APPARATUSES AND ASSEMBLIES FOR A SOLAR PANEL INSTALLATION
20170234580 · 2017-08-17
Inventors
Cpc classification
F16C2362/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C2300/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C35/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/47
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S30/42
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C2300/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S30/425
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S2030/15
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C17/022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F16C33/74
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A bearing assembly comprises a bearing wheel with a rotational axis, the bearing wheel including and extending radially between an inner surface and an outer surface, wherein the inner surface at least partially forms a bore, the bore extends axially through the bearing wheel along the rotational axis, and the bore has a cross-sectional geometry configured to receive a rotatable shaft with a complementary cross-sectional geometry, and wherein the outer surface extends circumferentially around the rotational axis, and the outer surface has a circular cross-sectional geometry. The bearing assembly also comprises a bearing collar comprising a collar base and a collar mount, wherein the collar base includes an inner surface configured to circumscribe and slidingly engage the outer surface of the bearing wheel, wherein the collar mount projects radially out from collar base to a distal mount end, and wherein a plurality of mounting apertures at the distal mount end extend axially through the collar mount, and the mounting apertures are configured to respectively receive fasteners for securing the collar mount to a stationary structural member.
Claims
1. A bearing assembly, comprising: a bearing wheel with a rotational axis, the bearing wheel including and extending radially between an inner surface and an outer surface, wherein the inner surface at least partially forms a bore, the bore extends axially through the bearing wheel along the rotational axis, and the bore has a cross-sectional geometry configured to receive a rotatable shaft with a complementary cross-sectional geometry, and wherein the outer surface extends circumferentially around the rotational axis, and the outer surface has a circular cross-sectional geometry; and a bearing collar comprising a collar base and a collar mount, wherein the collar base includes an inner surface configured to circumscribe and slidingly engage the outer surface of the bearing wheel, wherein the collar mount projects radially out from collar base to a distal mount end, and wherein a plurality of mounting apertures at the distal mount end extend axially through the collar mount, and the mounting apertures are configured to respectively receive fasteners for securing the collar mount to a stationary structural member.
2. The bearing assembly of claim 1, wherein the bearing wheel comprises a plurality of discrete segments, and the cross-sectional geometry of the base is polygonal.
3. The bearing assembly of claim 2, wherein a first of the segments is secured to a second of the segments.
4. The bearing assembly of claim 2, wherein an adjacent pair of the segments are not attached to one another.
5. The bearing assembly of claim 2, wherein the plurality of segments consist of a pair of bearing wheel halves.
6. The bearing assembly of claim 1, wherein the collar base comprises a plurality of discrete segments which are secured together, the base mount projects out from and is integrally formed with a first of the segments, and the cross-sectional geometry of the bore is polygonal.
7. The bearing assembly of claim 6, wherein the first of the segments extends between about 30 degrees and about 90 degrees around the rotational axis.
8. The bearing assembly of claim 1, further comprising a capture ring secured to an axial side of the collar base, wherein the capture ring radially overlaps at least a portion of the bearing wheel.
9. The bearing assembly of claim 1, further comprising a pair of capture rings secured to opposing axial sides of the collar base, wherein the capture rings project radially inward and thereby overlap opposing axial ends of the bearing ring.
10. An assembly for a solar panel installation, the assembly comprising: a stationary structural member; a rotatable shaft; a bearing wheel with a rotational axis, the bearing wheel including and extending radially between an inner surface and an outer surface, wherein the inner surface at least partially forms a bore, the bore extends axially through the bearing wheel along the rotational axis, and the bore has a cross-sectional geometry configured to receive the rotatable shaft which has a complementary cross-sectional geometry, and wherein the outer surface extends circumferentially around the rotational axis, and the outer surface has a circular cross-sectional geometry; and a bearing collar comprising a collar base and a collar mount, wherein the collar base includes an inner surface configured to circumscribe and slidingly engage the outer surface of the bearing wheel, wherein the collar mount projects radially out from collar base to a distal mount end, and wherein a plurality of mounting apertures at the distal mount end extend axially through the collar mount, and the mounting apertures are configured to respectively receive fasteners for securing the collar mount to the stationary structural member.
11. The assembly of claim 10, wherein the stationary structural member is configured to be securely anchored to the ground.
12. The assembly of claim 10, wherein the rotatable shaft comprises a length of square tubing.
13. The assembly of claim 10, wherein the rotatable shaft is configured to structurally support one or more solar panels.
14. An assembly for a solar panel installation, the assembly comprising: a stationary structural member with a plurality of slots; a rotatable shaft having a cross-sectional geometry and a rotational axis; a bearing wheel having a bore, wherein the rotatable shaft is mated with the bearing wheel and projects axially through the bore; a bearing collar comprising a collar base and a collar mount, wherein the collar base is configured to house the bearing wheel and provide a bearing surface for the bearing wheel to slidingly engage while moving with the rotatable shaft about the rotational axis, wherein the collar base projects radially out from the collar base to a distal mount end, and wherein a plurality of mounting apertures at the distal mount end extend axially through the collar mount; and a plurality of fasteners securing the bearing collar to the stationary structural member, each of the fasteners extending through a respective one of the slots and a respective one of the mounting apertures, wherein one or more of the fasteners is operable to be selectively positioned within the slots to change the vertical and/or lateral position of the bearing collar relative to the stationary structural member.
15. The assembly of claim 14, further comprising: a second bearing wheel having a bore, wherein the rotatable shaft is mated with the bearing wheel and projects axially through the bore of the second bearing wheel; a second bearing collar comprising a second collar base and a second collar mount, wherein the second collar base is configured to house the second bearing wheel and provide a bearing surface for the second bearing wheel to slidingly engage while moving with the rotatable shaft about the rotational axis, wherein the second collar base projects radially out from the second collar base to a second distal mount end, and wherein a plurality of second mounting apertures at the second distal mount end extend axially through the second collar mount; and a plurality of second fasteners securing the second bearing collar to the stationary structural member, each of the second fasteners extending through a respective one of the slots and a respective one of the second mounting apertures, wherein one or more of the second fasteners is operable to be selectively positioned within the slots to change the vertical and/or lateral position of the second bearing collar relative to the stationary structural member and the other bearing collar.
16. An assembly for a solar panel installation, the assembly comprising: a stationary structural member having an length that extends longitudinally to a distal member end, the stationary structural member comprising a first flange, a second flange and a web extending between the first flange and the second flange; a rotatable shaft having a rotatable axis, wherein the rotatable shaft is rotatably connected to the stationary structural member at the distal member end by one or more bearings; a drive arm secured to the rotatable shaft and aligned with the stationary structural member along the rotational axis; and an actuator pivotally connected to the drive arm and pivotally connected between and to the first and the second flanges, wherein a portion of the actuator projects through an opening in the web, and wherein the actuator is configured to change its length in order to move the drive atm relative to the stationary structural member and thereby rotate the rotatable shaft about the rotational axis.
17. The assembly of claim 16, wherein the portion of the actuator includes a motor.
18. The assembly of claim 16, further comprising an actuator mount clamped onto the actuator, wherein the actuator mount is pivotally connected to the stationary structural member by a shaft which extends between and is connected to the first and the second flanges.
19. The assembly of claim 16, wherein the actuator comprises a base and a pushrod, the base is pivotally connected to the stationary structural member and the pushrod is pivotally connected to the drive arm.
20. The assembly of claim 16, wherein the rotatable axis is generally perpendicular to the length of the stationary structural member.
21. The assembly of claim 16, wherein the actuator is pivotally connected to the drive arm between two flanges of the drive arm.
22. The assembly of claim 16, wherein the actuator comprises a hydraulic piston.
23. The assembly of claim 16, wherein the actuator comprises a screw drive mechanism.
24. An assembly for a solar panel installation, the assembly comprising: a stationary structural member having an length that extends longitudinally to a distal member end, the stationary structural member comprising a first flange, a second flange and a web extending between the first flange and the second flange; a rotatable shaft having a rotatable axis, wherein the rotatable shaft is rotatably connected to the stationary structural member at the distal member end by one or more bearings; a drive arm secured to the rotatable shaft and aligned with the stationary structural member along the rotational axis; and an actuator aligned with the stationary structural member and the drive arm along the rotational axis, the actuator comprising an actuator base and a pushrod projecting out of the actuator base, wherein the actuator base is pivotally connected to and between the first and the second flanges, wherein the pushrod is pivotally connected to and between two mounts of the drive arm, and wherein the pushrod is configured to move into and out of the actuator base in order to move the drive arm relative to the stationary structural member and thereby rotate the rotatable shaft about the rotational axis.
25. An assembly for a solar panel installation, the assembly comprising: a stationary structural member having a length that extends longitudinally to a distal member end; a rotatable shaft having a rotatable axis, wherein the rotatable shaft is rotatably connected to the stationary structural member at the distal member end by one or more bearings; a drive mechanism configured to rotate the rotatable shaft about the rotatable axis, the drive mechanism mounted to the stationary structural member; and a wind break plate mounted to the rotatable shaft, the wind break plate configured to at least partially cover the distal member end and the drive mechanism.
26. The assembly of claim 25, further comprising a pair of purlin members, wherein the purlin members are located on opposing sides of the stationary structural member along the rotational axis, and wherein the purlin members mount the wind break plate to the rotatable shaft.
27. The assembly of claim 25, further comprising a pair of solar panels, wherein the solar panels are located adjacent to the wind break plate and mounted to the rotatable shaft, and wherein the wind break plate substantially closes a gap between the solar panels.
28. The assembly of claim 25, further comprising a solar panel mounted to the wind break plate.
29. The assembly of claim 28, wherein the solar panel is operable to provide power to the drive mechanism.
30. The assembly of claim 28, wherein the solar panel is nested with an opening in the wind break plate over the distal member end.
31. A node controller for a solar panel installation with an actuator motor, the node controller comprising: a processor; a tilt measuring device configured to measure tilt of a solar panel; a clock; a memory with a lookup table for use with the processor to determine what the tilt of the solar panel should be for a time of day based on one or more of the following parameters: location, sun elevation, sun azimuth, row spacing and/or slope for backtracking analysis; one or more motor drivers configured to signal the actuator motor to turn until an appropriate tilt is reached; and a wireless communication device for communicating with another device.
32. The node controller of claim 31, wherein the other device is a master controller.
33. The node controller of claim 31, further comprising a snow depth sensor for providing data which can trigger a warning and/or an adjustment in an operational tilt range.
34. A master controller for communicating with a plurality of node controllers of a solar panel installation and for communicating with a wind speed sensor, the master controller comprising: a processor configured with a memory and a communication device in order to: periodically synch up clocks of the node controllers with a clock of the master controller to ensure uniform tilts of solar panels included in the solar panel array; and receive information from the node controllers about time of day and tilt to see if any of the solar panels are not at proper tilt or are not running.
35. The master controller of claim 34, wherein the processor is configured to relay data to another device or system using the communication device, and the data is indicative of information related to the operation of the solar panel installation.
36. A lateral capture device for a solar panel installation with a solar panel mounted on a rotatable shaft, which rotatable shaft is supported by a bearing, the lateral capture device comprising a U-bolt and a bracket, wherein the bracket is configured to mate with the U-bolt in a manner so as to clamp the lateral capture device onto the rotatable shaft adjacent the bearing such that the rotatable shaft cannot move laterally relative to the bearing.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
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[0058] Referring again to
[0059]
[0060] Referring still to
[0061]
[0062] Referring to
[0063] Referring to
[0064] The bearing wheel 64 may be formed as a single, integral body. Alternatively, the bearing wheel may be formed from a plurality of discrete segments (e.g., discretely formed halves) as shown in
[0065] Referring again to
[0066] In the exemplary embodiment of
[0067] The collar mount 78 projects radially out (e.g., down) from collar base 76 (e.g., the bottom segment) to a distal mount end 82. The collar mount 78 may be formed integrally with the collar base 76 (e.g., the bottom segment), or attached thereto. The collar mount 78 includes a plurality of mounting apertures 84, 85 at the distal mount end 82. Each of these mounting apertures 84, 85 extends axially through the collar mount 78. The mounting apertures 84, 85 are configured to respectively receive fasteners 88, 89 (e.g., bolts or otherwise) for securing the collar mount 78 to a respective one of the stationary structural members 22, 24 as shown in
[0068] The capture rings 68, 58 are secured to opposing axial sides of the collar base 76 using, for example, one or more fasteners (e.g., screws) 88-93. Each capture ring 68, 69 projects radially inward from the inner surface 78 of the collar base 76 and thereby overlaps an axial end of the bearing ring 66 to prevent that end from sliding out of the bore of the collar base.
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[0070] The actuator 100 is substantially axially aligned with the stationary structural member and the drive arm along the rotational axis. The actuator 100 is pivotally connected to the drive aim 98. More particularly, a first end of the actuator projects through an opening in the drive arm and is pivotally connected to and between two sides of the drive aim at its second end by a shaft; e.g., a threaded rod 102. The actuator is also connected to the stationary structural member 22; e.g., the center post. More particularly, an intermediate portion of the actuator 100 is pivotally connected to and between the first and second flanges 38, 39 of the stationary structural member 22. An end portion of the actuator 100 may project through an opening in the web of the stationary structural member to a second end of the actuator, where a motor 104 for actuating the actuator may be located. The intermediate portion of the actuator may be connected to the flanges 38, 39 by an actuator mount 106 clamped therearound, or with trunnion blocks welded to the actuator housing, and a shaft.
[0071] The actuator 100 may be a hydraulic piston actuator or a screw drive mechanism actuator. The actuator may thereby include a pushrod 107 and a base 108, where the push rod 107 projects out from and slides within and relative to the base. The pushrod 107 may be pivotally connected to the drive arm 98. The base 108 may be pivotally connected to the stationary structural member 22. Of course, the drive mechanism of the present disclosure is not limited to the foregoing exemplary actuator configuration or mounting scheme.
[0072]
[0073] Referring again to
[0074] The solar panel installation of
[0075] An exemplary embodiment of a node controller 118 is shown with the rotatable shaft 26 in
[0076] The master controller may be configured to communicate wirelessly with one or more node controllers. The master controller is configured to synch up the node controller clocks to a master controller clock periodically (e.g., every day) to make sure all of the clocks are all at the exact same time so tilts are uniform. The master controller is also configured to receive information from the node controllers about time of day and tilt to see if any solar panels are not at proper tilt or are not running The master controller may subsequently relay this data to another device such as a cell phone, or wireline the data to the cloud or customer communications network for service call notification and analysis.
[0077] The master controller may include or be connected to a wind speed sensor (e.g., an anemometer) configured to read wind speed. The master controller may monitor the wind speed and the tilt of the system as determined, for example, using a lookup table for the site. The master controller may calculate at what wind speed the system should move towards a stow position. The master controller may then broadcast control signals to the node controllers to move the solar panels toward their stow position in a certain increment in degrees of tilt. The master controller may then continue to monitor the windspeed, and if more adjustments are needed to move further towards full stow position due to increasing windspeed the master controller may send additional broadcast stow messages to the node controllers. By providing incremental partial stow messages and movements to match up tilt with windspeed and only change the tilt to that closest to optimal based on monitored windspeed, the solar panels may not need to be moved to the fully stowed position, battery drain may be minimized and/or the power output of the entire array may be maximized by reducing time that the solar panels are moved away from optimal power producing position in high speed wind conditions. Also, by having the stow position be at the fully retracted actuator position with panels facing west, positioning in the stow position may be optimized to be mostly in the afternoon hours when thunderstorms are prevalent, which increases the average stow windspeed dramatically, which again reduces battery usage and reduces any power loss from the array being moved out of optimal power producing tilt due to wind events.
[0078] In some embodiments, the solar panel array may include one or more lateral capture devices 122, 123 as shown in
[0079] While various embodiments of the present invention have been disclosed, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. For example, the present invention as described herein includes several aspects and embodiments that include particular features. Although these features may be described individually, it is within the scope of the present invention that some or all of these features may be combined with any one of the aspects and remain within the scope of the invention. Accordingly, the present invention is not to be restricted except in light of the attached claims and their equivalents.