Actuator for solar panels
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Solution Overview
Problem
Existing linear actuator systems for solar panels face issues such as unintentional movement of thrust bearing assemblies, internal condensation due to environmental conditions, damage from gear rotation, and sealing failures between the gearbox and its cover, which compromise their effectiveness and reliability.
Innovation Solution
The actuator assembly includes a gearbox with a motor, lead screw, thrust bearing assembly, castle nut with grooves, locking washer, and a sealing gasket, along with two-way air vents to prevent vacuum and condensation, and a separator to protect wires from gear exposure, addressing the issues of thrust bearing stability, environmental interference, and sealing integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a conventional thrust nut and secondary nut are used to position and secure thrust bearings, then the thrust bearing assembly can be positioned, but the secondary nut may get loose during operation allowing unintended movement of the thrust nut and thrust bearings
Solution Approach 1:
A locking washer with tabs is introduced as an intermediary component between the castle nut and thrust bearing assembly. The tabs engage with grooves in the castle nut to prevent loosening, serving as a mediator that secures the connection without interfering with the primary fastening function
Solution Approach 2:
The castle nut is designed with pre-formed grooves that align with the locking washer tabs before assembly. This preliminary configuration ensures that the anti-loosening mechanism is already in place before operational forces are applied, preventing the secondary nut from getting loose during operation
2Adaptability or versatility
If the actuator operates in rainy and humid conditions, then the solar tracker can function outdoors, but vapor may be drawn into the actuator system through vacuum effects created by thrust bearing operation, resulting in internal condensation
Solution Approach 1:
A two-way air vent is extracted from the gearbox assembly to provide a dedicated pathway for vapor and moisture to escape. This separate extraction system allows the thrust bearings to create vacuum for operation while the air vent simultaneously prevents condensation by allowing moisture to be expelled from the sealed interior
Solution Approach 2:
The air vent system creates a secondary breathing pathway that copies the function of the sealed gearbox while providing opposite functionality - instead of preventing air exchange entirely, it selectively allows vapor and moisture to pass through while maintaining operational vacuum conditions
3Ease of operation
If grease is liberally applied to the gears to aid movement, then the gears can operate smoothly, but a pathway may be formed for grease to enter the motor leading to its failure
Solution Approach 1:
The gearbox interior is segmented into distinct zones: a gear area where grease is applied for smooth operation, and a motor area that remains grease-free. The separator wall creates this segmentation, allowing liberal grease application to gears while preventing grease migration to the motor through physical division of the space
4Strength
If the gearbox and gearbox cover are joined with great compressive force to close off the internal space, then the seal between components is strengthened, but the seal created by the gasket seal may be compromised
Solution Approach 1:
The sealing approach changes from relying on high compressive force to relying on precise geometric fitting. The groove in the gearbox cover and corresponding protrusion on the housing create a mechanical interlock that maintains sealing through dimensional precision rather than compression, allowing strong connections without compromising gasket seals
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the stability and reliability of the actuator system by preventing unintended movement of thrust bearings, reducing environmental damage, and maintaining a secure seal, thereby improving the overall performance and longevity of the solar panel tracking system.
Implementation Method 1
the operation of the thrust bearings can create a vacuum effect, which may cause vapor to be drawn into the actuator system
Implementation Method 2
failure of a gasket seal between the gearbox and the gearbox cover
Implementation Method 3
a lead screw operatively attached to the gear assembly and mounted inside an inner tube
Implementation Method 4
a thrust bearing assembly disposed between the gear assembly and the lead screw
Data Source
AI summary
An actuator assembly for a solar tracking system. The actuator assembly includes a gearbox housing and a gearbox cover, a motor, and a lead screw. The gearbox housing and gearbox cover cooperate to define an internal chamber for receiving a gear assembly. The motor is mounted to the gearbox housing and is operatively connected to the gear assembly. The lead screw is operatively attached to the gear assembly and mounted inside an inner tube. A thrust bearing assembly is disposed between the gear assembly and the lead screw, with a portion of a thrust bearing nut being positioned within the thrust bearing assembly. A castle nut engages the thrust bearing nut, with the locking washer being frictionally engaged with the castle nut in an interlocking manner. An inner tube is mounted with in an outer tube for linear movement with respect to the outer tube.