Hexagonal Collar Device for Solar Racking Installation
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Solution Overview
Problem
Existing solar panel racking systems face complexity and time inefficiencies in installation due to multiple steps and on-site assembly of pile foundations, which can lead to misalignment and damage during installation and removal.
Innovation Solution
A collar device and ground screw assembly system that allows for easy transportation and on-site installation, featuring a collar device with a hexagonal aperture and fastener assembly for secure attachment to a ground screw device, enabling rapid and secure installation of a racking system without welding, and facilitating easy removal without damaging the foundation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional on-site installation methods are used with multiple separate components and welding, then the pile foundation can be securely attached to the ground, but the installation complexity and time increase significantly
Solution Approach 1:
The collar device integrates multiple functions into a single component: it combines the mounting bracket, fastening mechanism, and alignment features into one pre-assembled unit that attaches to the ground screw in a single operation, eliminating the need for separate welding steps and multiple fasteners
Solution Approach 2:
The collar device is pre-assembled with integrated fastening components and alignment features before delivery to the installation site, allowing for rapid attachment to the ground screw without requiring complex on-site assembly or welding operations
2Strength
If welding is used to secure the pile foundation to the solar panel installation, then strong attachment is achieved, but the risk of misalignment and damage increases
Solution Approach 1:
The invention replaces the welding process with a mechanical fastening system using the collar device that incorporates integrated fasteners and locking mechanisms, achieving strong attachment without the heat-affected zone and distortion risks associated with welding
Solution Approach 2:
The collar device serves as an intermediary component between the ground screw and the racking system, providing a precision-machined interface that ensures accurate alignment while distributing attachment forces through multiple contact points
3Productivity
If forceful removal methods are used to extract the pile foundation from the solar panel installation, then the foundation can be removed, but damage to the pile foundation occurs
Solution Approach 1:
The fastening system incorporates reversible mechanical connections that can be easily disengaged through controlled rotational motion, allowing the collar device to be detached from the ground screw without applying damaging forces to the pile foundation
Data Source
AI summary
The present disclosure relates to a collar device for a multi-part ground screw assembly. A ground screw device and an installed racking system are also both provided. A method of installing the racking system is provided as well. The collar device includes an annular main body with at least one aperture having a hexagonal shape. The collar device further includes at least one fastener assembly, comprising a fastener with a head and a threaded post, a locking washer, and a hexnut washer. The collar device is coupled to the ground screw device and the racking device. Advantageously, the collar device is easy to transport for on-site installation of a solar racking system and provides an efficient system capable of easily removing the collar device from the solar racking system as well.