Closed-Loop Screw Anchor Driving for Precise Depth Control
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Solution Overview
Problem
The installation of screw anchors for solar array foundations is inefficient and lacks consistency in various driving conditions, requiring simplified and accurate positioning for large-scale solar projects.
Innovation Solution
A closed-loop feedback control system using a programmable logic controller (PLC) with sensors and a control program to automate screw anchor driving operations, ensuring precise depth control and adaptability to different conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual screw anchor driving operations are used, then installation simplicity is maintained, but installation efficiency and positioning accuracy deteriorate
Solution Approach 1:
The patent implements a closed-loop feedback control system using sensors to monitor driving depth, rotation speed, and torque, with this information fed back to the PLC to automatically adjust driving parameters. This ensures consistent positioning accuracy while maintaining installation efficiency through automated real-time adjustments.
Solution Approach 2:
The control system automatically adjusts driving parameters based on sensor feedback without requiring manual intervention. The PLC autonomously modifies rotation speed, downforce, and hammering intensity based on real-time conditions, enabling the system to self-optimize performance throughout the installation process.
2Manufacturing precision
If automated control systems are implemented, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The system uses depth sensors, rotation sensors, and torque sensors to continuously monitor positioning parameters, feeding this data back to the PLC which automatically adjusts driving parameters to achieve target depth and orientation accuracy within specified tolerances.
Solution Approach 2:
The patent replaces manual mechanical control with an automated electromechanical control system. The PLC electronically controls motorized components including rotation motors, hydraulic downforce systems, and hammering mechanisms, substituting human-operated mechanical systems with automated electronic control for improved precision.
3Adaptability or versatility
If closed-loop feedback control is used, then adaptability to various driving conditions is improved, but device complexity increases
Solution Approach 1:
The control system dynamically adjusts driving parameters based on real-time sensor feedback. Rotation speed, downforce magnitude, and hammering frequency are continuously modified according to actual soil conditions, anchor resistance, and depth-dependent forces, enabling adaptation to varying ground conditions throughout the driving process.
Solution Approach 2:
The PLC automatically changes operational parameters including rotation speed, axial downforce, and hammering intensity based on sensor feedback. The system modifies these parameters in response to detected changes in soil resistance, anchor orientation, and depth, allowing seamless adaptation to different driving conditions without manual intervention.
Data Source
AI summary
A closed-loop feedback-control system for a screw anchor driving machine that uses a controller such as a programmable logic controller (PLC) and an array of sensors providing real-time data to control an automated screw anchor driving operation relying on a rotary driver, a crowd motor applying downforce to the rotary driver and a tool driver extending a tool through the rotary driver and screw anchor to drive screw anchors to a target depth. The tool driver is independently controllable to advance the tool at a different feed and speed than the rotary driver to respond to underground conditions encountered during driving.