Control method for improving tracking precision of solar tracking controller
By employing a dual-source comparison and calibration mechanism during initial debugging and daily operation, and utilizing a high-precision tilt angle sensing module and wireless communication, the mechanical damage problem caused by hard limiting of the photovoltaic tracking bracket was solved. This enabled high-precision tracking and stable operation of the solar tracking controller, extending equipment life and improving power generation efficiency.
Patent Information
- Application Number
- CN202511152089.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-18
- Publication Date
- 2025-11-11
AI Technical Summary
In existing solar photovoltaic power generation systems, the tracking accuracy of photovoltaic tracking brackets is reduced due to frequent mechanical collisions and hard limiting, leading to mechanical fatigue damage, loosening of connecting parts and microcracks, which affects equipment life and power generation efficiency.
The system employs an automatic impact push rod mechanical limiter during the initial debugging phase and a dual-source comparison calibration mechanism during daily operation. Through a high-precision tilt angle sensing module and wireless communication, it achieves soft limit correction, avoids mechanical damage caused by frequent hard limits, and improves tracking accuracy.
It significantly extends the mechanical life of the photovoltaic tracking bracket, reduces operation and maintenance costs, improves tracking accuracy and equipment stability, and ensures the efficient operation of the system.
Smart Images
Figure CN120928852A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of solar photovoltaic power generation technology, and in particular relates to a control method for improving the tracking accuracy of a solar tracking controller. Background Technology
[0002] In a solar photovoltaic power generation system, the tracking accuracy of the solar tracking controller directly affects the absorption efficiency of sunlight by the photovoltaic modules, and thus affects the power generation efficiency of the entire solar photovoltaic power generation system. With the long-term operation of the power station, the tracking accuracy of the photovoltaic tracking bracket is often affected and reduced due to factors such as tracking errors and equipment aging.
[0003] Most current solar photovoltaic (PV) power generation systems consist of a vertical column, with PV modules and a solar tracking controller mounted on a PV tracking bracket at the top of the column. The PV tracking bracket is rotatably connected to the vertical column, and a push rod drives the PV tracking bracket to swing, thereby causing the PV modules to change angles to better absorb sunlight. Currently, when calibrating deviations, PV tracking brackets commonly use a direct impact to achieve reset calibration. However, this mode of relying on physical collisions to force return to position will, with the accumulation of operating time, cause frequent impacts and vibrations to continuously aggravate fatigue damage to the mechanical structure. This will not only lead to loosening of connecting parts and widening of transmission gaps, but also cause micro-cracks at key stress points of the bracket. Over time, this will cause irreversible organic damage to the overall mechanical structure, directly weakening the load-bearing capacity and operational accuracy of core components, and significantly accelerating the aging process of the equipment, resulting in a substantial reduction in its service life. If such damage is not addressed in time, it may also trigger a chain of failures, further amplifying the risk of equipment malfunction, and the tracking accuracy of the PV tracking bracket will also be greatly reduced. Summary of the Invention
[0004] The main technical problem to be solved by this invention is to provide a control method that improves the tracking accuracy of a solar tracking controller, which can replace the direct impact hard limit method to achieve reset calibration, reduce fatigue damage to mechanical structures, and reduce the risk of loosening of connecting parts, widening of transmission gaps, and microcracks at key stress points of the bracket.
[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: A control method for improving the tracking accuracy of a solar tracking controller includes an initial debugging phase and a daily operation phase. The initial debugging phase includes the following steps: A1. After powering on, the system starts the initialization calibration process. The system immediately switches to the automatic impact push rod mechanical limit mode. The solar tracking controller controls the motor to run. The motor drives the push rod to run at a constant speed and smoothly, thereby pushing the photovoltaic tracking bracket to swing eastward. When the push rod hits the extreme east limit, the real-time data of that position is set to positive 47 degrees. A2. After the real-time data of the limit position is set, the photovoltaic tracking bracket rotates in the opposite direction. When the real-time data is 0 degrees, it is determined that the photovoltaic tracking bracket is in a horizontal state. The tilt angle data of the tilt angle sensing module integrated on the solar tracking controller circuit board is cleared to zero, and a 0-degree tilt angle reference point is provided for the tilt angle sensing module. A3. Subsequently, the system automatically executes the operation program from -45 degrees to +45 degrees. The photovoltaic tracking bracket swings smoothly within this angle range. The core purpose of this action is to verify the correctness of the system initialization settings. After the verification process is fully executed, the system will solidify and store all key parameters during the operation. Even if a power outage occurs later, the stored parameters can be stably retained, thus laying a solid data foundation for the continuous and stable operation of the equipment.
[0006] The following are further optimizations of the above technical solution by the present invention: The daily operation phase includes the following steps: B1. When the photovoltaic tracking bracket reaches the 0-degree reference point every day, the system will trigger the dual-source comparison and calibration mechanism between the tilt angle sensing module and the real-time angle. By cross-validating and analyzing the data from these two different measurement sources, the system can promptly detect any possible angle deviations in the photovoltaic tracking bracket. B2. When the deviation between the real-time data and the tilt angle data exceeds ±0.5 degrees, the solar tracking controller obtains the tilt angle data of the solar photovoltaic power generation systems around this system, compares the tilt angle data of the surrounding systems with the real-time data and tilt angle data of this system respectively, and finds the data in the solar tracking controller itself that is erroneous. B3. Correct the erroneous data.
[0007] Further optimization: The static detection accuracy of the tilt sensing module is ±0.001 degrees, and the dynamic response frequency is ≥1kHz.
[0008] Further optimization: The tilt sensor module has a built-in automatic temperature drift compensation mechanism.
[0009] Further optimization: In step B2, the solar tracking controller acquires the tilt angle data of the surrounding solar photovoltaic power generation systems via wireless communication.
[0010] This invention employs the above-mentioned technical solution, which is ingeniously conceived and highly practical. The system adopts a one-time hard limit impact calibration mechanism. After the initial calibration is completed, in the later daily operation stage, high-precision attitude sensing and multi-source data comparison technology are used to achieve soft limit dynamic deviation correction. This completely avoids the bracket damage caused by frequent impacts to the hard limit during subsequent normal operation, greatly improving the mechanical life of the photovoltaic tracking bracket. This design eliminates the problems of fatigue damage to the limit components and structural stress accumulation caused by frequent mechanical collisions at the root, significantly reducing the operation and maintenance costs of the bracket and greatly extending the fatigue life of the equipment. Furthermore, it greatly improves the stability of the photovoltaic tracking bracket, photovoltaic module and solar tracking controller, and significantly improves the tracking accuracy of the solar tracking controller.
[0011] The present invention will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description
[0012] Figure 1 This is a flowchart illustrating the initial debugging phase of an embodiment of the present invention; Figure 2 This is a flowchart illustrating the daily operation phase of an embodiment of the present invention. Detailed Implementation
[0013] like Figure 1-2 As shown, a control method for improving the tracking accuracy of a solar tracking controller includes an initial debugging stage and a daily operation stage. In the initial debugging stage, initial parameter values are set for the solar tracking controller. In the daily operation stage, a dual-source comparison calibration mechanism is used to eliminate tracking errors in a timely manner through daily calibration, which greatly improves the tracking accuracy of the solar tracking controller.
[0014] The initial debugging phase includes the following steps: A1. After powering on, the system initiates the initialization calibration process. The system immediately switches to the automatic impact push rod mechanical limit mode. The solar tracking controller controls the motor to run, and the motor drives the push rod to run at a constant speed and smoothly, thereby pushing the photovoltaic tracking bracket to swing eastward. When the push rod hits the extreme east limit, the real-time data of that position is set to positive 47 degrees.
[0015] In this embodiment, the operating angle range of the photovoltaic tracking bracket is ±47 degrees, which is limited by the mechanical structure of the photovoltaic tracking bracket. The impact hard limit is a calibration process. The solar tracking controller can automatically detect the impact hard limit and thus set the initial value (47 degrees) for the real-time data.
[0016] The daily operating angle range of the photovoltaic tracking bracket is set to ±45 degrees. This range is defined as "soft limit". Under normal operating conditions where the system does not experience tracking deviation, the constraint of the soft limit can effectively prevent the photovoltaic tracking bracket from frequently hitting the mechanical hard limit during operation, thereby reducing the risk of mechanical damage caused by this.
[0017] Real-time data is the real-time angle of the photovoltaic tracking bracket during operation, calculated by the solar tracking controller through conversion chain data of motor pulse count, motor revolution count, linear displacement of push rod, and angle change of photovoltaic tracking bracket, combined with transmission mechanism parameters, reduction ratio, and encoder data.
[0018] In addition to this embodiment, the daily operating angle range of the photovoltaic tracking bracket can also be other values around ±45 degrees, such as ±40 degrees, ±50 degrees, ±55 degrees, etc.
[0019] A2. After the real-time data of the limit position is set, the photovoltaic tracking bracket rotates in the opposite direction. When the real-time data is 0 degrees, it is determined that the photovoltaic tracking bracket is in a horizontal state. The tilt angle data of the tilt angle sensing module integrated on the solar tracking controller circuit board is cleared to zero, and a 0-degree tilt angle reference point is provided for the tilt angle sensing module.
[0020] This design eliminates the need for leveling tools such as spirit levels to check the horizontal status of the photovoltaic tracking bracket, making debugging convenient and quick, and greatly improving work efficiency.
[0021] In this embodiment, the tilt sensing module is based on a three-axis accelerometer chip and is equipped with peripheral circuitry. The tilt sensing module is integrated on the controller circuit board to detect the tilt angle data of the photovoltaic tracking bracket.
[0022] The tilt sensing module boasts excellent performance parameters, with a static detection accuracy of ±0.001 degrees and a dynamic response frequency of ≥1kHz, enabling it to keenly capture extremely subtle attitude changes during the operation of the photovoltaic tracking bracket.
[0023] The tilt sensor module has a built-in automatic temperature drift compensation mechanism, which can effectively offset the impact of ambient temperature fluctuations on measurement accuracy, ensuring that the measurement data remains accurate and reliable within a wide operating temperature range of -40℃ to +85℃, thereby ensuring that the system maintains a stable and reliable operating state over a wide temperature range.
[0024] A3. Subsequently, the system automatically executes the operation program from -45 degrees to +45 degrees. The photovoltaic tracking bracket swings smoothly within this angle range. The core purpose of this action is to verify the correctness of the system initialization settings. After the verification process is fully executed, the system will solidify and store all key parameters during the operation. Even if a power outage occurs later, the stored parameters can be stably retained, thus laying a solid data foundation for the continuous and stable operation of the equipment.
[0025] In this embodiment, all parameters refer to the tilt angle data detected by the tilt angle sensing module and the real-time data of the photovoltaic tracking bracket during operation calculated based on the encoder data for every 0.5 degrees the photovoltaic tracking bracket swings.
[0026] The daily operation phase includes the following steps: B1. When the photovoltaic tracking bracket reaches 0 degrees of tilt angle data every day, the system will trigger the dual-source comparison and calibration mechanism between the tilt angle sensing module and the real-time angle. By cross-validating and analyzing the data from these two different measurement sources, the system can promptly detect any angle deviations that may exist in the photovoltaic tracking bracket.
[0027] B2. When the deviation between the real-time data and the tilt angle data exceeds ±0.5 degrees, the solar tracking controller obtains the tilt angle data of the surrounding solar photovoltaic power generation systems through wireless communication, compares the tilt angle data of the surrounding systems with the real-time data and tilt angle data of the system, and identifies the data in the solar tracking controller itself that is erroneous.
[0028] B3. Correct erroneous data to ensure that the angle control accuracy remains stable within ±0.5 degrees during long-term operation.
[0029] This high-precision control and calibration capability effectively ensures the stable operation of the system around the clock, providing solid and reliable technical support for the efficient power generation of photovoltaic power plants.
[0030] For those skilled in the art, any changes, modifications, substitutions, and variations made to the embodiments without departing from the principles and spirit of the present invention, based on the teachings of the present invention, still fall within the protection scope of the present invention.
Claims
1. A control method for improving the tracking accuracy of a solar tracking controller, characterized in that: It includes an initial debugging phase and a daily operation phase. The initial debugging phase includes the following steps: A1. After powering on, the system starts the initialization calibration process. The system immediately switches to the automatic impact push rod mechanical limit mode. The solar tracking controller controls the motor to run. The motor drives the push rod to run at a constant speed and smoothly, thereby pushing the photovoltaic tracking bracket to swing eastward. When the push rod hits the extreme east limit, the real-time data of that position is set to positive 47 degrees. A2. After the real-time data of the limit position is set, the photovoltaic tracking bracket rotates in the opposite direction. When the real-time data is 0 degrees, it is determined that the photovoltaic tracking bracket is in a horizontal state. The tilt angle data of the tilt angle sensing module integrated on the solar tracking controller circuit board is cleared to zero, and a 0-degree tilt angle reference point is provided for the tilt angle sensing module. A3. Subsequently, the system automatically executes the operation program from -45 degrees to +45 degrees, and the photovoltaic tracking bracket swings smoothly within this angle range. The system will then solidify and store all key parameters during the operation.
2. The control method for improving the tracking accuracy of a solar tracking controller according to claim 1, characterized in that: The routine operation phase includes the following steps: B1. When the photovoltaic tracking bracket reaches the 0-degree tilt angle reference point every day, the system will trigger the dual-source comparison and calibration mechanism between the tilt angle sensing module and the real-time angle. By cross-validating and analyzing the data from these two different measurement sources, the system can promptly detect any possible angle deviations in the photovoltaic tracking bracket. B2. When the deviation between the real-time data and the tilt angle data exceeds ±0.5 degrees, the solar tracking controller obtains the tilt angle data of the solar photovoltaic power generation systems around this system, compares the tilt angle data of the surrounding systems with the real-time data and tilt angle data of this system respectively, and finds the data in the solar tracking controller itself that is erroneous. B3. Correct the erroneous data.
3. The control method for improving the tracking accuracy of a solar tracking controller according to claim 2, characterized in that: The tilt sensing module has a static detection accuracy of ±0.001 degrees and a dynamic response frequency of ≥1kHz.
4. The control method for improving the tracking accuracy of a solar tracking controller according to claim 3, characterized in that: The tilt sensing module has a built-in automatic temperature drift compensation mechanism.
5. The control method for improving the tracking accuracy of a solar tracking controller according to claim 4, characterized in that: In step B2, the solar tracking controller acquires the tilt angle data of the surrounding solar photovoltaic power generation systems via wireless communication.