Zenithal Rotation Module With Independent Raceways for Heavy Solar Panels
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Solution Overview
Problem
Existing solar panel rotation modules are inadequate for supporting large radial loads and are complex to assemble and maintain, leading to inefficiencies in energy output due to misalignment and contamination risks.
Innovation Solution
A zenithal rotation module with a structural casing and toothed crown featuring ball bearings for radial load support, independent lubrication, and circular seals to prevent contamination, allowing for precise alignment and easy assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard rotation modules are used for zenithal orientation, then the structure is simpler and easier to assemble, but they cannot support large radial loads and result in poor alignment precision
Solution Approach 1:
The rotation module is segmented into functionally independent components: the toothed crown assembly with ball bearings for radial load support, the endless screw mechanism for precision positioning, and the shaft assembly for solar panel mounting. This segmentation allows each component to be optimized for its specific function while simplifying assembly and maintenance procedures.
Solution Approach 2:
Ball bearings are introduced as intermediary elements between the toothed crown and the structural casing to handle radial loads. This intermediary component protects the toothed crown from direct radial contact, enabling precise alignment while supporting heavy radial loads through the bearing's rolling contact mechanism.
2Reliability
If a single common greasing system is used for the endless screw and crown bearings, then the device is simpler, but it cannot meet different lubrication requirements and risks impurity contamination
Solution Approach 1:
The lubrication system is segmented into two independent circuits: one dedicated to the endless screw and another to the crown ball bearings. This segmentation allows each lubrication circuit to be optimized with appropriate lubricants and sealing arrangements, preventing cross-contamination and ensuring reliable operation of both mechanisms with different lubrication requirements.
Solution Approach 2:
Sealing elements are introduced as intermediaries between the lubrication system and the external environment, as well as between the two lubrication circuits. These seals prevent impurity entry and cross-contamination while allowing the independent lubrication circuits to function separately, thus improving reliability without significant complexity increase.
3Strength
If multiple intermediate parts such as bearings and attachments are used to achieve precision and robustness, then the radial load support and alignment are improved, but the assembly and maintenance become more complex
Solution Approach 1:
The rotation module is designed with segmented, modular components where the toothed crown assembly with integrated ball bearings can be assembled and disassembled as a unit. This segmentation allows for easier maintenance compared to traditional designs with multiple separately mounted bearings and attachments, while still providing robust radial load support through the integrated bearing arrangement.
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 module effectively supports radial loads, ensures precise alignment, and simplifies assembly and maintenance, enhancing energy output by minimizing friction and preventing impurities from entering the system.
Implementation Method 1
The ball bearings disposed between the circular rings and the toothed crown reduce friction and allow the toothed crown to slide extremely gently within the structural casing
Implementation Method 2
with a good greasing system... the toothed crown must slide extremely gently within the structural casing, minimizing the friction
Data Source
AI summary
Capable of supporting large radial loads due to heavy panels, with a simplified assembly but without compromise in terms of precision and robustness. It comprises an annular structural casing (1), a toothed crown (2) mounted in the structural casing (1), whereon an endless screw (3) actuated by a motor (4) tangentially meshes, the toothed crown (2) of which comprises a central annular protuberance (5) with a toothing that meshes with the endless screw (3), and the circular projections (6) of which of the body of the toothed crown (2) comprise a plurality of threaded holes (7) for connecting the horizontal shafts that support the solar panels for their zenithal orientation, where the toothed crown (2) comprises a toothed track whereon the endless screw (3) tangentially meshes, and two independent raceways.