Torque Arm Assembly With Drive Shaft Enclosure for High-Wind Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solar collector installations face challenges in securely attaching torque arms to drive shafts, particularly in longer rows of solar collectors, where increased forces due to high winds can lead to joint failures in conventional bolted joint designs, and extensive welding required for stronger connections is costly and time-consuming.
Innovation Solution
A torque arm assembly with a U-bracket and drive shaft enclosure that provides a contiguous abutment structure through welding, shims, or adhesive to securely connect the torque arm to the drive shaft, allowing for a stronger and more reliable attachment without requiring extensive field welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bolted joint designs are used to attach torque arms to drive shafts, then ease of assembly is improved, but connection strength deteriorates under high wind loads
Solution Approach 1:
The attachment system is divided into two distinct components: a U-bracket that encloses the drive shaft and provides the primary structural connection, and a separate mounting plate with bolted joints that attaches the torque arm to the U-bracket. This segmentation allows each component to be optimized independently - the U-bracket for strength and the mounting plate for ease of assembly.
Solution Approach 2:
The U-bracket is pre-assembled around the drive shaft with welds or other permanent connections established before the torque arm mounting plate is attached. This preliminary action creates a strong, rigid base structure that can then support the bolted joint connection, combining the strengths of both connection methods.
2Strength
If extensive welding is performed to strengthen connections, then connection strength is improved, but installation cost and time increase
Solution Approach 1:
The connection system is segmented into a permanently welded U-bracket portion and a separately attachable mounting plate portion. This allows the critical structural connection to the drive shaft to be permanently bonded, while the torque arm attachment uses simpler, faster bolted joints that require no welding in the field.
Solution Approach 2:
The U-bracket acts as an intermediary component between the drive shaft and the torque arm mounting plate. It provides a stable, pre-prepared mounting surface that eliminates the need for field welding of the torque arm directly to the drive shaft, reducing installation complexity and time.
3Reliability
If torque arms are securely attached to prevent joint failure, then reliability is improved, but device complexity increases
Solution Approach 1:
The U-bracket serves multiple functions simultaneously: it encloses and secures the drive shaft, provides a mounting surface for the torque arm, and acts as a structural reinforcement. This multi-functionality reduces the need for additional separate components, maintaining simplicity while improving reliability.
Solution Approach 2:
The attachment system combines different connection methods (welding or permanent bonding for the U-bracket to the drive shaft, and bolted joints for the mounting plate to the U-bracket) to create a composite connection system that leverages the strengths of each method while maintaining overall structural simplicity.
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
The solution enhances the connection between the torque arm and drive shaft, preventing movement and failure under high loading conditions, such as in high winds, while allowing for efficient initial assembly with fasteners and optional later reinforcement, reducing installation costs and time.
Implementation Method 1
weld lines placeable along portions of the drive shaft enclosure and the drive shaft
Implementation Method 2
an adhesive located between the drive shaft enclosure and the drive shaft
Implementation Method 3
shims located between the drive shaft enclosure and the drive shaft
Data Source
AI summary
A torque arm assembly, used with a solar collector mounted to a drive shaft, comprises a torque arm with first and second ends and a torque arm coupling assembly including a drive shaft enclosure defining an open-ended channel sized to house the drive shaft. The channel has a circumferentially extending substantially continuous drive surface between the ends that lies adjacent to the drive shaft so the drive shaft and the drive shaft enclosure rotate together. In some examples, contiguous abutment structure, such as weld lines, shims and/or adhesive, connects each side of the drive shaft to the drive shaft enclosure. The invention may also be carried out as a connection improvement method.