Transportable and multi configurable, modular power platforms

Support platforms for one or more solar panels and systems and methods for securing support platforms are provided. In one embodiment, a frame of a support platform includes a plurality of support legs, each leg including a shoe plate. One or more toggle anchors with rod and/or cable are provided that include an anchor portion and a toggle portion pivotally coupled to the anchor portion, and a rod and/or cable is coupled to the toggle portion. Each anchor is driven into the ground with a driving rod such that an exposed end of the rod and/or cable extends from the ground. The driving rod is removed, and the rod and/or cable is pulled to deploy the anchor, and which the anchor is pull tested and measured in real time soil conditions whereupon the exposed end is coupled to the shoe plate of one of the support legs to apply a desired tensile force between the exposed end and the anchor to secure the support leg and, consequently, the support platform relative to the ground.

TECHNICAL FIELD

This present application relates to renewable energy systems using a surface mounted application, and more particularly, to transportable, customizable, multi-configurable, and/or surface mounted modular solar power platforms for on and off grid solar installation. The transportable, modular solar power platforms herein may be customizable, turnkey, portable, transportable, multi-configurable, and/or modular surface mounted solar power platforms (modular units) that may be installed temporarily or permanently on different types of earth surface conditions, ground, soil, and paved conditions, and other terrestrial terrain to achieve a desired power wattage depending on a desired power (kWh) output.

BACKGROUND

It is well known that alternative renewable energy resources are proven to be an important element in an overall energy plan for the off taker. Cost savings initiatives and a renewable and sustainable clean energy solution to lower the cost of energy (LCOE), is a critical factor as the cost of carbon based fuels and other fossil fuels are costly to use and continue to increase cost over time and these fossil fuels harm the environment and impact climate change. Grid parity has been achieved in large utility scale solar power plant installation, but not in distributed generation renewable energy applications. Solar (PV) energy, and energy storage systems (ESS) help recipients of this clean, renewable energy to load shift away from high rate tariffs and demand charges or be totally independent of the electrical grid. In order to produce sufficient usable and reusable clean energy from the sun, it is necessary to place one or more solar arrays in areas where they can capture the most solar radiation.

Conventional foundations and support structures required to install such solar arrays generally involve pre-development and engineering, geotechnical reports, environmental impact studies, site planning, grading, mobilization of heavy equipment, concrete, substantial procurement time and cost, installation time and cost, particularly for I beam steel piles, ballasted concrete blocks, pour in place cement piers or helical ground screw foundations used for surface mounted solar arrays, and involve substantial earth and project site disruption which impact the local environmental. Therefore, improved solar power platforms, support structures and foundations for solar arrays and methods for installing and/or using them would be useful, more economical and efficient and most beneficial to the environment.

SUMMARY

The present application is directed to alternative renewable energy systems using surface mounted applications, and more particularly, to transportable, customizable, multi-configurable, and/or surface mounted modular solar power platforms for grid connected and off grid solar installations. The transportable, modular solar power platforms herein may be customizable, turnkey, portable, transportable, multi-configurable, and/or modular surface mounted solar power platforms (modular units) that may be installed temporarily or permanently on different types of earth surface conditions, ground, soil, and paved conditions, and other terrestrial terrain to achieve a desired power wattage depending on a desired power (kWh) output.

A transportable, multi-configurable, modular solar power platform (modular units), according to the platform's systems and methods herein, may solve one or more problems associated with conventional or traditional surface mounted solar arrays, such as:Create methods and renewable energy system solutions in the solar industry downstream value chain for distributed generation and utility scale solar power markets to achieve a LCOE;Develop economical and efficient surface mounted racking systems, simplify engineering, stream line pre-development, planning, permitting and inspection processes, while using lower cost of labor and modular installation methodologies and solutions that save time and money for surface mounted solar arrays, which may be useful to drive down a LCOE;Provide expedited assembly and rapid deployment capability of surface mounted solar arrays for system installers and project developers using a less skilled and local workforce to benefit the local economy, which may be useful to achieve a LCOE;Create a greater power (watts) density per surface footprint of a surface mounted solar array using fixed tilt, adjustable tilt, single axis or multiple axis tracker systems to achieve a LCOE;Create minimal site disruption, minimal local environmental impact, and/or create sustainable and efficient construction methods and systematic processes for surface mounted solar arrays to achieve LCOE;Increase energy power production (kWh) by 20% or more compared to conventional fixed tilt surface mounted solar arrays, when configured as a transportable, modular solar power platform hosting single axis tracker components with solar modules or multiple axis solar tracker components with solar modules.

Transportable, modular solar power platforms (modular units) in accordance with the systems and methods herein do not require the use of concrete piers, ballasted concrete blocks, typical pile driven steel foundations or even ground screws that other surface mount racking systems generally require. There is no welding or cutting steel needed on an installation site. The use of heavy industrial onsite equipment, machinery, and large trucks is not required. Only the use of simple, low cost, portable hand-held power tools and a small portable power generator are needed.

A transportable, modular solar power platform (modular units), according to the systems and methods herein, may reduce the need for pre-development, geotechnical reports or environmental impact studies, unnecessary procurement time and cost, and installation time and cost, particularly compared to conventional surface mounted solar arrays, and may decrease earth and project site disruption and soil erosion. A transportable, modular solar power platform (modular units) may reduce project site logistical costs and transportation of concrete and the use of fossil fuels for heavy industrial onsite equipment and machinery and it helps to lower the overall cost of clean, renewable energy.

Conventional surface mounted solar arrays require a geo-technical report during the pre-development phase or even costly environmental impact studies, which may stall installation and increase costs and/or require site specific engineering and design all prior to a conventional surface mount racking system is ready for permitting. Typical ballasted surface mounted solar racking systems and pour in place cement piers rely on added concrete weight to secure the support structure and resist wind uplift, which requires heavy off-site trucks to deploy the cement, or uses pre-cast ballasted concrete blocks driven to project site. This installation process using cement also requires an additional special inspection.

A conventional or traditional pile driven foundation surface mount system or a system using helical ground screws requires the use of costly on-site industrial machines to deploy the steel foundations or screws with technical skilled certified labor driving these foundations up to fourteen feet (4.3 m) or greater into the ground to support the solar array above the surface of the ground.

In accordance with the systems and methods herein, a transportable, modular solar power platform (modular units) may use one or more small, inexpensive and easy to install toggle anchors attached to a rod and/or cable (as an earth anchoring foundation) to secure the transportable modular solar power platform beneath the surface in which it rests. No heavy pile driving equipment is used—only hand held tools for installation. Instead, toggle anchors with rod and/or cable attach to base plates (shoe plates) when installed to proper depth through access holes in the baseplate of the power platforms and become the foundational support mechanism to secure transportable, modular solar power platforms (modular units) to any earth surface, ground, soil condition or terrestrial terrain.

A transportable, modular solar power platform (modular unit) according to the systems and methods herein uses this toggle anchor with rod and/or cable application as an earth-anchoring foundation, which enables less skilled local labor (at a lower cost of labor) to install a completely turnkey modular power platform unit using only handheld power tools and a portable percussion hammer and small power generator. The use of an inexpensive and easy to install toggle anchor with rod and/or cable as an anchoring foundation, eliminates the need for pre-development geotechnical reports, environmental impact studies, and multiple traditional permit inspection requirements on site during construction by facilitating a real-time soil condition field vertical and lateral load lift (tension) test, e.g., including wind and seismic load requirements, conducted during the real time installation of the power platforms (modular units) to pass geotechnical and structural engineering specifications and local permitting and to measure the load tension results of the toggle anchor with rod and/or cable to assure compliance requirements are achieved with applicable local building codes and regulations.

Using the toggle anchor with rod and/or cable application as the foundation, an installer may perform a credible and permittable vertical and lateral load lift (tension) test in real time soil conditions measuring the tension capacity of the toggle anchor with rod and/or cable, e.g., to exceed 1.5 times the worst case design load capacity and/or as otherwise required by the authority holding jurisdiction (AHJ) for the project site, while the modular solar power platform unit is being installed. This load lift (tension) test may be conducted by the installer in real time using a Load Tension Device (LTD) including a come along hoist, a manual or automated winch or crank to add tension to the toggle anchor with rod and or cable during testing, and a device, e.g., a LED gauge, to measure the results in the field by the installer. The LED gauge may also upload the load test data results in real time to the cloud, e.g., via a WAN/LAN application or (SaaS), and/or otherwise communicated via a wireless and/or other communications network. The LTD may include a GPS device, which may be used to verify each load lift (tension) test performed on the toggle anchor with rod and/or cable tested.

Optionally, the LTD may include a controller with associated software and/or hardware that may provide one or more of the following features. For example, pre-determined optimal tension or load parameters may be programmed into the device, e.g., such that the cable and/or rod of the toggle anchor is pulled to the predetermined tension via the device to pass required load requirement. Once the desired load is achieved, the device may record the achieved load, relieve the tension and/or associated load achieved with operator identification. Optionally, additional information may recorded with the achieved load and/or other test data, e.g., a time stamp identifying the time and/or date of the test, GPS coordinates of the anchor associated with each test, operator identification, and the like, all of which may be downloaded to a portable electronic device at the installation site and/or uploaded to a remote data repository for access and review, e.g., at an office electronic device at the installation site or to one or more off-site electronic devices.

In one embodiment, a graphical user interface may be provided on the electronic device where the data is stored and/or received that may facilitate confirming that all of the installed toggle anchors with rods and/or cables have been properly tested. For example. the electronic device may include a display on which a visual array may be displayed that includes anchor points visually represented in software allowing a reviewer to see all of the stored data associated to the anchors. Cells of the array may also be conditionally formatted so that any discrepancy between load achieved and desired engineering loads are readily identified and may be corrected in the field. For example, all anchors that have been load tested and passed may be presented in a first color, e.g., green, while, anchors that have not yet been tested and/or that have failed may be presented in a different color, e.g., gray for untested anchors, red for anchors that failed the load test, and the like. Thus, a quick visual inspection of the array on the display may allow a reviewer to determine the status of the installation and/or immediately identify any problems. Additional data and information such as labor productivity may also be developed. This load lift (tension) test data may then be easily accessible and verifiable by the structural engineer of record (EOR) without the need for an onsite field review and to review and verify the load test results. After verification, the EOR can download the load test data to the AHJ.

The Load Test Device may be integrated or otherwise mounted to one or more support or extension legs of the modular unit, e.g., such that, when activated, the Load Test Device may automatically apply a preset tension to the toggle anchor with rod and/or cable. The resulting real-time soil condition load test data may then be communicated to give the EOR, permit jurisdictions, AHJs, municipals, customers, energy off takers, investors, and/or the installer complete confidence under applicable code requirements that the transportable, multi-configurable, modular solar power platform (modular unit) is secured to the ground with a stabilized foundation beneath the surface, e.g., to ensure that the resulting foundation exceeds the AHJs worst case load requirements by 1.5 times the design load required.

This real-time soil condition load testing removes other variables and uncertainties that other conventional surface mounted racking systems leave unanswered because the load test results are actually conducted in real time and not calculated results from a geotechnical report conducted months in advance. Testing in real time soil conditions is the preferred method of load testing verse calculated data for AHJs. Load testing in real time soil conditions also improves reliability of site conditions, avoids unforeseen obstacles underneath surface, speeds time to permitting, time to install, final inspection, verification of load test results and project cost savings.

Gaining power density on installation sites with challenging uneven terrain, unforeseen obstacles underneath surface, awkward boundaries or minimal space available for the conventional surface mount solar array are real problems for an installer and can cause financial trouble or costly project delays, which could be avoided using a modular solar power platform (modular units) with toggle anchor with rod and/or cable as the foundation. Transportable, multi-configurable, modular solar power platforms can host fix tilt and adjustable tilt configurations, including single axis tracker components with solar modules or multiple axis tracker components working concurrently and holding a plurality of solar modules. Axis sun trackers are proven to improve power production by as much as 20% over conventional fixed tilt surface mounted solar arrays.

A transportable, multi-configurable modular solar power platform may easily be deployed or unassembled, then re-deployed elsewhere without using heavy equipment or on site industrial machines. For example, a mining operation, needing to lift and shift a capital asset to a new location, can now remove the renewable energy capital asset to another location. The transportable modular solar power platform with toggle anchor rod and/or cable may provide a turnkey lift and shift application not achievable using conventional surface mounted solar arrays with steel I beam or screw foundations because these conventional surface mounted solar arrays leave behind vast amounts of material in the ground and or will require much logistical effort at a cost to remove completely.

The costs and time for removing a conventional solar array is typically about the same as the cost of installing it, while leaving behind material foreign to the project site that may erode or corrode the site over time, causing a negative environmental impact that may last for years. The impact of any material left behind in subterranean conditions may be tremendously harmful to the local environment. This requires installers to spend time and effort and increases the cost of the solar array installation and removal after the life of the conventional solar array system. A transportable, modular solar power platform may include multiple independently power adjustable, telescoping extension legs and shoe plates (e.g., twelve to eighteen inches (30-45 cm) in diameter) that are used to support the weight of the modular units while generating energy. These extension legs may be raised or lowered using a handheld impact tool or a motor that turns a mechanical crank or other actuator mechanism inside the extension leg frame. This helps the ease and speed of assembling the modular unit. Independently power adjusted extension legs may reduce site preparation and grading requirements and, when combined with a Load Test Device, may assist in the installation and load test of the toggle anchor, with rod and/or cable.

The size of base plates (shoe plates) may vary depending on the weight of modular units and/or the soil conditions below the shoe plate. These shoe plates may distribute the modular unit's weight equally (e.g., about two hundred pounds (91 kg) per leg) to avoid any disruption to the soil conditions beneath the modular unit.

At any time, the toggle anchor with rod and/or cable components may be clipped and the entire modular unit may be reloaded onto a transport flatbed truck or trailer and relocated to a new installation site. Only the toggle anchor with rod and/or cable would remain subterranean. Optionally, the toggle anchor with rod and/or cable may also be pulled out of the ground entirely by surpassing its vertical and lateral load capacity thus removing all the anchor foundation components and leaving nothing behind on the installation site. Consequently, the environmental impact of a modular solar power platform when compared to present conventional solar array systems and methods may be minimal and/or inconsequential.

Hosting or supporting the weight of renewable energy components such as a string inverter or energy storage batteries are not achievable using conventional surface mounted solar arrays with pile driven foundations because there is no support structure frame for the components to be mounted to. Instead, installers need to pour an independent concrete pad (separate from the conventional surface mounted solar array) to support these components. However, the transportable, multi-configurable and modular solar power platforms of the systems herein may include a steel frame uniquely and structurally engineered to support, mount, or ballast the weight of solar inverters, energy storage systems, and/or components and other material/components as needed.

In accordance with one embodiment, a system is provided that includes one or more transportable, customizable and/or multi-configurable modular solar power platforms, each having a support frame, multiple independently, power adjustable telescoping extension support legs and shoe plates, multiple toggle anchor with rod and/or cable foundation components and a support frame to hold a plurality of solar modules, solar inverters, and energy storage systems and components either in fixed tilt or an adjustable position or using single axis tracker components with solar modules and or multi axis solar tracker technology, with solar modules either hingedly connected or clamped to the support frame. A plurality of solar modules may be mounted on the support frame to produce a single modular solar power platform (modular unit), wherein a selected tilt angle is either pre-chosen or adjusted on site to increase the efficiency of the solar modules. Extension support legs, arms and back stays are used to keep each solar module frame at the selected angle or used to support the frame hosting the single or multi axis tracking system components, string solar inverters and energy storage components.

Optionally, the telescoping extension support legs may be independently power adjustable, e.g., using a mechanical actuator encased in or otherwise carried by the support legs, e.g., to raise and lower each modular unit for variable surface conditions or to raise or lower the tilt angle of the solar modules to maximize the sun's radiation. Toggle anchor with rod and/or cable components are used as the modular unit's anchoring foundation. One or more transportable modular solar power platforms may be vertically stacked (placed plum together) such that a plurality of modular units may then be transported to a selected installation site or one or more transportable modular solar power platform units may be placed over a trailer or flatbed truck with or without solar modules attached to support frame and transported from one location to another.

Once at the site, the modular solar power platform units are lifted from a transport vehicle and placed at their desired location or the modular unit extension support legs are lowered to surface and the independently power adjusted legs are raised to position. The truck or trailer may then be easily removed from under the modular unit. The extension support legs may then be adjusted individually for each modular solar power platform unit, e.g., if the surface is not level. Multiple toggle anchors with rods and/or cables are installed and load lift (tension) testing is performed concurrent in real time soil conditions with the modular units being installed. Multiple toggle anchors with rods and/or cables are measured using a simple portable Load Test Device, which may be mounted successively to each extension support leg (or alternatively incorporated into each extension support leg as one component), to verify building code and local AHJ vertical and lateral load requirements and the engineer of record (EOR) structural calculation requirements in a real-time soil condition test. Rapid deployment and load testing may thus be achieved using the systems and methods herein. The modular solar power platforms may then be interconnected to the grid to achieve the power output (kWh) required for any given installation site.

Alternatively, the transportable, modular solar power platform units may be shipped to an installation site with prefabricated components ready for assembly and final set up. Installation is achieved by connecting all the modular unit support frame components together using only hand-held power impact tools using simple fasteners, e.g., rivets, nuts, or bolts, and the like, to secure components together or using a portable handheld clinching tool that is used to clinch the steel components together and remove the need for any fasteners. For example, clinching may add rigidity, durability and bonded strength to a transportable, multi-configurable, modular solar power platform.

The transportable, multi-configurable modular solar power platform installation including a plurality of solar panels and load testing process may be achieved in less than one hour per modular unit using a three or four-person installation crew. Thus, relatively rapid deployment may be achieved with tremendous cost savings and limited to no impact on the local environment using the systems and methods herein.

In accordance with another embodiment, a system is provided for mounting a modular support platform for one or more solar panels relative to ground at an installation site that includes an extension support leg comprising one end mounted to a frame of the modular support platform and a second end; a shoe plate attached to the second end of the extension support leg comprising an opening therethrough; and an anchor comprising: a) an anchor portion comprising a penetrating end and a socket end opposite the penetrating end; b) a toggle portion pivotally coupled to the anchor portion between the penetrating end and the socket end, the anchor portion movable between a delivery orientation wherein the socket portion is disposed adjacent the anchor portion and a deployed orientation wherein the toggle portion is oriented transversely relative to the anchor portion; and c) an elongate member, e.g., a rod and/or cable, coupled to the toggle portion having a length sufficient such that an exposed end of the elongate member extends from the ground when the anchor is directed into the ground to direct the anchor portion from the delivery orientation to the deployed orientation, the exposed end receivable through the opening in the shoe plate. The system may also include a rigid driving member including a first end receivable in the socket end and a second driving end for directing the anchor into the ground in the delivery orientation; and a locking mechanism for securing the exposed end of the elongate member relative to the shoe plate and apply a desired tensile force between the exposed end and the anchor portion directed into the ground.

In accordance with another embodiment, a method is provided for securing a modular solar panel platform including a support frame and a plurality of extension legs including shoe plates at an installation site that includes providing an anchor comprising an anchor portion and a toggle portion pivotally coupled to the anchor portion, and an elongate member, e.g., a rod and/or cable, coupled to the toggle portion; directing the anchor into the ground at the installation site such that an exposed end of the elongate member extends from the ground; pulling the exposed end to deploy the anchor portion; coupling the exposed end to a shoe plate of a support leg to secure the support frame relative to the ground at the installation site; and applying a desired tensile force between the exposed end and the anchor to test the installation under real time soil conditions.

Other aspects and features of the present inventions will become apparent from the following description of the invention taken in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Turning to the drawings,FIGS. 1-4show an exemplary embodiment of a modular, multi-configurable solar power platform unit10that includes a frame12supported by a plurality of legs20and a rack14for mounting one or more solar panels50(not shown, see, e.g.,FIG. 10). As described elsewhere herein, one or more toggle anchors with rod and/or cable (not shown) may be attached to the frame12and/or legs20to secure the modular unit10, and consequently the solar panels50mounted to the support frame14, relative to the ground at an installation site, e.g., to provide an earth-anchoring foundation that may be used to substantially permanently or removably install the solar panels at a desired location.

Generally, the frame12includes front and rear chasses or struts12a,12bcoupled together by mid chasses or struts12cto provide a substantially rigid structure generally defining a plane. Similarly, the rack14includes a plurality of elongate rails14acoupled by a plurality of elongate supports14bto which the one or more solar panels may be mounted. The rack14may be fixedly mounted to the support frame14, e.g., at a predefined inclined angle, or may be adjustable, e.g., manually or using a motorized actuator, to change the inclined angle of the rack14, as described elsewhere herein.

For example, as shown, lower ends14b-1of the supports14bmay be mounted directly to the front strut12aof the frame12, e.g., at fixed or pivotable connection points, while upper ends14b-2of the supports14bmay be coupled to one or more back braces16that secure the upper ends14b-2spaced above the rear strut12b. In one embodiment, the braces16may be substantially permanently fixed relative to the frame12and rack14. Alternatively, the braces16may be adjustable, e.g., to vary a length of the braces16and consequently the tilt angle of the rack14relative to the frame12. For example, each brace16may include telescoping tubes, G-rails, or other elongate members that may be slidable or otherwise movable relative to one another to adjust their length. Such members may be adjustable manually and then secured at a desired length or may be coupled to a motor or other actuator (not shown), e.g., such that the length may be adjusted remotely and/or automatically, e.g., as part of a tracking system, as described elsewhere herein.

Alternatively, the braces16may be removable and a kit including a plurality of braces having different lengths may be provided, e.g., such that one set of braces16may be selected and mounted between the rack14and frame12to set the tilt angle as desired for a particular installation. If the rack14is adjustable, the lower ends14b-2of the supports14bmay be pivotally coupled to the frame12, e.g., using one or more hinges and the like (not shown).

It will be appreciated that the components of the platform10may be formed using conventional materials and methods, e.g., formed from metal such as steel or aluminum, plastics, or composites, having desired cross-sections or configurations. For example, the struts12a,12b, rails14a, and supports14bmay be elongate “C” channel members, tubular beams, I-beams, and the like, formed by roll forming, breaking, extrusion, casting, and the like. The components may be attached together using one or more conventional methods, for example, using one or more fasteners, e.g., screws, rivets, bolts, and the like, and/or directly by clinching, welding, bonding with adhesive, and the like.

The legs20may be attached to the front and rear struts12a,12bsuch that the legs20extend downwardly or otherwise orthogonal to the plane of the frame12. In an exemplary embodiment shown inFIG. 5, each leg20generally includes an upper end20aincluding a mounting bracket22for securing the upper end20ato the frame12, and a lower end20bincluding a plate or shoe24, e.g., attached to the leg20to define a relatively large area lower contact surface that extends substantially transversely, e.g., horizontally, for placement against a mounting surface, e.g., the ground at an installation site. For example, the area of the contact surface of the shoe24may be set based on the weight of modular units, soil conditions below the shoe plate, and/or other parameters, e.g., to ensure that the shoe plates sufficiently distribute the modular unit's weight equally to avoid any disruption to the soil conditions beneath the modular unit.

Optionally, the leg20may be adjustable, e.g., to change the distance between the mounting bracket22and the shoe24. For example, as shown inFIG. 5, the leg20may include an outer member26aand an inner member26b, e.g., tubular members, C-rails, and the like, that telescope or otherwise slide relative to one another, e.g., with the inner member26bsliding at least partially into the outer member26b. The leg20may include one or more connectors, e.g., a pin26cand corresponding set of holes (not shown) for receiving the pin26c, for fixing the leg20at a desired length. Alternatively, a mechanical system may be provided, e.g., including a rack and pinion, motorized track, and/or other mechanism (not shown), that may be actuated to adjust the length. In the embodiment shown, the shoe24includes a post that may be received in or otherwise attached to the lower end20band may include one or more mating fasteners, e.g., pin24a, for removably attaching the shoe24to the lower end20b. Alternatively, the shoe24may be substantially permanently attached to the lower end20b, e.g., by one or more fasteners, e.g., screws, rivets, bolts, and the like, clinching, welding, bonding with adhesive, and the like.

In another alternative, the upper end20aof the leg20may be substantially permanently attached to the frame12, e.g., attached to the struts12a,12bby one or more fasteners, e.g., screws, rivets, bolts, and the like, welding, bonding, and the like. In addition or alternatively, the legs20may be pivotally attached to the frame12, e.g., such that the legs20may be rotated between a retracted or storage position, e.g., extending substantially parallel to the struts12a,12b, and an extended or installation position, e.g., extending substantially perpendicular to the struts12a,12b.

For example,FIGS. 12A-12Dshow an example of a frame112including a plurality of legs120that are pivotable between a storage position (FIG. 12D) and an installation position (FIG. 12A). Generally, each leg120includes an outer member126athat is pivotally coupled to a strut112aat a joint128, an inner member126aextendable from the outer member126a, and a shoe plate124, as described further elsewhere herein. To store each leg120from the installation position shown inFIG. 12A, the shoe plate124may be removed (e.g., by removing a pin or other connector, not shown), and the inner member126bmay be retracted at least partially into the outer member126a, as shown inFIG. 12B. As shown inFIG. 12C, the outer member126amay then be rotated until positioned along the strut112ain the storage position, as shown inFIG. 12D. Optionally, the legs120and/or strut112amay include one or more locking features for securing the legs120in the storage position. The legs120may be returned to the installation position simply by reversing the process.

Turning toFIG. 6, an exemplary installation is shown in which the frame12is oriented substantially horizontally and the rack14and solar panel(s)90are tilted at an acute tilt angle relative to the frame12. As shown, the ground92is uneven and, consequently, the front leg20(1) has been retracted to a relatively shorter length and the rear leg20(2) has been extended to a relatively longer length to ensure that the lower surfaces of the shoes24are positioned securely against the surface of the ground92and the frame12is substantially horizontal. Optionally, the frame12may include a motorized self-leveling system (not shown) that may automatically adjust the lengths of the legs20to orient the frame12substantially horizontally.

During installation, the frame12and/or legs20may be secured relative to the ground92, using one or more anchor assemblies, e.g., including a toggle anchor30with rod and/or cable, as shown inFIGS. 7 and 8A-8D. For example, turning toFIG. 7, an exemplary embodiment of a toggle anchor30is shown that may be used in conjunction with one or more elongate rods40and/or cables (not shown). Generally, the toggle anchor30includes an anchor or foot portion32pivotally coupled to a bolt portion34at an intermediate location between first and second ends32a,32bof the foot portion32. The first end32aof the foot portion32may include a tapered, pointed, and/or other shaped tip to facilitate advancement into the ground92, and the second end32bincludes a socket33for removably receiving a rod40atherein, e.g., as shown inFIG. 8A.

The bolt portion34also includes a socket35for receiving a rod, cable, or other elongate member40btherein, also as shown inFIG. 8A. In one embodiment, a cable40bis substantially permanently attached to the bolt portion34, e.g., by looping one end of the cable40bthrough holes in the socket35and permanently attaching the end to an adjacent portion of the cable40b, e.g., by welding, crimping a sleeve over the cable40b, and the like. In another embodiment, an anchoring rod40bmay be substantially permanently received in the socket33, e.g., by one or more of welding, fusing, bonding with adhesive, interference fit, and the like. In a further alternative, the sockets33,35may be sized to slidably receive anchoring rods40therein. Alternatively, the sockets33,35and/or anchoring rods40may include threads or other features (not shown) for removably securing anchoring rods40in the sockets33,35.

The bolt portion34may pivot relative to the foot portion32between a delivery or low profile orientation where the bolt socket35is disposed adjacent the foot socket33, e.g., as shown inFIGS. 8A and 8B, to facilitate introduction of the toggle anchor30, and a deployed orientation where the bolt portion extends transversely, e.g., substantially perpendicular to a length of the foot portion32, e.g., as shown inFIG. 8D. As best seen inFIG. 7, the foot portion32may include a recess36along one side that extends partially between the first and second ends32a,32bfor receiving the bolt portion34in the low profile orientation, e.g., to minimize a profile of the toggle anchor30during advancement into the ground.

During installation, a driving rod40amay be inserted, e.g., threaded, into the socket33and the bolt portion34is positioned in the low profile orientation shown inFIG. 8Awith a cable40battached to the socket35extending substantially parallel to the rod40a. Alternatively, the cable40bmay be replaced with a rigid anchoring rod, similar to the driving rod40a. The anchor30may then be directed into the ground92at a desired location relative to the frame12, e.g., using handheld tools, e.g., a portable percussion hammer, to drive the driving rod40a, and consequently, the toggle anchor30and cable40b(or anchoring rod), a desired depth into the ground92with a second end of the driving rod40aand cable40bremaining exposed outside the ground92. Once the target depth is reached, the driving rod40ais unthreaded and/or otherwise removed from the socket33in the foot portion32, as shown inFIG. 8B, and out of the ground92. Then, as shown inFIG. 8C, the exposed second end of the cable40b(or anchoring rod) is pulled to cause the foot portion32to engage with the surrounding soil and pivot to the deployed orientation, e.g., substantially perpendicular to the cable40b(or anchoring rod), as shown inFIG. 8D. Once the anchor30is properly deployed, the exposed end of the cable40b(or anchoring rod) may extend out of the ground a desired distance. Optionally, any undesired length of the exposed end of the cable40b(or anchoring rod) protruding from the ground may be cut off or otherwise removed.

The exposed end of the cable40b(or anchoring rod) may be attached to the frame12in a desired manner to secure the frame relative to the ground92. Alternatively, if an anchoring rod is used instead of the cable40b, a cable may be attached to the exposed end of the anchoring rod and attached to the frame12. For example, as shown inFIGS. 10-1C, the cable40b(or anchoring rod) may be inserted through the shoe24and coupled to the leg20. Alternatively, as shown inFIG. 9A, the frame12may include a plurality of horizontal cables18extending between the struts12a,12bin a diagonal arrangement such that pairs of cables18intersect at locations19. Toggle anchors30(shown schematically) may be driven into the ground below the intersection locations19and cables38may be attached to the exposed cable or anchoring rod (not shown) and the locations19. In another alternative, shown inFIG. 9B, toggle anchors30may be driven into the ground at locations below the struts12a,12bof the frame12, and cables38may be attached between the exposed anchoring rods (not shown) and the struts12a,12b.

Turning toFIG. 10, the toggle anchors30may be driven into the ground at locations below one or more of the extension legs20and the exposed ends of the cables40b(or anchoring rods) may be attached to the shoes24and/or to the extension legs20. For example,FIG. 10Ashows an exemplary installation method for securing the shoe24, and consequently, the extension leg20, relative to a toggle anchor30deployed below the leg20. As best seen inFIG. 5, the shoe24includes a horizontal shoe plate25including one or more holes, e.g., a hole25a, adjacent the leg20through which the exposed end of the cable40may be inserted after delivering the anchor30. A fastener42may be advanced over the exposed end41of the rod40and engaged with the shoe24to apply a desired tension on the cable or rod40. For example, the fastener42may include a ratchet or other one-way mechanism (not shown) that may allow the fastener42to be advanced downwardly over the cable or rod40while preventing upward removal. Alternatively, if a rod is used instead of a cable for the anchor member40, the fastener42and rod40may include cooperating threads (not shown) that allow the fastener42to be threaded over the exposed end41of the cable40until the fastener42engages the shoe24.

Once the fastener42contacts the shoe plate25, any further advancement and/or retraction of the cable or rod40applies a tensile force along the cable or rod40between the anchor30and the shoe plate25. Thus, the fastener42maybe advanced (e.g., ratcheted or threaded) relative to the cable or rod40, as needed, to remove any slack and/or apply a desired tension pulling upwardly on the cable or rod40.

Optionally, the second end of the cable or rod40may include a loop43or other feature that may be engaged with the leg20to further attach the cable40. For example, the leg20may include one or more pins extending outwardly (not shown) over which the loop43may be placed once the fastener42is advanced to a desired distance.

Turning toFIG. 10B, before securing the cable or rod40to the leg20and/or shoe24, a load lift (tension) test may be performed to ensure that the toggle anchor30and cable or rod40satisfy engineering, regulatory, and/or other requirements to provide an earth-anchoring foundation for the modular unit10. In one embodiment, a single (or multiple) portable load test device60may be provided that may be used to test each anchor30and cable or rod40during installation. Alternatively, each extension leg20and/or shoe24may include an integral load test device (not shown), e.g., temporarily or permanently mounted to each extension leg20. As shown inFIG. 10B, the load test device60includes a housing62shaped to be positioned around and/or otherwise adjacent the extension support leg20on the shoe plate25including one or more handles62a, e.g., to facilitate carrying and/or position the device60such that the device60may be coupled to the cable or rod40to automatically test the anchor30and cable or rod40. The load test device60may include a motorized actuator, e.g., lead screw64carrying a hook64aor other element that may receive a loop43of the cable or rod40thereon, e.g., to pull upwardly on the cable or rod40to apply tension to the anchor30deployed below the extension leg20as the hook64ais directed upwardly along the lead screw64.

In addition, the load test device60may include a controller, e.g., including one or more processors and/or memory (not shown), a user interface66, and, optionally, a communication interface68. For example, the load test device60may include an input device66a, e.g., including one or more buttons, knobs, keypad, and the like, allowing a user to activate the device60and/or control operation of the lead screw64, e.g., to set a force applied to the cable or rod40. In addition, the device60may include an output device66b, e.g., a display that may present information to the user. In one embodiment, the user interface60may include a touchscreen (not shown) that may allow a user to present one or more menus and/or graphical interface that allows the user select information, set parameters, and/or otherwise control operation of the device60. The optional communication interface68may include a data port, e.g., such that the user may couple an external electronic device, e.g., portable computer, tablet, phone, flash drive, etc., to the device60, e.g., to receive data and/or control operation of the device60. In addition or alternatively, the communication interface68may include a wireless communications device, e.g., transmitter and/or receiver for transmitting data to and/or receiving instructions from a remote location, e.g., via a local wireless network, a telecommunications network, and the like. In another option, the device60may include clock and/or GPS device (not shown) such that the controller may associate a time stamp, GPS coordinates, and/or other information with test results obtained using the device60, as described elsewhere herein.

During use, the load test device60may be placed on the shoe plate25and mechanically coupled to the cable and/or rod40extending from ground, e.g., by placing a loop43around the hook64aand activated, e.g., by pressing a button or other actuator66a, such that the motorized mechanism64automatically applies a predetermined tension to the anchor30. In an exemplary embodiment, the controller and motorized mechanism may apply a present tension to the anchor30and cable or rod40, e.g., 1.5 times the design load for the modular unit10supported by the extension leg20. Thus, the load test device60may automatically confirm under real-time soil conditions that the anchor30with rod and/or cable40satisfies the applicable code and/or other requirements for the modular unit10for securing the modular unit to the ground92. The resulting load data, optionally along with other information, e.g., a time stamp, GPS coordinates, operator identifier, and the like may be stored in memory of the device60and/or communicated externally, e.g., to a device coupled to the data port68and/or transmitted wirelessly.

Upon completion of the test, the hook64amay automatically return to its lower position to remove the tension load, and the loop43may be removed from the hook64a. The cable or rod40may then be secured to the extension leg20and/or shoe24, e.g., using a fastener (not shown) advanced over the cable or rod40against the shoe plate25over the hole25aand/or securing the loop43over a pin (also not shown) on the extension leg20, as described elsewhere herein.

In an alternative embodiment, a manual load test device (not shown) may be provided. For example, the load device may include a tripod or other base to which a come-along hoist or other actuator is mounted. The user may couple the cable or rod40to the actuator, and manually apply the tension. The load test device may include a device that measures the tension and provides an output to the user, e.g., a mechanical or electronic scale.

This method may be repeated for each base plate (shoe plate)20, thereby securing the modular platform10relative to the ground92using the anchors30. Optionally, as the anchor foundations30are utilized to secure the platform10to the ground92, each anchor30may be tensioned independently to set the binding/toggle mechanism and obtain a tensioning value that may be recorded by the installer. This tensioning event may occur in real time soil conditions, and the data for each may be captured in a non-destructive manner while seating the anchors30using an appropriate tension to specified load conditions in real time soil conditions. This data may be made available to personnel in virtual real time through up loading of data to the “cloud” or other WAN/LAN based application in order to have a record of the anchor tensioning value at each anchor location, as described elsewhere herein.

For example, the load test device may include a communications interface, e.g., a Wi-Fi (e.g., Bluetooth) or telecommunications interface that may communicate the results of the test, e.g., to an operator device at the installation site, or remotely, e.g., to a storage or relay device. In one embodiment, the load test device may automatically associate other data with the test results, e.g., such that test results may be uniquely associated with a particular modular unit and/or particular leg of a modular unit. Such data may include one or more of GPS coordinates of the modular unit and/or leg, e.g., using an internal GPS in the load test device, a time stamp identifying the time and date of the test, an identifier corresponding to the operator and/or installer present during the test, and the like. Alternatively, the operator may input the results and/or other data into a portable device after each test, which may be stored and/or communicated to a remote location.

Turning toFIG. 14, the platform10may be assembled at an installation site or may be assembled in advance, e.g., at a manufacturing facility or other preparation location before delivery to the installation site. For example, in one embodiment, all of the components of the frame12and rack14may be delivered unassembled and assembled using conventional tools and methods. For example, turning toFIGS. 15A-15C, the struts12a-12cand legs20for the frame10may be manufactured separately and assembled together, e.g., using one or more fasteners and/or clinching, as described elsewhere herein. For example, brackets13may be attached to the ends of mid-struts12c, e.g., by a plurality of nuts and bolts (FIG. 15B), and the brackets13may then be attached to the front and rear struts12a,12b, e.g., using a plurality of nuts and bolts (FIG. 15C). Similarly, the mounting brackets22of the legs20may be attached to the front and rear struts12a,12b, e.g., using a plurality of nuts and bolts (FIG. 15C). In the exemplary embodiment shown inFIGS. 14 and 15A-15C, a leg20may be provided at the ends and midpoints of the front and rear struts12a,12b. It will be appreciated that the legs at the midpoints may be omitted or additional intermediate legs provided, as desired.

Optionally, as shown inFIGS. 15D and 15E, cross-braces15may be attached between the mid struts12cand legs20to further support the legs20relative to the frame12. For example, as shown inFIG. 15E, a plurality of bolts, may be directed through corresponding holes in the mid struts12cand the outer member26aof the legs20and secured with nuts to support the legs20substantially perpendicular relative to the frame12.

Similarly, as shown inFIGS. 15F-15J, the components of the rack14may also be delivered unassembled and assembled using conventional tools and methods. For example, turning toFIGS. 15F-15I, the supports14band back braces16of the rack14may be attached to the assembled frame12, e.g., using one or more fasteners and/or clinching. For example, opposite ends of the back braces16may include brackets16a,16bthat may be pivotally coupled to one end of the supports14b(FIG. 15G) and the mid struts12c(FIG. 15H), respectively, and the other end of the supports14bmay be attached to mounting brackets17attached to the front strut12a(FIG. 15I), to secure the supports14brelative to the frame12.

As shown inFIG. 15J, the rails14amay then be attached to the supports14b, e.g., using one or more nuts and bolts (or other fasteners and/or clinching, as described elsewhere herein), e.g., such that the rails14aextend the supports14bsubstantially parallel to the front strut12aof the frame12, e.g., as shown inFIG. 14. With the platform10assembled, one or more anchors (not shown) may be driven into the ground at the installation site and the exposed cables may be attached to the platform10, e.g., to the legs20, as described elsewhere herein, to secure the platform10relative to the ground at the installation site.

One or more solar panels90may then be attached to the rails14a, e.g., using one or more clips, fasteners, or other mechanisms, as described elsewhere herein, e.g., as shown inFIG. 10. Alternatively, other racks may be mounted to the frame12, e.g., a pivotable rack114such as that shown inFIGS. 11A-11E, to which a plurality of solar panels90may be mounted. In this alternative, the rack114may be pivotable around a horizontal axis115to adjust the incline of the solar panels90, e.g., to set the incline angle based on the location of the sun relative to the installation site and/or to allow the incline angle to be changed using a motorized actuator that automatically adjust the incline angle based on the time of day and/or other parameters, as described elsewhere herein. In a further alternative, other rack systems may be mounted to the frame12, e.g., having single axis or multiple axis pivoting capabilities, such as the rack shown inFIG. 11F.

Alternatively, the frame12and rack14(or any of the other racks described herein) may be preassembled with one or more solar panels, and the final assembly delivered to the installation site. Thus, in this alternative, a plurality of independent modular units may be delivered to an installation site, which may be secured using one or more toggle anchors with rods and/or cables as an earth-anchoring foundation. Optionally, in this alternative, the frame12may include legs20that are movable between storage and extended positions, as described elsewhere herein. For example,FIG. 13Ashows an exemplary embodiment of a platform110carrying one or more solar panels90. As described previously, the platform110includes a frame112including a plurality of legs120that are movable between the storage position shown for delivery to an installation site, e.g., nested together with other platforms, as shown inFIGS. 13B-13D.

Once the platforms are delivered to the installation site, the legs120may be directed to the extended position (e.g., as shown inFIG. 12A), anchors may be driven into desired locations, and cables from the anchors attached to the legs, as described elsewhere herein. Although each modular unit may be secured independently using its own set of one or more toggle anchors with rods and/or cables, the modular units may be adjusted as necessary to ensure that the solar panels mounted to the modular units are flush or otherwise oriented relative to one another to ensure efficient operation of the solar panels. For example, the extension legs120and/or frames may provide sufficient adjustability even in uneven terrain to ensure that the solar panels are properly oriented relative to one another.

Optionally, each modular platform10may include a powered control mechanism (not shown) which may be enclosed in the rear extension leg used as a support frame for adjusting the solar module frame12and/or rack14, e.g., to adjust the angle of the plane of the solar panels. For example, the mechanism may include a user interface that a user in the field may use to manually activate a motorized actuator coupled to the rack14to adjust the angle of the panels mounted to the rack14. Alternatively, the control mechanism may include a communications interface that may receive instructions remotely, whereupon the motorized actuator may be adjust the angle of the solar panels as desired, e.g., based on time of year, time of day, and/or other factors.

Turning toFIGS. 16A and 16B, another example of a modular, multi-configurable solar power platform210is shown that includes a frame212, support struts214, and a plurality of solar panels50, generally similar to other embodiments herein. Unlike previous embodiments, the frame212includes a plurality of leg subassemblies216with each subassembly216include a front leg218, a back leg220, and a cross member222extending between them. As best seen inFIG. 16B, each leg218,220includes an upper end218a,220acoupled to opposite ends222a,222b, of the cross member222and a lower end218b,220bcoupled to a shoe or base plate225. For example, each leg218,222may include a foot224integrally formed in, e.g., by bending the leg shaft, or attached to the lower end218b,220bto which the shoe plate225may be attached.

The legs218,220may be fixedly attached to the cross member222or one or both legs218,220may include a hinge coupling the upper ends218a,220bto the ends222a,222bof the cross member. In one embodiment, one or both legs218,220may include an adjustment member218c,220c, which may be used to adjust the lengths of the legs218,220, e.g., to adjust an overall height for the leg subassembly216and/or angle of the cross member222. For example, the legs218,220may include a manual adjustment member218c,220c, e.g., a telescoping structure similar to other embodiments herein, that may be adjusted manually using tools or automatically adjusted using a motorized actuator (not shown).

During installation, a plurality of leg subassemblies216may be provided for each modular unit210, e.g., two, three (as shown), four, or more, as desired based on the size and/or number of solar panels being mounted to the modular unit210. The leg assemblies216may be spaced apart and oriented with the feet224against the ground (not shown), and then struts214may be attached to the leg assemblies216, e.g., extending horizontally between the leg assemblies216as best seen inFIG. 16A. Optionally, additional structural supports may be added, e.g., one or more cables230attached to and/or extending between the leg subassemblies216. For example, a cable may be attached to the back legs220or adjacent leg subassemblies216, e.g., extending horizontally or diagonally between the leg subassemblies216to provide additional tensile and/or compressive support.

One or more toggle anchors30with cables and/or rods40may be inserted into the ground adjacent each leg218,220, tested, and coupled to respective shoe plates225and/or legs218,220, thereby providing an earth-anchoring foundation for the modular unit210, similar to other embodiments herein. One or more solar panels50may be mounted to the struts214and, optionally, one or more solar inverters, energy storage systems, and/or components may be mounted to the modular unit210, also similar to other embodiments herein. Alternatively, the modular unit210may be preassembled and delivered to an installation site (optionally with solar panels and/or components already mounted to the modular unit210), the legs218,220may be adjusted as desired, and anchors30with cables and/or rods40installed to secure the modular unit210at the installation site.

In accordance with each of the embodiments herein, once the modular units and solar panels and associated energy storage components are installed at an installation site, they may then be used to generate electricity, e.g., for use and/or energy storage at the installation site, similar to conventional solar panel systems. However, at any desired time, the cables and/or rods may be disconnected from the support legs (e.g., by removing the fasteners42and/or simply cutting the cables and/or rods), thereby allowing the modular units to be stored and/or transported for future use. For example, the legs120may be returned to the storage position, the modular units loaded onto a truck (e.g., as shown inFIGS. 13B-13D), whereupon the modular units may be transported to another location. Thus, the only material that may remain at the installation site are the anchors and cables within the ground, thereby minimizing the environmental impact of the platforms. Alternatively, sufficient tension may be applied to each of the rods and/or cables, e.g., equivalent to testing beyond load capacity, to pull the entire toggle anchor and associated subterranean rod and/or cable out of the ground, thereby leaving no material at the site after the panels are removed.

Further, in describing representative embodiments, the specification may have presented the method and/or process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims.