Toroidal Bearing Support for Solar Tracker Torque Tube Misalignment
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Solution Overview
Problem
Sun-tracking solar energy collection systems face challenges in alignment during installation due to the large and heavy components, leading to increased costs and complexity, particularly with conventional bearings that require precise alignment and are costly for torque tubes.
Innovation Solution
A support assembly with a bearing having a partially toroidal inner surface for reduced friction and misalignment accommodation, using fiber-reinforced composite materials for the upper bearing members to provide structural strength and low friction, and a bearing housing with a fixture portion for secure grounding, reducing material and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional roller bearings are used for torque tubes, then precise alignment is required, but this increases installation difficulty and cost
Solution Approach 1:
The bearing inner surface is formed with a toroidal (curved) geometry instead of a flat or cylindrical surface. This curved surface allows the bearing to accommodate misalignment between the torque tube pivot axis and the bearing rotational axis by distributing contact stresses across the curved interface, thereby eliminating the need for precise alignment during installation while maintaining reliable operation
2Reliability
If conventional roller bearings are used for torque tubes, then reliable support is provided, but manufacturing cost increases
Solution Approach 1:
The bearing is designed as a simpler, more economical component that can be manufactured at lower cost. The bearing members can be made from cost-effective materials such as polyethylene or other plastics, replacing expensive conventional roller bearings while providing sufficient reliability for the application through the toroidal surface design
3Ease of manufacture
If fiber-reinforced composite materials are used for upper bearing members, then material cost is reduced, but structural strength must be maintained
Solution Approach 1:
The upper bearing members are constructed from fiber-reinforced composite materials such as fiberglass-reinforced plastic or carbon fiber-reinforced plastic. These composite materials provide the necessary structural strength and load-bearing capacity while being lighter and less expensive than traditional metal bearing materials, thereby reducing both material cost and manufacturing 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
The solution simplifies the installation process, reduces material costs, and enhances the durability of the solar energy collection system by allowing for misalignment accommodation and using less robust, yet effective, upper bearing members made from fiber-reinforced composite materials.
Implementation Method 1
The bearing can comprise an inner surface that is at least partially toroidal... at least a first reduced friction member comprising an inner surface positioned so as to slide against the outer surface of the pivot when the first pivot pivots about the pivot axis
Data Source
AI summary
A solar energy collection system can include support devices made with bearings. Such bearings can include an inner partially toroidal surface for sliding contact and support of an outer surface of a torque tube. The toroidal surface can be made with a single radius of curvature or multiple radiuses of curvature and cylindrical portions. The bearings can include connectors for connecting the bearing members to a support housing. The connectors can be tool-less connectors.