Torque Tube Alignment Tool for Precise Solar Tracker Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The alignment of serially connected torque tubes in sun-tracking solar energy systems, particularly in remote locations, is challenging due to the need for high precision and accuracy, which is difficult to achieve with conventional methods.
Innovation Solution
A removable alignment tool that rigidly engages torque tubes, using alignment reference surfaces and engagement devices to ensure precise rotational alignment between shafts, allowing for easier and more accurate alignment with reduced labor and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional alignment methods are used for torque tubes in remote locations, then alignment precision deteriorates, but using sophisticated precision equipment increases device complexity and cost
Solution Approach 1:
The alignment tool serves as an intermediary device between the two torque tubes, providing a common reference framework. The tool includes reference surfaces that engage with corresponding surfaces on both torque tubes, establishing a precise geometric relationship without requiring complex external measurement equipment. This mediator approach enables high-precision alignment in remote locations using a relatively simple, portable device.
Solution Approach 2:
The alignment tool incorporates reference surfaces that are precise copies or replicas of the torque tube alignment reference surfaces. By creating and maintaining these reference surfaces on a portable tool, the system transfers the precision requirements from the field operation to the manufacturing process, where precision can be more easily achieved and maintained.
2Measurement precision
If sophisticated precision equipment is used for torque tube alignment, then alignment accuracy improves, but construction time and cost increase
Solution Approach 1:
The alignment reference surfaces are precisely manufactured and prepared in advance during the torque tube fabrication process. The alignment tool itself is pre-configured with the correct geometry and reference features. This preliminary preparation eliminates the need for complex field measurements and adjustments, enabling rapid alignment when the components are assembled.
Solution Approach 2:
By transferring precision requirements to the manufacturing phase through creating reference surface copies on the alignment tool, the field operation becomes a simple matching process rather than a measurement and adjustment process, significantly reducing construction time while maintaining high accuracy.
3Device complexity
If torque tubes are rigidly connected end-to-end to reduce component count, then system cost decreases, but alignment difficulty increases
Solution Approach 1:
The alignment tool acts as a mediator during the assembly process, enabling precise alignment of the rigidly connected torque tubes. The tool's reference surfaces engage with corresponding surfaces on adjacent torque tubes, providing a mechanical means to establish and maintain precise angular relationships without requiring complex alignment procedures or additional alignment components in the final system.
Data Source
AI summary
An alignment tool for aligning torque tubes of the solar collection system can include a rigid body member and two laterally extending alignment arms. Optionally, the alignment arms can include releasable clamps that can engage and disengage without the use of tools. The tool can be designed to straddle a sun-tracking drive of a sun-tracking solar system. Thus, the tool can be used both during initial construction as well as after construction is complete for alignment purposes.