Solar Tracker Lock-Out Bearing for Wind Load Distribution
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Solution Overview
Problem
Solar tracker systems face challenges in maximizing energy production while minimizing damage from wind loading, as existing designs often compromise energy output to accommodate structural rigidity and weight requirements, leading to reduced efficiency and increased component size.
Innovation Solution
The solar tracker incorporates a lock-out device with a cam shaft and eccentric groove mechanism that alternately engages and disengages pins with bearings, distributing wind loads across multiple piers, reducing torsional instability and allowing for reduced torque tube and slew drive dimensions without compromising structural stability or energy production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the solar tracker uses a rigid structure to accommodate wind loading, then structural stability is improved, but component size and weight increase
Solution Approach 1:
The patent applies dynamics by implementing a lock-out device that can transition between locked and unlocked states. The bearing system allows the torque tube to be dynamically locked at specific positions during windy conditions, rather than requiring continuous rigid support. This dynamic locking mechanism provides structural stability only when needed, reducing the overall weight requirements compared to a continuously rigid structure.
Solution Approach 2:
The lock-out device engages periodically when wind conditions require stabilization, rather than maintaining constant rigid support. The cam mechanism periodically locks the torque tube at predetermined positions during tracking operation, providing structural stability on-demand. This periodic engagement allows the system to use lighter components compared to a continuously rigid structure while maintaining stability when necessary.
2Stability of the object's composition
If the solar tracker uses a rigid structure to accommodate wind loading, then structural stability is improved, but device complexity increases
Solution Approach 1:
The lock-out device serves multiple functions: it acts as a positioning mechanism during normal tracking, provides structural stabilization during windy conditions, and enables the torque tube to be locked at predetermined positions. This multi-functionality reduces the need for separate stabilization components, thereby reducing overall system complexity while maintaining structural stability.
Solution Approach 2:
The cam mechanism in the lock-out device automatically engages and disengages the locking positions based on the torque tube's rotational position, without requiring external control systems. The bearing system self-locks at predetermined positions during tracking operation, providing structural stability autonomously. This self-service capability reduces control system complexity while maintaining structural stability.
3Stress or pressure
If the solar tracker drives to a flat position to reduce wind loading, then structural stress is reduced, but energy production decreases
Solution Approach 1:
The lock-out device provides preliminary anti-action by preemptively locking the torque tube at predetermined positions before wind loading can cause excessive stress. When wind conditions are detected or anticipated, the lock-out device engages to stabilize the torque tube, preventing the need to drive to a flat position for stress reduction. This allows the solar panels to maintain optimal energy-producing angles while still protecting against wind loading stress.
Solution Approach 2:
The lock-out device converts the potential harm of wind loading into a benefit by using the wind force itself to drive the torque tube into locked positions where the cam mechanism engages. The wind loading that would normally force the system into a flat, low-production position is instead harnessed to automatically position the torque tube at predetermined locked angles, maintaining both structural protection and energy production efficiency.
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 effectively mitigates wind loading effects, maintaining energy production efficiency by distributing loads and reducing component size, thereby enhancing structural stability and cost-effectiveness.
Implementation Method 1
The cam includes a eccentric groove configured to receive a follower of the lock out device. As the cam shaft and cam rotate, the follower which engages the eccentric groove causes the shaft support to rotate on the hinge
Implementation Method 2
a hinge configured to connect the shaft support to a pier and allow the shaft support to rotate relative to the pier
Data Source
AI summary
A solar tracker including a torque tube, a plurality of bearings configured to receive the torque tube, a plurality of piers each configured to receive one of the plurality of bearings, and a lock-out device mounted on one of the plurality of piers and operatively associated with at least one of the plurality of bearings, the lock out device configured to periodically engage and disengage openings formed in the bearings to limit movement of the torque tube and to transfer load from the torque tube to the pier on which it is mounted.