Threaded Pile Extension for Deep Solar Support Installation
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Solution Overview
Problem
Existing solar array support structures face challenges in installing vertical piles in hard soil or rock conditions, where the ground conditions make it difficult to drive the columns deep enough, and existing solutions often require above-ground extensions to achieve the necessary depth.
Innovation Solution
A vertical pile system with a conical portion and helical structures, featuring an internally threaded end that receives an externally threaded pile extension, allowing for deeper installations by combining the pile and extension as a single, longer column, enabling the use of machinery to drive the pile further into the ground.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If vertical piles are driven into hard soil or rock using existing machinery, then the piles can be installed at precise locations, but the machinery cannot drive the piles deep enough due to ground conditions and installation height limitations
Solution Approach 1:
The vertical pile system is divided into two segments: a driven pile portion that can be installed by existing machinery, and an extension portion that extends the total depth. The driven pile includes a pile body with a conical tip and helical structures, while the extension portion is attached via a threaded connection at the top of the driven pile, allowing the system to achieve greater installation depth than the machinery alone could provide.
2Length of moving object
If above-ground vertical extensions are added to extend pile depth, then the required installation depth is achieved, but the structural integrity and stability are compromised
Solution Approach 1:
The extension portion is merged with the driven pile through an internally threaded connection at the top of the driven pile. This threaded interface creates a unified, integrated structure where the extension and driven portion work together as a single load-bearing element, maintaining structural integrity and stability while achieving the required installation depth.
3Length of moving object
If the pile is made longer to extend beyond machinery installation height, then deeper installation is enabled, but the complexity of the pile structure increases
Solution Approach 1:
The pile is segmented into a driven portion and an extension portion connected by a threaded interface. This segmentation allows the driven pile to maintain its simple, efficient geometry (cylindrical body with conical tip and helical structures) while the extension portion provides the additional length needed to exceed machinery installation height limits, achieving greater depth without significantly increasing overall structural complexity.
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
Enables deeper and more efficient installation of solar array support structures by allowing the pile to extend beyond the typical installation height of the machinery, providing a stable and secure connection through the threaded interface, thus overcoming soil and rock installation challenges.
Implementation Method 1
a first helical structure extending around at least one of a portion of the main body and a portion of the conical portion
Implementation Method 2
the first end is internally threaded and has received the externally threaded pile extension
Data Source
AI summary
A solar array support structure includes a mounting structure extending a length and configured to receive a solar array, an externally threaded pile extension extending from the mounting structure toward a ground; and a vertical pile extending into the ground, the vertical pile including: a pile body extending between a first end and a second end and including a main body extending from the first end, the pile body further including a conical portion extending from the main body to the second end, and a first helical structure extending around at least one of a portion of the main body and a portion of the conical portion. The first end of the vertical pile is internally threaded and has received the externally threaded pile extension. A vertical pile for a solar array support structure and method of manufacturing the same is further disclosed.