Articulation Joint Design for Solar Tracker Terrain Adaptability
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Solution Overview
Problem
The installation of solar trackers on uneven terrain requires significant earth excavation and custom pier lengths, leading to high costs and logistical challenges due to the need for level sites, which is time-consuming and environmentally impactful.
Innovation Solution
A coupling system for solar trackers that includes a support flange, a swivel flange, and an articulation joint, allowing for poly-axial rotation of torque tubes, enabling installation on undulating terrain with identical pier lengths by accommodating varying angles and angles between adjacent torque tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If solar trackers are installed on uneven terrain using traditional methods, then the site must be leveled through earth excavation, but this leads to significant time consumption, high costs, and environmental impact
Solution Approach 1:
The patent employs dynamic articulation joints that allow the torque tube to rotate and adapt to varying terrain angles. The joint enables the solar tracker to dynamically follow the natural undulations of the terrain rather than requiring static leveling, thus reducing installation time and earthworks while maintaining operational effectiveness
Solution Approach 2:
The articulation joint acts as an intermediary element between the pier and the torque tube, accommodating angular misalignments caused by uneven terrain. This mediator component allows the system to bridge the gap between fixed pier locations and the required parallel orientation of torque tubes without extensive earthmoving
2Manufacturing precision
If custom pier lengths are used to address terrain variations, then the torque tube level can remain consistent, but this increases financial costs and logistical complexity
Solution Approach 1:
The patent employs universal, off-the-shelf piers with standard lengths rather than custom-made piers. The articulation joint provides the necessary adaptability to accommodate terrain variations, making the pier component itself universal and interchangeable. This reduces manufacturing complexity and logistical burden while maintaining precise torque tube alignment through the joint's rotational capability
3Ease of manufacture
If identical pier lengths are used to simplify logistics, then installation costs are reduced, but the torque tubes cannot maintain parallel orientation on uneven terrain
Solution Approach 1:
The articulation joint introduces dynamic adaptability to the system, allowing torque tubes to rotate and follow terrain undulations even when piers have identical lengths. This dynamic adjustment capability compensates for the simplicity of using standard piers, maintaining terrain-following functionality without requiring custom manufacturing
Solution Approach 2:
The articulation joint adds a rotational degree of freedom in the vertical plane, enabling the torque tube to change its angle relative to the pier. This dimensional change allows the system to accommodate terrain variations vertically while maintaining horizontal parallelism, thus achieving terrain adaptability with identical pier lengths
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the need for custom pier lengths and excavation, lowering installation costs and environmental impact while maintaining parallel orientation of torque tubes to the ground, allowing for efficient installation on uneven terrain.
Implementation Method 1
an articulation joint interposed between each of the support flange and the swivel flange and rotatably supported by each of the support flange and the swivel flange
Data Source
AI summary
A coupling system for use with a solar tracker includes a support flange, a swivel flange rotatably supported on the support flange, an articulation joint interposed between each of the support flange and the swivel flange and rotatably supported by each of the support flange and the swivel flange, wherein opposed first and second end portions of the articulation joint are configured to be operably coupled to a respective first and second torque tube, and at least one locking fastener selectively coupled to a portion of the support flange and a portion of the swivel flange, the at least one locking fastener configured to selectively inhibit rotation of the swivel flange relative to the support flange.