Solar Tracker Gear Torque Limiter With Friction Ring Slippage
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Solution Overview
Problem
Conventional solar tracking systems are prone to damage from excessive torque caused by wind, uneven snow buildup, and seismic activities, which can lead to component failure due to the large difference between static and dynamic slip torque in existing clutch systems.
Innovation Solution
The implementation of friction rings interposed between moving components of gears in the tracker drive assembly, which allow slippage when torque exceeds a threshold, reducing the difference between static and dynamic slip torque and preventing further rotation and potential damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing clutch systems are used to limit torque, then torque protection is provided, but the large difference between static and dynamic slip torque causes components to stop with more force and accelerate more quickly, increasing damage risk
Solution Approach 1:
The friction ring is designed with specific material properties and geometric parameters (thickness, radius, friction coefficient) that enable it to provide torque limitation with a small difference between static and dynamic slip torque. By changing the friction coefficient through material selection and controlling the contact pressure distribution, the system achieves smooth torque transition that prevents sudden component acceleration and reduces impact forces during slippage events.
2Reliability
If friction rings are interposed between gear components, then the difference between static and dynamic slip torque is reduced, but the device complexity increases
Solution Approach 1:
The friction ring serves as an intermediary element inserted between existing gear components (such as between the pinion and its mounting structure, or between gear teeth). This intermediary component provides the torque limitation function without requiring complete redesign of the gear system, maintaining most existing components while adding a single friction ring that mediates the torque transmission and enables controlled slippage with consistent friction characteristics.
3Productivity
If tracker drive assembly allows rotational freedom for sun tracking, then PV module efficiency is maximized, but wind and snow buildup can generate excessive torque that damages components
Solution Approach 1:
The friction ring torque limiter converts the harmful effect of excessive wind and snow torque into a beneficial controlled slippage mechanism. When environmental forces generate torque exceeding the friction ring's slip torque, the system intentionally allows controlled rotation through the friction ring, dissipating the excess energy through friction rather than transmitting it to vulnerable components. This transforms potentially damaging force into a protective mechanism that maintains system operation under adverse conditions.
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 friction ring torque limiter effectively reduces the speed at which components contact each other, stopping slippage quickly and minimizing damage to the tracker drive assembly components by allowing controlled movement relative to each other when excessive torque is applied.
Implementation Method 1
friction rings that may be interposed between moving components of one or more gears in a tracker drive assembly. When an amount of torque between these moving components exceeds a threshold, the torque limiter may slip
Data Source
AI summary
Torque limiters prevent the transmission of excessive torque between moving components of one or more gears in a tracker drive assembly. When an amount of torque between these moving components exceeds a threshold, the torque limiter may slip, thus allowing the components to move relative to each other. Embodiments disclosed herein may include a drive motor configured to rotate a drive shaft, at least one gear configured to translate rotation of the drive shaft into rotation of a PV module mounting structure, and a torque limiter interposed between an interior surface of a first component of the at least one gear and an exterior surface of a second component of the at least one gear to allow the first component to slip relative to the second component when an amount of torque between the first and second components exceeds a threshold.