Nested Torque Tube Flanges for Denser PV Tracker Shipping
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Solution Overview
Problem
Existing pre-fabricated torque tubes for sun tracking photovoltaic solar power systems have low shipping density due to excessive packaging material, which increases costs and logistical challenges during transportation.
Innovation Solution
The torque tubes feature a cylindrical body with radially extending lobes and concave portions on coupling flanges and saddle mounts, allowing for nesting during shipping, thereby reducing the need for additional packing materials and enhancing shipping density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If traditional torque tubes are used with standard coupling flanges, then structural integrity is maintained, but shipping density is low due to excessive packaging material
Solution Approach 1:
The coupling flange incorporates nested lobes and concave portions that allow torque tubes to nest within each other during shipping, similar to nested dolls. This nesting arrangement enables multiple torque tubes to be stacked compactly without requiring excessive packaging material, directly improving shipping density while reducing packaging waste.
Solution Approach 2:
The coupling flange features curved lobes with specific radii of curvature that complement the concave portions of adjacent torque tubes. These spherical/curved geometries enable smooth nesting and stacking, maximizing space utilization during transportation without compromising the structural integrity of the torque tubes.
2Reliability
If coupling flanges are designed for structural strength, then reliability is improved, but shipping efficiency deteriorates due to increased packaging requirements
Solution Approach 1:
The nested lobe and concave portion design allows torque tubes to interlock securely during shipping, maintaining structural integrity through the coupling flange geometry itself rather than relying on external packaging. This self-nesting mechanism ensures both reliability and shipping efficiency simultaneously.
Solution Approach 2:
The coupling flange integrates multiple functional elements (lobes, concave portions, mounting features) into a single composite structure that serves both structural and shipping purposes. This composite design eliminates the need for separate packaging materials while maintaining the required structural strength for reliable torque tube connection.
3Ease of manufacture
If torque tubes are designed with standard coupling flanges, then ease of manufacture is maintained, but transportation costs increase due to low shipping density
Solution Approach 1:
The coupling flange is segmented into distinct lobes and concave portions that can be manufactured using standard machining processes. Each lobe and concave portion is a discrete geometric feature that can be produced independently, maintaining manufacturing simplicity while enabling the nesting configuration for improved shipping density.
Solution Approach 2:
The curved lobes with defined radii of curvature can be manufactured using conventional CNC machining or forming processes. These spherical/curved geometries, while optimizing shipping density, remain compatible with standard manufacturing techniques, avoiding excessive complexity in the manufacturing process.
Data Source
AI summary
A sun tracking solar energy collection system can include torque tubes that can be configured to allow the cylindrical body of one torque tube to nest with projections extending from an adjacent torque tube. The torque tubes can be formed with a plurality of rotatable shafts connected to each other in an end to end fashion. The torque tubes may be connected with coupling flanges, shaped with a plurality of radially extending lobes. The coupling flanges can include a plurality of concave portions disposed between adjacent lobes. The rotatable shafts can be round and the concave portions can be curved with a radius of curvature that is about the same as a radius of curvature of outer surface of the rotatable shafts. The torque tubes can also have saddle mounts which can include a concave portion configured to nest with an adjacent torque tube.