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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.