Braced truss foundations for single-axis trackers and related systems and methods
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Solution Overview
Problem
Truss foundations for single-axis trackers are weak in resisting forces along the torque tube axis, leading to potential bending and increased costs when reinforcing the foundation to handle these forces, which can result in excessive loads on the motor foundation and require additional installation expenses.
Innovation Solution
The introduction of a three-legged truss foundation configuration with a third leg oriented towards the torque tube, combined with set screw collars that surround the torque tube to distribute and resist axial loads, preventing the torque tube from slipping and translating these forces into tension or compression, thus reducing the burden on the motor foundation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional two-legged truss foundations are used, then installation is simple and cost-effective for lateral loads, but the foundation becomes weak in resisting axial forces along the torque tube direction
Solution Approach 1:
The foundation structure is segmented into multiple independent truss units (two-legged and three-legged trusses) that can be selectively deployed along the tracker row. Each truss type handles specific load directions, allowing the system to distribute axial force resistance across multiple segments rather than requiring every foundation to be heavily reinforced.
Solution Approach 2:
Different truss configurations are applied locally based on specific needs: two-legged trusses are used where lateral load resistance is sufficient, while three-legged trusses with the third leg oriented toward the torque tube are deployed specifically where axial force resistance is required. This localized application of enhanced structure avoids unnecessary complexity elsewhere.
2Strength
If the motor foundation is reinforced to resist axial forces, then axial load resistance improves, but additional expense and excessive loads on the motor foundation result
Solution Approach 1:
The axial force resistance function is segmented from the motor foundation and distributed to multiple three-legged truss foundations positioned along the tracker row. Each three-legged truss independently contributes to resisting axial forces, collectively sharing the load that would otherwise concentrate on the motor foundation.
Solution Approach 2:
The third leg of the three-legged truss acts as an intermediary structural element that transfers axial forces from the torque tube to the ground through a different load path. This intermediary structure prevents direct transmission of axial loads to the motor foundation, reducing its burden.
3Strength
If double truss or heavier apex components are used to resist axial forces, then axial load capacity increases, but installation complexity and cost increase significantly
Solution Approach 1:
The foundation system is segmented into standardized two-legged and three-legged truss modules that can be manufactured and installed using consistent processes. Each module is a self-contained unit with clear assembly instructions, avoiding the need for complex custom fabrication that would result from using double trusses or heavily modified apex components.
Solution Approach 2:
Instead of making all foundations heavier and more complex (double truss approach), the invention inverts the strategy by using simpler two-legged trusses for most locations and adding the third leg only where specifically needed. This inverted selective approach reduces overall material usage and simplifies installation compared to universally reinforcing all foundations.
Data Source
AI summary
A truss foundation for single-axis trackers that distribute forces into the foundation through the torque tube. A truss adapter joins a pair of adjacent truss legs driven at angles to one another on either side of a tracker row so that the legs are perpendicular to the tracker torque tube. A third leg aligned with the torque tube is connected to the adapter to help resist axial forces in the torque tube. One or more collars placed on either side of a torque tube bearing include set screws to prevent axial slippage of the torque tube.