Tubular fluidic actuator system and method

An actuator comprising a bottom plate, a top-plate and one or more hub assembly extending between and rotatably coupling the bottom and top plates. The actuator also includes one or more bellows units disposed between the top plate and bottom plate, the one or more bellows units comprising a first and second inflatable bellows coupled by a web extending between the first and second bellows, the first and second bellows defining respective and separate first and second bellows cavities, with the first bellows of the bellows units disposed on a first side of the bottom plate, and the second bellows of the bellows units disposed on a second side of the bottom plate, opposing the first side, and between the top and bottom plates.

BACKGROUND

Conventional solar panel arrays are static and unmoving or configured to track the sun throughout the day to provide optimal capture of solar energy. Static solar panel arrays are often undesirable because they are unable to move and accommodate the changing angle of the sun during the day and throughout the year.

On the other hand, conventional moving solar panel arrays are also often undesirable because of their high cost of installation, the complexity of the mechanisms that move the solar panels, and the relatively high energy cost associated with actuating the solar panels. For example, some systems include motors that move individual solar panels or groups of solar panels. Such motors and other complex moving parts are expensive to install and maintain.

In view of the foregoing, a need exists for an improved solar panel actuation system and method in an effort to overcome the aforementioned obstacles and deficiencies of conventional solar panel actuation systems.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Since currently-available solar panel actuation systems are deficient, a fluidic actuation system as described herein can prove desirable and provide a basis for a wide range of applications, such as efficiently and cost-effectively moving solar panels about one or more axes. This result can be achieved, according to various embodiments disclosed herein, by a compliant pressurized fluid-filled actuator, hereafter referred to as a bladder, bellows, or the like, that can be part of an actuator assembly.

FIGS. 1aand 1billustrate respective top perspective and bottom perspective views of a solar tracker100in accordance with various embodiments.FIG. 2illustrates a side view of the solar tracker100. As shown inFIGS. 1a, 1band2, the solar tracker100can comprise a plurality of photovoltaic cells103disposed along a length having axis X1and a plurality of pneumatic actuators101configured to collectively move the array of photovoltaic cells103. As shown inFIG. 1b, the photovoltaic cells103are coupled to rails102that extend along parallel axes X2, which are parallel to axis X1. Each of the plurality of actuators101extend between and are coupled to the rails102, with the actuators101being coupled to respective posts104. As shown inFIG. 2, the posts104can extend along an axis Z, which can be perpendicular to axes X1and X2in various embodiments.

As shown inFIG. 2, and discussed in more detail herein, the actuators101can be configured to collectively tilt the array of photovoltaic cells103based on an angle or position of the sun, which can be desirable for maximizing light exposure to the photovoltaic cells103and thereby maximizing electrical output of the photovoltaic cells103. In various embodiments, the actuators101can be configured to move the photovoltaic cells103between a plurality of configurations as shown inFIG. 2, including a neutral configuration N where the photovoltaic cells103are disposed along axis Y that is perpendicular to axis Z. From the neutral configuration N, the actuators101can be configured to move the photovoltaic cells103to a first maximum tilt position A, to a second maximum tilt position B, or any position therebetween. In various embodiments, the angle between the neutral configuration N and the maximum tilt positions A, B can be any suitable angle, and in some embodiments, can be the same angle. Such movement can be used to position the photovoltaic cells103toward the sun, relative to an angle of the sun, to reflect light toward a desired position, or the like.

In one preferred embodiment as shown inFIGS. 1aand 1b, a solar tracker100can comprise a plurality of photovoltaic cells103that are collectively actuated by four actuators101disposed along a common axis. However, in further embodiments, a solar tracker100can comprise any suitable number of actuators101, including one, two, three, four, five, six, seven, eight, nine, ten, fifteen, twenty, fifty, one hundred, or the like. Similarly, any suitable number of photovoltaic cells103can be associated with a solar tracker100in further embodiments. Additionally, while photovoltaic cells103are shown in example embodiments herein, in further embodiments, actuators101can be used to move various other objects or structures, including mirrors, reflectors, imaging devices, communications devices, and the like.

In various applications, the ability to lock out actuator rotation can be desirable. In some embodiments, the lock out can be generated at predetermined angles. Locking out in a flat or 0 degree, 45 degree or max range of motion lock can be desired in various applications. Other applications can include instantaneous lock out, or the ability to freeze motion and increase stiffness at any angle.

In applications that may require specific angle lock outs, a variety of mechanism can be employed. For extreme angle lock outs, hard stops can be employed. A hard stop can be a solid state feature that prevents rotation past a set angle. In some examples, a bellows300(SeeFIG. 3) can be over pressurized to press up against a hard stop, increasing its stiffness at the extreme angle.

Hard stop features can take a variety of forms. For example, in some embodiments, the actuator assembly101can comprise one or more tensile rope or webbing coupled to and extending between top and bottom plates310,330of the actuator assembly101(seeFIG. 3). In another example, positive bosses can be provided as part of the actuator assembly101or proximate to the actuator assembly such that contact with the bosses constrains the range of motion of the actuator assembly. In various embodiments, such hard stops can be beneficial for preventing damage to the actuator assembly in high winds or exposure to other forces that might over-extend the actuator assembly. Pressurizing against a hard stop can also prevent excitation of destructive resonant frequencies induced by oscillatory loads (such as wind). In some embodiments, it can be beneficial to stow the actuator assembly against a hard stop when exposure to undesirable forces is anticipated (e.g., during a storm, or the like). These hard stops can also have a locking feature in order to stop all movement of the tracker when hit. This can serve as a stow mechanism that can further prevent damage to the tracker in a high-wind event.

In some embodiments, positional lock out at 0 degrees, or plumb to gravity, can be desirable. Mechanisms that can achieve this behavior include but are not limited to: 4 bar linkages, pneumatic rams, solenoids, lockable dampers, spring returns, inflated bladders, pressure sensitive toggles, and the like.

Stow, lock outs or hard stops can be provided in various suitable ways in accordance with further embodiments. For example, in one embodiment, there can be a separate actuator lock out for purposes of stow. For example, a separate small bladder can be used to actuate a locking mechanism that rigidly, or near rigidly, fixes an actuator assembly. In one embodiment, such a mechanism can comprise a pin that engages a corresponding hole or slot, or such a mechanism can comprise multiple pins or toothed arrangements that engage corresponding features enabling multiple locking positions. In another embodiment, such a mechanism can comprise corresponding brake pads that enable continuous locking independent of tracker position. Off-normal loading can also be used to engage a locking mechanism in accordance with some embodiments.

In further embodiments, a bar-linkage lock out can be used to stow or lock an actuator assembly101. For example, in one embodiment, an actuator piloted four bar linkage can be used to lock out tracker motion. In such an embodiment, An over-center four bar linkage between top and bottom plates310,330can be used to fix the position of the actuator assembly101for the purpose of stow, and the like. Such a mechanism can be actuated by an external actuator, collective bladder pressure, off-normal loading, or the like.

Other embodiments can require instantaneous lock out, or lock out in any position. Mechanisms that can be used to achieve this behavior include but are not limited to: air brakes, drum brakes, lock out pins. Lock out mechanisms can be piloted by pneumatics, hydraulics, electronics, passive means, or any other method.

In some embodiments, damping can be desirable for an actuator assembly101. Damping can be incorporated into the architecture of the actuator assembly101directly, or through a peripheral/add-on mechanism. A damper can be configured to smooth movement of a solar panel103coupled to the actuator assembly by providing resistance that reduces sudden or jerky movement of the solar panel. In other words, a damper can be configured to counter dynamic loading modes (for example, wind-induced oscillatory modes) and help with smoothing oscillation of an actuator assembly. Additionally, inclusion of dampers can be beneficial because it can allow an actuator assembly101to operate at a lower operating pressure, which can result in reduced stress on the actuator assembly, including stress on bellows, bladders, and the like.

To increase energy loss due to friction and enhancing damping, in some examples, material choice of high coefficient of friction materials can be employed. In some embodiments, including in various friction-based pivot dampers, the dampening coefficient can be modulated by varying the collective force applied by the bellows. By increasing collective bellows pressure, the stiffness provided by the dampener can be increased, ideal for high dynamic load cases.

In further embodiments, the damper can be configured in any suitable way. For example, the damper can be coupled to a top and bottom plate310,330(seeFIG. 3); the damper can be coupled to the bottom plate310and the second support; or the like. Add-on dampers can be linear or rotary in nature.

Add-on dampers can make use of viscous fluid dynamics, centripetal acceleration, friction losses, gas diffusion or any other applicable phenomenon. In further embodiments, a damper can be internally located or integrated directly into a compliant fluidic actuator, bellows or bladders. For example, the material of inflatable bellows can have a high damping coefficient, the inflatable bellows can be partially filled with a compliant material with a high damping coefficient, a block of porous material can be inserted into the inflatable bellows that restricts the passage of fluids in and out of said material thereby achieving damping, a block of elastomeric material that changes volume in response to external pressure with a significant damping coefficient, the bellows can be wrapped in a damping elastomeric material, and so forth.

Add-on mechanisms that increase damping and energy loss include but are not limited to: centrifugal clutches, viscous speed governors, linear viscous dampers, dashpots, viscoelastic crush ribs, or the like. In further embodiments, bladders or bellows can be filled with a fluid such as water, or the like, to generate a suitable damping effect. The damper can take both linear and rotary forms in accordance with various embodiments. In further embodiments a damper can be integrated with a flexure, hub or pivot system or between plates. For example, a flexure can be encased in an elastomeric damping material which might further serve to maintain separation of endplates, or elastomeric damping blocks can be stacked between plates.

The actuator assembly101can be fixed to a rack, a driven post, a space frame, directly to the ground, or any other suitable substrate. For example, the actuator assembly101can be coupled to the ground or other structure via a post104as shown inFIGS. 1a, 1band2. The actuator assembly101can be mounted to this post using bolts, nuts and washers through the flange of the member, or through a web of a bellows unit. An actuator bottom-plate can have built-in mounting features, or separate mounting brackets can be used.

The actuator assembly101can be attached to a substrate through a mounting bracket. A mounting bracket can comprise a plurality of components. A mounting bracket can allow for positional adjustment in one or many vectors or rotational angles. The mounting bracket can be incorporated into, or act in place of an actuator plate. In some embodiments, the actuator assembly101can be mounted directly on the substrate, such as a driven beam. In others, the actuator assembly101can utilize the mounting substrate, beam or frame to add strength to the actuator assembly101.

In another embodiment, the actuator assembly101can include a base that comprises a plurality of legs. In a further embodiment, the solar-actuator assembly101can include a base architecture that holds one or more weights. In one embodiment, the weights can comprise tanks that can be filled with fluid such as water. Such an embodiment can be desirable because the actuator assembly101can be lightweight for transport and then secured in place by filling the weights with water or other ballast at a desired location.

The actuator assembly can rotate a payload in various examples, including a payload of photovoltaic cells103as shown inFIGS. 1a, 1band2. The payload can be attached to the actuator assembly101in a variety of ways. In some embodiments, a top plate can be attached to the payload, while a bottom plate remains fixed to a mount. In embodiments with different architecture, the payload can be attached to a center plate, while the frame plate can be fixed to a static mount.

To attach the payload to the actuator assembly101, the use of spreader brackets or spreader rails can be employed. A spreader bracket rigidly attaches to the rotating plate or component of the actuator assembly101. The bracket can extend beyond the extreme end of the plate to which it can be attached. The distance of this spread can vary depending on the structural, regulatory or commercially stipulated needs of the payload.

A spreader bracket can be constructed of a metal, such as but not limited to steel, aluminum, a plastic, or a composite such as carbon fiber or fiberglass. A spreader bracket can comprise roll formed sections, extrusions, castings, composite layup or parts manufactured by any suitable method. A payload can be attached to rails that run perpendicular to and can be attached to spreader brackets.

Some embodiments of the actuator assembly101can attach a payload to the actuator via a central tube. The tube can couple the payload and the actuator assembly101and can transmit torsional load from the actuator to far down the axis of rotation. The torque tube can incorporate spreader brackets to spread attachment points to payload attachment points.

In some embodiments, one or more actuator assemblies101can be coupled together. For example, a pair of single-axis actuator assemblies101can be coupled together via one or more solar panels103and/or supports that extend between the actuator assemblies101. Similarly, another embodiment comprises a plurality of actuator assemblies101coupled together via one or more solar panels103and/or supports that extend between the actuator assemblies101(e.g., as shown inFIGS. 1aand 1b). In such embodiments, two or more actuator assemblies can move in concert to move a single solar panel array100. As shown in various embodiments, such an actuator assembly101can be anchored in the ground via posts104, or the like. Supports can be linked together using bolts and nuts with a connecting bracket, or with a nesting feature between the two lengths of support that can eliminate the need for an additional part. For example, an actuator assembly101can be coupled to a post104via a bolt assembly.

In one application, the actuator assembly can be used to move and position a solar panel103that is coupled to a top-plate. For example, in a first example the actuator assembly101can include a post104that the actuator assembly rests on. The post104can be held by a base or disposed in the ground (e.g., via a ground post, ground screw, or the like) in accordance with some embodiments. This post104can be driven into the ground at a variable length depending on loading conditions at the site. The post104can be a steel component with an I, C, hat, or other cross section. The post104can be treated with zinc plating, hot dip galvanizing, or some other method for corrosion resistance.

Although various example embodiments herein describe the use of an actuator assembly101with solar panels103, in further embodiments, an actuator assembly101can be used to actuate or otherwise move any other suitable object, including concentrators, reflectors, refractors, and the like.

An actuator assembly101having two bladders or bellows can be configured to move a solar panel103that is coupled to a top plate of the actuator assembly101via respective supports102that can be mounted perpendicularly to one another and extend along respective lengths of the solar panel. As discussed herein, the bladders or bellows of a one-axis actuator assembly can be configured to inflate and/or deflate to move the solar panel. Supports102can be some lightweight steel channel. This channel can have a C, Z, or some other desirable cross section. This channel can be roll formed, bent, or fabricated in some other manner.

FIG. 3illustrates a side view of an actuator101in accordance with one embodiment. As shown in the example ofFIG. 3, the actuator101comprises a V-shaped bottom plate310, a planar top-plate330, and a plurality of bellows300of a bellows assembly301disposed between the top and bottom plates330,310. A hub assembly370rotatably couples the bottom and top plates310,330and extends between the bottom and top plates310,330, with the hub assembly370.

The example embodiment ofFIG. 3illustrates the actuator101in a neutral configuration N (seeFIG. 2), where the top plate330extends along axis Y, which is perpendicular to axis Z in the neutral configuration N. However, as discussed herein, the top plate330can be configured to tilt to the left and right (or east and west as discussed herein) based on selective inflation and/or deflation of the bellows300of the bellows assembly301. Components of an actuator101can comprise various suitable materials, including metal (e.g., steel, aluminum, iron, titanium, or the like), plastic or the like. In various embodiments, metal parts can be coated for corrosion prevention (e.g., hot dip galvanized, pre galvanized, or the like).

A row controller380can be operably coupled with bellows300of the actuator via pneumatic lines390. More specifically, an east bellows300E can be coupled to a pneumatic circuit382of the row controller380via an east pneumatic line390E. A west bellows300W can be coupled to the pneumatic circuit382of the row controller380via a west pneumatic line390W. A pneumatic control unit384can be operably coupled to the pneumatic circuit382, which can control the pneumatic circuit382to selectively inflate and/or deflate the bellows300to move the top plate330of the actuator101to tilt photovoltaic cells103coupled to the top plate330.

For example, as described herein, bellows300of an actuator101can be inflated and/or deflated which can cause the bellows300to expand and/or contract along a width of the bellows300and cause rotation of the hub assembly370and movement of the bottom and top plates310,330relative to each other. Such movement of the hub assembly370can be generated when a solar tracker100is moving between a neutral position N and the maximum tilt positions A, B as shown inFIG. 2.

As discussed in more detail herein, a bellows assembly301can comprise any suitable plurality of bellows300, with the bellows300being any suitable size and shape. Additionally, as discussed in more detail herein a bellows assembly301can comprise one or more bellows units (see, e.g., bellows unit302ofFIGS. 5a-c) with each of the one or more bellows units comprising any suitable plurality of bellows, including in some embodiments, any suitable number of even numbers of bellows300. As discussed herein, in some embodiments, a plurality of bellows units that each have two bellows300can be stacked to form a bellows assembly301.

In various embodiments, the bellows300can be configured to expand along the width of the bellows300when fluid is introduced into the hollow bellows300or when the bellows300are otherwise inflated. Accordingly, the bellows300can be configured to contract along the width of the bellows300when fluid is removed from the hollow bellows300or when the bellows300are otherwise deflated.

Where bellows300are configured to expand width-wise based on increased pressure, fluid or inflation and configured to contract width-wise based on decreased pressure, fluid or inflation, movement of the photovoltaic cells103via one or more actuators101can be achieved in various ways. For example, referring to the example ofFIG. 3, rotating the photovoltaic cells103west (i.e., to the right in this example) can be achieved via one or more of the following:

Referring again to the example ofFIG. 3, rotating the photovoltaic cells103east (i.e., to the left in this example) can be achieved via one or more of the following:

Accordingly, in various embodiments, by selectively increasing and/or decreasing the amount of fluid within bellows300E,300W, the top plate330and photovoltaic cells103can be actuated to track the location or angle of the sun.

A tubular actuator assembly101can be a fluid driven, antagonistic type actuator. The Tubular actuator101can be driven by a pressurized working fluid. The working fluid can be gas, such as air, or a liquid, such as water, oil or the like.

The tubular actuator assembly101can work on a principle of antagonistic differential forces. For example, in an antagonistic actuator, two force-generating linear sub-actuators (e.g., bellows300, bellows assembly301and/or bellows units302) can be placed on either side of a pivot. The sub-actuators can generate forces of varying magnitudes. The extension length of the linear sub-actuator can be closely tied to a force it is generating. The sub-actuator can be said to have a “force to position” relationship. The magnitudes of the forces generated and thus the correlated length of the actuator assembly101can be dictated by a control system384. The control system384can choose the force values for both sub-actuators. When this is completed the free component or top plate330of the actuator assembly101can rotate until the torque generated by each actuator (force multiplied by the moment arm) sums to zero. If an external torque is applied to the rotating portion (e.g., top plate330) of the actuator assembly101, the actuator assembly101can rotate until the sum of the torques, external and internal, is zero.

In some examples of a tubular actuator assembly101, the sub-actuators can be inflated bladders or bellows300as discussed herein. These bladders or bellows300can be positioned on opposing sides of a pivot. Depending on the pressure, the controller384can inflate to the angle of a free plate (e.g., top plate330) of the actuator assembly101, the bellows300can supply a deterministic amount of force. The bladders or bellows300can apply this force given the specified angle, at a deterministic distance from the central hub assembly370. This can create a deterministic moment applied by each bellows300given an angle assumed by the rotating top plate330. All of this can result in a deterministic position given a specific control condition that can set the pressure in either bellows300. When the pressure in both bellows300has been set by the control unit384, the actuator assembly101can rotate until the torque (force times the moment arm) generated by both bellows300is equal. If an external torque is applied to the top plate330, the actuator assembly101can rotate until the sum of the torques, external and internal, is zero. Given external loading conditions, the actuator assembly101can exhibit a deterministic “pressure to position” relationship.

Depending on how the bellows300are affixed to the top and/or bottom plates310,330in some examples, the center of action can migrate in towards, or out away from a balance point or pivot of the hub assembly370. As an example, when a bellows300is at high pressure, and on the extended side of the hub assembly370, the contact patch, and thus the center of action of the force applied by the bellows300, can move closer towards a center pivot of the hub assembly370. As the top plate330rotates and the bellows300can go from an extended state to a compressed state, the contact patch can expand and the center of action can move out away from the pivot point of the hub assembly370. A variety of actuator configurations can be devised to take advantage of this effect.

In various embodiments, the hollow bellows300can be configured to be inflated and/or deflated with a fluid (e.g., air, a liquid, or the like), which can cause the bellows300to change size, shape and/or configuration. Additionally, the bellows300can be deformable such that the bellows300can change size, shape and/or configuration.

The bellows300can change between a first and second configuration in various suitable ways. For example, the bellows300can naturally assume the first configuration when unpressurized or at neutral pressure and then can assume the second configuration via physical compression and/or a negative pressurization of the bellows300. Additionally, the bellows300can naturally assume the second configuration when unpressurized or at neutral pressure and then can assume the first configuration via physical expansion and/or a positive pressurization of the bellows300.

Additionally, the bellows300can be in the second configuration at a first pressurization and expand to the first configuration by pressurization to a second pressure that is greater than the first pressure. Additionally, the bellows300can be in the first configuration at a first pressurization and contract to the second configuration by pressurization to a second pressure that is less than the first pressure. In other words, the bellows300can be expanded and/or contracted via selective pressurization and/or via physical compression or expansion.

In some embodiments, it can be desirable for the bellows300to engage the top and/or bottom plates330,310in a contacting and/or rolling manner in various configurations. In some embodiments, a contact-region of the top and/or bottom plates330,310can provide for a rolling contact between convolutions of a bellows300, which can be beneficial during movement of the bellows300as discussed in more detail herein. Additionally, such a contact-region can be beneficial because it can reduce strain on the bellows300during compression and can increase the stiffness of the bellows300in certain configurations.

Although certain example embodiments of bellows300are illustrated herein (e.g.,FIGS. 5a-c, 6a-c,20,21a,21b,22aand22b), these example embodiments should not be construed to be limiting on the wide variety of bellows shapes, sizes and geometries that are within the scope and spirit of the present invention. For example, in some embodiments, convolutions can have varying size and shape, including varying in a pattern, or the like. Additionally, the bellows300can have a curved or rounded contour or can include edges, square portions, or the like.

An actuator assembly101can move to assume a plurality of configurations based on the inflation and/or deflation of the bellows300. For example, the actuator assembly101can assume a first configuration A, where a plane TO of the top plate330is parallel to a plane BA of the base plate310. In this first example configuration A, the bellows300are of equal length and have a straight central axis CE that is perpendicular to top and bottom planes TO, BA. In such a configuration, the bellows300can be at a neutral pressure, partially inflated, or partially deflated. Accordingly, by selectively inflating and/or deflating the bellows300of the actuator assembly101, the plane TO of the top plate330can be moved to various desired positions.

In some embodiments, single degree of freedom (DOF) actuators can be stacked, to achieve 2 DOF, 3 DOF or any other numbers of DOF.

The architecture of the actuator assembly101can take a variety of forms. One example actuator101assembly can comprise a top plate330rotatably coupled to a bottom plate310. The bottom plate310is then rigidly coupled to a post104, frame or any other suitable substrate. Inflatable, flexible sub-actuators, bladders, or bellows300can be disposed on either side of the coupling. When inflated differentially, the bellows300can rotate the top plate330to a specific position. This example architecture can be modified in any suitable manner.

In one embodiment, a top plate330can be rotatably coupled to a bottom plate310in the shape of an inverted V. The bellows300can engage with the top plate330on the underside of its wings and with legs311of the V-plate bottom plate310. The V-plate can take any suitable angle to achieve the desired range of motion, stiffness or any other behavior or performance. In some embodiments, it can be desirable for the V plate angle to be 90 degrees. For greater range of motion, the V-Plate can have an angle less than 10 degrees. For greater stiffness, the actuator assembly101can have a bottom plate angle greater than 120 degrees. In some embodiments, it can be desirable to have a bottom plate angle at the extremes, 180 degrees, flat, where bellows300press on the wings of the plate on either side of the coupling. It can also be desirable in some examples to have a plate with an angle of 0 degrees. In some examples, the bottom plate310can more aptly be called a middle plate, in that the bellows300can act on either side of the thin plate, rather than on opposing lobes. Likewise, the top plate330can take a V-shape and can be configured in any angle (e.g.,FIGS. 15b, 17a-c,18and19). The V-shape in either plate310,330can also be inverted in some examples. An actuator assembly101can comprise any combination of top and bottom plates310,330.

Another embodiment can comprise an A-frame that is rigidly affixed to a mounting substrate. A center plate can be rotatably coupled to the center of the A-frame. The bellows300can mount to engage with either side of the center plate. The bellows300can be attached to a coupling point by a web or fascia attached to the bellows300. The bellows300can also be affixed to either the frame or the center plate.

Turning toFIG. 4, in various embodiments, a plurality of solar trackers100can be actuated by a row controller380in a solar tracking system400. In this example, four solar trackers100A,100B,100C,100D can be controlled by a single row controller380, which is shown being operably coupled thereto. As described in more detail herein, in some examples, a plurality of trackers100or a subset of trackers100can be controlled in unison. However, in further embodiments, one or more trackers100of a plurality of trackers100can be controlled differently than one or more other trackers100.

While various examples shown and described herein illustrate a solar tracking system400having various pluralities of rows of trackers100, these should not be construed to be limiting on the wide variety of configurations of photovoltaic panels103and fluidic actuators101that are within the scope and spirit of the present disclosure. For example, some embodiments can include a single row or any suitable plurality of rows, including one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, fifteen, twenty, twenty five, fifty, one hundred, and the like.

Additionally, a given row can include any suitable number of actuators101and photovoltaic panels103, including one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, fifteen, twenty, twenty five, fifty, one hundred, two hundred, five hundred, and the like. Rows can be defined by a plurality of physically discrete tracker units. For example, a tracker unit100can comprise one or more actuators101coupled to one or more photovoltaic panels103.

In some preferred embodiments, the axis of a plurality of solar trackers100can extend in parallel in a north-south orientation, with the actuators101of the rows configured to rotate the photovoltaic panels about an east-west axis. However, in further embodiments, the axis of trackers100can be disposed in any suitable arrangement and in any suitable orientation. For example, in further embodiments, some or all rows may not be parallel or extend north-south. Additionally, in further embodiments, rows can be non-linear, including being disposed in an arc, circle, or the like. Accordingly, the specific examples herein (e.g., indicating “east” and “west”) should not be construed to be limiting.

Also, the rows of trackers100can be coupled to the ground, over water, or the like, in various suitable ways, including via a plurality of posts. Additionally, while various embodiments described herein describe a solar tracking system400configured to track a position of the sun or move to a position that provides maximum light exposure, further examples can be configured to reflect light to a desired location (e.g., a solar collector), and the like.

Turning toFIGS. 5a-c, three example embodiments302A,302B,302C of a bellows unit302are illustrated. As shown inFIGS. 5a-c, a bellows unit302can comprise a pair of bellows300that are coupled via a web303, with each of the bellows300defining one or more bellows cavity305. For example,FIG. 5aillustrates a bellows unit302A comprising a pair of bellows300connected via a web303with the bellows300defining a respective and separate single bellows cavity304.FIG. 5billustrates a bellows unit302B comprising a pair of bellows300connected via a web303with the bellows300defining a respective and separate first and second bellows cavity304A,304B.FIG. 5cillustrates a bellows unit302C comprising a pair of bellows300connected via a web303with the bellows300defining a respective first and second bellows cavity304A,304B that are connected via a port305that allows for fluid to pass between the bellows cavities304A,304B.

While three examples302A,302B,302C of a bellows unit302are illustrated, this should not be construed to be limiting on the wide variety of further embodiments of a bellows unit that are within the scope and spirit of the present disclosure. For example, further embodiments can include bellows300having any suitable plurality of cavities304(e.g., three, four, five, ten, twenty, and the like).

Additionally, in various embodiments, the bellows unit302can comprise one or more plane of symmetry. For example, as shown in examples302A,302B,302C ofFIGS. 5a-c, a bellows unit can include a first plane of symmetry that extends vertically through the web303; and can include a second plane of symmetry that extends horizontally through the web303and the bellows300and can include a third plane of symmetry that extends vertically through the web303and the bellows300. In some embodiments, one or more of such planes of symmetry can be absent.

Also, in various embodiments, the bellows300can have a shape such that the bellows300become increasingly thicker from the web303outward as shown inFIGS. 5a-cand then thinner toward a terminal end. However, the bellows can have various suitable shapes and sizes in further embodiments. For example, in some examples, the bellows can comprise convolutions, ribs, or the like.

Turning toFIGS. 6a-c, one embodiment301A of a bellows assembly301is illustrated that comprises a first and second bellows unit302X,302Y. As shown in this example embodiment301A, the first bellows unit302X comprises a first and second elongated tubular bellows300X1,300X2that are coupled via a first web303X and a second bellows unit302Y comprises a first and second bellows300Y1,300Y2that are coupled via a second web303X.

The first and second bellows units302X,302Y are shown stacked and coupled together via elongated top and bottom clamp-down bars307,308disposed at and extending along a length of the webs303of the bellows units302. More specifically, the top clamp-down bar308is disposed abutting the first web303X of the first bellows unit302X with the bottom clamp-down bar307disposed abutting the second web303Y of the second bellows unit302Y. The top and bottom clamp-down bars307,308are coupled via bolts309that extend through the webs303.

As shown in the example ofFIGS. 6a-c, the portions of the top and bottom clamp-down bars307,308that engage the webs303of the bellows units302can have a rounded profile, which can be desirable for being less likely to damage and introduce failure points to the webs303; however, in further examples, the top and bottom clamp-down bars307,308can have any suitable profile. Also, top and bottom clamp-down bars307,308can be coupled together in various suitable ways in addition to or as an alternative to bolts309.

The first and second bellows units302X,302Y further comprise ports306that communicate with cavities304(see, e.g.,FIGS. 5a-c) defined by the bellows300. For example, the first bellows unit302X comprises a first port306X1associated with the first bellows300X1and a second port306X2associated with the second bellows300X2. The second bellows unit302Y comprises a first port306Y1associated with the first bellows300Y1and a second port306Y2associated with the second bellows300Y2. All of the ports306are shown disposed on the same side of the bellows assembly301A. For example, the first bellows unit302X comprises a first port306X1associated with the first bellows300X1and a second port306X2associated with the second bellows300X2. The second bellows unit302Y comprises a first port306Y1associated with the first bellows300Y1and a second port306Y2associated with the second bellows300Y2. All of the ports306are shown disposed on the same side of the bellows assembly301A.

The first and second bellows units302X,302Y can be configured in various suitable ways, including configurations302A,302B,302C, shown inFIGS. 5a-c, or any other suitable configuration. Also, while the example bellows assembly301A ofFIGS. 6a-chas two bellows, units302, further examples can include any suitable plurality of bellows units302or can have a single bellows unit302.

Although certain example embodiments of an actuator assembly101shown herein comprise a specific number of bellows300(e.g., four, two, one, zero), these examples should not be construed to be limiting on the wide variety of configurations of an actuator assembly101that are within the scope and spirit of the present invention. For example, various embodiments of an actuator assembly101can include any suitable plurality of bellows300(e.g., 3, 5, 6, 7, 8 or more); can include a single bellows300; or bellows300can be absent. The orientation of the bellows300and the direction of the force they exert can also change. Rotational motion of an actuator assembly101can be accomplished with bellows300providing a force that is not parallel and in the same direction, but the bellows300can be oriented on the same side of a pivot point of the rotational actuation, so that the forces are parallel but in opposite directions, or the bellows300can be oriented so that they are offset 90 degrees from the pivot point, so that the forces are perpendicular, or in many other orientations where the moments created by each bellows300in an actuator assembly101are in different directions.

In some embodiments it can be desirable for a bellows300to comprise one or more ultra-violet (UV) stabilizers, UV-absorber, anti-oxidant, thermal stabilizer, hydrolysis stabilizer, carbon black, glass fill, fiber reinforcement, electrostatic dissipater, lubricant concentrate or the like. Materials of the bellows300can be selected based on a desired manufacturing technique, bellows strength, bellows durability, range of motion, compliance, sun-resistance, temperature resistance, wear resistance, fatigue resistance and the like. In some embodiments, where the bellows300is employed in a location that experiences sun exposure, it can be desirable to include a protective UV coating or UV stabilizer in the bellows300.

While some embodiments of the bellows300can only comprise a single layer, others can comprise a plurality of layers. For example, the thickness of a bellows300can comprise three layers. An inner layer can be constructed of thin impermeable layer of thermoplastic elastomer that is flexible and holds pressure when inflated. A middle layer can comprise a structural layer constructed of a biaxially stretched PET or other material capable of higher tensile loads. Such a layer can provide structural integrity or aid in the restraint of the bladders. A third, external layer can comprise a carbon black doped HDPE to protect against UV, wind-blown sand abrasion, or other environmental irritants. In this sense, the external layer can act as a shielding layer. An external layer can also act as a sacrificial layer. The outer layer can also exhibit other special properties, such as low coefficient of friction, special texture, or desirable optical or aesthetic properties that can enhance the performance or value of the product. In other embodiments, a bellows300can be made of two or more materials in sequence. For example, one embodiment can comprise a bellows300with sequentially alternating HDPE and PP convolutions, or the like. A bellows300can comprise any suitable constructions with the purpose of offloading particular functions or requirements of the bellows300to different layers while keeping aggregate costs down. Bellows300can include strengthening or protective shrouding.

Multilayer bellows300can be constructed by any suitable manufacturing processes, including: co-extrusion, sequential co-extrusion, co-extrusion blow molding, glue lamination, heat lamination, fabric wrapping, filament winding and any other manner of manufacturing. In some embodiments bladders can be manufactured from sheet material. In these embodiments, fabric or plastic sheeting can be sewn, heat welded, ultrasonically welded, laser welded, glued laminated, clamped or bonded by any other suitable manufacturing processes.

Flexible bellows300can have fabric or fiber reinforcement. Such incorporations can afford a bellows300with enhanced tensile strength or wear properties, while preserving flexibility and function. Enhanced tensile strength from fiber reinforcement can allow for greater factors of safety, increased operating pressures and associated stiffness, longer fatigue life, enhanced resistance to puncture, and generally boosted durability.

Fiber reinforcement can be incorporated via filament winding, sewn fabric shrouding, extrusion-coated fabric. Fiber reinforcement can be directly incorporated into the bellows300, for example, as an additive to plastic extrusion. Fiber reinforcement can be incorporated into a bellows300through the welding, fusing or laminating of a fabric or fibered layer to a plastic or elastomeric bladder wall. Fiber reinforcement can also be indirectly incorporated. For example, a fabric sheet can be wrapped around a hermetic bladder and then secured to actuator plates. An architecture of this nature can, in some examples, reinforce and strengthen the bladder while simultaneously affixing it to the rigid plate components.

In some embodiments, multiple bellows300can be formed as a single part. In some manufacturing processes multiple bellows300chambers can be joined by a connecting fascia. Manufacturing processes in which such a construction could be formed include, but are not limited to, extrusion blow molding, injection stretch blow molding, fabric sewing, injection molding, and dip molding.

In one such embodiment, a two-chambered bellows300can be formed through extrusion blow molding. An oversized tube of molten plastic can be extruded, a two-chambered mold can be closed around it, and the chambers can be pressurized to set the part shape. The resulting part can have two independent chambers connected at the center by a solid plastic fascia. The independent chambers can each have in-molded barb tubes for pneumatic connections, or can have molded features that enable attachment of another appropriate connection type. This method of manufacture can also place features such as weld or pinch lines in ideal areas, where operation stress and strain can be minimized. The material connecting the chambers of the bellows300can be thicker than the chambers of the bellows and capable of taking high tensile loads. For example, the material connecting the chambers of the bellows300can be twice as thick as the chambers of the bellows300. In some actuator architectures, a connecting web303of a bellows unit302can be slung over the pivot ridge312on the bottom plate310, or any other suitable attachment point in the actuator assembly101. This web303, in some examples, can act as a constraint, affixing the bellows300, and obviating the need for a secondary or external method of bellows constraint.

A similar bellows300construction can be achieved by sewing fabric. A fabric sheet can be folded and sewn in such a way to create independent bellows300chambers, as well as a connecting web303.

Parts with a plurality of bellows chambers can also be made so that the chambers are not independent of each other. In such an embodiment, two chambers can be connected to each other by a tube, channel, pillow plate bead, or any other feature that allows for unimpeded fluid flow between the chambers. Such a construction can be useful in actuator architectures that utilize stacked bellows300. In this architecture, a multi-chamber bellows300can be folded such that one bellows300resides on top of the other on one side of the actuator pivot ridge312. A similar architecture can be found on the other side of the pivot ridge312. A channel between the chambers of the bellows300that allows for fluid flow can generate equal pressurization of both chambers and can obviate the need for separate fluid connections to the chambers in some examples.

Bellows300can be any suitable thickness in various portions, including about between 0.002 inches and 0.125 inches, and about between 0.0005 inches and 0.25 inches. In various embodiments, the thickness of various portions of the bellows300can be selected based on a desired manufacturing technique, bellows strength, bladder durability, range of motion, compliance, sun-resistance, temperature resistance, and the like.

Embodiments of the actuator assembly101can comprise bellows300of various shapes and sizes. For example,FIGS. 5a-c, 6a-c,20,21a,21b,22aand22billustrate some example embodiments300A,300B,300C,300D,300E,300F,300G,300H and300J of a bellows300, but these examples should not be construed to be limiting. Additionally, any of the internal structures of embodiments300A,300B and300C can be present in embodiments300D,300E,300F,300G,300H and300J or other embodiments.

A bellows300can be designed to have one of a variety of diameters. The diameter of a bellows300incorporated into an actuator assembly101can dictate the pressure-to-position relationship achieved by the actuator assembly101. In some embodiments, a small diameter can be chosen to optimize for cost or packing efficiency. In other embodiments a large diameter can be chosen to optimize for strength, stiffness and dynamic performance.

A bellows300can be designed to be of any length. For bellows300having shapes with an extended or extruded body section, the body section can be of any length. A bellows300with a short body section can approximate a sphere. A bellows300with a longer body section can have a pill shape or a noodle shape. A body of a bellows300can be extended indefinitely and take the form of a true tube or hose.

A bellows300can be designed to have one of a variety of fundamental shapes. Some embodiments can feature a bellows300that comprises an extruded form body. The extruded cross-section can be circular, oval, teardrop-shaped, have convoluted lobes or take on any extrudable profile. In some embodiments, a bellows300may not have a defined body section. In these embodiments the boundary between body and cap can be blurred. Some examples of bellows300in this category can be cone-shaped, tapered, spherical, kidney bean-shaped, incorporate convolutions, or have some other amorphous shape.

A body section of bellows300can be terminated at either end with caps. Caps of a bellows300can take on various shapes depending on the application. The terminations or end caps on the bellows300can take a variety of shapes, including hemispheres, truncated cones, right cones, oblique cones, convoluted bladder, ellipsoid, or the like.

In some embodiments, features can be formed into bellows300during the molding process. Such features can include, but are not limited to, locating bosses, hard stops, convolutions, tubing, pneumatic connectors, and the like. In other embodiments, features can be attached to bellows300in any number of suitable manners. Attachment methods can include hot plate welding, ultrasonic welding, heat sealing, gluing, press fitting, or a variety of other methods.

In some examples a tube/bulbous bellows300can be desirable over other types of inflatable fluidic actuators. The following provides some examples of potential benefits of some embodiments.

Stronger Pressure to Position Relationship—A large areal change can generate a stronger pressure to position relationship (>>Δ psi/Δ degree). In some embodiments, this not only means greater static stiffness, but can also generate better accuracy (e.g., actual angle to command angle), and/or intra-tracker precision (e.g., tracker to tracker consistency). Some examples can include hysteresis and accuracy that is less dependent on recent actuator positional history. Further examples can have better leak tolerance (e.g., positional stability given a leak rate).

Better Static Stiffness—Due to the large areal change from the compressed to extended positions in some examples, as well as a change in effective moment arm over the full range of motion, a tube actuator of some examples can provide 2-5× the static stiffness of other types of actuators. If static stiffness is a limiting factor in some examples (e.g., interior tracker), this can mean the actuator can be tolerant to increased load and allow more W/Actuator in some examples.

Reduced Compressed Air Burden—In some examples, a tubular actuator operating at the same peak pressure as an alternative fluidic actuator design may exhibit substantially reduced compressed air consumption while retaining at least the same dynamic stiffness as other types of bellows300. This can reduces the parasitic power loss, can decrease the needed compressor output (e.g., per 2 MW array) and can also increase the number of actuators per row controller (e.g., if stow or another fill related metric can be limiting).

Simpler Pivot Solution—In some examples, a bellows-based actuator can utilize a pure pivot instead of a bending wire rope flexure. In some embodiments, a simple pivot design can enable the inclusion of a viscous damper; however, in some embodiments, a viscous damper may not be included on every actuator in every tracker, but can be used in various situations (e.g., exterior trackers) to deal with excessive wind/dynamic loads, and the like.

Lower Payload Center of Mass—In some embodiments, a simple pivot can enable a low center-of-mass design. An actuator assembly101configured with a lower center-of-mass can take a greater payload while keeping performance constant, compared to other types of actuators.

Less Complexity—In some examples, tube actuator constraints can be less complex and embody less material than constraints in other actuator systems. Accordingly, in various embodiments, the assembly part count of bellows actuators can be greatly reduced compared to other actuator systems.

Efficient Plate Geometries—Actuator configurations of some embodiments of a bellows actuator can allow the top and bottom plates310,330to take more efficient shapes compared to other actuator systems. Plates310,330can be designed to be bent at high angles to make use of compressive and tensile elements that effectively and efficiently bear the antagonistic forces with less material.

Enhanced Bladder Protection—Various bellows actuator configurations can better protect pneumatic bellows from UV, blown sand and accidental puncture (e.g., during installation or maintenance) compared to other actuator systems.

Improved Moldability—In various examples, tube bellows can be much easier to blow mold compared to other actuator systems. For example, cylinders can be the easiest thing for some molders to process. This can mean that various examples of tube bellows can have less value-added cost and better average quality (e.g., better material distribution/low thickness variation) compared to other actuator systems.

Reduced Part Weight—Compared to some other actuator systems, a bellows can comprise about one-quarter to one-eighth less material. In addition to the material savings, the lower part weight can also result in reduced molding cycle times. Cycle times of bellows actuator systems can be on the order of 15-30 seconds, as opposed to 80-110 seconds for other actuator systems. This can mean less value added per part and more annual output per mold for some embodiments of bellows actuators.

Fiber Reinforcement—In some examples, cylindrical bellows, or the like, can be desirable for fiber incorporation. For example, filament winding, fabric wrapping, and the like can be used in bellows of bellows actuators. Fiber reinforcement can allow for increased operating pressures, greater durability/resistance to puncture, a reduction in expensive engineered materials per molded part, and the like.

Turning toFIGS. 7aand 7b, the bellows assembly301ofFIGS. 6a-cis shown with pneumatic lines390coupled to ports306of the bellows300. More specifically, a pair of pneumatic lines390E,390W are shown with each comprising lines705that are coupled to respective ports via crimps710at a first end of the lines705. A second end of the lines705are coupled to a Y-connector715that communicates with a coupler720. The east pneumatic lines390E are coupled to the first bellows300X1,300Y1of the first and second bellows units302X,302Y and the west pneumatic lines390W are coupled to the second bellows300X2,300Y2of the first and second bellows units302X,302Y.

As discussed herein, the pneumatic lines390can provide for fluid being introduced to and/or removed from the bellows assembly301to move an actuator assembly101as discussed herein (see, e.g.,FIGS. 2 and 3). For example, the east pneumatic lines390E can allow the first bellows300X1,300Y1to be inflated and/or deflated in unison. In various embodiments, the east pneumatic lines390E are configured to provide the same amount of fluid and the same fluid pressure to the first bellows300X1,300Y1. Similarly, the west pneumatic lines390W can be configured to provide the same amount of fluid and the same fluid pressure to the second bellows300X2,300Y2. For example, the coupler720of the east pneumatic lines390E can be fluidically coupled to a first fluid source that controls the first bellows300X1,300Y1, and the coupler720of the west pneumatic lines390W can be fluidically coupled to a second fluid source that controls the second bellows300X1,300Y1.

FIG. 8illustrates a close-up side view of ports306and couplers710of the bellows assembly301A ofFIGS. 6a, 6b, 7aand 7b. Tubing705is shown coupled to ports306of bellows300via a barbed fitting711disposed within ends of the tubing705and ports306with crimps710locking the fittings711to the ports306.FIGS. 7a, 7band 8dillustrate example embodiments of how pneumatic lines390can be coupled to a bellows assembly301; however, in further embodiments, pneumatic lines390can be coupled to a bellows assembly301in various other suitable ways.

Various examples can include use of interference fit barbed fittings pressed into blow-molded bladders. Various examples can include a pneumatic architecture, including: Harness tube branch→orifice connector→Y connector→2× tube to top bladder.

In some examples, locating the flow limiting orifice on the harness side of the Y connector results in twice the flow through the orifice relative to putting orifices on the bladder side. This can enable greater flow restriction from the same orifice geometry.

Flow restriction devices can include any suitable device or structure. For example, a restrictor can comprise a body that defines a fluid passage having a pair of ports that provide for entry and/or exit of fluid into the fluid passage. Another example can include a coiled fluid passage. A further example can include a serpentine fluid passage. In various embodiments, such a restrictor can be a portion of a bladder, cap, or the like. In other embodiments, a restrictor can comprise a multi-layer fluid passage, or the like.

The hub assembly top portions372can comprise at least a portion of a shoulder bolt374, which can rotatably couple with hub assembly bottom portions376(See, e.g.,FIGS. 10a, 10b, 11a, 11b) to define a hub assembly370.

Turning toFIGS. 10aand 10b, a perspective and side view the bottom plate310ofFIG. 3is illustrated which comprises a pair of arms311that extend from a ridge312where the arms311are coupled to hub assembly bottom portions376. The arms311define faces313on which bellows300of bellows assemblies301can bear against to move the actuator101as discussed herein (see, e.g.,FIGS. 2 and 3). The arms311can further define a slot314that is defined by sidewalls316of the arm311. In various embodiments, the slot314and sidewalls316can be configured to couple with various structures such as a post, or the like, which can serve as a stand or support for the actuator assembly101and tracker100(see, e.g.,FIGS. 1 and 2).

The hub assembly bottom portions376can include a bolt hole378that can comprise or engage with a shoulder bolt374(FIGS. 9a, 9b) such that the bottom plate310can be rotatably coupled with the top plate330via the hub assembly370defined by the top and bottom hub assembly portion372,376.

Additionally, the hub assembly bottom portions376can include one or more coupling holes379, which can provide a location for a bellows assembly301to couple with the base plate310. While a hub assembly370defined by top and bottom hub assembly portions372,376and including a shoulder bolt374is shown in various examples, further embodiments can include various suitable structures to couple the top and bottom plates310,330such that the top and bottom plates310,330can move relative to each other by inflation and/or deflation of bellows300of a bellows assembly301having one or more bellows units302.

For example, in some embodiments, the hub assembly370can comprise a joint, a pivot, a hinge, a bending flexure, a linkage, or another suitable mechanism or form of attachment.

In some embodiments, a hub assembly370can comprise pivot or an axle seated in bearing or bushing and can be employed to connect the mount to the payload. An actuator assembly101can comprise a single hub assembly370, or a plurality of hub assemblies370. Hub assemblies370can be cantilevered, supported on both sides, or have any other suitable construction. An axle component of a hub assembly370can be a hardened steel shaft, a flanged clevis pin, a shoulder bolt, or any other type of axle. An axle can be threaded on one or both ends and screwed into a threaded hole, or fastened with a nut and washer assembly. The axle can be fastened with shaft clamps or any other securement method for smooth shafts. Additionally, a shaft can have any number of features formed into it to aid fastening, or location of assembly components. Some such features can include girdling grooves for circlip fasteners, transverse holes for securement by cotter pin, set screw or twisted wire, or shaft shoulders, for locating other assembly components or features.

A bearing component of a hub assembly370can include a ball bearing, a sleeve bushing or any other species of bearing. The bearing can be constructed of metal, included, but not limited to, steel, copper, brass, bronze, as well as plastics, including, but not limited to, acetal, HDPE, nylon, and Teflon. The bearing can also be some combination of materials, or made of oil impregnated or alloyed material.

In some embodiments, a hub assembly370can comprise a flexure to attach the payload to the base or to connect top and bottom plates310,330of an actuator assembly101. A flexure, or flexible/bending connector, can take a variety of forms in various examples. A flexure can be constructed of metal sheets or twisted strands such as spring steel sheets flexures, wire rope, or springs, or the like. A flexure can take any suitable length. Metal flexures can also comprise assemblies of metal flexure components such as crossed or angled wire rope, spring steel crosses or the like.

A wire rope can be used as a flexure. The flexure can hold the actuator plates310,330together under tensile load, while still allowing for rotation of the free plate relative to the fixed plate. The wire rope can be made of any suitable material and can have any suitable strand and bundle configuration. The flexure can be coupled via a Nicopress fitting, via swaging, via a Spelter socket, or the like.

In further embodiments, a flexure for a single-axis actuator assembly101can comprise a parallel rope flexure, a planar flexure, a load bearing pivot, a four-bar linkage, a tetrahedral linkage, or the like. Such flexures can comprise any suitable material, including a metal, plastic, fiber reinforced composite, or the like.

For example, an embodiment of an actuator assembly101can comprise a flexible planar flexure that extends between a bottom and top plate310,330. Another embodiment of an actuator assembly101can comprise a flexible tetrahedral linkage defined by a rope that extends between a bottom and top plate310,330. A further embodiment of an actuator assembly110can comprise a pivot that extends between a bottom and top plate310,330.

An actuator assembly101can also comprise snap-in connections, twist-in connections, one-way push-in barb connections, toggle locks or any other suitable mechanism or connection to facilitate quick and inexpensive assembly of an actuator assembly101.

In some embodiments, a 2-degree-of-freedom actuator can be employed. The corresponding attachment method can comprise a universal joint, a spring, a spherical bearing, a wire rope or any other mechanism.

The faces313of the arms311of the bottom plate can have flat profile as shown inFIGS. 10aand 10b; however, in further embodiments, the faces313can have a convex or concave profile. Similarly, while the slab331of the top plate330can have a flat profile on the underside of the top plate330where bellows300of a bellows assembly301engage the underside of the top plate330, in further embodiments, the underside of the top plate330can have a convex or concave profile. The angle θ between the faces313of the arms311is shown as being 70° in the example ofFIGS. 10aand 10b; however, in further examples, the angle θ can be within the range of 90°-60°, 75°-65°, 71°-69°, and the like.

An actuator can comprise one or a plurality of plates in various examples. An actuator assembly101with multiple plates can have plates that are rotatably coupled. Bellows300can be disposed between the plates, with the surface of the plates interfacing with the bellows300. An actuator assembly300can comprise plates in any suitable architecture, in any suitable shape. This can include strain plates, angled plates, ribbed plated, extruded section plates, multi-piece plates, or the like.

In some embodiments, the interfacing faces of the plates310,330can be curved, or have some complex geometry. Modifying the topography of a plate can change the performance of an actuator assembly101in some examples. Actuator performance or durability can be optimized by such deviations from the baseline, flat, plate design. Geometric deviations can be of a variety of forms, including single plane curvature, compound, multi-plane curvature, the addition of bosses or holes, or the like. Top and bottom plates310,330can be fabricated through a variety of processes, including die casting, progressive stamping, laser cut and bent, injection over-molded, or the like.

In various embodiments, the top and bottom plates310,330can comprise any suitable material, including a polymer, metal, wood, composite material, a combination of materials, or the like. Additionally, although specific configurations of the top and bottom plates310,330is shown herein, further embodiments can include plates having any suitable configuration. For example, various suitable embodiments of the top and bottom plates310,330can be configured to interface with the bellows300so as to distribute a point load from a flexure, pivot, axel or hub assembly. Plates can also comprise and leverage existing structures, such as mounting piles, spanning beams or the like.

Top and bottom plates310,330can be made in any suitable way. For example, in one embodiment, a cold rolling process can be used in conjunction with metal stamping to create a C-channel plate with the appropriate interfacing features for the top and bottom plates310,330as described herein. Plates can also be formed of standard hot and cold-rolled sections. Plate features can be die cut, CNC punched, laser cut, waterjet cut, milled or any other suitable subtractive manufacturing method. A plate can also comprise multiple standard sections or custom formed parts. Plates of this nature can be bonded together with a variety of fasteners, including rivets, nuts and bolts, welds or the like.

In another embodiment, manufacture of the top and bottom plates310,330can include the creation and processing of composite panels. For example, a composite top or bottom plate310,330can comprise a multi-material sandwich plate that takes advantage of a lightweight and inexpensive core material and the stiffness and strength of thinner sheets of skin material that can adhere to either side of the core substrate. Such composite paneling can be used as high stiffness, high strength, low weight, low-cost flooring or construction material.

In some embodiments, a composite top or bottom plate310,330can comprise a honeycombed polymer core that can take compressive and shear loads, sandwiched between two metal skins that can bear the high tensile stresses caused by bending. It is possible to bind the top or bottom plate310,330with bolts, heated staked columns, ultrasonic welding, or the top or bottom plates310,330can be assembled with an adhesive.

Utilizing metal stamping, top and bottom plates310,330can be produced having multi-planar curvature stamped metal skins and an injection-molded polymer core. The structure that such geometry creates can give greater stiffness to a top and bottom plate310,330per the volume of material used and provides an opportunity to cut down on the expensive metal skin material. Stiffening features, such as ribs, bosses, deep drawn pockets and webbing, can also be incorporated into the design of top and bottom plates310,330in some embodiments.

In some embodiments, the plates need not be single planar elements. For instance, the bottom plate310can be two individual surfaces each parallel to the two opposing flanges of the post such that the bellow interfaces point 180 degrees away from one another rather than 0 degrees as in other example configurations. The body of each of the bellows300then could bend through 90 degrees to meet the top plate330when the actuator assembly101is level. In this case, the plate may not be a bending element, but instead be compressive. The plates310,330can also take a V-shape with major angle dictated by the desired range of motion of the actuator assembly101.

For example, an actuator assembly101, in accordance with a further embodiment, can include a top plate having first and second portions that are rotatably coupled at a joint. Such first and second bellows300can be coupled to respective bottom sides of the first and second portions and to a side of a post. Inflation of the bellows300can make the top plate assume a flat configuration, whereas deflation of the bellows300can make the top plate assume a V-shape configuration.

Bellows300can be affixed to the actuator assembly101and top and bottom plates310,330in various suitable ways. Bellows300that are not securely attached in some examples can fall out of position, causing improper actuator behavior and performance, or can cause the actuator assembly101to cease to work together. A feature or mechanism used to keep the bellows300in place can be a “constraint,” or the like.

In one embodiment, such a constraint can comprise a fabric sheath that wraps around the bellows300and connects them to an attachment point on the plates310,330and/or hub assembly370of the actuator101. The fabric wrap can encircle a single bellows300in some embodiments. In such an embodiment, the wrap can be terminated with a slotted rod, hooks, grommets or any other suitable feature. These features can then be used to attach the constraint-wrapped bellows300to the actuator assembly101. In another embodiment, the constraint can be designed to encircle two separate bladders and connect them by an interstitial web303. This web303can be perforated with grommets or have any other features or fasteners incorporated to it. The connected wrapped bellows300can then by disposed on either side of the actuator pivot point or ridge312, between top and bottom plates310,330, the web303draped either over the pivot point or ridge312, the center axis of the top or bottom V-plate310,330, or over any other suitable feature.

As an example, a flat sheet of polymer-coated fabric can be laid out on a table. Two bellows300can be disposed, parallel to each other on top of the fabric. The two edges of the fabric, parallel to the long axis of the bellows300, can be pulled over their respective bellows300. The edges can be then joined in the middle and pinned to the center of the fabric sheet. This assembly of two bellows300can be wrapped in fabric and connected to each other via a web303, which can define a bellows unit302, as discussed herein. The web303can be perforated or can have grommets installed. These holes can then be draped over interfacing bolts or pins, located on the ridge312of a bottom V-Plate310. Nuts or other suitable fasteners can be used to secure the constraint and, thus, the bellows300in the appropriate location.

In another example, the aforementioned construction, two separate bellows300wrapped by fabric and connected via an interstitial fascia, can be disposed on the same side of the pivot on an actuator assembly101to form a stacked bellows configuration. This can be mirrored onto opposing side of the actuator assembly101, across the pivot point for a total of four bellows300, two on each side in a stacked configuration. A wire rope can then be looped to girdle the interstitial webs303between each bellows chamber pair and constrain them to the central pivot point, hub assembly370or V-plate ridge312.

Constraints can be made of any suitable material, including steel, aluminum, HDPE, PVC, fiberglass, carbon fiber, fabric, polymer-coated fabric, spun polymer like Spectra or Dyneema, or the like. Constraints can be reinforced with nylon webbing, wire rope, fabric, Spectra, Dyneema, or any other suitable method. Constraints can be manufactured by sewing, heat welding, extrusion, injection molding, blow molding, roto-molding, die casting, stamping or any other suitable method.

In various examples, the bottom plate310can be configurable from an angled configuration as shown inFIGS. 10aand 10b, to a flat configuration as shown inFIGS. 11aand 11b, where the arms311can be folded from being disposed relative to each other at angle θ to being generally flat. Such a flat configuration can be desirable in some embodiments for shipping and transportation of an assembled actuator assembly101having the bottom plate or transportation of the bottom plate310as a separate unit.FIGS. 12aand 12billustrate an embodiment101A of an actuator assembly101having a top plate330, bottom plate310and bellows assembly301, with the bottom plate310in a flat configuration (e.g., as shown inFIGS. 11aand 11b).

While various embodiments of an actuator assembly101include top and bottom plates310,330that are spaced apart via a hub assembly370(e.g., actuator assembly101A ofFIGS. 6a-12b) in some embodiments, the top and bottom plates310,330can be directly coupled or proximately coupled via a hub assembly370(e.g., an actuator assembly101B,101C,101D,101F as shown inFIGS. 13, 14a,14b,15a,15band18a).

Additionally, various embodiments discussed herein include a planar top plate330and a triangular or V-shaped bottom plate310. For example,FIG. 15aillustrates an example embodiment101C of an actuator assembly101having a planar top plate330and a triangular or V-shaped bottom plate310, whereasFIG. 15billustrates an example embodiment101D of an actuator assembly101having a V-shaped top plate330and a triangular or V-shaped bottom plate310.

In further embodiments, the top plate330of an actuator assembly101can have other non-planar configurations. For example,FIGS. 16 and 17illustrate an embodiment101E of an actuator assembly101having a top plate330with a planar portion1605and a pair of arms1610that extend at an angle from the planar portion1605of the top plate.

Also, while various embodiments can comprise a hub assembly370having a top and bottom hub assembly portion372,376rotatably coupled via a shoulder bolt374, a hub assembly370can be configured in various other suitable ways. For example,FIG. 18billustrates an example embodiment of an actuator assembly101G having a hub assembly370comprising a flexure1870that couples the top and bottom plates310,330. In various examples, the flexure1870can include a flexible member that bends as the top plate330is actuated by bellows300of a bellows assembly301. In another example,FIG. 18cillustrates a further example embodiment of an actuator assembly101H having a hub assembly370comprising a rod1872that extends from the top plate330and coupled with an axle1874that is rotatably coupled to the base plate310such that the top and bottom plates310,330are rotatably coupled.

Turning toFIGS. 19aand 19b, in some embodiments, a top plate330can be T-shaped and can include a bar1930with a spine1932that extends from a central location of the bar1930. The T-shaped top plate330can be rotatably coupled to a peak of a bottom plate310via a hub assembly370. The bottom plate310can comprise an actuator cavity1932defined by arms1914of the base plate310. In these example embodiments101J,101K, a bellows assembly301can be disposed within the actuator cavity with bellows300engaging and disposed on opposing sides of the spine1932. As the bellows300are inflated or deflated, the bellows300can push and/or pull on the spine1932such that the top plate330rotates relative to the base plate310.

In the embodiment101J ofFIG. 19a, the top plate330can be coupled to the hub assembly370along a length of the spine1932, whereas in the embodiment101K ofFIG. 19bthe top plate330can be coupled to the hub assembly370at a junction of the spine1932and bar1930.

In some embodiments, V-plate bulbous actuators can be antagonistically positioned in a V-configuration with a flexure or pivot at the turning point. Compliant cylinders can be inflated antagonistically so as to effect a strong pressure to position ratio. The cylinders can be constructed in multiple ways, including blow molding, rotomolding, with a fabric tube with sealed ends, with a sewn fabric envelope with separate impermeable bladder, and the like. Multiple bulbous actuators can be stacked for greater range of motion.

For example, one example embodiment of an actuator assembly can comprise a first and second bellows300, which can be respectively disposed in chambers of a cavity defined by a sector body and a spine that is rotatably coupled to the sector body at an axle. The sector body can be defined by a pair of radial arms and an arc rim. The radial arms can extend from the axel with the arc rim extending between the opposite ends of the radial arms.

The spine can be coupled to a portion of a plate, which, in this example, is coupled at an approximately 90 degree angle from a face of the plate substantially at the center of the plate. The sector body can maintain a fixed position relative to the ground (e.g., via a post or the like) and the plate can be rotated by selective inflation and/or deflation of one or both of the actuators.

In the example configuration, the plate can be in a flat configuration where a top face of the plate is generally parallel with the ground or perpendicular to gravity. In such a configuration, the first and second actuator can be inflated substantially the same amount, which makes them of equal width within the respective chambers. In contrast, a tilted configuration where the first actuator is less inflated than the second actuator can cause the volume of the first chamber to decrease and the volume of the second chamber to increase. Accordingly, the spine can be rotated within the cavity, which in turn can cause the plate to tilt.

The described embodiments are susceptible to various modifications and alternative forms, and specific examples thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the described embodiments are not to be limited to the particular forms or methods disclosed, but to the contrary, the present disclosure is to cover all modifications, equivalents, and alternatives.