Adjustable bearing supports for single-axis trackers
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Solution Overview
Problem
Single-axis solar trackers with mechanically balanced designs, such as the NX Horizon Series, face limitations in X-axis and pitch adjustability due to their wider bearing housing assemblies, which can lead to mechanical interference and reduced tolerance for position errors, especially when installed on non-flat terrain or with H-pile foundations.
Innovation Solution
A two-piece truss cap adapter system that provides X-axis and pitch adjustability by using a lower truss cap portion with angled connecting portions and an upper BHA support with orthogonal slots, allowing for flexible positioning without mechanical interference with rotating tracker components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanically balanced tracker design with a wide bearing housing assembly is used, then there is no overturning moment regardless of tilt angle, but the tracker has very little tolerance for position error in the X-direction and requires leaving a gap between modules
Solution Approach 1:
The bearing housing assembly is divided into two separate pieces: a lower portion that attaches to the foundation and an upper portion that supports the torque tube. This segmentation allows independent optimization of each component, enabling the lower portion to be narrow (reducing X-direction gap requirements) while the upper portion provides the necessary structural support for mechanical balance.
Solution Approach 2:
The invention introduces vertical separation between the bearing housing components, utilizing the vertical dimension to resolve the horizontal space conflict. By stacking the bearing housing portions vertically rather than expanding horizontally, the design maintains mechanical balance properties while reducing the lateral footprint that would otherwise require gaps between modules.
2Reliability
If a wide bearing housing assembly is used to support the bearing pin, then the torque tube can swing through an arc without overturning moment, but the foundation must be wider than conventional H-pile
Solution Approach 1:
The bearing housing is segmented into lower and upper portions that can be mounted on a narrower foundation. The lower portion attaches to the foundation at a first location while the upper portion supports the bearing pin at a second location, allowing the foundation width to be reduced while maintaining the arc swing capability through proper vertical and horizontal positioning of the segmented components.
3Reliability
If the top of the bearing housing assembly protrudes up into the module plane, then there is no overturning moment, but it is necessary to leave a gap between modules at each foundation point
Solution Approach 1:
Dividing the bearing housing into lower and upper portions allows the upper portion to be positioned closer to the module plane while the lower portion remains set back on the foundation. This vertical stacking arrangement maintains the structural integrity needed for overturning moment resistance while reducing the horizontal protrusion that would create gaps between modules.
Solution Approach 2:
The invention resolves the horizontal space conflict by utilizing the vertical dimension. The bearing housing components are arranged vertically rather than expanding horizontally into the module plane, allowing full module coverage without gaps while maintaining the structural properties needed for mechanical balance and overturning moment resistance.
Data Source
AI summary
Adjustable bearing supports for single-axis trackers supported by truss foundations. A two-piece assembly joins a pair of adjacent truss legs to form a rigid foundation while providing a movable support for a tracker bearing housing assembly or other structure. The movable support may slide in-plane, or alternatively, enable the bearing housing assembly to slide and rotate with respect to the truss cap structure joining the adjacent truss legs.