SUBSURFACE DATA TO DETERMINE FOUNDATION INSTALLATION PARAMETER

RELATED APPLICATIONS

[0001]This application claims the benefit of U.S. Provisional Patent Application No. 63/710,883, filed Oct. 23, 2024, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

[0002]This disclosure relates generally to systems, methods, and machines for using subsurface condition data to determine one or more foundation component installation parameters and using such one or more determined foundation component installation parameters to embed a foundation component.

BACKGROUND

[0003]As the price of solar has dropped relative to fossil fuel-based energy sources, single-axis solar trackers are becoming the preferred form factor for so-called utility-scale solar arrays. Utility-scale arrays may span a few megawatts of capacity up to hundreds of kilowatts. Single-axis trackers are configured as North-South oriented single or double rows of solar panels attached to a torque tube. The torque tube is attached to a motor or other drive mechanism that slowly rotates all the attached panels at once, so they move from East-facing to West-facing to follow the sun's daily movement through the sky.

[0004]Tracker companies usually supply all the components that attach to the torque tube (e.g., bearings, motors or drive assemblies, dampers and module brackets), but rely on other companies to supply the foundation that anchors their systems to the Earth using a standard interface.

[0005]When installing a solar tracker foundation in the ground, soil conditions at subsurface the solar tracker foundation installation location can vary. In particular, for a given utility-scale solar tracker array that can span a large area, subsurface soil conditions can vary considerably on a localized basis. For example, one foundation for a utility-scale solar tracker may be embedded in the ground at a first location having relatively soft subsurface soil conditions (e.g., muddy soil), while another foundation for the utility-scale solar tracker may be embedded in the ground at a second, different location having relatively hard subsurface soil conditions (e.g., granite boulder embedded in the muddy soil). Such different subsurface soil conditions can warrant one or more different foundation installation parameter(s) when embedding the foundation in order to achieve sufficient foundation load bearing capacity and structural stability at the different subsurface soil conditions.

SUMMARY

[0006]This disclosure relates generally to systems, methods, and machines for acquiring and using subsurface condition data to determine one or more foundation component installation parameters. Such embodiments can then implement such one or more determined foundation component installation parameters to embed a foundation component in the ground.

[0007]As noted, subsurface soil conditions at a solar tracker installation site can vary considerably on a localized basis, and such differences in subsurface soil conditions can impact embedded foundation load bearing capacity and structural stability. Embodiments disclosed herein can procure subsurface data relating to one or more subsurface soil conditions at one or more locations where a foundation component is to be installed. By examining subsurface soil conditions at a location where a foundation component is to be embedded, embodiments disclosed herein can use data relating to one or more subsurface soil conditions to determine one or more foundation component installation parameters that, when implemented, can better optimize embedment of the foundation component for the particular subsurface soil conditions at that particular embedment location.

[0008]In this way, embodiments disclosed herein can determine one or more foundation component installation parameters adapted to the particular subsurface soil conditions at that foundation embedment location. For instance, embodiments disclosed herein can determine the presence of first subsurface soil conditions at a first foundation installation location and, based on presence of first subsurface soil conditions at a first foundation installation location, select a first foundation component installation parameter for that first foundation installation location. And, such embodiments disclosed herein can determine the presence of second, different subsurface soil conditions at a second, different foundation installation location and, based on presence of the second subsurface soil conditions at the second foundation installation location, select a second, different foundation component installation parameter for that second foundation installation location. This, in turn, can help to improve solar tracker installation efficiency and effectiveness while also reducing the need for foundation structural remediation efforts post-installation.

[0009]One embodiment disclosed herein is a control system for a solar tracker foundation component embedment machine. This control system embodiment includes at least one control node, a non-transitory storage device, and a programmable processor. The storage device stores program code for controlling the at least one control node to embed one or more solar tracker foundation components into underlying ground. The programmable processor is communicatively coupled to the storage device and the at least one control node. Executing the stored program code causes the programmable processor to: acquire subsurface condition data from a subsurface sensing device, the subsurface condition data relating to at least one subsurface condition at a first solar tracker foundation installation location; use the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location; and cause the at least one control node to embed the at least one solar tracker foundation component at the first solar tracker foundation installation location using the determined at least one solar tracker foundation installation parameter.

[0010]In a further embodiment of this control system, using the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location includes determining at least one of: a type of foundation component and an embedment depth into the underlying ground. For example, using the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location can include determining the type of foundation component based on the acquired subsurface condition data. For instance, determining the type of foundation component using the acquired subsurface condition data can include selecting the type of foundation component from the group consisting of a screw anchor foundation component, a helical pile foundation component, and a blade pile foundation component. As another additional or alternative example, using the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location can include determining the embedment depth into the underlying ground based on the acquired subsurface condition data.

[0011]In a further embodiment of this control system, the subsurface sensing device includes a subsurface radar device that is configured to emit and receive subsurface radar data at the first solar tracker foundation installation location. According to such an embodiment, using the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location includes using the received subsurface radar data to determine at least one of: a type of foundation component and an embedment depth into the underlying ground. In other additional or alternative examples, the subsurface sensing device can include a soil sample collection mechanism, which is configured to collect a physical sample of subsurface soil at the foundation installation location, and a sensor, which is configured to examine the content of the physical soil sample collected by the subsurface soil sample collection mechanism. According to one such additional or alternative example, using the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location includes using data from the sensor relating to the content of the physical soil sample to determine at least one of: a type of foundation component and an embedment depth into the underlying ground.

[0012]In a further embodiment of this control system, the at least one control node is coupled to a rotary driver, and executing the stored program code causes the programmable processor to actuate the rotary driver to embed the at least one solar tracker foundation component at the first solar tracker foundation installation location using the determined at least one solar tracker foundation installation parameter. For example, the determined at least one solar tracker foundation installation parameter can include an embedment depth into the underlying ground for the at least one solar tracker foundation component at the first solar tracker foundation installation location determined using the acquired subsurface condition data from the subsurface sensing device.

[0013]In a further embodiment of this control system, the control system further includes a user interface communicatively coupled to the programmable processor. Executing the stored program code can further cause the programmable processor to: cause the user interface to output an indication relating to the determined at least one solar tracker foundation installation parameter. For example, executing the stored program code can cause the programmable processor to: (i) use the acquired subsurface condition data to determine at least a type of foundation component to be installed at the first solar tracker foundation installation location, and (ii) output, to the user interface, an indication relating to the determined type of foundation component to be installed at the first solar tracker foundation installation location.

[0014]Another embodiment disclosed herein includes a machine for driving foundation components. This machine embodiment includes a base machine, an adjustable mast attached to the base machine, a rotary driver movably attached to the mast and controllable to drive a foundation component into underlying ground, and a control system. The control system includes a programmable controller executing a control program for controlling the rotary driver to drive the foundation component into underlying ground at a first foundation installation location. The control program contains program code causing the programmable controller to: acquire subsurface condition data from a subsurface sensing device, the subsurface condition data relating to at least one subsurface condition at the first foundation installation location; use the acquired subsurface condition data to determine at least one foundation installation parameter for driving the foundation component into the underlying ground at the first foundation installation location; and cause the rotary driver to embed the foundation component at the first foundation installation location using the determined at least one foundation installation parameter.

[0015]In a further embodiment of this machine, the program code causes the programmable controller to use the acquired subsurface condition data to determine at least one foundation installation parameter for driving the foundation component into the underlying ground at the first foundation installation location includes determining a type of foundation component based on the acquired subsurface condition data. For example, determining the type of foundation component based on the acquired subsurface condition data can include selecting at least the type of foundation component from the group consisting of a screw anchor foundation component, a helical pile foundation component, and a blade pile foundation component.

[0016]In a further embodiment of this machine, the program code causes the programmable controller to use the acquired subsurface condition data to determine at least one foundation installation parameter for driving the foundation component into the underlying ground at the first foundation installation location by at least determining an embedment depth into the underlying ground based on the acquired subsurface condition data.

[0017]In a further embodiment of this machine, the machine includes the subsurface sensing device in communication with the control system, and the subsurface sensing device is configured to emit and receive subsurface energy waves at the first solar tracker foundation installation location to acquire the subsurface condition data relating to the at least one subsurface condition at the first foundation installation location.

[0018]In a further embodiment of this machine, the program code causes the programmable controller to actuate the rotary driver to embed the foundation component into underlying ground at the first solar tracker foundation installation location using the determined at least one solar tracker foundation installation parameter. For example, in one such embodiment, the program code can cause the programmable controller to automatically actuate the rotary driver to embed the foundation component into underlying ground at the first solar tracker foundation installation location using the determined at least one solar tracker foundation installation parameter.

[0019]An additional embodiment disclosed herein includes a method of controlling a machine for driving foundation components. This method embodiment includes the steps of: with a programmable controller communicatively coupled to the machine, acquiring first subsurface condition data from a subsurface sensing device, the first subsurface condition data relating to at least one subsurface condition at a first foundation installation location; with the programmable controller communicatively coupled to the machine, using the acquired first subsurface condition data to determine at least one foundation installation parameter for installing at least one foundation component at the first foundation installation location; and embedding the at least one foundation component at the first foundation installation location using the determined at least one foundation installation parameter.

[0020]In a further embodiment of this method, the method can additionally include the step of: prior to embedding the at least one foundation component at the first foundation installation location, outputting, at a user interface that is in communication with the programmable controller, a first indication relating to a first type of foundation component for the at least one foundation component to be embedded at the first foundation installation location. Embedding the at least one foundation component at the first foundation installation location using the determined at least one foundation installation parameter can include embedding the first type of foundation component at the first foundation installation location.

[0021]In a still further embodiment of this method, the method can additionally include the steps of: with the programmable controller communicatively coupled to the machine, acquiring second subsurface condition data from the subsurface sensing device, the second subsurface condition data relating to at least one subsurface condition at a second, different foundation installation location; with the programmable controller communicatively coupled to the machine, using the acquired second subsurface condition data to determine at least one foundation installation parameter for installing at least one foundation component at the second foundation installation location; prior to embedding the at least one foundation component at the second foundation installation location, outputting, at the user interface that is in communication with the programmable controller, a second, different indication relating to a second, different type of foundation component for the at least one foundation component to be embedded at the second foundation installation location; and embedding the second, different type of foundation component at the second foundation installation location.

[0022]The details of one or more examples are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF DRAWINGS

[0023]The following drawings are illustrative of particular examples of the present invention and therefore do not limit the scope of the invention. The drawings are intended for use in conjunction with the explanations in the following detailed description wherein like reference characters denote like elements. Examples of the present invention will hereinafter be described in conjunction with the appended drawings.

[0024]FIG. 1 illustrates a perspective view of a screw anchor foundation component that can be driven by the machine according to various embodiments of the invention.

[0025]FIG. 2 is an exemplary EARTH TRUSS foundation in accordance with various embodiments of the invention.

[0026]FIGS. 3A-3C illustrate a foundation component driving machine in accordance with various embodiments of the invention. FIG. 3A is a perspective view of this foundation component driving machine embodiment, and FIGS. 3B and 3C show a portion of the foundation component driving machine's mast oriented at different driving angles.

[0027]FIG. 4 is an isolation view of the mast and attached components of the embodiment of the foundation component driving machine of FIG. 3A.

[0028]FIG. 5 is an exemplary control circuit usable with the various embodiments of the invention.

[0029]FIG. 6 is a block diagram showing an exemplary control system for using subsurface condition data to determine at least one foundation installation parameter and then using that determined at least one foundation installation parameter to drive a foundation component into the ground according to various embodiments of the invention.

[0030]FIG. 7 is a block diagram showing an exemplary control system architecture for a foundation component driving machine according to various embodiments of the invention.

[0031]FIGS. 8A and 8B illustrate schematic, block diagrams of a foundation component driving machine in accordance with various embodiments of the invention procuring subsurface condition data from a subsurface sensing device to determine at least one foundation installation parameter. FIG. 8A shows the foundation component driving machine procuring first subsurface condition data, at a first installation location, from a subsurface sensing device to determine a first foundation installation parameter. FIG. 8B shows the foundation component driving machine procuring second, different subsurface condition data, at a second, different installation location, from the subsurface sensing device to determine a second, different foundation installation parameter.

[0032]FIG. 9 is a flow diagram showing steps of a method for acquiring subsurface condition data and using this acquired subsurface data to determine at least one foundation installation parameter for embedding a foundation component into the ground.

[0033]FIG. 10 is a flow diagram showing steps of a method for embedding solar tracker foundation components at different locations using subsurface data acquired at the different locations.

DETAILED DESCRIPTION

[0034]The invention will now be described in the context of the drawing figures where like elements are referred to with like designations. This description is intended to convey a thorough understanding of the embodiments described by providing a number of specific embodiments and details involving methods, machines and systems for embedding foundation components, such as for single-axis solar trackers. It should be appreciated, however, that the present invention is not limited to these specific embodiments and details, which are exemplary only. Although the various embodiments of the invention may be especially useful for adapting one or more foundation installation parameters to the particular subsurface soil conditions at that intended single-axis solar tracker foundation embedment location, they may also be useful for controlling and improving the embedment process for foundation components for a variety of numerous other structures. It should be further understood that one possessing ordinary skill in the art in light of known systems and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative embodiments, depending upon specific design and other needs.

[0035]Embodiments disclosed herein can use subsurface condition data, corresponding to a location where a foundation anchor component is to be embedded, to determine at least one foundation installation parameter that is then used when embedding that foundation anchor component at that location where the subsurface condition data was previously procured. In this way, embodiments disclosed herein can be capable of implementing one or more different foundation anchor component installation parameters at locations having different subsurface soil conditions. This can allow embodiments disclosed herein to use information about one or more subsurface soil conditions (e.g., subsurface soil load bearing capacity) at a specific foundation installation location to then execute a foundation anchor component embedment using one or more foundation anchor component installation parameters suited for the particular subsurface soil conditions present at a specific foundation installation location.

[0036]FIG. 1 illustrates a perspective view of a foundation component 10 that can be driven by a foundation component driving machine to embed the foundation component 10 in underlying ground, according to various embodiments of the invention. Such foundation component 10 can thus be referred to a foundation anchor component to which one or more above ground support legs can be attached. The illustrated embodiment here shows the foundation component 10 as a screw anchor type foundation component configured to be embedded at least partially in the ground. The screw anchor foundation component 10 can have a generally uniform interior and/or exterior diameter with an open end at the distal and/or proximal ends. Other examples of foundation components 10 can be used, such as a helical pile type anchor foundation component that is configured to be embedded at least partially in the ground and/or a blade pile foundation component that is configured to be embedded at least partially in the ground. The helical pile type foundation component can include one or more blade members extending out from a shaft around at least some of the perimeter of that shaft. Some helical pile type foundation components can include a pair of blade members extending out from generally opposite sides of the shaft and around some or all or a perimeter of the shaft. For some embodiments, the blade pile foundation component can be a blade pile as disclosed in PCT Published Patent Application No. WO2023/060315, the disclosure of which is hereby incorporated by reference.

[0037]FIG. 1 shows exemplary foundation component 10 usable with various embodiments of the invention. Foundation component 10 of the screw anchor type can consist of a hollow, substantially uniform diameter shaft 11 that is open at both ends with external threads 12 at one end and a driving collar 15 at the other. The illustrated embodiment shows external threads 12 at a uniform diameter across the external diameter of the screw anchor shaft, though in other embodiments threads 12 may have a tapered profile so that their outside diameter increases moving up the shaft to create a lead-in. The threads may also, in various embodiments, be tilted slightly upwards, that is, towards collar 15 to provide additional resistance to pull out. The length of foundation component 10 may be variable depending on the desired depth of embedment (e.g., 1-2 meters). In the context of foundations for single-axis trackers and other axial solar arrays, embedment depth may be dictated by subsurface soil type, grade of land, torque tube height, among other factors. The inside diameter of the shaft may be between two and half and three inches and the thickness on the order of a few millimeters. It may be formed from galvanized alloy steel or other suitable material. In some cases, it may be coated with one or more additional anti-corrosion coatings such as fusion bonded epoxy, polyurethane, and acrylic among others. Driving collar 15 may be a separate cast structure welded on to the upper end of shaft 11 or, alternatively, may be stamped or otherwise formed in the upper end. Threads 12 may be welded to the outside of shaft 11 at the lower end, may be attached with bent tabs or, in some cases may even be stamped into the lower end. The threads enable screw anchor type foundation component 10 to be driven into, and at least partially embedded at, supporting ground with a combination of torque and downforce. The open end allows a drill or other tool to be extended through foundation component 10 while the anchor is being driven into the ground to enable it to go through dense soil, rocks or other strata that might refuse the anchor itself.

[0038]The Applicant of this disclosure has developed a foundation system for axial solar arrays that reduces the amount of steel required to support an array relative to conventional H-piles and can include a pair of foundation components 10, such as a pair of screw anchors such as shown at FIG. 1. One variant of this foundation system that is particularly well-suited for supporting single-axis trackers and known commercially as EARTH TRUSS, is shown in FIG. 2. The EARTH TRUSS system 5 shown in FIG. 2 consists of a pair of adjacent screw anchor type foundation components 10 that have been driven into supporting ground at angles to one another on the East and West sides of an intended North-South line of a tracker row. Though it is to be noted embodiments within the scope of this disclose could likewise utilize other types of solar tracker foundation components other than a screw anchor type, for instance, such as a pair of helical pile type foundation component 10. Once foundation components 10 have been driven to their target embedment depth, an upper leg 16 is attached to each foundation component 10 via driving collar 15. In various embodiments, each upper leg 16 may be temporarily sleeved over one of the collars 15 while an adapter or truss cap 20 is fitted into the opposing ends of each upper leg 16 to complete the foundation. In various embodiments, the foundation component driving machine may include a jig or other device that orients the adapter or truss cap so that it is level and aligned with a laser line to be at the at the same Y (East-West) and Z (up-down) position as every other adapter in the current row. In various embodiments, once the adapter or truss cap 20 has been properly aligned, upper legs 16 may be crimped at each end, that is, at the areas of overlap with foundation components 10 and with truss cap or adapter 20, thereby forming a rigid A-frame structure. In various embodiments, assembling the EARTH TRUSS at the time the pair of foundation components 10 (e.g., pair of screw anchors) are driven will obviate the need for later alignment steps, such as when the solar tracker components are later installed at the foundation.

[0039]Exemplary adapter 20 shown at FIG. 2 consists of a pair of open connecting portions that, in this example, are received within respective upper legs 16, and a H-pile like mounting portion 22 that extends upward and approximates the web and flange geometry of a standard W6x9 or W6x12 H-pile. With this geometry, adapter 20 may support any tracker system that is designed to attach to an H-pile. It should be appreciated, however, that in other embodiments adapter 20 may take on a different geometry that includes an integrated bearing portion and/or that is optimized to integrate with one or more specific tracker systems. The various systems, methods and machines according to the various embodiments of the invention are agnostic as to which particular adapter is used. Regardless of which is used, in various embodiments the machine may provide a jig, bracket or other guide to hold the adapter at the desired orientation so that the EARTH TRUSS can be constructed in a fast, precise and repeatable manner using acquired subsurface condition data.

[0040]FIGS. 3A-3C illustrate a foundation component driving machine 100 in accordance with various embodiments of the invention. FIG. 3A is a perspective view of this foundation component driving machine 100, and FIGS. 3B and 3C show a portion of the foundation component driving machine's mast 150 oriented at different driving angles.

[0041]As one example, foundation component driving machine 100 can be a type manufactured by the applicant of this disclosure and known commercially as the TRUSS DRIVER according to various exemplary embodiments of the invention. The TRUSS DRIVER can be used to drive adjacent foundation anchor components (e.g., screw anchor pairs) into underlying ground along the tracker row according to one or more installation parameters that are determined using subsurface soil condition data (e.g., prior to driving the foundation component(s) into the ground). The machine 10 can also be configured to support the adapter, bearing adapter or other apex hardware while upper legs are attached to the ground embedded foundation components. As shown, machine 100 is built on tracked chassis 110 with diesel motor 112 and a hydraulic drive system. It should be appreciated that future versions of the machine may be electrically powered. Such modifications are within the spirit and scope of the invention. Also, it should be appreciated that machine 100 could instead ride on tires, on a combination of tires and tracks, on a floating barge, on rails or on another movable platform.

[0042]Machine 100 supports articulating mast 150. In the figure, mast 150 is shown as an elongated ladder-like truss structure extending approximately 15-20 feet in the long direction. It is connected to machine 100 by one or more hydraulic actuators. In various embodiments, articulating mast 150 can move through an arc in at least one plane extending from the front to the back of the machine that spans approximately 90-degrees to allow mast 150 to go from a stowed position where the mast is substantially parallel to the machine's tracks to an in-use position where the mast is substantially perpendicular to them. Therefore, when mast 150 is in the stowed position, its height will be minimized, whereas when mast 150 is in-use, it will extend far above machine 100. In various embodiments, rotator 140 is positioned in front of the one or more actuators connecting mast 150 to machine 100 so that mast 150 may rotate through a range of angles about a point of rotation (e.g., plus or minus 35-degrees from plumb) so that foundation anchor components (e.g., screw anchors) may be driven into the ground at a range of angles. This also decouples the driving angle from the left to right slope of the ground under the machine, allowing it to compensate for uneven terrain.

[0043]In various embodiments, in addition to rotating in plane, articulating mast 150 may move with respect to machine 100 so that it can self-level, adjust its pitch, and yaw and move in the X, Y and Z-directions (where X is North-South, Y is East-West, and Z is vertical) without moving the machine. This may be accomplished with additional actuators or slides that move an intermediate frame that supports rotator 140 and that is positioned between the rotator and machine 100. The components of machine 100 used to drive foundation components, such as screw anchors, as opposed to positioning the mast, are mounted on mast 150. Mast 150 includes parallel tracks 151 that define the plane that those components move in. Therefore, the mast's orientation dictates the vector or driving axis that screw anchors are driven along. Alternatively, mast components may travel on wheels retained on a track running along the mast. As described further herein, some embodiments can include a subsurface sensing device 170 at the mast 150, such as illustrated for the example shown here. Including the subsurface sensing device 170 at the mast 150 can enable the subsurface sensing device 170 to move with the mast 150 such that the subsurface sensing device 170 is oriented relative the driving axis as the mast 150 moves to thereby change the driving axis. This can be useful in configuring the subsurface sensing device 170 to procure subsurface soil data that is at the location beneath the surface where the foundation component is to be driven along the driving axis since the subsurface sensing device 170 can be aligned and rotatable with the driving axis. In other embodiments, the subsurface sensing device 170 can be at locations at the machine 100 other than the mast 150 or even at locations remote from the machine 100.

[0044]As shown, the driving components include rotary driver 154 with chuck 155 that connects to driving collar 15 of screw anchor 10. Some embodiments of the machine 100 can also include a tool driver 156, located above the rotary driver 154. In various embodiments, rotary driver 154 may be powered by hydraulics or by electric current. Similarly, tool driver 156 may be powered by hydraulics, compressed air or electric current. In various embodiments, tool driver 156 is a hydraulic drifter that drives a tool consisting of shaft 158 and bit or tip 159 that extends along mast 150, passing through rotary driver 154, chuck 155 and the center of foundation component 10. In various embodiments, and as shown in the figures, rotary driver 154 and tool driver 156 may be oriented concentrically on mast 150 in the direction of tracks 151 so that shaft 158 can pass through rotary driver 154 while it is driving a foundation component (e.g., screw anchor). In this manner, the tool tip 159 may operate ahead of the foundation component's tip, projecting out of its open, lower end. In various embodiments, rotary driver 154 is loaded by sleeving a foundation component over tip 159 and shaft 158 until it reaches chuck 155. Alternatively, tool driver 156 may be withdrawn up mast 150 until shaft 158 and tip 159 are substantially out of the way. Then, mast 150 can be moved to the desired driving vector. In some embodiments, this may comprise aligning the mast and then rotating it in the aligned plane. In other embodiments, the entire mast may be moved so that the point of rotation is oriented somewhere along the driving axis. This will ensure that the driven foundation component 10 points at the desired work point. In various embodiments, an operator may then adjust a slide control for the mast to lower the mast foot 161 to the point where at least a portion of it reaches the ground.

[0045]In conjunction, as will be described further herein, the machine 100 can use subsurface soil condition data to determine one or more installation parameters to be implemented at the machine 100 in view of the subsurface soil condition data. Then the machine 100 can initiate a drive operation (e.g., an automated drive operation), that as discussed in greater detail herein, utilizes the determined one or more installation parameters based on the subsurface soil condition data to embed a foundation component at least partially in the ground. This can result in the foundation component being driven to a desired embedment depth (e.g., a desired embedment depth determined based on the subsurface soil condition data for that location). When the operation is complete, rotary driver 154 (and tool driver 156 if included) travels back up mast 150 so that another foundation component may be loaded before moving mast 150 in the opposing direction to drive the adjacent foundation component so that the pair straddles the intended North-South line of the tracker row and points at a common work point.

[0046]For some embodiments, machine 100 can itself be configured to acquire subsurface soil condition data at each of one or more locations where a foundation component is to be embedded. For example, the machine 100 can include a subsurface sensing device 170 that is configured to acquire subsurface soil condition data at each of one or more locations where a foundation component is to be embedded. The subsurface sensing device 170 can be included at the machine 100, for instance at a main body of the machine (e.g., between or in front of track rollers) or at the mast 150 as illustrated for the example shown here. As one example, the subsurface sensing device 170 can be an energy emitting device that is configured to emit energy waves into the ground at a location where a foundation component is to be embedded and receive back reflected energy waves. The reflected energy waves can be processed to discern subsurface soil conditions, such as procure data relating physical content of the subsurface soil where a foundation component is to be embedded. As one such example, the subsurface sensing device 170 can be a subsurface radar device that is configured to emit radar waves and receive reflected radar waves indicative of subsurface soil data. As another example, the subsurface sensing device 170 can be configured to procure and analyze a physical subsurface soil sample taken at a location where a foundation component is to be embedded. One such example could include the subsurface sensing device 170 having a soil sample collection mechanism, which is configured to collect a physical sample of subsurface soil at the foundation installation location, and a sensor, which is configured to examine the content of the physical soil sample collected by the subsurface soil sample collection mechanism.

[0047]For other embodiments, machine 100 can acquire subsurface soil condition data from an external source in addition to or in lieu of the machine 100 itself carrying subsurface sensing device 170. For instance, machine 100 can acquire subsurface soil condition data, for a location where a foundation component is to be installed, from an external subsurface sensing device which communicates (e.g., wirelessly communicates) acquired subsurface soil condition data to the machine 100. In one such example, an external subsurface sensing device can be deployed at the tracker installation site and used to log (e.g., in the cloud, at the controller of the machine 100, etc.) this subsurface soil condition data in association with a specified location (e.g., GPS coordinate location) where a solar tracker foundation anchor component is indicated for installation. This subsurface soil condition data generated by the external subsurface sensing device can be communicated to the machine 100 and then used by the machine 100 to determine one or more foundation installation parameters for installing the solar tracker foundation anchor component at the specified location where the solar tracker foundation anchor component is indicated for installation.

[0048]FIG. 4 is an isolation view of the mast 150 and attached components of the embodiment of the foundation component driving machine 100 in greater detail. Mast 150 is formed from elongated sections of steel that are welded together along the seams to form a structure with a generally box-shaped cross-section. Planar portions on opposing side edges of the outer face of mast 150 form tracks 151 running substantially the entire length of mast 151. In this exemplary system, lower crowd motor 152 is mounted near the base of mast 150 on the back side. In various embodiments, lower crowd motor 152 powers a drive train including heavy-duty single or multi-link chain 170 that runs substantially the entire length of mast 150 between a pair of chain tensioners 157 positioned at the top and bottom ends of mast 150. Lower carriage 153 is mounted on tracks 151 and is connected to chain 170 so that when lower crowd motor 152 pulls down on chain 170, carriage 153 causes rotary driver 154 to push down on the head of the attached foundation component 10 (e.g., screw anchor) with the same force. As shown, rotary driver 154 is attached to lower carriage 153 so that the two move together. Rotary driver 154 includes chuck 155 on its lower portion that receives the head of a foundation component (e.g., a head of a screw anchor) and imparts torque and downforce to the head to drive it into the underlying ground. Upper carriage 162 is also tracked on mast 150 and attached to chain 170 driven by lower crowd motor 152. As shown, tool driver 156, in this example, a hydraulic drifter, is attached to upper carriage 162. Hydraulic drifters are often employed in rock drilling machines to provide a selectable combination of rotation and hammering depending on the type of bit used. Herein, the word “tip” in reference to element 159 is used generically to refer to the tool attached to the end of shaft 158 controlled by tool driver 156 and may be a drill bit (button, drag, cross, tri-cone, etc.), a pointed mandrel tip, or other suitable tool. As shown, tip 159 is controlled by tool driver 156 via a shaft 158 connected to the output of tool driver 156 and extending lengthwise down mast 150, through an opening in rotary driver 154 and out through chuck 155. With this configuration, tool driver 156 may impart torque and hammering force to tip 159 through rotary driver 154 and attached screw anchor 10 while rotary driver 154 is driving the screw anchor. Though other embodiments of the machine 100 may not include the tool driver 156.

[0049]With the configuration shown in FIG. 4, there are several components that can be individually controlled to effect a driving operation. For example, actuating lower crowd motor 152 will begin to pull lower carriage 153 and in turn rotary driver 154 towards the ground, supplying downforce to foundation component 10 through the rotary driver 154. At substantially the same time, rotary driver 154 may be actuated to begin applying torque to the head of foundation component 10. In various embodiments, it may be advantageous to start the driving operation by applying mostly downward pressure with lower crowd motor 152 because the top layer of soil is usually not structured enough to allow rotation to pull the screw anchor down without simply augering (i.e., drilling) the soil. Therefore, in various embodiments lower crowd motor 152 may be controlled to at least initially lead the driving operation while rotary driver 154 is controlled to rotate at a speed that advances foundation component 10 at the same rate as crowd motor 152. In other words, if the crowd motor is pulling down at the rate of one meter per minute, and the pitch of the screw anchor threads is 0.2 meters (e.g., one revolution results in 0.2 meters of embedment), then the rotary driver may be operated at 5 revolutions per minute to keep pace with the rate of embedment attributable to the lower crowd motor. In practical application, at certain points during the driving operation, there may be reasons for operating the rotary driver slightly faster that this but mismatches between the rotary driver's rate of advance and the rate of advanced resulting from lower crowd motor 152 should be kept small. Even a 5% mismatch may result in augering or coring of soil. Moreover, this or other rotary driver related data (e.g., rotary driver motor data) can be used to discern a length to which foundation component 10 has been embedded in the ground and, using the predetermined length of the foundation component, thereby discern a remaining length of foundation component available for further embedment.

[0050]As shown, machine 100 can include a series of manual hydraulic controls in a manual control panel as shown in FIG. 3A. These controls may allow manual control of the machine tracks as well the mast, the rotary driver, tool driver, lower crowd motor, upper crowd motor, and/or subsurface sensing device. Notwithstanding these manual controls, maximum accuracy and driving throughput using one or more determined subsurface soil condition data points may in many cases be possible by relying only on machine automation. To that end, in various embodiments, machine 100 and mast 150 of FIGS. 3A and 4 may include one or more programmable logic controllers (PLCs) executing a control program that controls the driving functions of machine 100 and mast 150 and that uses real-time sensor data along with stored program code to control of the lower crowd motor, rotary driver, tool driver and/or upper crowd motor to optimize the screw driving operation in view of the acquired subsurface soil condition data.

[0051]FIG. 5 shows one exemplary configuration of a control circuit that may be used to acquire subsurface soil condition data and use this acquired subsurface soil condition data to determine at least one foundation installation parameter for driving embedment of a foundation anchor component into the ground. For example, subsurface soil condition data can be acquired and used to determine at least one foundation installation parameter based at least on the acquired subsurface data at the location where the foundation anchor component is to be embedded into the ground. Then, the at least one foundation installation parameter, which is determined based at least on the acquired subsurface data at the location where the foundation anchor component is to be embedded into the ground, can be implemented at the machine to embed the foundation anchor component into the ground at that same location. This can be repeated to at other locations where other foundation anchor components are to be embedded in the ground and can, thereby, allow the installation parameters used for embedding a particular foundation anchor component at a particular location to be tailored to the specific subsurface soil condition(s) at that particular location for embedment.

[0052]The control circuit 200 includes the PLC labeled controller 210 at FIG. 5. The PLC may be an off-the-shelf black-box device from Rockwell Automation or other supplier or merely a circuit board containing a programmable microprocessor and other necessary components mounted in a box on the machine and controllable via a user interface and/or remote control. Controller 210 may execute program code stored in non-volatile, non-transitory memory, labeled storage 220 at FIG. 5. The program code executed by controller 220 may be written in structured text, instruction list or other suitable IEC 61131-3 textual or graphical programming language standard. As shown, controller 210 is connected to a communication bus that is used to relay sensor data and control signals between the circuit components. The bus may be a wired bus, such as an N-bit communication line, a wireless bus operating on one or more suitable wireless communication protocols (e.g., Wi-Fi, Bluetooth, Zigbee, ZWave, Digi Mesh, 2G-5G, etc.), or combinations of wired and wireless protocols. Multiple sensors are shown on control circuit 200 that provide substantially real-time information to controller 210. In this example, these can include encoders (e.g., linear and rotary encoders) used to incrementally count the movement of moving objects with respect to a non-moving reference, pressure sensors for measuring hydraulic pressure, downforce, air pressure, and/or resistance, among other variables, and subsurface sensor that can be used to acquire subsurface soil condition data. The sensors may also include one or more inclinometers used to facilitate self-leveling adjustment prior to driving, to determine the extent of roll adjustment needed to self-level, and also to monitor changes in level that occur during driving as the mast and machine lift-up in response to driving resistance. In some situations, it may be necessary to calculate the extent of such movement for the purpose of recalculating the embedment depth based on the machine's new position. Because such movement changes the location of reference locations on the mast relative to their location before driving started, linear and rotary encoders will not detect this type of movement, resulting in a failure to achieve the desired driving depth. Controller 210 may also receive real-time state information from lower crowd motor 152, upper crowd motor 160, rotary driver 154, tool driver 156, air compressor (not shown), subsurface sensor, and/or a hydraulic control system (not shown) and may send commands to these components as part of the automated control program for driving foundation components (e.g., screw anchors). This could include output torque, rate of rotation, rate of travel, etc. The direction of the arrows shown in control circuit 200 can indicate the direction of information flow. Controllable nodes (e.g., upper crowd, lower crowd, etc.) have two-way arrows while sensors merely transmit information and therefore are connected with one-way arrows. Though not shown here, a separate power bus may supply power and/or hydraulic pressure to one or more of the nodes.

[0053]For instance, controller 210 can use subsurface soil condition data from the subsurface sensor to determine one or more foundation installation parameters, then use the one or more determined foundation installation parameters along with real-time state information from one or more of the other components shown at FIG. 5 to embed a foundation component in the ground. For example, controller 210 can use subsurface soil condition data from the subsurface sensor to determine one or more foundation installation parameters that are then implemented, in some instances along with real-time state information from one or both of the encoder(s) and pressure sensor(s) to embed a foundation anchor component in the ground as part of an automated control program for driving one or more foundation components (e.g., a pair of foundation anchor components).

[0054]The storage 220 may also contain acquired subsurface soil condition data and/or information generated during driving operations. In various embodiments, it may be desirable to store acquired data remotely (e.g., in a cloud-based database) because it may be useful to have this information stored with other information about the job site that is not necessary for operation of the driver control system. Therefore, the circuit may store this information temporarily and transfer it to available cloud-storage via the bus when in proximity to a network or via a USB port or SD card. Alternatively, a smartphone application or other external device may be used to initiate transfer of this data. In various embodiments, stored information may include information corresponding to a solar tracker foundation installation job, such as, for example a single-axis tracker, including high level information about a job including job owner, system operator, location, maps/images, the type of system, size of the system, components of the system and job plans (e.g., what size/type foundations to install where relative to subsurface soil condition data for corresponding foundation installation locations). Stored information may also include information generated during driving operations including the specific location where foundation components were driven, sensor data received during the driving operation, acquired subsurface condition data for that installation location, and/or control signals send to controllable nodes (e.g., lower crowder, upper crowder, rotary driver, tool driver, etc.).

[0055]FIG. 6 is a block diagram showing an exemplary control system, for instance which can be implemented at the machine for driving foundation component(s) described elsewhere herein. The control system illustrated at exemplary FIG. 6 can use subsurface condition data to determine at least one foundation installation parameter, and the control system can then implement that at least one determined foundation installation parameter to drive a foundation component into the ground according to various embodiments of the invention. The feedback control loop can be a virtual structure formed from programmable logic controller (PLC) that executes a control program sending information to control nodes and receiving information from sensors connected to the output of the control nodes. Therefore, the components shown at FIG. 6 can be distributed on the machine and connected by information flows. “Subsurface condition data” can be acquired from a subsurface sensing device component that can in the example system at FIG. 6 be carried at the machine. Portions may be implemented as a computer, a circuit board, an application specific integrated computer (ASIC), firmware or a combination of hardware and software. Portions may reside in a standalone enclosure communicatively coupled to the control nodes by physical connection or via one or more wireless communication links.

[0056]For some specific such examples, the control system as shown at FIG. 6 can be a closed-loop feedback control system. Generally speaking, sensor data from the output is monitored in real-time and that data is compared to the current set point. If necessary, adjustments are made to the inputs to achieve the current setpoint. In the context of the present disclosure, the inputs are supplied to the control nodes to impact the foundation anchor component driving process. The inputs could be instructions from a user interface (e.g., initiate a screw anchor driving process) or lower level inputs like control signals from a controller to an actuator to cause the actuator to perform a process step in the screw anchor driving process (e.g., power the lower crowd motor to provide a specific amount of force, power the rotary driver to spin at a specific rate, etc.). Sensors capture output parameters (e.g., rate of penetration, rotational speed, pressure, etc.) and that information may be communicated back to the PLC or controller so that it can determine if the output is consistent with the set point. If not, the PLC may adjust an input to one or more of the control nodes to achieve the desired setpoint.

[0057]In the context of the screw anchor driving machine according to the various embodiments of the invention, the tool driver may communicate the real-time magnitude of the downward force it is exerting on the drive train and/or the rotary driver, the amount of resistance force it is experiencing, and/or the frequency and force of hammering by the tool driver. Similarly, the rotary driver may communicate its real time speed of rotation, direction of rotation, rotary pressure, and/or rate of advance. This information may be used by the PLC to optimize each installation, for instance, within the confines of foundation installation parameter(s) determined using the subsurface condition data. The PLC may store one or more tables of optimal operating parameters or ranges of parameters corresponding to various, different subsurface soil conditions. The PLC can store such tables in non-volatile memory and issue commands to control nodes (e.g., rotary driver) to execute and maintain performance according to the foundation installation parameter(s) determined using the subsurface condition data. The PLC may also store this information corresponding to the driving process for each foundation anchor component in association with a location (e.g., global positioning system coordinate location) and/or other identifier for that foundation anchor component. This information, including for example the subsurface soil condition data and corresponding determined and implemented foundation installation parameter(s), can be useful post-installation for the project developer, financier, geotechnical engineer or other interested party for future embedment iterations or other purposes.

[0058]For instance, once subsurface condition data which is acquired and input into the PLC, closed-loop feedback control may be used to implement one or more foundation installation parameters, which can be determined by the PLC using the subsurface condition data, according to which a foundation component is embedded into the ground. In addition, in some examples, such closed-loop feedback control can help to optimize driving time, respond to driving conditions, and to prevent damage to the equipment as well as the anchor itself, for instance, using the subsurface condition data and/or substantially real-time feedback data from one or more control nodes. As one specific such example, the control system at FIG. 6 can use the subsurface condition data to determine and then implement one or more foundation installation parameters. Then, as a foundation anchor component is driven into the ground using at least the one or more determined and implemented foundation installation parameters, closed-loop feedback control at the control system can use substantially real-time feedback data from at least one of the rotary driver, encoder(s), and pressure sensor(s) to cause the rotary driver to drive the a foundation anchor component into the ground using the one or more determined foundation installation parameters. In this way, acquiring subsurface condition data and using the acquired subsurface condition data at a control system to determine and implement one or more foundation installation parameters can allow for foundation component embedment that is tailored to the subsurface conditions at that specific embedment location. This, in turn, can help to increase the efficiency of foundation anchor component installation and, thereby, help to reduce costs and labor.

[0059]FIG. 7 is a block diagram showing exemplary control system architecture for a foundation component driving machine according to various embodiments of the invention. FIG. 7 can be a more specific implementation of the more generic control system illustrated and described previously in reference to FIG. 6. The control system shown at FIG. 7 can be implemented at a foundation anchor component driving machine, such as that disclosed previously herein. FIG. 7 represents a functional block diagram showing elements of a virtual system to execute a foundation anchor component embedment using one or more foundation installation parameters that are determined using subsurface soil condition data. For example, the control system at FIG. 7 can perform closed-loop feedback control to drive a foundation anchor component into the ground according to at least one or more foundation installation parameters that are determined using subsurface soil condition data. In the context of the illustration at FIG. 7, virtual designates the fact that these elements are communicatively coupled to form a system but not contained in a single discrete enclosure. In fact, they may be distributed around the machine. In this exemplary architecture a single controller controls all system components and performs feedback control. In practical application there may be two or more controllers. The box labeled controller here may be one or more PLCs, microcontrollers, computers, PC boards, or other known computing device. The controller may receive inputs and send outputs to user interface (“U/I”) device. The U/I may include a display (e.g., digital touch screen), a set of knobs, dials and buttons (e.g., physical user interface), lights, speakers, and/or other indicators mounted on the machine. Alternatively, the U/I may reside on a separate device (e.g., smartphone app, remote control, etc.) and communicate the other system elements via a wired or wireless communication protocol such as Wi-Fi, Bluetooth, ZigBee, 3G, 4G, LTE, etc. The user interface can used to send commands that are translated by the controller into machine language and sent to the various control nodes (e.g., machine, mandrel driver, rotary driver, upper/lower crowd motors, etc.). The user interface can also used to receive information from the controller such as status information, real-time operating parameters, and alerts.

[0060]For instance, in some cases, the user interface can be configured to output an indication (e.g., visual indication, audible indication) corresponding to one or more of the installation parameters determined by the controller using subsurface condition data acquired by the subsurface sensor. In one such example, the controller can use the subsurface condition data acquired by the subsurface sensor to determine an installation parameter that includes a type of foundation component (e.g., a ground screw foundation anchor component or a helical pile foundation anchor component) selected for embedment in the ground at a particular location, and the user interface can output an indication that corresponds to the type of foundation component selected for embedment in the ground at that particular location. This output at the user interface can allow a user to place the specified type of foundation component at the machine (e.g., “screw anchor” placed at the machine for the illustration at FIG. 7) followed by the machine then driving such specified type of foundation component into the ground at that particular location. Depending on the specific subsurface soil conditions detected, the machine can drive such specified type of foundation component into the ground at that particular location using one or more other installation parameters (e.g., an embedment depth into the underlying ground) determined using the subsurface condition data.

[0061]FIGS. 8A and 8B each illustrate a schematic, block diagram of foundation component driving machine 100 that uses subsurface condition data to execute a foundation anchor component embedment installation into ground 803. According to this example, the machine 100 can procure subsurface condition data, at a location below ground 803 where a foundation anchor component is to be embedded, from subsurface sensing device 170 that is carried at the machine 100 (e.g., carried at the mast 150 of the machine 100). Namely, machine 100 can use subsurface condition data, corresponding to a location where a foundation anchor component is to be embedded by the machine 100, to determine at least one foundation installation parameter that is then used when embedding that foundation anchor component at that location where the subsurface condition data was previously procured. In this way, machine 100 can be capable of implementing one or more different foundation anchor component installation parameters at locations having different subsurface soil conditions. This can allow the machine 100 to use information about one or more subsurface soil conditions (e.g., subsurface soil load bearing capacity) at a specific foundation installation location to then execute a foundation anchor component embedment using one or more foundation anchor component installation parameters suited for the particular subsurface soil conditions present at a specific foundation installation location.

[0062]FIG. 8A shows the foundation component driving machine 100, at a first location 801, using subsurface condition data to execute a foundation anchor component embedment installation into ground 803. Subsurface sensing device 170 (e.g., carried at machine 100) can acquire subsurface condition data at the first location 801. The subsurface condition data acquired at the first location 801 can relate to at least one subsurface condition present beneath ground 803 at the first location 801. The first location 801 can be a first solar tracker foundation installation location where solar tracker foundation component 10 is to be driven into the ground 803. For the illustrated example, the subsurface sensing device 170 is configured to emit and receive subsurface energy (e.g., radar) 804 at the first location 801 beneath the ground 803, and the received/reflected subsurface energy 804 can be analyzed (e.g., by the controller) to determine one or more subsurface conditions at the first location 801. Machine 100 can execute stored program code to cause the controller to acquire the subsurface condition data corresponding to the first location 801 and use this acquired subsurface soil condition data to determine at least one foundation component installation parameter for embedding the solar tracker foundation component in the ground 803 at the first location 801.

[0063]For the example at FIG. 8A, the subsurface condition data acquired at the first location 801 can indicate the presence of relatively low load bearing capacity soil, such as the presence of relatively high water content and/or soft subsurface soil conditions, such as muddy subsurface soil conditions 805 at the first location 801. Machine 100 can execute stored program code to cause the controller to use the acquired subsurface condition data corresponding to the first location 801 to determine one or more foundation component installation parameters to implement at the machine 800 for driving the foundation component as tailored to these subsurface conditions at the first location 801. For example, based on the subsurface soil condition at the first location 801 determined as being relatively low load bearing capacity soil conditions 805, machine 100 can execute stored program code to cause the controller to determine at least one or a type of foundation component and an embedment depth into the underlying ground 803 as suitable for the relatively low load bearing capacity soil conditions 805 at the first location 801. In one specific such example, such relatively soft, low load bearing capacity subsurface soil conditions 805 at the first location 801 can result in the controller determining that that helical pile 10A is the type of foundation anchor component is to be driven into the ground 803 at the first location 801. User interface at machine 100 can, in some examples, output an indication that the helical pile 10A is the type of foundation component to be used at the first location 801, for instance, so that the helical pile type foundation anchor component can be attached to the machine for embedment. Additionally or alternatively, such relatively soft, low load bearing capacity subsurface soil conditions 805 at the first location 801 can result in the controller determining an embedment depth for that foundation anchor component (e.g., determining an embedment depth into the ground 803 for the selected type helical pile 10A). Once the machine 100 has used the subsurface condition data for the first location 801 to determine one or more foundation component installation parameters for the first location 801 (e.g., determined type of foundation component and/or an embedment depth), the machine 100 can implement the determined one or more foundation component installation parameters to drive and embed that foundation component into the ground 803 at the first location 801. For instance, if an embedment depth for the foundation anchor component 10A at the first location 801 is determined using the acquired subsurface condition data corresponding to the first location 801, the machine 100 can use feedback from the rotary driver 154, encoder(s), and/or pressure sensor(s) to cause the foundation anchor component 10A to be driven into the ground 803 at the first location 801 to the determined embedment depth for that foundation component at the first location 801.

[0064]FIG. 8B shows the foundation component driving machine 100, at a second location 802, using subsurface condition data to execute a foundation anchor component embedment installation into ground 803. The second location 802 where the machine 100 is shown at FIG. 8B is different than the first location 801 where the machine 100 is shown at FIG. 8A. For example, the second location could be a different location along a common, axially aligned row of a solar tracker such that the first and second locations 801, 802 are different locations spaced apart from one another along a north—south extending axis that can represent a common row of a solar tracker.

[0065]Continuing to refer to FIG. 8B, subsurface sensing device 170 can acquire subsurface condition data at the second, different location 802. The subsurface condition data acquired at the second location 802 can relate to at least one subsurface condition present beneath ground 803 at the first location 802. The second location 802 can be a first solar tracker foundation installation location where solar tracker foundation component 10, different from the component 10 referenced at FIG. 8A, is to be driven into the ground 803. For the illustrated example, the subsurface sensing device 170 is configured to emit and receive subsurface energy (e.g., radar) 804 at the second location 802 beneath the ground 803, and the received/reflected subsurface energy 804 can be analyzed (e.g., by the controller) to determine one or more subsurface conditions at the second location 802. Machine 100 can execute stored program code to cause the controller to acquire the subsurface condition data corresponding to the second location 802 and use this acquired subsurface soil condition data to determine at least one foundation component installation parameter for embedding the solar tracker foundation component in the ground 803 at the second location 802.

[0066]For the example at FIG. 8B, the subsurface condition data acquired at the second location 802 can indicate the presence of relatively high load bearing capacity soil, such as the presence of relatively hard subsurface soil conditions, such as rocky soil and/or a boulder (e.g., granite boulder) 806 present beneath the ground 803 at the second location 802. Machine 100 can execute stored program code to cause the controller to use the acquired subsurface condition data corresponding to the second location 802 to determine one or more foundation component installation parameters to implement at the machine 800 for driving the foundation component as tailored to these subsurface conditions at the second location 802. For example, based on the subsurface soil condition at the second location 802 determined as being relatively high load bearing capacity soil conditions 806, machine 100 can execute stored program code to cause the controller to determine at least one or a type of foundation component and an embedment depth into the underlying ground 803 as suitable for the relatively high load bearing capacity soil conditions 806 at the second location 802. In one specific such example, such relatively hard, high load bearing capacity subsurface soil conditions 806 at the second location 802 can result in the controller determining that that ground screw foundation anchor component 10B is the type of foundation anchor component is to be driven into the ground 803 at the second location 802. User interface at machine 100 can, in some examples, output an indication that the ground screw 10B is the type of foundation anchor component to be used at the second location 802, for instance, so that the ground screw type foundation anchor component can be attached to the machine for ensuing embedment. Additionally or alternatively, such relatively hard, high load bearing capacity subsurface soil conditions 806 at the second location 802 can result in the controller determining an embedment depth for that foundation anchor component (e.g., determining an embedment depth into the ground 803 for the selected type ground screw 10B). Once the machine 100 has used the subsurface condition data for the second location 802 to determine one or more foundation component installation parameters for the second location 802 (e.g., determined type of foundation component and/or an embedment depth), the machine 100 can implement the determined one or more foundation component installation parameters to drive and embed that foundation component into the ground 803 at the second location 802. For instance, if an embedment depth for the foundation anchor component 10B at the second location 802 is determined using the acquired subsurface condition data corresponding to the second location 802, the machine 100 can use feedback from the rotary driver 154, encoder(s), and/or pressure sensor(s) to cause the foundation anchor component 10B to be driven into the ground 803 at the second location 802 to the determined embedment depth for that foundation component at the second location 802. The determined presence of different subsurface soil conditions 805, 806 at the respective different foundation component embedment locations 801, 802 can result in the machine's controller causing the rotary driver 154 to drive foundation anchor component 10A a first depth into ground 803 at first location 801 but to drive foundation anchor component 10B a second, different (e.g., lesser) depth into ground 803 at the second location 802, as determined using at least the acquired subsurface soil condition data at the first and second locations 801, 802.

[0067]FIG. 9 is a flow diagram showing steps of an embodiment of a method 900. The method 900 can be carried out to acquire subsurface condition data and use this acquired subsurface data to determine at least one foundation installation parameter for embedding a foundation component into the ground. Some examples can execute the method 900 using, at least in part, stored program code that causes a programmable processor to execute the steps of the method 900. One such example can execute the method 900 in a fully automated manner without manual intervention. Other examples can execute the method 900 using at least some manual input, such as to place a selected type of foundation anchor component at an automated foundation embedment machine.

[0068]At step 901, the method 900 includes acquiring subsurface condition data from a subsurface sensing device. This acquired subsurface condition data can relate to at least one subsurface condition at a first solar tracker foundation installation location. For instance, the acquired subsurface condition data can be data relating to a material content and/or load bearing capacity underneath the ground at a location of the first solar tracker foundation installation location. Subsurface data can be acquired by a subsurface sensing device, for instance carried by the same machine that embeds the foundation component or can be carried remotely from such machine.

[0069]At step 902, the method 900 can include using the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location. Using the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location, at step 902, can include determining at least one of: a type of foundation component and an embedment depth into the underlying ground. For example, using the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location to determine the type of foundation component based on the acquired subsurface condition data can include selecting the type of foundation component from the group consisting of a ground screw foundation component and a helical pile foundation component. As an additional or alternative example, using the acquired subsurface condition data to determine at least one solar tracker foundation installation parameter for installing at least one solar tracker foundation component at the first solar tracker foundation installation location can include determining the embedment depth, for that foundation anchor component to be embedded at the first location, into the underlying ground based on the acquired subsurface condition data. Thus, one example can use the acquired subsurface data at the first location to determine both the type of foundation anchor component to be embedded and an embedment depth for that type of foundation anchor component at the first location.

[0070]For some cases, step 902 of the method 900 can include outputting, at a user interface, an indication relating to the determined at least one solar tracker foundation installation parameter. As one such example, the acquired subsurface condition data can be sued to determine at least a type of foundation component to be installed at the first solar tracker foundation installation location, and then the user interface can output the indication relating to the determined type of foundation component to be installed at the first solar tracker foundation installation location so that the indicated type of foundation anchor component can be attached to the rotary driver for embedment at that location corresponding to the acquired subsurface soil condition data.

[0071]At step 903, the method 900 can include causing the at least one control node to embed the at least one solar tracker foundation component at the first solar tracker foundation installation location using the determined at least one solar tracker foundation installation parameter. As one example, the at least one control node can be coupled to a rotary driver. Fin this example, executing the stored program code can cause the programmable processor to actuate the rotary driver to embed the at least one solar tracker foundation component at the first solar tracker foundation installation location using the determined at least one solar tracker foundation installation parameter. For instance, according to this example, the rotary driver can be actuated to drive a foundation anchor component into the ground using the one or more foundation installation parameters that were determined at step 902 using at least the subsurface soil condition data. This could additionally include actuating the rotary driver to drive the foundation anchor component into the ground using the one or more foundation installation parameters that were determined at step 902 using at least the subsurface soil condition data and feedback from encoder(s) and/or pressure sensor(s) at a machine having the rotary driver.

[0072]FIG. 10 is a flow diagram showing steps of an embodiment of a method 1000. The method 1000 can be carried out to embed solar tracker foundation components at different locations using subsurface data acquired at these different locations. Some examples can execute the method 1000 using, at least in part, stored program code that causes a programmable processor to execute the steps of the method 1000. One such example can execute the method 1000 in a fully automated manner without manual intervention. Other examples can execute the method 1000 using at least some manual input, such as to place a selected type of foundation anchor component at an automated foundation embedment machine. For instance, some embodiments can execute the method 1000 using, at least in part, a programmable controller storing executable program code and communicatively coupled at least to a subsurface sensing device and a rotary driver.

[0073]Steps 1001-1004 can relate to embedment of a first solar tracker anchor component at a first location, while steps 105-1008 can relate to embedment of a second solar tracker anchor component at a second, different location.

[0074]At step 1001, the method 1000 includes acquiring first subsurface condition data from a subsurface sensing device. This acquired subsurface condition data can relate to at least one subsurface condition at a first solar tracker foundation installation location. For instance, the acquired subsurface condition data can be data relating to a material content and/or load bearing capacity underneath the ground at the first solar tracker foundation installation location. At step 1002, the method 1000 includes using this acquired subsurface condition data to determine at least one foundation installation parameter for installing at least one foundation component at the first foundation installation location. At step 1003, the method 1000 includes outputting, at a user interface, a first indication relating to a first type of foundation component for the at least one foundation component to be embedded at the first foundation installation location. For instance, the user interface can output such first indication relating to one of a ground screw type foundation anchor component or a helical pile type foundation anchor component that is to be embedded at the first foundation installation location (e.g., as determined using the acquired subsurface soil condition data for the first location). Such output at the user interface can occur prior to embedding the at least one foundation component at the first foundation installation location. At step 1004, the method 1000 includes embedding the at least one foundation component at the first foundation installation location using the determined at least one foundation installation parameter. For instance, a length over which the foundation component is to be embedded beneath the ground at the first location can be determined using the acquired subsurface soil condition data for the first location, and a rotary driver can then be used to drive the foundation component this determined embedment depth into the ground at the first location.

[0075]After embedding the first type of foundation component at the first location, the machine used for driving the foundation components can be moved to a second location different from, and spaced apart from, the first location referenced previously at steps 1001-1004.

[0076]At step 1005, the method 1000 includes acquiring second subsurface condition data from a subsurface sensing device. This acquired second subsurface condition data can relate to at least one subsurface condition at a second solar tracker foundation installation location that is different than the first solar tracker foundation installation location. For instance, the second acquired subsurface condition data can be data relating to a material content and/or load bearing capacity underneath the ground at the second, different solar tracker foundation installation location. At step 1006, the method 1000 includes using this second acquired subsurface condition data to determine at least one foundation installation parameter for installing at least one foundation component at the second, different foundation installation location. At step 1007, the method 1000 includes outputting, at a user interface, a second indication relating to a second type of foundation component for the at least one foundation component to be embedded at the second foundation installation location. For instance, the user interface can output such second indication relating to one of a ground screw type foundation anchor component or a helical pile type foundation anchor component that is to be embedded at the second foundation installation location (e.g., as determined using the acquired subsurface soil condition data for the second location). Such output at the user interface can occur prior to embedding the at least one foundation component at the first foundation installation location. When the acquired subsurface soil data indicates different subsurface soil conditions at the first and second locations, different types of foundation components can be selected for embedment at the different soil types and locations using the acquired subsurface soil data at each of the different first and second locations. At step 1008, the method 1000 includes embedding the at least one foundation component at the second foundation installation location using the determined at least one foundation installation parameter for that second location. For instance, a length over which the foundation component is to be embedded beneath the ground at the second location can be determined using the acquired subsurface soil condition data for the second location, and a rotary driver can then be used to drive that foundation component this determined embedment depth into the ground at the second location.

[0077]The embodiments of the present invention are not to be limited in scope by the specific embodiments described herein. For example, although many of the embodiments disclosed herein have been described with reference to systems and methods for installation of foundation components for single-axis solar trackers, the principles herein are equally applicable to systems and methods for installing foundations for other structures. Indeed, various modifications of the embodiments of the present invention, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such modifications are intended to fall within the scope of the following appended claims. Accordingly, the claims set forth below should be construed in view of the full breath and spirit of the embodiments of the present inventions as disclosed herein.