Solar Array Piling Alignment via Laser and Guide Template
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Solution Overview
Problem
The installation of solar panel arrays is inefficient and inaccurate due to the need for precise positioning of numerous pilings, which requires extensive surveying and manual alignment, leading to high costs and potential safety hazards from manual labor and weather-related disruptions.
Innovation Solution
A system utilizing a true site laser, guide template, pile driver with hammer target, aligning bracket, and handheld target for precise alignment and adjustment of pilings, allowing for corner pilings to be surveyed and the rest installed with high accuracy and speed, reducing the need for extensive surveying and manual alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If extensive surveying and manual alignment are used for piling installation, then positioning accuracy is improved, but installation time and cost increase
Solution Approach 1:
The patent replaces traditional mechanical surveying instruments and manual alignment methods with a laser-based automated positioning system. The system uses a laser transmitter, receiver, and control unit to automatically determine piling positions and guide installation, eliminating the need for extensive manual surveying while maintaining high positioning accuracy.
Solution Approach 2:
The system enables self-service positioning by providing real-time feedback to operators through visual displays and audible signals. The automated control unit continuously monitors laser measurements and guides piling installation without requiring external surveying crews, allowing the installation team to self-correct positions based on system feedback.
2Measurement precision
If extensive surveying and manual alignment are used for piling installation, then positioning accuracy is improved, but installation cost increases
Solution Approach 1:
The laser-based positioning system serves multiple functions: it acts as a surveying instrument, alignment guide, position verification tool, and installation guide simultaneously. This multi-functional device replaces multiple separate tools and procedures (total station, transit, manual measurements), simplifying the overall installation process while maintaining accuracy.
Solution Approach 2:
The system introduces a control unit as an intermediary between the laser measurements and the installation process. This intermediary automatically processes measurements, calculates positions, and provides guidance signals, eliminating the need for complex manual calculations and coordination between surveyors and installers.
3Ease of operation
If manual labor is used for piling installation, then flexibility is maintained, but safety hazards increase
Solution Approach 1:
The system replaces manual surveying and alignment operations with automated laser-based measurement and control. This substitution eliminates safety hazards associated with manual labor in difficult terrain and weather conditions while maintaining operational flexibility through electronic control and real-time adjustment capabilities.
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
This method enables the accurate and efficient installation of solar panel array pilings with side-to-side alignment accuracy of ¼ inch and height accuracy within ¼ inch, significantly reducing installation time and costs by eliminating the need for extensive surveying and manual alignment crews.
Implementation Method 1
a laser assembly including a housing, a rotating vertical laser mounted in the housing and a horizontal laser mounted in the housing
Data Source
AI summary
A system for installing an array of pilings for an array of solar panels is highly accurate and efficient. The system includes a horizontal laser and a rotating vertical laser that are mounted on a first piling and aligned with a target on a second piling on the opposite side of the array. An alignment template is placed against a piling and aligned with the vertical rotating laser. The aligned template provides a designated location where the next piling is driven. A hammer target on the pile driver allows the installer to precisely install the next piling. After installation, the next piling is measured for accuracy and if errors are found, an alignment bracket is used to correct the error. The process is repeated until the array of pilings is complete.