Systems, methods, and machines for joining truss foundation components
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Solution Overview
Problem
Monopile foundations for single-axis solar trackers are inefficient due to their wasteful use of steel and labor, as they resist lateral loads through bending moments, requiring over-specification and deeper embedment depths.
Innovation Solution
A truss foundation system using A-frame-shaped trusses that translate lateral loads into axial forces, reducing steel usage and embedment depths by aligning screw anchors to optimize load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If monopile foundations are used to resist lateral loads, then the foundation can support the tracker system, but heavier beams and greater embedment depths are required due to bending moments
Solution Approach 1:
The monopile foundation is segmented into multiple components: screw anchors driven into the ground, upper legs connected to the anchors, and adapters connecting the upper legs. This segmentation allows each component to be optimized for its specific function, with the screw anchors providing lateral resistance through axial forces rather than bending moments
Solution Approach 2:
The foundation system transitions from a vertical monopile structure to a three-dimensional truss configuration with angled upper legs and interconnected adapters. This dimensional change enables the structure to resist lateral loads through axial forces in multiple members rather than bending in a single vertical member
2Strength
If monopile foundations are used, then the tracker system can be supported, but steel usage and labor costs increase due to over-specification
Solution Approach 1:
The invention changes the fundamental parameter of load resistance from bending moments to axial forces. By configuring the foundation as a truss system where members primarily experience tension and compression rather than bending, the steel can be used more efficiently, reducing the total quantity required while maintaining or improving lateral load resistance
3Strength
If truss foundation components are driven into the ground, then lateral loads can be efficiently resisted, but misalignment of components from intended axes may occur
Solution Approach 1:
Alignment jigs are used during the assembly process to pre-establish the correct geometric relationships between screw anchors, upper legs, and adapters before final connection. This preliminary alignment action ensures that components are properly positioned relative to each other, compensating for potential misalignment that could occur during driving or assembly operations
4Quantity of substance
If multi-piece truss construction is used, then steel efficiency is improved, but alignment precision and connection complexity increase
Solution Approach 1:
The adapter component serves multiple functions: it connects the upper legs to each other, provides alignment tolerance through its geometry, and interfaces with the screw anchors. This multi-functionality reduces the need for separate alignment components and simplifies the overall connection process despite the multi-piece construction
Data Source
Figure 1~2A
Figure 2B
Figure 2C
AI summary
A coupler for joining truss leg components provides angular adjustability between the respective axis of the leg components. A prolate spheroid-shaped coupler with three channels circumscribing its surface enables the upper leg components to compensate for axial misalignment of driven screw anchors in all directions. A hydraulic crimping device with upper and lower crimping guides registers its position with features on the truss hardware to insure that blind triple crimps are performed consistently each time.