PV Tracker Ballast Arm Assembly for Torque Tube Wind Protection

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Solution Overview

Problem

Conventional single-axis photovoltaic trackers are susceptible to wind damage, leading to maintenance issues due to torsion and oscillations in the torque tube, which increases costs and reduces the viability of solar energy generation systems.

Innovation Solution

The implementation of ballast arm assemblies with a worm drive mechanism and ballast, allowing the torque tube to freely rotate and reducing twisting stress, while maintaining optimal solar orientation through adjustable ballast arm angles calculated to balance moments from PV modules and environmental forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If PV modules are fixed in place with a driving mechanism to maintain orientation, then energy generation is optimized, but the torque tube becomes susceptible to wind damage and torsion

Engineering Contradiction:

Improveenergy generationVSAvoidtorque tube durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs ballast weights positioned on the torque tube to counterbalance the moments generated by wind forces acting on the PV modules. This counterweight mechanism reduces the net torsional stress on the torque tube, allowing the system to maintain optimal PV orientation for energy generation while protecting the torque tube from wind-induced damage and excessive twisting

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Solution Approach 2:

The system dynamically adjusts the position and distribution of ballast weights along the torque tube based on wind conditions and PV module orientation. By changing the parameters of ballast placement, the system optimizes the counterbalancing effect to match varying operational conditions, maintaining both energy generation efficiency and torque tube reliability

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If the torque tube is prevented from rotating to maintain PV orientation, then tracking accuracy is improved, but wind-induced oscillations and damage increase

Engineering Contradiction:

Improvetracking accuracyVSAvoidwind damage

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The ballast system provides preliminary counterbalancing forces that oppose wind-induced moments before they can cause significant oscillations or damage to the torque tube. By pre-positioning ballast weights to counteract expected wind loads, the system reduces the amplitude of oscillations and prevents damage while maintaining tracking accuracy

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The ballast weights act as a cushioning mechanism that absorbs and dissipates wind-induced shocks and oscillations before they can transmit significant stress to the torque tube structure. This prior cushioning effect protects the system from wind damage while allowing the PV modules to maintain precise solar tracking orientation

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If ballast arm assemblies are added to reduce wind damage, then torque tube stress is reduced, but device complexity increases

Engineering Contradiction:

Improvetorque tube protectionVSAvoidtracker mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The ballast arm assemblies serve multiple functions simultaneously: they provide counterbalancing forces to reduce torque tube stress, act as adjustable weights to optimize tracking performance, and function as structural components integrated into the existing tracker mechanism. This multi-functionality reduces the need for separate protective devices, thereby limiting the increase in overall system complexity while achieving reliable torque tube protection

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This solution reduces maintenance costs and enhances the durability of photovoltaic tracker systems by minimizing wind-induced damage and optimizing energy generation through self-balancing and adaptive orientation adjustments.

Implementation Method 1

ballast arm assemblies with a worm drive mechanism and ballast, allowing the torque tube to freely rotate and reducing twisting stress, while maintaining optimal solar orientation through adjustable ballast arm angles calculated to balance moments from PV modules and environmental forces

Methodology Applied

Scientific EffectGravitation: Gravitation

Implementation Method 2

ballast arm assemblies with a worm drive mechanism and ballast

Methodology Applied

Scientific EffectMechanical Advantage: Mechanical Advantage

Data Source

PatentUS10651782B2Ballasted tracker drive assembly

Publication Date: 2020.05.12 TESLA INC

AI summary

PV modules and ballast arm assemblies are mounted onto a torque tube suspended from a support structure. The support structures allows torque tube, and mounted PV modules and ballast arm assemblies, to freely rotate. The ballast arm assembly includes a drive mechanism, an arm and a ballast. The drive mechanism allows the adjustment angle between the PV module and the arm and ballast to be changed. Changing the adjustment angle causes the torque tube, and mounted PV modules, to freely rotate to a different orientation angle in order to balance the moments of PV modules and ballast arm assemblies caused by gravity. The orientation angle can be changed throughout the day by changing the adjustment angle in order for the PV modules to track the sun.