Axially adjustable connectors for truss legs and related systems and methods
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Solution Overview
Problem
The complexity of constructing multi-component truss foundations for single-axis trackers increases costs and installation time due to additional process steps required for joining leg components and tracker hardware, which hinders the full savings potential of truss foundations compared to plumb monopiles.
Innovation Solution
The development of a novel truss-based foundation system with improved coupling mechanisms, such as driving couplers and retaining nuts, that allow for efficient angular and axial adjustments between truss legs and tracker components, enabling simpler and faster installation while maintaining structural integrity under tensile and compressive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-component truss foundations are constructed to translate lateral wind loads into axial forces, then steel usage and foundation depth are reduced, but construction complexity and installation time increase due to additional joining process steps
Solution Approach 1:
The patent combines the leg-to-leg joining function and the leg-to-apex hardware joining function into a single universal connector. This universal connector integrates multiple joining capabilities, allowing the same component to perform both functions, thereby reducing the number of different part types and simplifying the overall assembly process while maintaining the structural integrity needed to translate lateral loads into axial forces
2Weight of stationary object
If multi-component truss foundations are constructed to save steel relative to plumb monopiles, then lighter weight components and shallower embedding depths are achieved, but installation time increases due to additional joining process steps
Solution Approach 1:
The universal connector is designed to perform multiple functions: joining leg components to each other and joining legs to apex hardware. This multi-functionality reduces the number of different connector types needed, simplifies inventory management, and speeds up installation by allowing workers to use the same connector design for different joining tasks, thereby reducing installation time while maintaining the lightweight foundation structure
3Productivity
If simpler joining processes are used to reduce installation time, then cost savings are achieved, but the ability to maintain structural integrity under lateral loads may be compromised
Solution Approach 1:
The universal connector incorporates spherical bearing surfaces that allow for angular adjustment and self-alignment during assembly. This curved geometry enables simpler, faster installation procedures while maintaining structural integrity, as the spherical interface provides robust load-bearing capability and accommodates minor misalignments without compromising the connection strength under lateral loads
Data Source
AI summary
Systems and methods for quickly and securely interconnecting foundation components when axially misaligned without hydraulic tools. Upper to lower leg connections are made with threaded connections or with ball and socket connections that permit angular adjustment. One or more retaining nuts bias the connection to lock it in place at the desired orientation. Foundation component to single-axis tracker connections are facilitated by various wedge and clamp connector assemblies that rely on mechanical engagement to lock components in place and resist axial forces. Other connections are made with hemispherical washers and adapter plates that enable rigid connections through a range of angles.