Systems, methods, and machines for joining truss foundation components
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Solution Overview
Problem
The inefficiency of monopile foundations in supporting single-axis solar trackers due to their wasteful use of steel and labor, as they require over-specification to resist bending moments from wind loads, and the challenges of misalignment in constructing truss foundations which can lead to strain on the torque tube and installation issues.
Innovation Solution
The development of a truss foundation system using A-frame-shaped trusses that translate lateral loads into axial forces, reducing the need for deep embedment and heavy steel, and the use of adjustable couplers to correct misalignment between screw anchors and upper legs, enabling secure and rapid interconnection of foundation components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If monopile foundations are used to support single-axis solar trackers, then the foundation can resist lateral loads, but excessive steel and embedment depth are required due to bending moments
Solution Approach 1:
The monopile is divided into multiple segments (lower pile section, upper pile section, and truss components) that work together to resist lateral loads. This segmentation allows each component to be optimized for its specific function, reducing the overall material requirement compared to a single oversized monopile.
Solution Approach 2:
The foundation transitions from a vertical monopile structure to a three-dimensional truss configuration with multiple members arranged in a triangular geometry. This dimensional change enables the structure to resist lateral loads through axial forces in multiple members rather than bending in a single member, significantly reducing steel requirements.
2Strength
If monopile foundations are used to support single-axis solar trackers, then the foundation can resist lateral loads, but greater embedment depth is required due to bending moments
Solution Approach 1:
The pile is segmented into lower and upper sections with different functions. The lower pile section provides lateral support through interaction with the soil, while the upper pile section connects to the truss. This segmentation allows for optimized embedment depth, reducing the required length compared to a full-depth monopile.
Solution Approach 2:
The foundation system transitions from a single vertical element to a three-dimensional truss structure. This dimensional change distributes lateral load resistance across multiple members and soil interaction points, reducing the embedment depth requirement compared to a monopile that must rely solely on its embedded length for bending resistance.
3Productivity
If truss foundation components are driven into the ground, then lateral loads are translated into axial forces, but misalignment between components may occur
Solution Approach 1:
The coupler incorporates adjustable parameters including angular orientation and axial position that can be modified during installation. This allows the coupler to accommodate misalignment between truss members and screw anchors, ensuring proper connection without requiring precise pre-alignment of all components.
Solution Approach 2:
The coupler is designed with dynamic adjustment capabilities, allowing operators to modify its orientation and position during the installation process. This dynamic adaptability enables the system to compensate for field conditions and achieve proper alignment even when initial component placement has variations.
4Strength
If heavier beams and greater embedment depths are used for monopiles, then lateral load resistance is improved, but labor costs and installation complexity increase
Solution Approach 1:
The foundation system is divided into modular components (screw anchors, truss members, couplers) that can be manufactured separately and assembled in the field. This segmentation reduces the complexity of handling and installing single heavy monopiles, as the truss components are smaller and more manageable while achieving equivalent or superior lateral load resistance.
Data Source
AI summary
A coupler for joining truss leg components provides angular adjustability between the respective axis of the leg components. A prolate spheroid-shaped coupler with three channels circumscribing its surface enables the upper leg components to compensate for axial misalignment of driven screw anchors in all directions. A hydraulic crimping device with upper and lower crimping guides registers its position with features on the truss hardware to insure that blind triple crimps are performed consistently each time.