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: 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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.