Systems, methods and machines for aligning and assembling single-axis tracker foundations
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Solution Overview
Problem
The installation of truss foundations for single-axis trackers is complex due to the need for specialized machines to drive angled screw anchors and align interconnected legs, which increases costs and reduces material savings compared to monopile foundations.
Innovation Solution
Automated machine control systems and alignment jigs are used to align screw anchor driving machines and orient truss foundation components, ensuring the rotational axis of single-axis trackers is aligned with a predetermined point in space, simplifying the assembly process and maintaining material savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated machine control systems and alignment jigs are used to align screw anchor driving machines and orient truss foundation components, then manufacturing precision and alignment accuracy are improved, but device complexity increases
Solution Approach 1:
An alignment jig is introduced as an intermediary device between the screw anchor driving machine and the truss foundation components. The jig includes alignment features that physically guide and constrain the positioning of components, ensuring precise alignment without requiring complex automated control systems. This mediator translates the alignment requirements into simple mechanical constraints.
Solution Approach 2:
The patent replaces complex automated machine control systems with a mechanically-based alignment solution. Instead of using sensors, actuators, and control algorithms to achieve alignment, the invention uses mechanically-formed alignment features on the jig that passively enforce correct positioning through physical constraints, thereby reducing system complexity while maintaining precision.
2Manufacturing precision
If specialized machines are used to drive angled screw anchors and assemble interconnected legs, then manufacturing precision is improved, but ease of operation deteriorates
Solution Approach 1:
The alignment jig serves as a mechanical intermediary that simplifies the assembly operation. By incorporating alignment features directly into the jig, the system provides built-in guidance that reduces the skill level and complexity required for installation. The jig mechanically enforces correct positioning, making the assembly process more intuitive and easier to perform accurately.
Solution Approach 2:
The alignment features on the jig enable the assembly system to self-align components during installation. The mechanical constraints and guide features automatically position components correctly without requiring external measurement or adjustment, allowing the system to self-correct positioning errors and reducing the operational complexity for installers.
Data Source
AI summary
An automated control system for a screw anchor driving and truss assembly machine. A positioning subsystem determines an orientation of a machine mast's driving axis relative to an intended drive axis and controls the mast to be positioned so that the mast's driving axis is aligned with the intended drive axis of the screw anchor foundation component. After a pair of adjacent screw anchors are driven, the controller causes motion controllers to orient the mast so that an alignment jig for supporting truss apex hardware is held in place relative to the driven screw anchors at a predetermined point in space above them so that upper leg sections can be sleeved over connecting portions of the apex hardware and down on to the driven screw anchors.