Abstract

Disclosed is a chuck for a rotary driver having a main body, a flange at a first end of the main body, a receiving portion at a second end and having repeating indentations dimensioned to receive a driving ring of a foundation component, and a pair of opposing pawls extending into the receiving portion at first ends that are displaced when a foundation component is loaded into the receiving portion. The pawls resist displacement with a first force when a foundation component is loaded and with a second force when a foundation component is removed. The chuck may also include a release mechanism having levers that move a second end of opposing pawls to release the foundation component when one of the levers of the pair is compressed towards the flange.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down

Abstract

Disclosed is a chuck (100) for a rotary driver having a main body (105), a flange (106) at a first end of the main body, a receiving portion at a second end and having repeating indentations dimensioned (107, 108) to receive a driving ring of a foundation component, and a pair of opposing pawls (122) extending into the receiving portion at first ends that are displaced when a foundation component is loaded into the receiving portion. The pawls resist displacement with a first force when a foundation component is loaded and with a second force when a foundation component is removed. The chuck may also include a release mechanism having levers (130) that move a second end of opposing pawls to release the foundation component when one of the levers of the pair is compressed towards the flange.

IPC Classes  ?

• B23B 31/12 - Chucks with simultaneously-acting jaws, whether or not also individually adjustable
• E02D 5/56 - Screw piles
• E02D 7/22 - Placing by screwing down
• B23B 31/103 - Retention by pivotal elements, e.g. catches, pawls

Abstract

A method of embedding a threaded foundation component in ground with a layer of reactive soil with a combined drilling and driving machine includes: with an automated controller executing a control program, controlling the machine to begin an automated embedment operation to drive a threaded foundation component into a reactive soil; with the automated controller, controlling the machine to decouple a feed rate of the component from a rotary speed rate of the component to cause sheering of the soil around the foundation component by threads of the foundation component; and with the automated controller, controlling the machine to recouple the feed rate of the component to rotary speed rate of the component to reduce sheering of the soil around the foundation component by the threads of the foundation component until a target embedment depth for the foundation component is reached.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 5/56 - Screw piles
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces

Abstract

A method of embedding a threaded foundation component in ground with a layer of reactive soil with a combined drilling and driving machine includes: with an automated controller executing a control program, controlling the machine to begin an automated embedment operation to drive a threaded foundation component into a reactive soil; with the automated controller, controlling the machine to decouple a feed rate of the component from a rotary speed rate of the component to cause sheering of the soil around the foundation component by threads of the foundation component; and with the automated controller, controlling the machine to recouple the feed rate of the component to rotary speed rate of the component to reduce sheering of the soil around the foundation component by the threads of the foundation component until a target embedment depth for the foundation component is reached.

IPC Classes  ?

• E02D 7/26 - Placing by using several means simultaneously
• E02D 5/80 - Ground anchors

Abstract

Disclosed is a foundation component having an elongated open shaft, an external thread form beginning at a first end and extending along the shaft, a driving coupler at a second end, opposite to the first end, and a cone received by the first end and extending from the first end. The cone is of a material having a lower elastic modulus than the elongated open shaft.

IPC Classes  ?

• E02D 5/56 - Screw piles
• E02D 5/72 - Pile shoes
• E02D 7/22 - Placing by screwing down

Abstract

A crimper for joining truss leg components to form a unitary truss foundation with the ground without needing mechanical fasteners. A crimping tool has upper and lower crimp guides that register the position of jaws on the crimping tool with respect to grooves formed in a connecting portion of a truss cap and in a driving coupler of a driven screw anchor. Registering the position of the jaws ensures that blind crimps between the upper leg and screw anchor and upper leg and truss cap are performed consistently each time.

IPC Classes  ?

• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 30/425 - Horizontal axis
• F24S 50/20 - Arrangements for controlling solar heat collectors for tracking
• H02S 20/10 - Supporting structures directly fixed to the ground
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

Disclosed is a foundation component having an elongated open shaft, an external thread form beginning at a first end and extending along the shaft, a driving coupler at a second end, opposite to the first end, and a cone received by the first end and extending from the first end. The cone is of a material having a lower elastic modulus than the elongated open shaft.

IPC Classes  ?

• E02D 5/80 - Ground anchors
• E02D 5/56 - Screw piles
• E02D 7/22 - Placing by screwing down

Abstract

An automated driving and assembly machine for driving foundation components, such as screw anchors, and for assembling foundations, such as truss foundations, using the driven screw anchors. The machine has a rotary driver and a hydraulic drilling tool. Sensors monitoring hydraulic pressure at the drilling tool will take incremental pressure readings during a driving operation. If the readings become clustered around a relative maximum, the controller will pause the driving operation and begin a drill stall mitigation sub-routine. This may involve retracting the drill and then hammering and releasing pressurized air to clear the stall. Clearance of the stall may also be derived by the controller from pressure readings. If the relative maximum is below a predetermined threshold, this is indicative of a malfunction of the hydraulic system. As a result, the controller will generate a service flag for the hydraulic system to a user interface of the machine to alert an operator of the need to have the machine serviced.

IPC Classes  ?

• E02D 7/14 - Components for drivers
• E02D 13/00 - Accessories for placing or removing piles or bulkheads
• E21B 44/00 - Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systemsSystems specially adapted for monitoring a plurality of drilling variables or conditions

Abstract

A one-piece truss adapter for supporting single-axis trackers with truss foundations. A upside-down Y-shaped structure has bearing support portion and an opposing pair of legs with an angularly adjustable connector for securely joining the one-piece adapter to a pair of driven screw anchors at different angular orientations. Each leg terminates in a connector that is received in a socket integral to a driving coupler at the head of each screw anchor. A retaining nut may hold the connector in place to complete the angularly adjustable assembly.

IPC Classes  ?

• E04C 3/38 - Arched girders or portal frames
• E04B 1/32 - Arched structuresVaulted structuresFolded structures
• E04C 3/02 - JoistsGirders, trusses, or truss-like structures, e.g. prefabricatedLintelsTransoms

Abstract

Methods of method of making a portable crimping device for joining foundation components are disclosed. A portable crimper transfers hydraulic forces back into the hydraulic cylinder and not just into a pinned or fixed connection supporting it. To withstand these forces, the cylinder is milled out of a single piece of source metal and the arm that transfers the forces is joined to the cylinder via pair of flanges extending the entire length of the cylinder to distribute them over a wider surface area.

IPC Classes  ?

• B25B 27/02 - Hand tools or bench devices, specially adapted for fitting together or separating parts or objects whether or not involving some deformation, not otherwise provided for for connecting objects by press fit or detaching same

Abstract

A combined truss adapter and bearing assembly for a tracker. The truss adapter has a pair of connecting portions and a bridge portion. The bridge portion has two pairs of opposing channels. The assembly has adapter plates on opposing surfaces of the bridge portion. Bolts extend through the adapter plates, in the channels, and to the bearing assembly to secure the bearing assembly to the bridge portion and to enable the bearing assembly to pivot with respect to the bridge portion.

IPC Classes  ?

• H02S 20/10 - Supporting structures directly fixed to the ground

Abstract

A combined truss adapter and bearing for a single-axis tracker. The truss adapter has a pair of connecting portions joined together by a bridge. A pair of parallel flanges on the bridge extend upward and away from bridge to support flanges of a bearing assembly. Bolts passing through the flanges and bearing assembly enable the bearing assembly to be rotated with respect to the bridge portion.

IPC Classes  ?

• H02S 20/10 - Supporting structures directly fixed to the ground

Abstract

A truss foundation for single-axis trackers that are installed in climates that experience significant frost heave. In some cases, truss legs are oriented plumb, to eliminate adfreeze moment on below-ground components in the frost zone. Different truss caps may be used depending on the type of single-axis tracker and/or tracker component is supported. In some cases, truss legs may curve just before entering the ground. In others, below-ground and above-ground components may extend along the same axis and remain plump with the truss cap providing additional elevation to for the tracker to clear the wider truss legs.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• F24S 25/10 - Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• H02S 20/10 - Supporting structures directly fixed to the ground
• F24S 25/00 - Arrangement of stationary mountings or supports for solar heat collector modules

Abstract

In a machine for driving screw anchors and other foundation components, a desired embedment depth is calculated based on a minimum required embedment depth, work point height and length of available upper leg sections. Once calculated, the machine automatically drives the screw anchor to the depth so that one of the available upper leg lengths will fit between the driven screw anchor and apex truss hardware. If a secondary condition is satisfied that guarantees sufficient pull-out strength, a new upper leg length may be selected and the driving operation terminated prior to reaching the desired embedment depth, reducing the amount of material necessary to construct the truss foundation.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 5/56 - Screw piles

Abstract

A truss foundation for single-axis trackers that are installed in climates that experience frost heave or reactive soils. Truss legs are oriented to be substantially plumb, to eliminate adfreeze moment on below-ground components in the frost zone. Elbow couplers are attached to the upper end of each embedded component and used to change the leg angle from plumb to angled.

IPC Classes  ?

• F16M 11/00 - Stands or trestles as supports for apparatus or articles placed thereon
• F16M 11/10 - Means for attachment of apparatusMeans allowing adjustment of the apparatus relatively to the stand allowing pivoting around a horizontal axis
• F16M 11/18 - Heads with mechanism for moving the apparatus relatively to the stand
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

An assembly for a truss foundation embedment and installation machine. The machine mast has a rotary driver, target assembly, and a truss component holder. After a pair of foundation components are embedded, the truss component holder is moved to an orientation location that aligns the rotational axis of a specific tracker bearing with respect to a work point of the truss foundation. A truss cap is placed on the truss component holder and held in place while upper leg sections are sleeved over the truss cap and down onto the embedded foundation components. A hydraulic crimper is used to crimp the portions of each upper leg section that overlap with the truss cap and the embedded foundation components to unify the truss foundation.

IPC Classes  ?

• E02D 7/14 - Components for drivers
• B23P 19/10 - Aligning parts to be fitted together
• E02D 5/80 - Ground anchors
• E02D 7/22 - Placing by screwing down
• E02D 13/00 - Accessories for placing or removing piles or bulkheads
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Goods & Services

Machines for assembling and installing solar foundation systems to support solar panels, equipped with a grade control system, GPS receivers, computer hardware, software, and firmware for the transmission of data, the correction of data and navigation for use in the solar industry.

Abstract

Bearing adapters for use with truss foundations supporting mechanically balanced single-axis trackers. The bearing adapter joins the free ends of a pair of adjacent truss legs to form a rigid A-frame shaped foundation structure. A bearing is formed in an upper portion of the bearing adapter to allow a torque tube to be suspended from a pin in the bearing and to swing through an arc bounded by the bearing adapter. The bearing may have a catenoid shape to compensate for misalignment in multiple directions.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• E02D 5/80 - Ground anchors

Abstract

A crimper for joining truss leg components to form a unitary truss foundation with the ground without needing mechanical fasteners. A crimping tool has upper and lower crimp guides that register the position of jaws on the crimping tool with respect to grooves formed in a connecting portion of a truss cap and in a driving coupler of a driven screw anchor. Registering the position of the jaws ensures that blind crimps between the upper leg and screw anchor and upper leg and truss cap are performed consistently each time.

IPC Classes  ?

• F24S 25/00 - Arrangement of stationary mountings or supports for solar heat collector modules
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 30/425 - Horizontal axis
• F24S 50/20 - Arrangements for controlling solar heat collectors for tracking
• H02S 20/10 - Supporting structures directly fixed to the ground
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

A method for installing and assembling a truss foundation to support a single-axis solar tracker. A positioning subsystem determines an orientation of a machine mast's driving axis relative to an intended drive axis and controls the mast to be positioned so that the mast's driving axis is aligned with the intended drive axis of the screw anchor foundation component. After a pair of adjacent screw anchors are driven, the controller causes motion controllers to orient the mast so that an alignment jig for supporting truss apex hardware is held in place relative to the driven screw anchors at a predetermined point in space above them so that upper leg sections can be sleeved over connecting portions of the apex hardware and down on to the driven screw anchors.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 13/00 - Accessories for placing or removing piles or bulkheads
• E02D 5/56 - Screw piles

Abstract

Improved masts for solar pile driving machines are provided that incorporate inline drilling as well as alignment and assembly devices that enable greater positional accuracy than possible with conventional equipment. In some cases, a jig, holder, or other device on the mast of the machine can be used to place a bearing assembly for a single-axis tracker while the foundation is being installed. Also disclosed are various multi-piece foundation piles that enable positional adjustment between below and above-ground components to compensate for misalignment.

IPC Classes  ?

• E02D 5/28 - Prefabricated piles made of steel
• E02D 5/80 - Ground anchors
• E02D 27/32 - Foundations for special purposes
• E02D 27/12 - Pile foundations
• E02D 7/26 - Placing by using several means simultaneously

Abstract

An automated driving and assembly machine for driving foundation components, such as screw anchors, and for assembling foundations, such as truss foundations, using the driven screw anchors. The machine has a rotary driver and a hydraulic drilling tool. Sensors monitoring hydraulic pressure at the drilling tool will take incremental pressure readings during a driving operation. If the readings become clustered around a relative maximum, the controller will pause the driving operation and begin a drill stall mitigation sub-routine. This may involve retracting the drill and then hammering and releasing pressurized air to clear the stall. Clearance of the stall may also be derived by the controller from pressure readings.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down

Abstract

An automated driving and assembly machine for driving foundation components, such as screw anchors, and for assembling foundations, such as truss foundations, using the driven screw anchors. The machine has a rotary driver and a hydraulic drilling tool. Sensors monitoring hydraulic pressure at the drilling tool will take incremental pressure readings during a driving operation. If the readings become clustered around a relative maximum, the controller will pause the driving operation and begin a drill stall mitigation sub-routine. This may involve retracting the drill and then hammering and releasing pressurized air to clear the stall. Clearance of the stall may also be derived by the controller from pressure readings.

IPC Classes  ?

• E02D 7/06 - Power-driven drivers
• E02D 5/80 - Ground anchors
• E02D 13/04 - Guide devicesGuide frames

Goods & Services

Machines for assembling and installing solar foundation systems to support solar panels, equipped with a grade control system, GPS receivers, computer hardware, software, and firmware for the transmission of data, the correction of data and navigation for use in the solar industry

Abstract

Fixed-tilt solar arrays constructed from screw anchors. A row of truss foundation is installed, with each foundation consisting of a pair of adjacent angled truss legs. A truss cap or adapter joins the legs and provides a support structure to support a rail that in turn supports purlins extending between adjacent, spaced apart truss foundations. Solar panels are attached directly to the purlins using clamps or other conventional mounting systems.

IPC Classes  ?

• H02S 20/30 - Supporting structures being movable or adjustable, e.g. for angle adjustment
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• F24S 25/30 - Arrangement of stationary mountings or supports for solar heat collector modules using elongate rigid mounting elements extending substantially along the mounting surface, e.g. for covering buildings with solar heat collectors
• F24S 25/16 - Arrangement of interconnected standing structuresStanding structures having separate supporting portions for adjacent modules
• E02D 5/80 - Ground anchors
• F24S 25/12 - Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface using posts in combination with upper profiles

Abstract

An alignment and installation jig for a screw anchor driving machine. The alignment and installation jig includes a laser target that can be moved from an alignment position to a driving position. The jig may also include one or more automated crimping assemblies to form permanent connections between overlapping foundation components while the machine is correctly oriented to assembly a truss foundation. One crimping assembly device may effect crimp joints between a foundation component held by the jig and overlapping upper ends of a pair of adjacent foundation legs. Second crimping assemblies may telescope down each leg to effect respective crimp joints between the lower end of the leg and the upper end of a driven foundation component.

IPC Classes  ?

• E02D 7/14 - Components for drivers
• B23P 19/10 - Aligning parts to be fitted together
• E02D 5/80 - Ground anchors
• E02D 7/22 - Placing by screwing down
• E02D 13/04 - Guide devicesGuide frames
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• E02D 13/00 - Accessories for placing or removing piles or bulkheads

Abstract

A universal adapter for enabling truss foundations to support conventional single-axis trackers. In some cases, the adapter has a main body with an upper portion that presents a standard I-beam interface with pre-drilled holes to interface to a specific single-axis tracker. A pair of connecting portions point down and away from the main body and enable upper leg sections to connect the adapter to a pair of driven screw anchors located below it. The connecting portions may orient the truss so that the rotational axis of the single-axis tracker is aligned with the work point of the truss foundation made from the adapter, upper legs, and driven screw anchors. This will enable to the truss to interface with many different trackers much like conventional plumb-driven H-pile foundations.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• E02D 5/80 - Ground anchors
• F24S 25/61 - Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing to the ground or to building structures
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• F24S 30/425 - Horizontal axis
• H02S 20/10 - Supporting structures directly fixed to the ground
• F24S 30/00 - Arrangements for moving or orienting solar heat collector modules

Abstract

A machine for driving a pair of screw anchors at substantially the same time. An attachment supports a pair of independent drive assemblies. Each assembly consists of a rotary driver and tool driver that moves along respective driving arms to independently drive a pair of screw anchors into supporting ground at different angles. Each assembly may move with respect to the machine independently to drive anchors into the ground in overlapping time, or both may rotate at once to drive anchors into the ground sequentially.

IPC Classes  ?

• E02D 7/06 - Power-driven drivers
• E02D 7/22 - Placing by screwing down
• E02D 7/26 - Placing by using several means simultaneously
• E02D 27/16 - Foundations formed of separate piles
• E02D 5/28 - Prefabricated piles made of steel
• E02D 5/54 - Piles with prefabricated supports or anchoring partsAnchoring piles
• E02D 5/56 - Screw piles
• E02D 5/80 - Ground anchors
• E02D 27/50 - Anchored foundations

Abstract

A passive locking chuck for a rotary driver. The chuck receives the driving end of a foundation component such a screw anchor to be driven into the ground. As the driving end is inserted into the chuck, spring biased pawls are displaced until insertion is complete. The geometry of each pawl dictates that less force is required to insert the foundation component than to remove it. The chuck has a geometry that mates with the geometry of the driving end of the foundation component.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down

Abstract

An automated feedback-based system for driving foundation components to a desired embedment depth. A digital controller executing a stored control program controls driving components arranged on a mast of the driving machine including a drive chain motor, a rotary driver, a tool driver, and a source of compressed air. An array of sensors provides real-time feedback to a digital controller about the automated driving operation that enables the controller to adjust the operation of one or more of the driving components based on real-time driving conditions.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 7/24 - Placing by using fluid jets
• E02D 13/00 - Accessories for placing or removing piles or bulkheads

Abstract

A two-piece truss leg system for an A-frame-shaped truss foundation system for single-axis trackers. A driving coupler at the head of each screw anchor used to drive the component into the ground as well as to join the upper leg component to the screw anchor. A connecting portion of the coupler extending above a main body of the coupler is received within an open end of an upper leg component. A curved outer surface of the connecting portion enables the upper leg component to be angularly adjusted relative to the screw anchor. A channel in the connecting portions enables the upper leg component to be deformed into the channel with a crimp connecting.

IPC Classes  ?

• F24S 25/00 - Arrangement of stationary mountings or supports for solar heat collector modules
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 30/425 - Horizontal axis
• F24S 50/20 - Arrangements for controlling solar heat collectors for tracking
• H02S 20/10 - Supporting structures directly fixed to the ground
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

A one-piece truss adapter for supporting single-axis trackers with truss foundations. A upside-down Y-shaped structure has bearing support portion and an opposing pair of legs with an angularly adjustable connector for securely joining the one-piece adapter to a pair of driven screw anchors at different angular orientations. Each leg terminates in a connector that is received in a socket integral to a driving coupler at the head of each screw anchor. A retaining nut may hold the connector in place to complete the angularly adjustable assembly.

IPC Classes  ?

• E04C 3/38 - Arched girders or portal frames
• E04C 3/02 - JoistsGirders, trusses, or truss-like structures, e.g. prefabricatedLintelsTransoms
• E04B 1/32 - Arched structuresVaulted structuresFolded structures

Abstract

A portable crimping device and method of making such a crimping device is disclosed. A portable crimper transfers hydraulic forces back into the hydraulic cylinder and not just into a pinned or fixed connection supporting it. To withstand these forces, the cylinder is milled out of a single piece of source metal and the arm that transfers the forces is joined to the cylinder via pair of flanges extending the entire length of the cylinder to distribute them over a wider surface area.

IPC Classes  ?

• B25B 27/02 - Hand tools or bench devices, specially adapted for fitting together or separating parts or objects whether or not involving some deformation, not otherwise provided for for connecting objects by press fit or detaching same

Abstract

Adjustable bearing supports for single-axis trackers supported by truss foundations. A two-piece assembly joins a pair of adjacent truss legs to form a rigid foundation while providing a movable support for a tracker bearing housing assembly or other structure. The movable support may slide in-plane, or alternatively, enable the bearing housing assembly to slide and rotate with respect to the truss cap structure joining the adjacent truss legs.

IPC Classes  ?

• G01S 3/786 - Systems for determining direction or deviation from predetermined direction using adjustment of orientation of directivity characteristics of a detector or detector system to give a desired condition of signal derived from that detector or detector system the desired condition being maintained automatically
• F16M 11/12 - Means for attachment of apparatusMeans allowing adjustment of the apparatus relatively to the stand allowing pivoting in more than one direction
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

A foundation system for manufactured homes, prefabricated houses, and other structures. Multiple screw anchors are driven into the ground at the desired location of the structure. Preformed grade bars may be placed over the screw anchors to provide a modular foundation without pouring concrete or digging footers. Alternatively, adapters may be attached to one or more of the driven screw anchors to provide a pedestal to receive the grade bar or prefabricated sections of concrete.

IPC Classes  ?

• E02D 27/16 - Foundations formed of separate piles
• E02D 27/32 - Foundations for special purposes

Abstract

An automated control system for a screw anchor driving and truss assembly machine. A positioning subsystem determines an orientation of a machine mast's driving axis relative to an intended drive axis and controls the mast to be positioned so that the mast's driving axis is aligned with the intended drive axis of the screw anchor foundation component. After a pair of adjacent screw anchors are driven, the controller causes motion controllers to orient the mast so that an alignment jig for supporting truss apex hardware is held in place relative to the driven screw anchors at a predetermined point in space above them so that upper leg sections can be sleeved over connecting portions of the apex hardware and down on to the driven screw anchors.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 5/56 - Screw piles
• E02D 13/00 - Accessories for placing or removing piles or bulkheads

Abstract

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.

IPC Classes  ?

• E02D 5/80 - Ground anchors

Abstract

A solar power plant is constructed using a reverse workflow whereby the grid connection that will ultimately feed electricity to the grid is constructed before the array so that one or more transformers and portable charging stations may be deployed onsite to transform grid power so that it can recharge electrically powered heavy equipment including solar pile drivers, truss drivers, and telehandlers as well as electrically powered hand tools such as cordless impact drivers while the plant is constructed. Once complete, the fixed electrical infrastructure and grid connection are used to supply power from the solar power plant to the grid.

IPC Classes  ?

• H02S 10/00 - PV power plantsCombinations of PV energy systems with other systems for the generation of electric power
• H02J 7/02 - Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from AC mains by converters
• B60L 53/30 - Constructional details of charging stations
• B60L 53/51 - Photovoltaic means

Abstract

An A-frame shaped truss foundation system for a single-axis tracker with moderately sloped legs that translate lateral loads into tension and compression without substantially increasing the magnitude of the lateral load force while optimizing material usage. Several such truss foundation systems are installed in a row to support a torque tube of a single-axis solar tracker. An adapter joins ends of adjacent upper legs and separates the truss legs by an angle more than 35-degrees up to 70-degrees. In some cases, the adapter may have an integrated bearing.

IPC Classes  ?

• F24S 25/00 - Arrangement of stationary mountings or supports for solar heat collector modules
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 30/425 - Horizontal axis
• F24S 30/00 - Arrangements for moving or orienting solar heat collector modules

Abstract

In a machine for driving screw anchors and other foundation components, a desired embedment depth is calculated based on a minimum required embedment depth, work point height and length of available upper leg sections. Once calculated, the machine automatically drives the screw anchor to the depth so that one of the available upper leg lengths will fit between the driven screw anchor and apex truss hardware. If a secondary condition is satisfied that guarantees sufficient pull-out strength, a new upper leg length may be selected and the driving operation terminated prior to reaching the desired embedment depth, reducing the amount of material necessary to construct the truss foundation.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 5/56 - Screw piles
• H02S 20/10 - Supporting structures directly fixed to the ground
• E02D 33/00 - Testing foundations or foundation structures

Abstract

A single-axis solar tracker consisting of a series of A-frame shaped foundation with actuators attached to each leg that are connected at one end to a common rotating assembly supporting multiple solar panels. Concerted action of the actuators causes the common rotating assembly to rotate about an axis of rotation. The system may include a central torque tube supported by the series of A-frame foundations or a frame assembly that is hingedly attached to each A-frame foundation via a torque arm.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• H02S 20/30 - Supporting structures being movable or adjustable, e.g. for angle adjustment
• H02S 30/10 - Frame structures
• F16M 11/10 - Means for attachment of apparatusMeans allowing adjustment of the apparatus relatively to the stand allowing pivoting around a horizontal axis

Abstract

A center structure support for single-axis trackers to support tracker driver motors and tracker center structures that transfer torque across rows to enable a single tracker motor to rotate the torque tubes of several adjacent rows. A pair of driven screw anchors are joined above ground with a center structure support and a pair of clamp assemblies that capture the driving coupler at the upper end of each screw anchor. The clamp assemblies are captured in distal ends of the center structure support via bolts that enable adjustment center structure relative to the driven legs.

IPC Classes  ?

• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 50/20 - Arrangements for controlling solar heat collectors for tracking
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• H02S 30/10 - Frame structures

Abstract

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.

IPC Classes  ?

• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 30/425 - Horizontal axis
• H02S 20/10 - Supporting structures directly fixed to the ground
• F24S 50/20 - Arrangements for controlling solar heat collectors for tracking
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

A truss foundation for single-axis trackers that distribute forces into the foundation through the torque tube. A truss adapter joins a pair of adjacent truss legs driven at angles to one another on either side of a tracker row so that the legs are perpendicular to the tracker torque tube. A third leg aligned with the torque tube is connected to the adapter to help resist axial forces in the torque tube. One or more collars placed on either side of a torque tube bearing include set screws to prevent axial slippage of the torque tube.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• F24S 30/425 - Horizontal axis
• F24S 30/00 - Arrangements for moving or orienting solar heat collector modules

Abstract

A truss foundation for supporting single-axis solar tracker drive motors and center structures. An adapter joins a pair of adjacent truss legs and provides a mounting platform to support a drive motor and/or center structure of a solar tracker. The adapter has a pair of connecting portions that are received in the legs of the truss foundation. The adapter may be a unitary structure or consist of a pair of slidably connected members that are joined with fasteners to accommodate truss legs spaced apart at different distances.

IPC Classes  ?

• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 25/16 - Arrangement of interconnected standing structuresStanding structures having separate supporting portions for adjacent modules
• F24S 30/00 - Arrangements for moving or orienting solar heat collector modules
• F24S 25/632 - Side connectorsBase connectors

Abstract

In a machine for driving screw anchors and other foundation components, a desired embedment depth is calculated based on a minimum required embedment depth, work point height and length of available upper leg sections. Once calculated, the machine automatically drives the screw anchor to the depth so that one of the available upper leg lengths will fit between the driven screw anchor and apex truss hardware. If uplift is detected during driving, the machine will add additional embedment depth. In-situ validation of driven screw anchors may be performed after the embedment depth is reached.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 5/56 - Screw piles
• E02D 33/00 - Testing foundations or foundation structures
• H02S 20/10 - Supporting structures directly fixed to the ground

Abstract

In a machine for driving screw anchors and other foundation components, a desired embedment depth is calculated based on a minimum required embedment depth, work point height and length of available upper leg sections. Once calculated, the machine automatically drives the screw anchor to the depth so that one of the available upper leg lengths will fit between the driven screw anchor and apex truss hardware. If a secondary condition is satisfied that guarantees sufficient pull-out strength, a new upper leg length may be selected and the driving operation terminated prior to reaching the desired embedment depth, reducing the amount of material necessary to construct the truss foundation.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 5/56 - Screw piles

Abstract

A tool for adjusting driven truss components and assembled truss foundations. A bridge separates a pair of collars, each having a pair of offset bearing surfaces that fit around the truss legs. A lever arm terminating in a handle extends away from the bridge to give leverage to the tool operator. The bridge width is adjustable to enable positioning of the tool at different heights along the driven truss components. An additional receiver proximate to one of the collars may enable single leg operation. Lateral and angular adjustment of the lever arm with respect to the bridge may enable greater force to be applied to one leg relative to the other.

IPC Classes  ?

• E02D 5/80 - Ground anchors
• E04G 21/18 - Adjusting toolsTemplates
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• F24S 25/70 - Arrangement of stationary mountings or supports for solar heat collector modules with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surfaceArrangement of stationary mountings or supports for solar heat collector modules with means for compensating mounting tolerances
• H02S 20/10 - Supporting structures directly fixed to the ground
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

A passive locking chuck for a rotary driver. The chuck has a pair of rings, one fixed and the other rotatable between a first orientation where recesses formed in the rotatable ring are aligned with recesses formed in the fixed ring, and a second orientation where the recesses are offset from one another. When an upper end of a foundation component having a toothed coupler is inserted into the chuck and rotated axially, the movable ring is moved to the second orientation and the foundation component is thereby captured in the chuck. As soon as resistance is encountered from the soil, the ring moves back to the first orientation so that upon reaching the desired embedment depth, the rotary driver may be withdrawn without counter rotation.

IPC Classes  ?

• B23B 31/113 - Retention by bayonet connection
• B25D 17/08 - Means for retaining and guiding the tool bit, e.g. chucks
• B23B 31/00 - ChucksExpansion mandrelsAdaptations thereof for remote control

Abstract

A truss foundation for single-axis trackers that are installed in climates that experience significant frost heave. Truss legs are oriented to be substantially plumb, to eliminate adfreeze moment on below-ground components in the frost zone. Different truss caps may be used depending on the type of single-axis tracker and/or tracker component is supported. In some cases, truss legs may curve just before entering the ground. In others, below-ground and above-ground components may extend along the same axis and remain plump with the truss cap providing additional elevation to for the tracker to clear the wider truss legs.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• F24S 25/10 - Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• H02S 20/10 - Supporting structures directly fixed to the ground
• F24S 25/00 - Arrangement of stationary mountings or supports for solar heat collector modules

Abstract

A truss foundation for single-axis trackers that are installed in climates that experience significant frost heave. Truss legs are oriented to be substantially plumb, to eliminate adfreeze moment on below-ground components in the frost zone. Different truss caps may be used depending on the type of single-axis tracker and/or tracker component is supported. In some cases, truss legs may curve just before entering the ground. In others, below-ground and above-ground components may extend along the same axis and remain plump with the truss cap providing additional elevation to for the tracker to clear the wider truss legs.

IPC Classes  ?

• H02S 30/10 - Frame structures
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

Truss foundations for supporting single-axis trackers. A motor truss may be constructed from a pair of adjacent trusses that are braced and interconnected to resist axial loads and bending moments experienced at the drive motor or center structure. Dampers may be added to one or more trusses to protect the tracker from unintended rotation by resisting these forces with the truss legs.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• H02S 20/10 - Supporting structures directly fixed to the ground
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• F24S 30/425 - Horizontal axis

Abstract

Fixed-tilt solar arrays constructed from screw anchors. In some cases, purlins are attached directly to truss legs. In others, they are attached to truss caps joining the free end of each truss leg. In still further ones, screw anchors are driven in rows and interconnected by a pair of hinged members, one of which provides a mounting plane for solar panels. Each screw anchor may serve as a connection point for the trailing hinged member of the first foundation and the leading hinged member of the next foundation. In still further cases, a hinged truss cap may be used to accommodate different tilt angles with the same foundation.

IPC Classes  ?

• H02S 20/30 - Supporting structures being movable or adjustable, e.g. for angle adjustment
• H02S 30/10 - Frame structures

Abstract

Truss foundations for supporting single-axis trackers. A motor truss may be constructed from a pair of adjacent trusses that are braced and interconnected to resist axial loads and bending moments experienced at the drive motor or center structure. Dampers may be added to one or more trusses to protect the tracker from unintended rotation by resisting these forces with the truss legs.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• F24S 25/65 - Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for coupling adjacent supporting elements, e.g. for connecting profiles together
• F24S 25/70 - Arrangement of stationary mountings or supports for solar heat collector modules with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surfaceArrangement of stationary mountings or supports for solar heat collector modules with means for compensating mounting tolerances
• F24S 30/425 - Horizontal axis

Abstract

Drill bits are provided for a drilling while driving machine. In some cases, the drill bit is a multi-stage bit capable of selectively cutting at two different diameters. In others, the bit is an expanding bit that can be passed through a foundation component while its being driven. The bit has a pair of cutting wings that can move between a retracted orientation where the bit's diameter is narrower than the inner diameter of the driven component, to a splayed orientation where the diameter is equal to or larger than the driven component's outside diameter.

IPC Classes  ?

• E21B 10/32 - Drill bits with leading portion, i.e. drill bits with a pilot cutterDrill bits for enlarging the borehole, e.g. reamers with expansible cutting tools
• E21B 10/54 - Drill bits characterised by wear resisting parts, e.g. diamond inserts the bit being of the rotary drag type, e.g. fork-type bits
• E21B 44/02 - Automatic control of the tool feed

Abstract

A machine for rotary driving screw anchors into underlying ground and related. The machine has a mast with a rotary driver and a mandrel driver oriented on a common axis. The mandrel driver passes a mandrel through the rotary driver and the screw anchor to allow the mandrel to be actuated ahead of the screw anchor while the rotary driver drives the screw anchor into the ground. Alternatively, the mandrel driver may also drive a hammering drill through the screw anchor to clear a path ahead of it through subsurface rocks.

IPC Classes  ?

• F16B 25/00 - Screws that form threads in the body into which they are screwed, e.g. wood screws, self-tapping screws
• F16B 19/10 - Hollow rivetsMulti-part rivets fastened by expanding mechanically
• F24S 30/00 - Arrangements for moving or orienting solar heat collector modules
• F24S 30/425 - Horizontal axis

Abstract

Improved masts for solar pile driving machines are provided that incorporate inline drilling as well as alignment and assembly devices that enable greater positional accuracy than possible with conventional equipment. In some cases, a jig, holder, or other device on the mast of the machine can be used to place a bearing assembly for a single-axis tracker while the foundation is being installed. Also disclosed are various multi-piece foundation piles that enable positional adjustment between below and above-ground components to compensate for misalignment.

IPC Classes  ?

• E02D 27/32 - Foundations for special purposes
• H02S 20/10 - Supporting structures directly fixed to the ground
• E02D 7/00 - Methods or apparatus for placing sheet pile bulkheads, piles, mould-pipes, or other moulds

Abstract

A closed-loop feedback-control system for a screw anchor driving machine that uses a controller such as a programmable logic controller (PLC) and an array of sensors providing real-time data to control an automated screw anchor driving operation relying on a rotary driver, a crowd motor applying downforce to the rotary driver and a tool driver extending a tool through the rotary driver and screw anchor to drive screw anchors to a target depth. The tool driver is independently controllable to advance the tool at a different feed and speed than the rotary driver to respond to underground conditions encountered during driving.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 13/00 - Accessories for placing or removing piles or bulkheads
• E02D 7/24 - Placing by using fluid jets

Abstract

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.

IPC Classes  ?

• F24S 25/00 - Arrangement of stationary mountings or supports for solar heat collector modules
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 30/425 - Horizontal axis
• H02S 20/10 - Supporting structures directly fixed to the ground
• F24S 50/20 - Arrangements for controlling solar heat collectors for tracking
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

A truss foundation for single-axis trackers that is optimized to resist moments. For foundations that experience lateral loads as well as moments, the foundation supports the rotational axis via a moment connection that is deliberately offset below the work point to reduce the impact of the bending moment. Spacing between the truss legs and the angle of the legs impact the height of the truss work point and, by extension, the available offset below the work point down to the minimum height of the axis of rotation specified by the tracker maker.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• H02S 20/10 - Supporting structures directly fixed to the ground
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 25/61 - Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing to the ground or to building structures
• F24S 30/42 - Arrangements for moving or orienting solar heat collector modules for rotary movement with only one rotation axis
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• F24S 30/425 - Horizontal axis

Abstract

An alignment and installation jig for a screw anchor driving machine. The alignment and installation jig includes a laser target that can be moved from an alignment position to a driving position. The jig may also include one or more automated crimping assemblies to form permanent connections between overlapping foundation components while the machine is correctly oriented.

IPC Classes  ?

• E02D 5/56 - Screw piles
• E02D 7/22 - Placing by screwing down
• E02D 13/00 - Accessories for placing or removing piles or bulkheads

Abstract

In a machine for driving screw anchors and other foundation components, a desired embedment depth is calculated based on a minimum required embedment depth, work point height and length of available upper leg sections. Once calculated, the machine automatically drives the screw anchor to the depth so that one of the available upper leg lengths will fit between the driven screw anchor and apex truss hardware. If uplift is detected during driving, the machine will add additional embedment depth. In-situ validation of driven screw anchors may be performed after the embedment depth is reached.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 7/26 - Placing by using several means simultaneously
• E02D 5/28 - Prefabricated piles made of steel
• E02D 27/50 - Anchored foundations
• E02D 5/54 - Piles with prefabricated supports or anchoring partsAnchoring piles
• E02D 27/16 - Foundations formed of separate piles
• E02D 5/56 - Screw piles
• E02D 5/80 - Ground anchors
• E02D 7/06 - Power-driven drivers

Abstract

In a machine for driving screw anchors and other foundation components, a desired embedment depth is calculated based on a minimum required embedment depth, work point height and length of available upper leg sections. Once calculated, the machine automatically drives the screw anchor to the depth so that one of the available upper leg lengths will fit between the driven screw anchor and apex truss hardware. If uplift is detected during driving, the machine will add additional embedment depth. In-situ validation of driven screw anchors may be performed after the embedment depth is reached.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 5/56 - Screw piles
• E02D 33/00 - Testing foundations or foundation structures
• H02S 20/10 - Supporting structures directly fixed to the ground

Abstract

An alignment and installation jig for a screw anchor driving machine. The alignment and installation jig includes a laser target that can be moved from an alignment position to a driving position. The jig may also include one or more automated crimping assemblies to form permanent connections between overlapping foundation components while the machine is correctly oriented.

IPC Classes  ?

• E02D 7/14 - Components for drivers
• E02D 7/22 - Placing by screwing down
• E02D 13/04 - Guide devicesGuide frames
• B23P 19/10 - Aligning parts to be fitted together
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• E02D 5/80 - Ground anchors
• E02D 13/00 - Accessories for placing or removing piles or bulkheads

Abstract

Adjustable bearing supports for single-axis trackers supported by truss foundations. A two-piece assembly joins a pair of adjacent truss legs to form a rigid foundation while providing a movable support for a tracker bearing housing assembly or other structure. The movable support may slide in-plane, or alternatively, enable the bearing housing assembly to slide and rotate with respect to the truss cap structure joining the adjacent truss legs.

IPC Classes  ?

• H02S 30/10 - Frame structures

Abstract

Adjustable bearing supports for single-axis trackers supported by truss foundations. A two-piece assembly joins a pair of adjacent truss legs to form a rigid foundation while providing a movable support for a tracker bearing housing assembly or other structure. The movable support may slide in-plane, or alternatively, enable the bearing housing assembly to slide and rotate with respect to the truss cap structure joining the adjacent truss legs.

IPC Classes  ?

• G01S 3/786 - Systems for determining direction or deviation from predetermined direction using adjustment of orientation of directivity characteristics of a detector or detector system to give a desired condition of signal derived from that detector or detector system the desired condition being maintained automatically
• F16M 11/12 - Means for attachment of apparatusMeans allowing adjustment of the apparatus relatively to the stand allowing pivoting in more than one direction
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

Systems and methods are provided for performing site preparation work when building a single-axis tracker solar power plant. An installation and assembly machine is outfitted with a positioning system. At the time of installation, a reference laser is located at one end of an intended tracker row and is aligned positionally with an intended axis of rotation of the tracker (e.g., the tracker torque tube). The machine is moved to the first desired installation location based on the positioning information so that the laser beam impinges on a target on the machine. The distance between the laser and target is measured. A portion of the machine containing the target is moved with respect to the beam until the measured distance is equal to a predetermined distance. Once the correct distance is confirmed, the portion of the machine containing the target may be moved to confirm that the machine mast is oriented correctly in other axes including Y, Z and yaw.

IPC Classes  ?

• E02D 13/04 - Guide devicesGuide frames
• E02D 7/06 - Power-driven drivers

Abstract

Various embodiments of the disclosure enable installation of a utility scale solar array or other project requiring a site survey and survey markers at every ground penetration to be replaced with survey markers only at the end of each row. In addition, machine mast alignment for driving H-piles with an impact or vibratory hammer, or for driving screw anchors, helical anchors or other foundation with a rotary driver to be automated with the use of range finding lasers to orient the driving mast in X, Y and Z as well as pitch, roll and yaw based on range finding laser measurements.

IPC Classes  ?

• H02S 30/10 - Frame structures
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking

Abstract

A solar power plant is constructed using a reverse workflow whereby the grid connection that will ultimately feed electricity to the grid is constructed before the array so that one or more transformers and portable charging stations may be deployed onsite to transform grid power so that it can recharge electrically powered heavy equipment including solar pile drivers, truss drivers, and telehandlers as well as electrically powered hand tools such as cordless impact drivers while the plant is constructed. Once complete, the fixed electrical infrastructure and grid connection are used to supply power from the solar power plant to the grid.

IPC Classes  ?

• H02S 10/00 - PV power plantsCombinations of PV energy systems with other systems for the generation of electric power
• H02J 7/02 - Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from AC mains by converters
• B60L 53/30 - Constructional details of charging stations
• B60L 53/51 - Photovoltaic means

Abstract

A shared frame photovoltaic module and related mounting system for single-axis trackers. Each module has no frame, or a partial frame on two of four sides. A shared frame rail captures adjacent modules edges, providing frame support and attaching them to the tracker torque tube eliminating structural redundancy in conventional module frames. In some embodiments, each module is unframed with mounting pucks attached to the underside of the photovoltaic laminate. Torque tube mounting brackets have connecting portions for attaching respective pairs of mounting pucks on opposing sides of the torque tube.

IPC Classes  ?

• H02S 30/10 - Frame structures
• H02S 20/23 - Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures

Abstract

A shared frame photovoltaic module and related mounting system for single-axis trackers. Each module has no frame, or a partial frame on two of four sides. A shared frame rail captures adjacent modules edges, providing frame support and attaching them to the tracker torque tube eliminating structural redundancy in conventional module frames. In some embodiments, each module is unframed with mounting pucks attached to the underside of the photovoltaic laminate. Torque tube mounting brackets have connecting portions for attaching respective pairs of mounting pucks on opposing sides of the torque tube.

IPC Classes  ?

• H02S 30/10 - Frame structures
• F16M 13/02 - Other supports for positioning apparatus or articlesMeans for steadying hand-held apparatus or articles for supporting on, or attaching to, an object, e.g. tree, gate, window-frame, cycle
• H02S 40/36 - Electrical components characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection

Abstract

A two-piece truss leg with an articulating coupler for an A-frame-shaped truss foundation system for single-axis trackers. The coupler is attached to the head of each screw anchor to enable it to be driven. A connection portion extends above the coupler and is received within an open end of an upper leg to allow the upper leg to be misaligned with respect to it corresponding screw anchor.

IPC Classes  ?

• E04D 13/18 - Roof covering aspects of energy collecting devices, e.g. including solar panels
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 30/425 - Horizontal axis
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• F24S 50/20 - Arrangements for controlling solar heat collectors for tracking
• H02S 20/10 - Supporting structures directly fixed to the ground

Abstract

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.

IPC Classes  ?

• E02D 5/80 - Ground anchors
• H02S 20/30 - Supporting structures being movable or adjustable, e.g. for angle adjustment
• E02D 27/50 - Anchored foundations

Abstract

A one-piece truss adapter for supporting single-axis trackers with truss foundations. A y-shaped structure has a pair of legs with an angularly adjustable connector for securely joining the one-piece adapter to a pair of driven screw anchors at different angular orientations. Each leg terminates in a ball-shaped connector that is received in a socket integral to a driving coupler at the head of each screw anchor. A retaining nut holds the connector in place to complete the angularly adjustable assembly.

IPC Classes  ?

• E04C 3/38 - Arched girders or portal frames
• E04C 3/02 - JoistsGirders, trusses, or truss-like structures, e.g. prefabricatedLintelsTransoms
• E04B 1/32 - Arched structuresVaulted structuresFolded structures

Abstract

A foundation system for manufactured homes, prefabricated houses, and other structures. Multiple screw anchors are driven into the ground at the desired location of the structure. Preformed grade bars may be placed over the screw anchors to provide a modular foundation without pouring concrete or digging footers. Alternatively, adapters may be attached to one or more of the driven screw anchors to provide a pedestal to receive the grade bar or prefabricated sections of concrete.

IPC Classes  ?

• E02D 5/56 - Screw piles
• E02D 5/80 - Ground anchors
• E02D 27/50 - Anchored foundations
• E02D 27/48 - Foundations inserted underneath existing buildings or constructions

Abstract

An automated control system for a screw anchor driving and truss assembly machine. A positioning subsystem determines an orientation of a machine mast's driving axis relative to an intended drive axis and controls the mast to align with the intended drive axis. After a pair of adjacent screw anchors are drive, the controller orients the mast so that an alignment jig for supporting truss apex hardware is held relative to a predetermined point in space.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 5/56 - Screw piles
• E02D 13/00 - Accessories for placing or removing piles or bulkheads

Abstract

An A-frame-shaped truss foundation system for a single-axis tracker with a bearing assembly sitting atop a pair of adjacent angled truss legs joined together with an adapter so that the axis of rotation of the tracker is aligned with a work point of the A-frame. Several such foundation systems are arranged along a North-South row to support a tracker torque tube.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• F24S 25/61 - Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing to the ground or to building structures
• F24S 30/425 - Horizontal axis
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• H02S 20/10 - Supporting structures directly fixed to the ground
• E02D 5/80 - Ground anchors
• F24S 30/00 - Arrangements for moving or orienting solar heat collector modules

Abstract

A truss foundation for single-axis trackers that is optimized to resist moments. For foundations that experience lateral loads as well as moments, the foundation supports the rotational axis via a moment connection that is deliberately offset below the work point to reduce the impact of the bending moment. Spacing between the truss legs and the angle of the legs impact the height of the truss work point and, by extension, the available offset below the work point down to the minimum height of the axis of rotation specified by the tracker maker.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• H02S 30/10 - Frame structures

Abstract

A truss foundation for single-axis trackers that is optimized to resist moments. For foundations that experience lateral loads as well as moments, the foundation supports the rotational axis via a moment connection that is deliberately offset below the work point to reduce the impact of the bending moment. Spacing between the truss legs and the angle of the legs impact the height of the truss work point and, by extension, the available offset below the work point down to the minimum height of the axis of rotation specified by the tracker maker.

IPC Classes  ?

• H02S 20/10 - Supporting structures directly fixed to the ground
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• F24S 30/425 - Horizontal axis

Abstract

Bearing adapters for use with truss foundations supporting mechanically balanced single-axis trackers. The bearing adapter joins the free ends of a pair of adjacent truss legs to form a rigid A-frame shaped foundation structure. A bearing is formed in an upper portion of the bearing adapter to allow a torque tube to be suspended from a pin in the bearing and to swing through an arc bounded by the bearing adapter. The bearing may have a catenoid shape to compensate for misalignment in multiple directions.

IPC Classes  ?

• F16C 17/03 - Sliding-contact bearings for exclusively rotary movement for radial load only with tiltably-supported segments, e.g. Michell bearings
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• H02S 30/10 - Frame structures

Abstract

Bearing adapters for use with truss foundations supporting mechanically balanced single-axis trackers. The bearing adapter joins the free ends of a pair of adjacent truss legs to form a rigid A-frame shaped foundation structure. A bearing is formed in an upper portion of the bearing adapter to allow a torque tube to be suspended from a pin in the bearing and to swing through an arc bounded by the bearing adapter. The bearing may have a catenoid shape to compensate for misalignment in multiple directions.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• H02S 30/10 - Frame structures

Abstract

A pair of truss legs forming an A-frame-shaped truss foundation system, wherein each truss leg is formed from a hollow lower screw anchor having threading around its lower end connected to an upper leg, wherein both the screw anchor and the upper leg have corrosion protection layers formed on their inner and outer surfaces thereof, but wherein only the screw anchor also has a second corrosion protection layer formed over the first protection layer on its outer surface only.

IPC Classes  ?

• E02D 5/80 - Ground anchors
• H02S 20/10 - Supporting structures directly fixed to the ground

Abstract

A machine for driving a pair of screw anchors at substantially the same time. An attachment supports a pair of independent drive assemblies. Each assembly consists of a rotary driver and tool driver that moves along respective driving arms to independently drive a pair of screw anchors into supporting ground at different angles. Each assembly may move with respect to the machine independently to drive anchors into the ground in overlapping time, or both may rotate at once to drive anchors into the ground sequentially.

IPC Classes  ?

• E02D 7/06 - Power-driven drivers
• E02D 7/22 - Placing by screwing down
• E02D 7/26 - Placing by using several means simultaneously
• E02D 27/16 - Foundations formed of separate piles
• E02D 5/80 - Ground anchors
• E02D 27/50 - Anchored foundations
• E02D 5/54 - Piles with prefabricated supports or anchoring partsAnchoring piles
• E02D 5/28 - Prefabricated piles made of steel
• E02D 5/56 - Screw piles

Abstract

A closed-loop feedback-control system for a screw anchor driving machine that uses a programmable logic controller (PLC) and array of sensors providing real-time data to control an automated screw anchor driving operation relying on a rotary driver, a crowd motor applying downforce to the rotary driver and a tool driver extending a tool through the rotary driver and screw anchor to drive screw anchors to a target depth.

IPC Classes  ?

• E02D 7/22 - Placing by screwing down
• E02D 13/00 - Accessories for placing or removing piles or bulkheads
• E02D 7/24 - Placing by using fluid jets

Abstract

A machine, method and system for installing helical foundation piers that sues a driving tamper connected to a rotary tool to drive helical piers into the ground. Once the pier reaches the target depth, the tamper is decoupled, and counter rotated away from the pier. While it is withdrawn the soil between the driven and pier and the driving tamper is compressed by intermittent downward action of the tamper.

IPC Classes  ?

• E02D 3/054 - Improving by compacting by tamping or vibrating, e.g. with auxiliary watering of the soil involving penetration of the soil, e.g. vibroflotation
• E02D 7/26 - Placing by using several means simultaneously
• E02D 27/26 - Compacting soil locally before forming foundationsConstruction of foundation structures by forcing binding substances into gravel fillings
• E02D 5/24 - Prefabricated piles
• E02D 5/52 - Piles composed of separable parts, e.g. telescopic tubes
• E02D 5/56 - Screw piles

Abstract

An A-frame shaped truss foundation system for a single axis tracker with moderately sloped legs that translate lateral loads into tension and compression without substantially increasing the magnitude of the lateral load force while optimizing material usage. Several such truss foundation systems are installed in a row to support a torque tube of a single-axis solar tracker. An adapter joins ends of adjacent upper legs and separates the truss legs by an angle more than 35-degrees up to 70-degrees.

IPC Classes  ?

• E04D 13/18 - Roof covering aspects of energy collecting devices, e.g. including solar panels
• F24S 25/617 - Elements driven into the ground, e.g. anchor-pilesFoundations for supporting elementsConnectors for connecting supporting structures to the ground or to flat horizontal surfaces
• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• F24S 25/13 - Profile arrangements, e.g. trusses
• F24S 30/425 - Horizontal axis
• F24S 30/00 - Arrangements for moving or orienting solar heat collector modules

Abstract

An A-frame shaped truss foundation system for a single axis tracker with moderately sloped legs that translate lateral loads into tension and compression without substantially increasing the magnitude of the lateral load force while optimizing material usage. Several such truss foundation systems are installed in a row to support a torque tube of a single-axis solar tracker. An adapter joins ends of adjacent upper legs and separates the truss legs by an angle more than 35-degrees up to 70-degrees.

IPC Classes  ?

• H02S 20/32 - Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• H02S 30/10 - Frame structures

Abstract

An A-frame-shaped truss foundation system for a single-axis tracker with a bearing assembly sitting atop a pair of adjacent angled truss legs joined together with an adapter so that the axis of rotation of the tracker is aligned with a work point of the A-frame. Several such foundation systems are arranged along a North-South row to support a tracker torque tube.

IPC Classes  ?

• H02S 20/30 - Supporting structures being movable or adjustable, e.g. for angle adjustment
• H02S 30/10 - Frame structures
• H02S 20/10 - Supporting structures directly fixed to the ground