Single-Axis Solar Tracker With Worm Drive Obstruction Clearing
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Solution Overview
Problem
Existing solar tracking systems face challenges in minimizing initial installation costs, flexibility in adapting to site conditions, and reliability over their long lifetime, particularly due to high wind force resistance requirements and complex mechanical linkages, which increase material and labor costs and reduce flexibility in site layout.
Innovation Solution
A mechanically linked single-axis solar tracking system that uses a worm-drive gear assembly to distribute wind forces locally within each tracker row, eliminating the need for robust mechanical linkages and large foundations, and allows for flexible installation on uneven terrain with articulating joints, driven by a single motor and controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If robust mechanical linkages are used to resist wind forces, then structural strength is improved, but material cost and device complexity increase
Solution Approach 1:
The system divides the tracker array into independently supported rows, where each row's mechanical linkage only needs to support its own modules rather than the entire array. This segmentation allows lighter, simpler linkages while maintaining adequate wind force resistance for each segment.
Solution Approach 2:
The patent applies different structural characteristics to different parts of the system - robust support at foundation points for wind force resistance, and lighter linkage components for module support. This local differentiation optimizes material usage and reduces overall complexity while maintaining necessary strength where required.
2Stability of the object's composition
If large foundations are used to support tracker structures, then stability is improved, but land cost and installation complexity increase
Solution Approach 1:
The system uses multiple smaller foundation support points distributed along each tracker row rather than one large foundation. This segmentation provides adequate stability for each segment while reducing overall material requirements and simplifying installation compared to large monolithic foundations.
3Manufacturing precision
If fixed site layout configurations are used, then manufacturing precision is improved, but adaptability to site conditions worsens
Solution Approach 1:
The patent incorporates adjustable and adaptable elements in the tracker design that allow the system to accommodate variations in site conditions while maintaining installation precision. The mechanical linkages and support structures are designed with flexibility to adapt to different terrain configurations.
4Reliability
If complex mechanical linkages are used to distribute wind forces, then reliability is improved, but maintenance cost and device complexity increase
Solution Approach 1:
By segmenting the tracker array into independently supported rows with simplified linkages, the system achieves reliability through redundancy and localized support rather than complex interconnected structures. This reduces maintenance requirements while maintaining system reliability.
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 material and labor costs, increases reliability, and enhances flexibility in site layout, enabling efficient solar energy collection while minimizing the structural components and maintenance needs, and allows for automatic obstruction clearing and remote monitoring.
Implementation Method 1
Each tracker row includes a worm-drive gear assembly that transforms the application of a force in a first direction into movement of the tracker row in a second direction that is perpendicular to the first direction
Implementation Method 2
A torsion tube is affixed to each tracker row... the torsion tube returns the tracker row to an initial position
Data Source
AI summary
A solar tracking system with a plurality of tracking assemblies moved by a single motor. A method and system that prevents overloading the motor or tripping a circuit breaker due to an obstructed or impeded tracker includes sensing movement of the tracker assemblies and entering into obstruction clearing modes. Obstruction clearing mode 1 (OCM1) is a high frequency adjustable mode that prompts movement for an adjustable period of time. If movement commences, the system returns to a normal mode. If there is no movement, the system enters into an obstruction clearing mode 2 (OCM2) with is an adjustable lower frequency series of attempts. If there is no movement, no further attempts are made. Each of these steps are monitored and controlled remotely. There are two types of secure connections for drivelines, torque tubes or affixing driveline linkages for high torque conditions.