Solar tracker support frame hard stops and braces
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Solution Overview
Problem
Solar tracker systems face challenges in maintaining structural integrity and stability under dynamic loads, such as wind, while requiring cost-effective installation solutions that minimize the number of components and fastening members.
Innovation Solution
Incorporation of hard stop members and brace members into solar tracker support frames, which include interference surfaces to impede torque tube movement and extend between frame legs, enhancing structural stability without increasing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If hard stop members and brace members are added to solar tracker support frames to increase structural stability, then the structural integrity and stability under dynamic loads improve, but the number of components and fastening members increases
Solution Approach 1:
The hard stop member and brace member are combined into a single integrated component that performs both functions simultaneously. The hard stop portion provides rotational limitation through interference surfaces, while the brace portion provides structural support between frame legs, eliminating the need for separate hard stop and brace components.
Solution Approach 2:
The integrated hard stop and brace member serves multiple functions: it acts as a hard stop to limit torque tube rotation, provides bracing support between frame legs for structural stability, and reduces the overall component count. This multi-functional design directly addresses the contradiction by improving structural stability while reducing device complexity.
2Reliability
If more fastening members are used to secure hard stop and brace members to the support frame, then the reliability of the connection improves, but the installation cost and complexity increase
Solution Approach 1:
By merging the hard stop and brace into a single component, the number of connections and fastening members required is reduced. Instead of securing two separate components, only one integrated component needs to be installed, maintaining connection reliability while reducing installation complexity and cost.
Solution Approach 2:
The integrated hard stop and brace member is designed with distinct functional segments (hard stop portion and brace portion) that are formed as one piece. This segmentation within unity allows each function to be optimized while minimizing the total number of fastening operations required during installation.
3Manufacturing precision
If the torque tube is positioned at a higher elevation to improve solar tracking performance, then the solar module orientation accuracy improves, but the dynamic loads on the foundation increase
Solution Approach 1:
The hard stop member is positioned to preemptively limit the torque tube's rotational movement before excessive dynamic loads can develop. By providing mechanical interference surfaces that prevent over-rotation, the hard stop counteracts the increased leverage effects of higher torque tube positioning, protecting the foundation from excessive dynamic loads while maintaining orientation accuracy.
Solution Approach 2:
The system allows controlled dynamic movement of the torque tube within limits set by the hard stop member. The torque tube can rotate freely within the designed range for solar tracking, but the hard stop provides dynamic limitation when approaching extreme positions, preventing excessive forces from transferring to the foundation while maintaining tracking performance.
Data Source
AI summary
A solar tracker support frame assembly includes a multi-leg solar tracker support frame, a hanging bearing housing assembly, a hard stop member, and a brace member. The hanging bearing housing assembly is at the multi-leg solar tracker support frame and is configured to support a torque tube below a bridge of the frame. The hard stop member interfaces with at least one of a first leg, a second leg, and the bridge of the frame. The hard stop member includes an interference surface configured to contact the torque tube and thereby impede further movement of the torque tube beyond the interference surface. The brace member extends between the first and second legs of the frame below the bridge and below the hard stop member.