of the inner surface 574 of the torque tube section 562.

[0067] Torque sections 560 and 562 may comprise single metal sheets cut, stamped, or otherwise removed from a single sheet of pre-galvanized metal. Alternatively, the single metal sheet may be galvanized after forming. For example, the single metal sheet may undergo a hot-dip galvanizing process after forming. The single metal sheet may comprise a thickness such that openings 568a-d of the forged end 564 and openings 572a-d of the torque section 562 can be formed and tapped. For example, the single metal sheet may comprise a thickness equal to that of a No. 14 metal material.

[0068] In the example shown, torque sections 560 and 562 have an octagonal shape. However, torque sections 560 and 562 can include any suitable shape. For example, the shapes of torque sections 560 and 562 can include square, pentagonal, hexagonal, heptagonal, nonagonal, circular, or any other shape.

[0069] The forging end 564 may include a shape corresponding to the shape of the torque tube segment 562. For example, as shown, the forging end 564 has an octagonal shape corresponding to the octagonal shape of the torque tube segment 562. However, the forging end 564 may include any suitable shape, such as a square shape, a pentagonal shape, a hexagonal shape, a heptagonal shape, a nonagonal shape, a circular shape, or any other shape corresponding to the shape of the torque tube segment 562. For example, the torque tube segment 562 may include a square shape, and the forging end 564 may include a rectangular shape. As another example, the torque tube segment 562 may include a circular shape, and the forging end 564 may include an elliptical shape.

[0070] refer to Figure 6 An example of a sleeve 229 including a collar 607 is shown. In some embodiments, the collar 607 may be sized and shaped such that the outer surface 609 of the collar 607 and the outer surfaces 122a-b of the torque tube segments 102a-b form flush outer surfaces. Specifically, the thickness of the collar 607 may be set such that the outer surface 609 of the collar 607 and the outer surfaces 122a-b of the torque tube segments 102a-b form a flush outer surface 124. The collar 607 may selectively contact a portion of the outer surface 234 of the sleeve 229. Alternatively, the collar 607 may be permanently coupled to the sleeve 229 or otherwise formed part of the sleeve 229.

[0071] The collar 607 can be configured to be positioned between torque tube sections 102a-b. The collar 607 can be sized to help align the openings 228a-d with the countersunk openings 142a-d. For example, the collar 607 can be positioned to prevent the region 240a-b of the sleeve 229 from over-inserting into the internal volume 232a-b of the torque tube section 102a-b, thereby preventing the openings 228a-d from extending beyond the countersunk openings 142a-d.

[0072] Therefore, sleeve 229 is fitted within the internal volumes 232a-b of torque tube sections 102a-b, and torque tube coupler 127 couples torque tube sections 102a-b together without restricting the position of PV modules 112a-c that can be coupled to torque tube 125, thus eliminating the inefficiency of the solar energy device. Furthermore, forged end 564 is fitted within the internal volume 580 of torque tube section 562, and forged end 564 couples torque tube sections 560 and 562 together without restricting the position of PV modules that can be coupled to torque tube sections 560 and 562, which also eliminates the inefficiency of the solar energy device.

Claims

1. A torque tube coupler, comprising: Sleeve, including: The outer surface is configured to physically engage with a portion of the inner surface of the first torque tube segment and a portion of the inner surface of the second torque tube segment. The first opening is configured to be positioned close to the first countersunk opening of the first torque tube section; and The second opening is configured to be positioned near the second countersunk opening of the second torque tube section. The first opening and the second opening are configured to receive fasteners via the first countersunk opening and the second countersunk opening to couple the first torque tube section and the second torque tube section to the sleeve, thereby forming a torque tube with a flush outer surface.

2. The torque tube coupler according to claim 1, wherein, The sleeve also includes: A third opening, located within a surface segment of the sleeve different from the surface segment including the first opening, is configured to be positioned close to the third countersunk opening of the first torque tube segment; and A fourth opening, located within a surface section of the sleeve different from the surface section of the sleeve including the first opening, is configured to be positioned close to a fourth countersunk opening of the second torque tube section, wherein the third opening and the fourth opening are configured to receive additional fasteners via the third countersunk opening and the fourth countersunk opening to further couple the first torque tube section and the second torque tube section to the sleeve.

3. The torque tube coupler according to claim 2, wherein: The third opening is located within the surface section of the sleeve opposite to the surface section of the sleeve that includes the first opening; and The fourth opening is located within the surface section of the sleeve opposite to the surface section of the sleeve that includes the second opening.

4. The torque tube coupler according to claim 1, wherein, The first opening and the second opening include threaded portions configured to mate with the fastener to attach the fastener to the sleeve.

5. The torque tube coupler according to claim 1, further comprising: A first nut is coupled to the inner surface of the sleeve near the first opening; and A second nut is coupled to the inner surface of the sleeve near the second opening, wherein the first nut and the second nut are configured to receive and abut the fastener via the first opening and the second opening to attach the fastener to the sleeve.

6. The torque tube coupler according to claim 1, wherein, The first opening and the second opening are configured to receive the fastener, such that rotating the fastener pulls a portion of the sleeve toward the inner surfaces of the first torque tube segment and the second torque tube segment.

7. The torque tube coupler according to claim 1, wherein, The first opening and the second opening are located on the same surface of the sleeve.

8. The torque tube coupler according to claim 1, wherein, The sleeve is sized to fit within a portion of the inner volume of the first torque tube segment and a portion of the inner volume of the second torque tube segment, such that a portion of the outer surface of the sleeve physically engages with a portion of the inner surface of the first torque tube segment and a portion of the inner surface of the second torque tube segment.

9. The torque tube coupler according to claim 1, wherein, The first opening, the second opening, the first countersunk opening, and the second countersunk opening are positioned such that when the first torque tube segment and the second torque tube segment are coupled to the sleeve, the first torque tube segment and the second torque tube segment are in contact with each other.

10. The torque tube coupler according to claim 1, wherein, The sleeve also includes a collar, the size and shape of which are such that the outer surface of the collar is flush with the outer surface of the torque tube section.

11. A torque-rated pipe section, comprising: Forging end, including: The outer surface is configured to physically engage with a portion of the inner surface of different torque tube segments; The first opening is configured to be positioned close to the second opening of the different torque tube segments; and The third opening is configured to be positioned close to the fourth opening of the different torque tube segments. The first opening and the third opening are configured to receive fasteners via the second opening and the third opening to couple the torque tube segments and the different torque tube segments together, thereby forming a torque tube including a flush outer surface.

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