Torque tube coupler
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Solution Overview
Problem
Existing torque tube couplers for solar tracking systems often extend beyond the torque tubes, causing blockages and constraints in mounting and adjusting solar arrays, as they are designed with large external hardware that interferes with photovoltaic module installation and alignment.
Innovation Solution
A torque tube coupler design featuring a central ring with radially extending fingers that fit within the torque tube, an angled core mechanism to increase frictional force, and set screws to secure the coupler within the tube, allowing for a low-profile connection that minimizes external hardware exposure and maximizes installation flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional coupling devices are used to join torque tube segments, then the torque tubes can be connected, but the coupling devices extend beyond the torque tube outer surface causing blockages and constraints
Solution Approach 1:
The coupling device is nested entirely within the torque tube segments, with the outer body fitting inside the torque tube and the set screws inserting through the tube wall to secure the connection. This nesting approach eliminates external protrusions while maintaining coupling strength.
2Reliability
If coupling hardware extends beyond torque tubes, then secure connection is achieved, but PV modules and mounting hardware cannot slide past during installation
Solution Approach 1:
The harmful external protrusions are extracted from the design by relocating all coupling components inside the torque tube. The set screws are the only external element, and they are designed to be recessed or minimally protruding, eliminating blockages for PV module installation while maintaining connection reliability through internal friction and mechanical engagement.
3Force
If large external hardware is used for coupling, then torque transmission is sufficient, but the profile of the torque tube is increased
Solution Approach 1:
The coupling device is nested entirely within the torque tube segments, with the outer body fitting inside the torque tube and the set screws inserting through the tube wall to secure the connection. This nesting approach eliminates external protrusions while maintaining coupling strength.
4Strength
If conventional couplers are used, then torque tube segments can be joined, but constraints are placed on mounting locations and adjustment positions
Solution Approach 1:
The harmful external protrusions are extracted from the design by relocating all coupling components inside the torque tube. The set screws are the only external element, and they are designed to be recessed or minimally protruding, eliminating blockages for PV module installation while maintaining connection reliability through internal friction and mechanical engagement.
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 solution enables secure, low-profile coupling of torque tube segments, reducing installation complexities and constraints, while ensuring stable and efficient tracking of solar arrays without obstructing the mounting of photovoltaic modules.
Implementation Method 1
tightening one or more of the set screws may force the first abutting surface away from the second abutting surface to press the outer body against an inner surface of a torque tube
Implementation Method 2
an angled core mechanism to increase frictional force
Data Source
AI summary
A torque tube coupler may include an outer body that includes a first abutting surface and a second abutting surface adjacent to the first abutting surface. Set screws may be inserted into one or more channels of the first abutting surface. Tightening the set screws may force the abutting surfaces away from each other and the outer body to press against an inner surface of a torque tube. Another embodiment of the torque tube coupler may include a central ring sized based on a size of a torque tube. The torque tube coupler may also include a set of fingers that extend away from a first side of the central ring and are shaped to flex radially outward. The torque tube coupler may include a core disposed within the set of fingers that, when drawn towards the central ring, causes the fingers to flex radially outwards.