Patent Application
20100101630
The present application is directed to a terrestrial solar tracking photovoltaic array and, more particularly, to a modular array with solar cell modules that are simultaneously movable about first and second orthogonal axes to maintain the solar cell modules aligned with the sun.
Terrestrial solar tracking photovoltaic arrays are used for various applications. The arrays are designed for a specific output capacity and cannot be modified in a convenient manner for different capacities. The set capacity of the arrays may vary from being relatively small, such as a few kilowatts, to relatively large in excess of hundreds of kilowatts. The arrays may be installed at various locations that have exposure to the sun for adequate periods of time to produce the required power capacity.
The photovoltaic arrays generally include a frame with one or more solar cell modules in the form of panels. The frame may be adjustable to position the solar cell modules towards the sun. The frame may adjust the position of the solar cell modules throughout the day to ensure they remain directed to the sun to maximize the power capacity.
Many existing photovoltaic arrays include large frames that support the solar cell modules. The size of the frames and installation requirements often result in their costs being substantial. Initially, the frames are moved by large trucks or other like equipment to the installation site. Cranes or other like lifting equipment are necessary to lift the frames from the trucks and position them at the correct location. This installation process often requires a large workforce due to the extensive moving and assembly requirements of mounting the frame and attaching the associated solar cell modules. These prior designs did not allow for a single person or just a few persons to install the frame and solar cell modules.
These prior frames also provide for mounting a predetermined number of solar cell modules. There was no ability to modify the number of solar cell modules to accommodate the specific needs of the array. Particularly, there is no manner of modifying the design out in the field during or after the installation.
The present application is directed to a terrestrial solar tracking photovoltaic array. The array may include a modular design that is sized and weighted to facilitate installation with a small amount of manpower. The array further is adapted to be adjusted during or after installation to accommodate the necessary power requirements.
The terrestrial solar tracking photovoltaic array includes a longitudinal support that may be constructed of discrete sections. The overall length of the array may be adjusted depending upon the necessary size of the array. A drive may be configured to rotate the longitudinal support in first and second directions about a first axis. The drive may include a slew speed reducer. The slew speed reducer may include embedded first and second members and a gear. Solar cell modules are positioned along the longitudinal support and may each include a case with a plurality of lenses that are positioned over corresponding receivers. The receivers may include III-V compound semiconductor solar cells. Linkages may be connected to frames and may be axially movable along the longitudinal support to rotate the solar cell modules within second planes that are each orthogonal to the first plane to further track the sun during the course of the day.
The various aspects of the various embodiments may be used alone or in any combination, as is desired.
The present application is directed to a terrestrial solar tracking photovoltaic array.
Frame 110 positions the solar cell modules 200 to track the movement of the sun. Frame 110 includes a longitudinal support 120 that is positioned above a surface 300 by spaced-apart vertical supports 130. In one embodiment, the longitudinal support 120 is a single continuous piece. In one specific embodiment, the longitudinal support 120 is a pipe with a diameter of about 4-5.63 inches and includes a thickness of about 0.167-0.188 inches. The pipe has a length of about 170″ and weighs about 110 lbs.
In another embodiment, the longitudinal support 120 may be constructed from a number of discrete sections 121 that are connected together in an end-to-end arrangement. The lengths and construction of each section 121 may be the same or may be different. In one embodiment, each section 121 is sized to mount a pair or multiple pairs of solar cell array modules 200. The modular design provides for a user to construct the longitudinal support 120 to a length needed to support a necessary number of solar cell modules 200. Sections 121 may be added to an existing frame 110 to accommodate additional solar cell modules 200 as is necessary for the array 100 to produce the desired power output.
Mounts 160 support the solar cell modules 200 and are connected to the longitudinal support 120. Mounts 160 may be connected to the longitudinal support 120 at least in part through a base 161 as best illustrated in
Mounts 160 may also include a pivot member 165 that facilitates pivoting motion of the solar cell modules 200 about second axes B as will be explained in detail below. Pivot member 165 may extend through the base 161, or may be located away from the base 161. Further, the pivot member 165 may be a single elongated member or may be constructed of separate members that are positioned in an end-to-end orientation and connected at the base 161.
The mounts 160 may be positioned at various spacings along the length of the longitudinal support 120.
The vertical supports 130 are spaced apart along the length of the longitudinal support 120. The vertical supports 130 include a length adequate to position the solar cell modules 120 above the surface 300 for rotation about the first axis A. Therefore, the vertical supports 130 are longer than a height of the mounts 160 and the solar cell modules 200.
The vertical supports 130 are positioned along the longitudinal support 120 away from the mounts 160 to prevent interference with the movement of the solar cell modules 200. As illustrated in
A drive 170 is connected to the longitudinal support 120 to provide a force to rotate the longitudinal support 120 about axis A. In one embodiment, drive 170 may be positioned at an end of the longitudinal support 120. Drive 170 may include a drive train with one or more gears that engage with the longitudinal support 120. Additional drives 170 may be connected along the length of the longitudinal support 120 to provide additional rotational force.
A coupling 150 is attached to each mount 160 to enable the mount 160 and attached solar cell modules 200 to rotate about the second axis B. As best illustrated in
The couplings 150 are connected to rotate about the first axis A during rotation of the longitudinal support 120. The couplings 150 are also attached in a manner to rotate about the second axis B with the mounts 160. Because the arms 151, 152 are not connected to the base 161, the coupling 150 moves relative to the base 161 and longitudinal support 120 during rotation about the second axis B. In one embodiment, the arms 151, 152 are connected to the pivot member 165 that extends along a rear of the mounts 160.
Linkages 140 are connected to the mounts 160 for rotating the solar cell modules 200 about the second axes B. Each linkage 140 includes a first end 141 and a second end 142. The linkages 140 are attached together in a string aligned substantially parallel to the longitudinal support 120.
A drive 180 is attached to a drive linkage 144 as illustrated in
The array 100 is constructed to facilitate rotation of the longitudinal support 120 about the first axis A. The array 100 is designed to balance the power load requirements of the drive 170 during rotation through the various angular positions about the first axis A. One manner of balancing the load requirements is placing the mounts 160 and solar cell modules 200 such that a center of gravity of the array 100 is aligned with the longitudinal support 120.
During an initial period of the day, the weight of the array 100 is such that the drive 170 applies a force to rotate the array 100 in the direction X. At some point during the day, the distribution of mass of the array 100 shifts and the weight tends to rotate or pull the array 100 in the direction X. This shifting that causes the array to tend to rotate forward is referred to as backlash. In one embodiment, once this occurs, the drive 170 applies a braking force to slow the rotation such that the array 100 continues to track the elevation of the sun during the remainder of the day. In one embodiment, this point starts immediately after the solar cell modules 200 reach a specific rotational position, such as but not limited to a top-dead-center rotational position relative to the longitudinal support 120. When this occurs, the weight of the array 100 causes a strain on the drive 170 as the drive 170 now acts against the pulling force of the array 100. This may negatively affect the positional accuracy of the array 100 causing the modules 200 to become out of alignment with the sun during the course of the day.
Further, this backlash shift could cause gears in the drive 170 and/or the longitudinal support 120 to become disengaged.
In the event of a backlash shift as illustrated in
To prevent this from occurring, a balancing or dynamic anti-backlash mechanism 350 may be connected to the array 100.
In use, the weight 352 may be spaced a distance from the longitudinal support 120 at the start of the day. As the day progresses, the drive 170 rotates the longitudinal support 120 in a first direction causing the cable 352 to wrap around the pulley 351 and move the weight upward towards the longitudinal support 120. The mechanism 350 applies a counterbalance force to the array 100 to counteract the backlash weighting that may occur at some point during the day. At the end of the day, the weight 352 is positioned in closer proximity to the longitudinal support 120. Prior to beginning tracking during the next day, the drive 170 rotates the longitudinal support in a second opposite direction. This causes the cable 353 to unwind from the pulley 351 and the weight 352 to move downward away from the longitudinal support 120. This force applied by the mechanism 350 to the array 100 assists the drive 170 in rotating the array 100 back to the starting position.
The dynamic anti-backlash mechanisms 350 may be configured for the drive 170 to apply a constant torque to the longitudinal support 120 during rotation in the first direction. The drive 170 may further include a controller to apply a constant torque to the longitudinal support 120.
The dynamic anti-backlash mechanisms 350 may balance an unbalanced array 100. The uneven balancing may be caused by and uneven number of mounts 160 and solar cell modules 200 on one side of the longitudinal support 120. The amount of the weight 352 and length of the support 354 are determined to counterbalance the otherwise uneven weight distribution on the longitudinal support 120.
The balanced weighting of the array 100 eliminates or reduces weight loading and frictional loading issues with the drive 170. This reduces power requirements for the drive 170 and frictional wear on the drive train. The balanced weighting may also improve tracking of the array 100 due to reduced strain in the drive 170 and drive train.
The dynamic anti-backlash mechanism 350 may also include one or more tension members connected to the longitudinal support 120.
In one specific embodiment, the dynamic anti-backlash mechanism 350 includes two tension springs each with a 160 lb maximum force that are anchored to one of the vertical supports 130. The longitudinal support 120 includes a sprocket that is connected to the springs with a chain. In one embodiment, the sprocket is a Martin 50A65 sprocket, and the chain includes three feet of #50 chain. During the course of the day, the dynamic anti-backlash mechanism 350 applies varying amounts of force as the array moves to track the sun. In the morning, the moment created by the array 100 acts counterclockwise and the dynamic anti-backlash mechanism 350 works as an anti-backlash device with the springs in a relaxed condition and contributing very little force. By noon, the array 100 is practically balanced and the springs produce about half of the force (about 80 lbs each in the embodiment of the 160 lb springs) creating a counterclockwise anti-backlash moment. Later in the afternoon, the moment created by the array 100 changes polarity and acts in the opposite direction with the springs producing near full force that is capable to overpower the force in the opposite direction and still act as an anti-backlash mechanism.
In one embodiment, the solar cell modules 200 are each about 43″ by 67″.
When mounted on the surface 300, the longitudinal support 120 may be positioned in a north N-south S orientation as illustrated in
In addition to the rotation of the longitudinal support 120, the one or more drives 180 move the linkages 140 to further maintain the solar cell modules 200 aligned with the sun. The drive(s) 180 are periodically activated to move the first linkage 140a and attached string of linkages 140. This movement causes the couplings 150 and attached mounts 160 and solar cell modules 200 to pivot about the various axes B. These axes B may be orthogonal to the axis A. The string of linkages 140 provides for each of the solar cell modules 200 to again move in unison about their respective axis B. The movement about the B axes may allow the solar cell modules 200 to track the azimuthal position of the sun during the course of the day.
A controller 190 may control the movement of the terrestrial solar tracking array 100. The controller 190 may include a microcontroller with associated memory. In one embodiment, controller 190 includes a microprocessor, random access memory, read only memory, and in input/output interface. The controller 190 controls operation of the one or more drives 170 for rotating the longitudinal support 120 and the solar cell modules 200 about the first axis A. The controller 190 further controls the one or more drives 180 for driving the linkages 140 and rotating the solar cell modules about the second axes B. The controller 190 may include an internal timing mechanism such that the operation of the drives corresponds to the time of day for the solar cell modules 200 to track the azimuth and elevation of the sun.
The shadow cast by a given solar cell module 200 depends on its size and shape, and also on its location relative to the location of the sun in the sky. In the East-West direction, the sun location can vary by up to 150°. In this connection, it should be noted that it is generally accepted that, where the elevation of the sun is below 15° above the horizon, its rays are of insufficient strength to generate a useful amount of electricity. The latitude at which the solar cell array 100 is positioned is, therefore, of little influence.
In the North-South direction, the sun location varies by 46°, given that the earth's axis is tilted at an angle of 23° with respect to its orbit around the sun. In this connection, it will be appreciated that latitudes below 23° are subject to different conditions, and that latitudes above 45° are probably not relevant due to poor direct normal insolation (DNI) levels.
The solar cell array 100 is constructed in a manner to eliminate or minimize shadowing problems between solar cell modules 200. In one embodiment, the longitudinal support 120 and the individual sections 121 of the solar cell modules 200 are sized to space apart each module 200 such that it is fully illuminated for positions where the sun is 15° above the horizon, and that there is no shadowing of any given module 200 by any other module 200.
U.S. Pat. No. 7,381,886 assigned to Emcore Corporation discloses solar cell arrays and positioning relative to the sun path and is herein incorporated by reference in its entirety.
In one embodiment, the terrestrial solar tracking array 100 can be installed in a straight-forward manner. The various components are sized to fit within a standard vehicle and are light-weight to allow installation by a single person or limited number of persons. Further, the modular aspect of the array 100 facilitates modifications after the initial installation. Additional sections 121 and vertical supports 130 may be added to the frame 110 to accommodate a desired number of additional solar cell modules 200. Further, the size of the array 100 may be reduced after installation by removing one or more solar cell modules 200. One or more dynamic anti-backlash mechanisms 350 may be added to the array 100 as necessary. In one embodiment, additional mechanisms 350 are added when the size of the array 100 is increased to accommodate additional solar cell modules 200. Further, the weight 352 or number or sizes of the biasing mechanisms may be altered to provide the necessary balancing forces.
A slew speed reducer 500 may rotate the longitudinal support 120. The slew speed reducer 500 may deliver high torque and smooth rotational positioning to the longitudinal support 120 to accurately maintain the alignment of the solar cell modules 200 during the course of the day. The slew speed reducer 500 may also rotate heavier and/or larger solar cell modules 200 and supporting framework than other drives. The slew speed reducer 500 may also include a reduced size that does not interfere with the movement of the other elements of the solar cell array 100.
The slew speed reducer 500 may be positioned along a central section of the longitudinal support 120. As illustrated in
The inner slew ring 501 includes an inner radial surface 515 and an outer radial surface 516. The inner slew ring 501 also includes lateral sides 532 that extend between the inner and outer surfaces 515, 516. One or more apertures 533 may extend through the lateral sides 532. Bearings 517 are positioned between the rings 501, 503 to accommodate relative rotation between the rings 501, 503.
The worm 502 is positioned at the outer surface 511 of the outer gear ring 503. The worm 502 includes a helical tooth 518 that engages with the plurality of teeth 512 on the outer gear ring 503. A housing 519 may extend around a portion or entirety of the worm 502. The housing 519 may protect the worm 502 from debris or environmental elements (e.g., ice, rain, snow) to which the array 100 may be exposed.
A connecting member 550 connects the worm 502 to the inner slew ring 501 such that the two elements rotate together.
The inner slew ring 501 is connected to opposing discrete sections 121 of the longitudinal support 120 by adapters 507. A first adapter 507 extends between the inner slew ring 501 and a first discrete section 121, and a second adapter 507 extends between the inner slew ring 501 and a second discrete section 121.
As illustrated in
The second discrete section 121 on the opposing side of the slew speed reducer 500 may be connected in a similar manner. A second adapter 507 extends between and connects the slew speed reducer 500 to the second discrete section 121. The second adapter 507 may be the same or different than the first adapter 507. In another embodiment, one or both discrete sections 121 are connected directly to the inner slew ring 501 (i.e., without an adapter 507).
A bracket 700 connects the slew speed reducer 500 to a vertical support 130 as best illustrated in FIGS. 23 and 25-27. The bracket 700 includes a first section 701 that connects to the vertical support 130, and a second section 702 that connects to the outer gear ring 503. Each of the sections 701, 702 may be substantially flat and perpendicular to each other. The bracket 700 may also include other configurations. The first section 701 may connect to the vertical support 130 by various mechanisms, including fasteners 710 as illustrated in
In one embodiment, the outer diameter of the outer gear ring 503 is sized to extend outward beyond the second section 702 of the bracket 700. This exposes the teeth 512 on the outer gear ring 503 and facilitates engagement with the helical tooth 518 of the worm 502.
In use, the slew speed reducer 500 is activated by the controller 190 which rotates the worm 502. The helical tooth 518 engages with the teeth 512 on the outer gear ring 503. The engagement with the fixed outer gear ring 503 causes the worm 502 and the inner slew ring 501 rotate around the outer gear ring 503. The worm 502 and connecting inner slew ring 501 rotate around the outer gear ring 503 because the outer gear ring 503 is fixedly connected to the vertical support 130 through the bracket 700.
Illustrations of various positions of these elements during the course of operation are illustrated in
The amount of rotation of the worm 502 about the outer gear ring 503 may vary depending upon the specifics of the array 200. In one embodiment, the worm rotates about 180° around the outer gear ring 503. The amount of angular range defining the rotation for array 100 could be different depending on many factors such as, the geographical location of the solar array or the time of year, and could therefore be adjusted at anytime during the installation or operation of the solar tracking array.
The controller 190 may control the movement of the slew speed reducer 500 during the course of the day. At the end of the day, the controller 190 may cause the worm 502 to rotate in an opposite direction to return the array 100 to the starting position in preparation for the subsequent day.
The slew speed reducer 500 is typically designed to have a compact size and low profile such that the movement of the worm 502 and housing 519 does not interfere with the movement of the solar cell modules 200. The positioning and structure of the slew speed reducer 500 may particularly be configured to not interfere with the movement of the linkages 140.
A single slew speed reducer 500 may be adequate to rotate the longitudinal support 120. Alternatively, two or more slew speed reducers 500 may be positioned along the longitudinal support 120 to drive the various discrete sections 121 as necessary.
In one embodiment, the longitudinal support 120 includes one or more tubes that receive torque from the drive 170. Therefore, the longitudinal support 120 and the discrete sections 121 may be referred to as a “torque tubes”.
While particular embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from this invention and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the scope of this invention. Furthermore, it is to be understood that the invention is solely defined by the appended claims.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations).
The present application is a continuation-in-part of U.S. patent application Ser. No. 12/478,567 filed Jun. 4, 2009 which itself is a continuation-in-part of U.S. patent application Ser. No. 12/257,670 filed Oct. 24, 2008. Each of these references is herein incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12478567 | Jun 2009 | US |
| Child | 12574508 | US | |
| Parent | 12257670 | Oct 2008 | US |
| Child | 12478567 | US |
