ELEVATED DUAL-AXIS PHOTOVOLTAIC SOLAR TRACKING ASSEMBLY

Abstract

An elevated dual-axis photovoltaic solar tracking assembly tracks the position of the sun with a high efficiency photovoltaic array, orienting photovoltaic array orthogonal to the sun, for optimal efficiency in generating electricity every minute of every day year-round. The assembly provides a pole, typically 20 feet, to elevate the photovoltaic array, thereby allowing a minimum 13 feet clearance from the ground at all times to retain use of the real estate space below the photovoltaic array. A structural frame carries photovoltaic array. A drive-core unit has two interdependent slew drives, driven by all-electric motors, to adjust positioning of photovoltaic array in the orthogonal orientation relative to sun while maintaining the photovoltaic array longitudinal axis orientation to the support pole. This drive-core unit includes the control system with GPS, anemometer, snow sensor and encoder transducers that provide data for a positional algorithm to calculate the sun's position, and move the photovoltaic array to optimally track it, at preset time intervals; as well as to move the array to other desired positions for wind and snow safety or owner preference. The control system energizes the slew drives via electric motors for movement and optimal sun tracking.

Claims

1. A portable elevated dual axis photovoltaic solar tracking assembly comprising in combination, an elongated pole having a proximal end and a distal end, the pole length at least ten feet in length, the proximal end is configured for removable mounting to a foundation surface, an integrated dual drive core unit removably attached to the distal end of the pole, said dual drive core unit includes a second slew drive removably secured to distal end of the pole along the pole's longitudinal axis, the first slew drive removably secured directly to the second slew drive along the second slew's drive rotational axis, at least one encoder interfacing with said first and second slew drives, a control system interfacing with said controller and a global positioning system configured to work with a positioning algorithm, a movable support frame extending from the dual drive core unit, a central portion of the support frame secured to and driven by said first slew drive, defining a rotational axis center of gravity for the support frame along the pole's longitudinal axis detachably positioned from the second slew drive along the dual central vertical and rotational axis, the integrated dual drive core unit enables support frame articulation in orthogonal orientation with both the azimuth and elevation motion of the sun, at least one photovoltaic array carried by the support frame is in parallel relationship therewith.

2. The assembly of claim 1 wherein said dual rotatable axis center of gravity of said frame is maintained along the dual slew drive's central vertical axis during both horizontal frame rotation plane and rotating the frame to a selective angle 0-90 with respect to the horizontal plane.

3. The assembly of claim 1, wherein the second slew drive comprises a second worm gear, the second slew drive being actuated by a second motor to rotate the second worm gear while transmitting torque to a second drive torque arm for rotating the frame to a desired angle between 0-360 degrees in the horizontal plane.

4. The assembly of claim 1, wherein the control system orients the photovoltaic array to a horizontal stowed position during night or upon receiving a signal from an anemometer system that supplies wind speed information.

5. The assembly of claim 1, wherein the control system orients the photovoltaic array to within 30 degrees of vertical stowed position upon receiving a signal from a snow detection system that supplies snow load information.

6. The assembly of claim 1, wherein the encoders monitor the worm gear rotations of the slew drives to determine array rotation from a limit-switched position reset from the stowed position or on user reset.

7. The assembly of claim 1, further comprising an electrical vehicle charging station and electrical charging outlets.

8. The assembly of claim 1, wherein the global positioning system verifies date, time, and location allowing an internal clock to track the position of the sun relative to the assembly and emitting a correlating positioning signal at a continuous predetermined time interval of time ranging from 5 to 10 minutes.

9. The assembly set forth in claim 1 wherein said first and second slew drives are removably secured directly to one another and to a mounting plate on the distal end of elongated pole along the pole's longitudinal axis.

10. A dual axis drive-core unit of a photovoltaic solar tracking assembly, wherein the drive-core unit comprises a pair of independent unitary drive assembly including a plurality of positioning controllers and processors, a first slew drive, a second slew drive, secured directly together, along the longitudinal axis of a support pole, a control system operationally interfacing with the first slew drive and the second slew drive, a global positioning system interfacing with the control system, and an encoder interfacing with the first slew drive, with another encoder interfacing with the second slew drive and the control system, the one encoder configured to work with the global positioning system and a positioning algorithm to enable articulation of photovoltaic array of the assembly in orthogonal orientation with the altazimuth motion of the sun.

11. The assembly of claim 10 wherein each of the first motor and the second motor is a direct current motor with planetary gears.

Description

DESCRIPTION OF THE DRAWINGS

[0029] The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

[0030] FIG. 1 illustrates a front perspective view of an exemplary elevated dual-axis photovoltaic solar tracking assembly, in accordance with an embodiment of the present invention;

[0031] FIG. 2 illustrates a rear perspective view of the elevated dual-axis photovoltaic solar tracking assembly shown in FIG. 1, in accordance with an embodiment of the present invention;

[0032] FIG. 3 illustrates a front perspective view of an exemplary drive-core unit, in accordance with an embodiment of the present invention;

[0033] FIG. 4 illustrates a front perspective view of the drive-core unit shown in FIG. 3 attached to a frame and a pole, in accordance with an embodiment of the present invention;

[0034] FIG. 5 illustrates a perspective view of the elevated dual-axis photovoltaic solar tracking assembly with the photovoltaic array detached from the frame, in accordance with an embodiment of the present invention;

[0035] FIG. 6A illustrates a side view of the elevated dual-axis photovoltaic solar tracking assembly at stowed position, in accordance with an embodiment of the present invention;

[0036] FIG. 6B illustrates a side view of the elevated dual-axis photovoltaic solar tracking assembly at vertical position, in accordance with an embodiment of the present invention;

[0037] FIG. 7 illustrates a side view of the elevated dual-axis photovoltaic solar tracking assembly showing an electrical vehicle charging outlet, a lighting system, a battery-backup system and a service platform in accordance with an embodiment of the present invention; and

[0038] FIG. 8 illustrates a block diagram showing work flow of a drive-core unit in accordance with an embodiment of the present invention.

[0039] Like reference numerals refer to like parts throughout the various views of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

[0040] Referring to FIGS. 1-8 of the drawings, an elevated dual axis photovoltaic solar tracking assembly, hereafter “assembly 100”. The assembly 100, best seen in FIG. 1, provides an elongated pole 102 of variable length, typically ten to thirty feet height, wherein the pole is having a distal end 104 and a proximal end 106, the proximal end 106 is configured to be mounted on to a foundation surface or a ground surface, while the distal end 104 is configured attach a frame 108 to mount plurality of photovoltaic arrays 114 comprising the solar modules (panels) and inverter(s) 134 known in the art of solar energy generation. As shown in FIG. 2 the elongated pole allows to elevate the photovoltaic array 114 at a predetermined height above the ground surface, so as to maintain an elevated position keeping electrical and mechanical systems out of reach, and maintain continued use of the land below the assembly, while tracking the position of the sun to generate electricity therefrom. The electrical inverter(s) 34 are typically hung on the underside of the array, or may be mounted on the pole. The power produced can be Direct Current (DC), or single or three-phase Alternating Current (AC) in a variety of voltages. The entire assembly is engineering and tested to withstand wind speed of 125 mph when the assembly 100 is stowed in a flat/horizontal position. This strong design ensures the assembly to be accepted and applicable in schools, parking lots, residential buildings and market areas.

[0041] Referring now to FIG. 3-8, the assembly 100 provides a dual drive-core unit 116 consisting of two slew drives 118, 124 driven by low-voltage DC motors 120, 126. Each slew drive 118, 124 rotates the frame to adjust the positioning of the photovoltaic array 114 along a different respective axis in the orthogonal orientation relative to the sun and other desired orientations.

[0042] As seen in FIG. 8, the assembly 100 also provides a drive-core unit 116 comprising control system 130 utilizing a global positioning system 150 to track and calculate the position of the sun at preset intervals (typically at 7.5 to 10 minutes intervals). The control system 130 processes data from the internal clock verified by the global positioning system 150 signals and a positioning algorithm (not shown) to regulate the slew drives, motors, and encoders 132 for optimal tracking of the sun. The orientation of the photovoltaic array 114 is calculated using encoders 132 that provide information to the control system 130 which powers the slew drive motors 120,126 and monitors the slew drives 118, 124 worm gear rotations via the encoders 132 from a limit-switched position reset that is established at least every morning.

[0043] A mounting pole 102 being of variable length and typically ten to thirty feet long; easily unbolted and moved to other installation locations and able to safely support the entire tracker assembly 100 to maintain space below the assembly for compatible uses such as parking, recreation, business and agriculture; a frame 108 defined by horizontal beams 110 and vertical beams 112 arranged in a crossing pattern is detachably attached to the drive-core 116 unit which is in turn attached distal end 104 of the pole 102; the photovoltaic array 114 is being carried by the frame 108 in a parallel relationship; single or multiple electrical inverter(s) hung on the underside of the array 114, or mounted on the pole 102, whereby the power produced by the electrical inverter(s) can be converted to single or three-phase AC in a variety of voltages; the dual drive-core unit 116 has a first slew drive 118 comprising a first worm gear, is actuated by a first motor 120 to support radial and axial loads and moments while transmitting torque to a first drive torque arm 108 for rotating the frame 108 to a desired inclination angle between 0-90 degrees with respect to horizontal plane. A second slew drive 124 comprising a second worm gear actuated by a second motor 126 to support radial and axial loads and moments while transmitting torque to a second drive torque arm consisting of the pole 102 for rotating the frame to a desired angle between 0-360 degrees in the horizontal plane, whereby the first and second slew drives 118, 124 operate independently of each other. A control system 130 utilizing global positioning system 150 inputs provides a signal to the motors to operate the slew drives to the calculated position of the sun relative to the assembly 100 at regular preset intervals (typically every 7.5 minutes); the control system 130 further signals the motor 120 to operate the first slew drive 118 to move the array to the stowed position whenever winds exceed preset values (typically 30 mph) and at night, and optionally at user command or in the event of a power outage. Encoders 132 are in communication with the control system 130 as part of the drive-core mechanism 116, the encoders 132 providing information to the control system 130 to aid the control system 130 in calculating commands for the slew drives 118, 124, the encoders 132 monitoring the worm gear rotations of the slew drives 118, 124 from a limit-switched position reset that is established periodically.

[0044] In another aspect, the motors 120, 126 can be either direct current (DC) or Alternating current (AC) motors in any of a wide a variety of voltage inputs and utilize any appropriate gearing technology to move the arrays at predetermined speed.

[0045] In another aspect, the assembly 100 tracks the sun in an altazimuth motion.

[0046] In another aspect, the drive-core unit 116 moves the frame 108 to its most horizontal (stow) position in the event of high winds, at night, on user command from the optional user stow button, optionally on loss of system power, or optionally on command from a remote-control station.

[0047] The assembly 100 of the present invention helps overcome the problems of the prior art by elevating the photovoltaic array 114 of the assembly to at least twenty feet above the ground surface, thereby allowing continued use of valuable real estate below the photovoltaic array 114 for compatible uses while providing at least partial shading. Further the assembly 100 of the present invention allows tracking and following the path of sun in a manner that allows the photovoltaic array 114 to remain elevated and orthogonal to the sun at all times of the day for optimal harvest of sun energy for conversion to electrical energy. In addition, the assembly's height allows for optimizing energy harvest with the industry's current highest producing bifacial PV modules, which collect solar energy from the back, as well as the front, of the assembly. The modular pole design allows installation almost anywhere and the system height lifts the PV array 114 above the shade cast by trees and buildings in many circumstances. Thus, users, such as businesses and residences looking for solar energy, particularly those where traditional rooftop does not work, can use the assembly 100. Also owing to the minimum 13 feet ground clearance, under assembly 100 land use is maintained, and partially shaded, for most uses, such as car parking lots, homes, businesses, recreational and agricultural properties.

[0048] As FIG. 3 illustrates, the drive-core unit 116 includes a variety of positioning controllers and processors, including two slew drives 118, 124, motors 120, 126, a control system 130, a positioning algorithm, a global positioning system 150, and encoders 132, that work together to enable articulation of the frame 108 in line with the sun, and thereby the photovoltaic array 114 is always maintained in a near orthogonal orientation with the altazimuth motion of the sun throughout the daytime; as well as enable efficient movement to the stow 136 or snow-shed positions 138 (shown in FIG. 6A-B) when appropriate.

[0049] Those skilled in the art will recognize that the elevated position of the photovoltaic array 114 creates two value propositions: (1) the efficiency of the photovoltaic array 114 is greatly increased because of the optimal orientation orthogonal to the sun at all times; and (2) real estate below is retained for compatible uses such as parking lots, picnic areas, feedlots, and the like.

[0050] Turning now to FIG. 4, the assembly 100 utilizes the dual drive-core unit 116 that articulates the frame 108 to a desired orientation relative to the sun, or the ground in snow and wind protection modes. The drive-core mechanism 116 comprises a first slew drive 118 and a second slew drive 124. The first slew drive 118 comprises a first worm gear known in the art to rotate in two directions, and in one plane. In one embodiment, the first slew drive supports structural radial and axial loads and moments while transmitting torque to a first drive torque arm 108A. The first drive torque arm 108A attaches to the frame 108 for rotating the frame 108 to a desired angle between 0-90 degrees with respect to horizontal plane. A first motor 120 powers the first slew drive 118. In one embodiment, the first motor 120 is a low voltage direct current motor. In another embodiment, the first motor 120 is an electric motor with planetary gears.

[0051] The second slew drive 124 of the dual drive core unit 116 supports both radial and axial structural loads and moments while transmitting torque to the distal end 104 of the pole 102. This second slew drive 124 attaches through the drive-core to the frame 108 for rotating the frame 108 to a desired angle between 0-360 degrees in the horizontal plane. In this manner, the first slew drive 118 and the second slew drive 124 independently rotate the frame 108 to position the photovoltaic array in an orthogonal orientation relative to the sun. A second motor 126 powers the second slew drive 124. In one embodiment, the second motor 126 is a low voltage direct current motor. In another embodiment, the second motor 126 is an electric motor with planetary gears. In one embodiment, eight bolts fasten the drive-core unit 116 to the pole. The drive-core unit 116 is fastened to the frame assembly 108 and the photovoltaic array 114 with an engineered bolt pattern typically consisting of 40 bolts. This simple detachability allows for easy replacement of components needing replacement or major repair.

[0052] In another non-limiting embodiment shown in FIGS. 2, 4, 5, 7 and 8, the assembly 100 includes a control system 130 as part of the drive-core unit 116, wherein the control system 130 may be mounted to the drive-core on the stiffener plate 148 (FIG. 3). The control system 130 is configured to communicate with the slew drives 118, 124 via the motors 120, 126, to regulate articulation of the frame 108 and the photovoltaic array 114 thereon. The control system 130 is adapted to process the signal transmitted from the global positioning system 150, anemometer, snow sensors and optional remote-control sensors (not shown). The control system 130 also processes a positioning algorithm to achieve optimal tracking of the sun. The positioning algorithm requires timers, satellite coordinates, and encoder coordinates to coordinate articulation of the frame 108 with the motion of the sun. The control system 130 can have an internet interface to allow users to monitor function and alarms related to the control system 130 and power drive-core unit 116 circuits. In one non-limiting embodiment, GPS is used to provide input to the control system 130.

[0053] The global positioning system 150 provides relevant information for the control system 130 allowing it to use an advance algorithm to know the position of the sun relative to the assembly 100 and position the array 114 to accurately track the sun at appropriate regular intervals (typically every 7.5 minutes).

[0054] In another non-limiting embodiment, the assembly 100 comprises encoders 132 that are in communication with the control system 130. The orientation of the photovoltaic array 114 is calculated using the encoders 132 that relay the current array 114 position to the control system 130 which then transmits commands to the relays of the motors 120, 126 to provide movement of the slew drives 118, 124 to properly move the array 114 to the optimal position. The encoders 132 monitor the worm gear rotations of the slew drives 118, 124 from a limit-switched position reset that is established periodically such as after any system reset and every morning.

[0055] In one embodiment, the control system 130 comprises devices, circuits, transducers, a software program and an algorithm that converts the processed information of the encoders 132 and the signals from the global positioning system 150, anemometer, snow sensor, button or remote-control location from one format or code to another, for the purposes of standardizing the motion of the drive-core unit 116.

[0056] In one alternative embodiment as shown in FIG. 7, the assembly 100 comprises an electrical vehicle charging station and electrical charging outlets 142 for charging electrical vehicles. The charging power is generated by the photovoltaic array 114 and augmented by standard power from the utility grid. In another alternative embodiment, the assembly 100 comprises a lighting system 146 for illuminating a parking lot and providing showcase lighting. The lighting power is generated by the photovoltaic array 114 and augmented by standard power from the utility grid. In yet another alternative embodiment, the assembly 100 comprises a battery-backup system 140 that automatically controls the drive mechanism 116 to orient the frame 108 to its safe stow position 136 on the loss of system power.

[0057] Referring now to FIGS. 3 and 4, the unitized dual drive modular drive core unit 116 is as noted characterized by the slew drivers 118 and 124. The slew driver 124 is attached to the distal end 104 of the pole 102 on a mounting support plate 102A of the drive core unit 116 assembly which is secured by multiple fasteners F that will allow for unitized removal and replacement as hereinbefore described.

[0058] One of the key aspects of the dual core unit 116 is therefore the utilization of the dual slew drives with the first slew drive 118 being mounted directly to the second slew drive 124 on a mounting frame 148A with the upstanding stiffener plate 148.

[0059] It will therefore be seen that while the horizontal access orientation of the second slew drive 124 provides for the drive core unit's 116 axial rotation relative the pole 102. Correspondingly, the first slew drive 118 upstanding angular orientation mounting on and extending directly from the second slew drive 124 provides for the photovoltaic array's mounting frame 108 rotating to the desired angle orientation between 0-360 in horizontal plane as hereinbefore described.

[0060] It will therefore be evident that due to this unique orientation of the photovoltaic array mounting frame 108, its effective center of gravity is positioned along the longitudinal axis of the support pole 102 affording enhanced resistance to extreme weather conditions.

[0061] These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.

[0062] Because many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.