Solar Tracker Cardan Drive Design to Reduce Panel Vibration and Shadow
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Solution Overview
Problem
Single-row photovoltaic solar trackers face issues with dynamic stability against wind, causing damage like 'flutter' and 'gallop', and generate shadows and vibrations that reduce energy output and shorten panel lifespan due to complex mechanical drive systems and high material costs.
Innovation Solution
A solar tracker design with actuation means not directly connected to panel supports, using a torque tube with radial arms and linear actuators driven by gear-endless screw assemblies with Cardan-type joints, allowing for angular movement and reduced shadow generation, and enabling assembly without pre-installed panel supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the drive shaft is directly supported on the straps that support the solar panels, then the mechanical drive between actuators is achieved, but stresses and vibrations are transmitted to the panels causing cracking and reduced lifespan
Solution Approach 1:
The drive shaft is segmented into multiple sections supported by individual supports distributed along the torque tube, separating the drive function from the panel support function. This segmentation prevents stress transmission to panels while maintaining mechanical drive capability between actuators.
Solution Approach 2:
Multiple intermediate supports are introduced between the drive shaft and the panel supports. These supports act as mediators that bear the drive shaft's weight and transmit mechanical drive forces without transmitting vibrations and stresses to the solar panels, thus protecting panel integrity.
2Ease of operation
If a complex structuring with multiple prominent elements is used for the tracker, then the actuation function is achieved, but greater shadows are generated reducing energy generation
Solution Approach 1:
The drive shaft supports are merged with the torque tube structure, allowing the supports to be positioned along the torque tube without requiring separate prominent mounting structures. This integration reduces shadow generation while maintaining actuation functionality.
Solution Approach 2:
The drive shaft and its supports are positioned in the diagonal section closest to the actuators, utilizing three-dimensional space efficiently. This spatial arrangement minimizes the projection of structural elements into the sunlight path, reducing shadows on bifacial panels while preserving actuation capability.
3Manufacturing precision
If bevel gearboxes with high mechanical reversibility are used, then precise mechanical drive is achieved, but motorised actuation systems require brakes or anti-reversibility elements increasing complexity
Solution Approach 1:
The patent replaces complex mechanical anti-reversibility mechanisms (brakes, locks) with a simplified motor control system. The motorised actuation system uses electronic control to prevent reversibility, eliminating the need for additional mechanical components and reducing overall system complexity while maintaining precise mechanical drive.
4Ease of manufacture
If the actuation system is connected to the straps that support the panels, then the tracker can be assembled, but assembly becomes complex and requires pre-installed straps
Solution Approach 1:
The actuation system is segmented into independent components (motor, gearbox, drive shaft with supports) that can be assembled separately from the panel support structure. This allows the actuation system to be pre-assembled and tested independently, then integrated with the torque tube and panels, significantly reducing assembly time and complexity.
Solution Approach 2:
The actuation system components are prepared and pre-assembled before final installation. The drive shaft with its supports is pre-configured, and the motor-gearbox assembly is pre-mounted, allowing for streamlined final assembly without requiring pre-installed straps or complex sequencing.
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
Enhances dynamic stability, minimizes shadow generation, reduces vibrations and material costs, and simplifies assembly by supporting the drive shaft along the torque tube, ensuring robust and efficient operation with reduced torque requirements.
Implementation Method 1
a drive, formed by Cardan-type joints and drive shafts (telescopic in the diagonal sections closest to the actuators), so that said drive will be driven by one or more electric motors
Implementation Method 2
each linear actuator will be actuated from a gear-endless screw assembly
Implementation Method 3
each linear actuator will be actuated from a gear-endless screw assembly
Data Source
AI summary
A plurality of posts and actuator posts connected to a foundation and to a torque tube on which solar panels are duly mounted is disclosed. The actuator posts include a hinge next to a radial arm that is disposed solidly connected to the torque tube, the arm being hinged at the other end to a linear actuator with screw drive, the bottom end is connected to the actuator post by a joint. Each linear actuator is actuated by a gear that engages with an endless screw solidly connected to a Cardan-type drive shared by all the actuators and is actuated by an electric motor, the Cardan-type drive fitting closely to the torque tube by supports.