Multi-Piece Truss Leg Coupler for Solar Tracker A-Frame Alignment
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Solution Overview
Problem
Single-axis solar trackers built on monopile foundations require oversized structural members to withstand bending moments, leading to inefficiency and waste, while A-frame foundations face challenges in misalignment that can induce strain and installation issues.
Innovation Solution
The EARTH TRUSS foundation system uses A-frame truss legs that translate lateral loads into axial forces, with adjustable couplers to correct misalignment between screw anchors and upper legs, allowing for smaller steel usage and improved alignment with the tracker's axis of rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If monopile foundations are used to support single-axis solar trackers, then the foundation can withstand bending moments from wind loads, but oversized structural members are required leading to steel waste and inefficiency
Solution Approach 1:
The foundation is divided into multiple segments: screw anchors driven into the ground, truss legs connecting the anchors, and a torque tube supporting the tracker. This segmentation allows each component to be optimized for its specific function, with truss legs using smaller steel sections because they work in tension/compression rather than bending.
Solution Approach 2:
Instead of using a single vertical monopile that resists bending, the invention inverts the approach by using an A-frame truss configuration where lateral wind loads are converted into axial tension and compression forces in the truss members. This inversion of the load path eliminates the need for oversized bending-resistant members.
2Loss of substance
If A-frame foundations are used to reduce steel consumption, then smaller foundation components can be used, but misalignment between screw anchors and upper legs can occur inducing strain and installation issues
Solution Approach 1:
The coupler is designed with articulating capabilities that allow it to dynamically adjust and accommodate misalignment between the screw anchor and upper leg. This dynamic adjustment mechanism enables the structure to self-correct for installation tolerances while maintaining structural integrity.
Solution Approach 2:
The coupler acts as an intermediary component between the screw anchor and upper leg, providing a flexible connection that can absorb misalignment. This mediator element prevents the transmission of strain to the structural members while still maintaining the load path.
3Force
If two separate screw anchors are driven into the ground at non-plumb angles to form an A-frame, then lateral loads can be converted to axial forces, but the respective axes may not intersect at the desired height causing misalignment
Solution Approach 1:
The coupler provides adjustment parameters including angular adjustment capability that allows installers to compensate for variations in screw anchor alignment. By changing the operational parameters of the connection (angular position, position along the member), the system can accommodate installation tolerances while maintaining the force conversion function.
Data Source
AI summary
A two-piece truss leg system for an A-frame-shaped truss foundation system for single-axis trackers. A driving coupler at the head of each screw anchor used to drive the component into the ground as well as to join the upper leg component to the screw anchor. A connecting portion of the coupler extending above a main body of the coupler is received within an open end of an upper leg component. A curved outer surface of the connecting portion enables the upper leg component to be angularly adjusted relative to the screw anchor. A channel in the connecting portions enables the upper leg component to be deformed into the channel with a crimp connecting.