Ground Screw Adaptor for Adjustable Solar Beam Anchoring
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Solution Overview
Problem
Solar panel support assemblies experience significant mechanical stress due to weight, terrain, wind-loading, and thermal expansion, requiring innovative anchoring solutions to securely attach upright beams to anchored ground screws while accommodating various forces and adjustments.
Innovation Solution
The development of novel ground screw adaptors with cylindrical or hollow connectors, intermediate plates, and upright beam connectors, featuring multiple bolt holes for secure attachment and torque-based friction, allowing for telescoping and rotational adjustments to withstand uplift, downward, and moment forces, along with a method for mounting upright beams to anchored ground screws using these adaptors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional ground screw anchoring is used, then installation is simple, but the connection cannot withstand significant mechanical stresses from wind-loading, thermal expansion, and terrain variations
Solution Approach 1:
The anchoring system is divided into distinct functional segments: the ground screw anchor embedded in the ground, the adaptor connecting to the anchor, and the upright beam connector. This segmentation allows each component to be optimized for its specific function while collectively providing high strength to withstand mechanical stresses from wind-loading, thermal expansion, and terrain variations.
Solution Approach 2:
The connection transitions from a simple single-point anchoring to a multi-dimensional rigid connection. The adaptor incorporates multiple bolt holes arranged in different orientations and planes, creating a three-dimensional connection geometry that resists forces from multiple directions including uplift, lateral wind loads, and moment forces.
2Stability of the object's composition
If rigid fixed connections are used, then structural stability is improved, but installation and alignment become difficult especially for out-of-plumb installations
Solution Approach 1:
The adaptor incorporates adjustable elements that allow dynamic adaptation during installation. The connection geometry and bolt hole arrangement enable the system to accommodate variations in installation alignment while maintaining structural stability once installed, resolving the conflict between rigid stability and installation flexibility.
3Reliability
If multiple bolt holes are added to resist moment forces, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The adaptor design integrates multiple functions into a single component: it provides anchoring connection, resists moment forces through strategically placed bolt holes, allows for alignment adjustment, and accommodates various installation conditions. This multi-functionality achieves high connection reliability without proportionally increasing device complexity.
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
The adaptors provide a secure, adjustable, and durable connection that resists mechanical stresses, allowing for easy installation and alignment of solar panel support structures, reducing the need for additional bracing and accommodating out-of-plumb installations, while withstanding significant wind and snow loads.
Implementation Method 1
tightening set screws in the two sets of bolt holes such that the set screws provide frictional force against the outer surface of the anchor
Data Source
AI summary
An adaptor for connecting a ground screw to an upright beam of a solar panel support assembly includes (a) a cylindrical connector having an open ground-screw receiving bottom end and a top end, the cylindrical connector having an inner circumferential surface with a diameter slightly larger than that of the ground screw and at least two sets of bolt holes, each set of bolt holes including at least three bolt holes uniformly distributed circumferentially about the cylindrical connector at an axial level, and the at least two sets of bolt holes being axially distanced from one another; (b) an intermediate plate having a top surface and a bottom surface fixed to the top end of the cylindrical connector; and (c) an upright beam connector fixed to the top surface of the intermediate plate and extending upward from the intermediate plate.