Segmented Axle Module for Low-Torsion Solar Trackers
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Solution Overview
Problem
Uniaxially tracked solar elements face increased torsional forces and material costs due to the displacement of the mounting plane from the axis of rotation, causing torques and requiring expensive special components, especially when inclined, which complicates the attachment of photovoltaic modules.
Innovation Solution
A support structure with a rotatably mounted axle module formed from multiple jacket section profiles, allowing cross members to be inserted through access openings without moving the axis module out of its plane, reducing torsional moments and using thin materials to avoid damaging corrosion protection and minimize component costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cross members are mounted transversely on the rotation axis to support solar modules, then the solar modules can be secured along their long edges, but the mounting plane moves away from the center of the rotation axis, resulting in increased torsional forces and higher material requirements
Solution Approach 1:
The axis module is segmented into multiple casing section profiles that can be assembled together. These profiles include access openings positioned to receive cross members, allowing the axis to be constructed in modular sections rather than as a single monolithic component.
Solution Approach 2:
The access openings in the casing section profiles are positioned such that cross members can be inserted through the axis module from opposite sides. This allows the cross members to pass through the axis rather than being mounted on the exterior, keeping the module mounting plane at the axis center.
2Ease of manufacture
If the axis module is made as a monolithic structure with access openings, then cross members can be inserted, but the zinc coating serving as corrosion protection is permanently damaged
Solution Approach 1:
Instead of creating access openings in a monolithic axis, the axis is divided into multiple casing section profiles. The access openings are formed in these separate profiles during manufacturing, allowing cross member insertion without compromising the integrity and corrosion protection of the complete axis assembly.
3Strength
If thicker material is used for the axis to maintain corrosion protection with access openings, then structural integrity is improved, but material costs and weight increase
Solution Approach 1:
The axis is constructed from multiple casing section profiles that can be joined together. This segmentation allows the use of thinner materials in each individual profile while maintaining overall structural integrity through the assembled configuration, reducing weight and material costs compared to a monolithic thick-walled axis.
Solution Approach 2:
Multiple thinner casing section profiles are combined to form the complete axis module. The collective structure of these joined profiles provides the necessary structural integrity and corrosion protection, achieving the same performance as a thick monolithic axis but with reduced weight and material usage.
4Ease of manufacture
If the axle module is displaced out of the plane of the axis of rotation to accommodate cross members, then modules can be attached, but torques increase requiring expensive special components
Solution Approach 1:
The access openings are positioned in the casing section profiles such that cross members can be inserted through the axis module along the axis of rotation. This keeps the module mounting plane coincident with the axis plane, eliminating the need to displace the axis module and avoiding additional torques that would require special components.
Data Source
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AI summary
Uniaxial-tracking photovoltaic systems achieve a higher output than fixed-position solar installations because the solar modules can follow the position of the sun throughout the day and the radiation can thus be used at the optimum angle. The inherent weight and the additional wind loads, however, mean that high forces prevail, and this results in requirements for a large cross section and, ultimately, in higher costs being incurred for these structures. In order to solve this problem, the present invention proposes producing an axis module (2) from a plurality of casing-portion profiles, which on the one hand allows for a very stable structure made of a comparatively small quantity of materials, but on the other hand makes it possible for crossmembers (11) for supporting the solar modules to be guided through the axis module (2), and therefore for the torsional forces to which the axis module (2) is subjected to be reduced.