Segmented Torque Tube Coupler for Multi-Drive Solar Tracker Stiffness
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Solution Overview
Problem
Single-drive sun-tracking solar power systems face limitations due to high wind loads that twist torque tubes, requiring either reduced lengths to minimize energy collection or increased sizes to enhance stiffness, leading to increased costs and system failures.
Innovation Solution
A multi-drive solar-tracking PV system with torque tube segments coupled by a torque tube coupler, where multiple drives input torque at longitudinally separated locations, reducing the span between driven supports to maintain system stiffness and distribute torsion and bending stresses, allowing for thinner, lighter, and less costly torque tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If torque tube length is reduced to minimize wind load effects, then system reliability improves, but energy collection area decreases
Solution Approach 1:
The torque tube assembly is divided into multiple torque tube segments (first torque tube segment, second torque tube segment, etc.) that are coupled together by intermediate torque tube couplers. This segmentation allows the system to achieve the necessary stiffness to resist wind loads while maintaining a longer overall length for energy collection, as each segment can be independently supported by driven support assemblies.
2Reliability
If torque tube size is increased to enhance stiffness, then system reliability improves, but manufacturing cost increases
Solution Approach 1:
By segmenting the torque tube assembly and introducing intermediate driven support assemblies, the patent reduces the span length between supports. This allows the use of thinner, lighter torque tube segments with lower individual stiffness requirements, thereby reducing manufacturing costs while maintaining overall system reliability through distributed support.
Solution Approach 2:
The patent transitions from a single-drive system to a multi-drive system by adding driven support assemblies at longitudinally separated locations. This dimensional change in the support structure allows for reduced torque tube sizing while maintaining stiffness, as the load is distributed across multiple support points along the length of the assembly.
3Strength
If torque tube span between driven supports is reduced, then system stiffness improves, but device complexity increases
Solution Approach 1:
The torque tube assembly is segmented into multiple sections coupled by intermediate torque tube couplers, with driven support assemblies positioned at specific longitudinal locations. This segmentation creates shorter spans between supports, enhancing stiffness and reducing angular deflection under wind loads, while the modular coupler design manages the complexity through standardized connection components.
Data Source
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AI summary
A solar-tracking photovoltaic (PV) system having several PV modules mounted on a torque tube is described. The torque tube may include several sections joined by a torque tube coupler. For example, the torque tube coupler may having a medial section and end sections to join to the torque tube sections. The medial section and the torque tube sections may have a same outer diameter.