Winch-Pulley Drive System for Solar Tracker Misalignment Tolerance
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Solution Overview
Problem
Single-axis solar trackers with center torque tubes face challenges in efficiently rotating solar modules from 45° east to 45° west while maintaining alignment and tolerating misalignment, which affects reliability and increases costs due to the need for precise alignment and vulnerability to wind.
Innovation Solution
A drive system utilizing pulleys and wire ropes or cables with a slew drive mechanism that includes a winch-pulley and partial pulleys attached to the torque tube, allowing for leveraged drive forces and high tolerance in misalignment, with the pulleys attached at a slight angle to maintain alignment and reduce material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a center torque tube drive system is used for single-axis solar trackers, then the solar modules can be rotated from 45° east to 45° west, but the system requires precise alignment and has high vulnerability to wind, increasing cost and reducing reliability
Solution Approach 1:
The patent uses flexible cable elements instead of rigid mechanical connections in the drive system. The cable-driven mechanism with pulleys allows for misalignment tolerance while maintaining functional integrity, replacing rigid torque tube connections with flexible cable pathways that can accommodate positioning variations without compromising reliability
Solution Approach 2:
The patent changes the mechanical parameters of the drive system by using a cable-driven pulley mechanism instead of direct torque tube driving. This parameter change allows the system to tolerate misalignment up to certain degrees while maintaining operational reliability, reducing the need for precise alignment during installation and operation
2Productivity
If higher tilt angles (50°, 55°, 60°) are used to increase solar module tracking range, then the tracking gain is improved, but the cost, height, and vulnerability to wind increase with diminishing returns
Solution Approach 1:
The patent implements a dynamic cable tensioning system that adjusts cable tension based on wind conditions and tracker position. The flexible cable-driven mechanism allows the structure to dynamically respond to wind loads rather than resisting them rigidly, reducing vulnerability to wind while maintaining the ability to achieve high tilt angles for improved tracking gain
3Adaptability or versatility
If a cable-driven pulley system is used instead of traditional torque tube driving, then misalignment tolerance is improved, but the device complexity changes requiring pulleys and cable management
Solution Approach 1:
The patent designs the pulley system to serve multiple functions: guiding cables, providing mechanical advantage, accommodating misalignment, and enabling compact winding. The pulleys are integrated into the tracker structure to perform both drive transmission and alignment tolerance functions simultaneously, reducing overall system complexity despite the cable-driven approach
Solution Approach 2:
The patent extracts the alignment precision requirement from the drive system by using flexible cables that can accommodate misalignment. The cable-driven mechanism separates the driving function from the alignment function, allowing the structure to be less precise while maintaining operational effectiveness, thus reducing installation and maintenance 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 system enhances reliability by allowing high misalignment tolerance, reduces material and cost, and maintains alignment through adjustable slew drives and pulley configurations, improving the efficiency and durability of solar module tracking.
Implementation Method 1
The at least one partial pulley is connected to a torque tube. The at least one partial pulley is configured to accept the at least one wire rope and to transfer leveraged drive forces to the torque tube.
Data Source
AI summary
One embodiment provides a drive system that includes a drive device with at least one drum for spooling at least one wire rope. A mounting device is connected to the drive device and a single-axis tracker. At least one partial pulley is connected to a torque tube. The at least one partial pulley is configured to accept the at least one wire rope and to transfer leveraged drive forces to the torque tube.