Single-Axis Solar Tracker Worm Drive for Wind Load Backtracking
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Solution Overview
Problem
Existing solar tracking systems face challenges in initial installation costs, flexibility in adapting to site conditions, and reliability over their long lifetime, particularly due to high wind forces and complex mechanical linkages that require substantial materials and labor, as well as limitations in land usage and maintenance costs.
Innovation Solution
A mechanically linked single-axis solar tracking system that uses a worm-gear drive mechanism to distribute wind forces locally within each tracker row, eliminating the need for robust mechanical linkages and large foundations, allowing for flexible installation on various terrains and reducing structural material requirements, while using a single motor to drive multiple trackers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If robust mechanical linkages are used to connect tracker rows, then wind forces can be resisted, but material cost and device complexity increase significantly
Solution Approach 1:
The patent divides the tracker array into independent rows, each with its own drive mechanism. This segmentation eliminates the need for complex mechanical linkages connecting multiple rows, as each row operates independently. The segmentation principle resolves the contradiction by distributing the wind force resistance requirement to individual rows rather than requiring a complex unified linkage system.
Solution Approach 2:
The patent extracts the drive mechanism from a centralized location and places it at the center of gravity of each tracker row. This extraction eliminates the need for long mechanical linkages that would otherwise be required to transmit motion from a centralized drive to multiple rows. Each row has its own extracted drive system, simplifying the overall mechanical structure while maintaining wind force resistance.
2Device complexity
If a single centralized drive mechanism is used to rotate multiple rows, then device complexity is reduced, but the foundation requirements and material costs increase
Solution Approach 1:
The patent segments the drive mechanism allocation from a centralized approach to a distributed approach. Instead of one large centralized drive requiring a massive foundation, multiple smaller drive mechanisms are distributed to individual rows. This segmentation reduces the foundation size and material requirements while maintaining the ability to rotate multiple rows, resolving the contradiction between device complexity and stationary object weight.
3Productivity
If trackers are positioned at higher elevations to optimize sun tracking, then energy production increases, but wind force exposure and structural material requirements increase
Solution Approach 1:
The patent extracts the drive mechanism and places it at the center of gravity of each tracker row, which allows the solar modules to be positioned at optimal elevations for energy production. The drive mechanism being co-located with the center of gravity eliminates the need for additional structural support to resist wind forces on long linkages, resolving the contradiction between productivity and wind force resistance.
4Adaptability or versatility
If mechanical linkages are designed to accommodate uneven terrain, then adaptability to site conditions improves, but device complexity and material requirements increase
Solution Approach 1:
The patent segments each tracker row into an independent unit with its own drive mechanism. This segmentation allows each row to be independently positioned and adjusted to accommodate uneven terrain without requiring complex linkage mechanisms to connect rows. The independent segmentation provides terrain adaptability while maintaining simple mechanical structures, resolving the contradiction between adaptability and device complexity.
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 installation and maintenance costs, increases reliability, and allows for efficient land use by minimizing structural components, enabling flexible layout and high-density module installation, while maintaining peak performance across different tracking geometries.
Implementation Method 1
A drive shaft, positioned at right angles to the torsion tube and attached to each worm-gear drive, enables rotary motion of the torsion tube by applying rotary motion to the driven drive shaft
Implementation Method 2
The embodiment of the presently claimed invention specifically eliminates the need for a robust mechanical linkage capable of resisting high-load forces induced by the wind. The design of the current embodiments eliminate the transmittance of these wind forces to the linkage
Data Source
AI summary
A solar tracking system with a torque tube supporting solar panels. Columns support the system and have bearings for rotation of the torque tube. A drive is coupled to the torque tube and is driven by a gearbox, such as a worm gear assembly, for rotating the array of solar panels to follow the sun's diurnal motion. The array can rotate in an opposite direction, or backtrack, to prevent shadowing from one module row to another. Multiple gearboxes can be mechanically linked by drive shafts and driven by a single motor. The drive shafts may incorporate universal joints for uneven terrain or staggered configurations. Harmonic dampers can be affixed to the solar panels to decouple wind forces which allows the use of larger solar panels.