VARIABLE TERRAIN SOLAR TRACKER
20230208349 · 2023-06-29
Assignee
Inventors
- Yezin Taha (San Francisco, CA, US)
- Kyam Krieger (San Francisco, CA, US)
- Jared Niemiec (San Francisco, CA, US)
Cpc classification
F24S2025/019
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S30/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/50
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
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
H02S10/00
ELECTRICITY
F24S2030/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S30/425
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S2030/15
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
Solar trackers that may be advantageously employed on sloped and/or variable terrain to rotate solar panels to track motion of the sun across the sky include bearing assemblies configured to address mechanical challenges posed by the sloped and/or variable terrain that might otherwise prevent or complicate use of solar trackers on such terrain.
Claims
1. A solar tracker comprising: a first solar panel support configured to support a first solar panel assembly; a first support post; and a first bearing assembly attached to the first support post and a first solar panel support configured to support a first solar panel assembly, the first bearing assembly enabling rotation of the first solar panel support around a first rotation axis; wherein the first bearing assembly comprises an axial load bearing surface arranged to support an axial load from the first solar panel support directed along the first rotation axis and transfer the axial load through the first bearing assembly to the first support post; and wherein the first bearing assembly comprises a slip joint disposed over the first support post and arranged to accommodate relative motion between the first solar panel support and the first bearing assembly.
2. The solar tracker of claim 1, wherein the first bearing assembly comprises a first support coupler configured to support and be in direct contact with the first solar panel assembly.
3. The solar tracker of claim 1, wherein the first support coupler comprises the axial load bearing surface.
4. The solar tracker of claim 1, wherein the first support coupler comprises an attachment plate having a first surface facing away from the first bearing assembly and the axial load bearing surface is comprised on the attachment plate on an opposite side of the first surface.
5. The solar tracker of claim 4, wherein the first support coupler comprises a first holder extending from the first surface.
6. The solar tracker of claim 4, wherein the first support coupler comprises a coupler shaft extending from the axial load bearing surface.
7. The solar tracker of claim 6, wherein the first bearing assembly comprises a bearing support through which the coupler shaft extends.
8. The solar tracker of claim 6, wherein the first bearing assembly further comprising a rotation bearing around the coupler shaft.
9. The solar tracker of claim 5, wherein the first support coupler comprises a coupler shaft extending from the axial load bearing surface, and a center axis of the coupler shaft does not intersect with a center axis of the first holder.
10. The solar tracker of claim 5, wherein the first holder comprises axial slots configured to attach the first solar panel assembly.
11. The solar tracker of claim 1, wherein the relative motion results from expansion and contraction of the first solar panel support.
12. The solar tracker of claim 1, wherein the relative motion results from displacement of the first solar panel support with respect to the first bearing assembly.
13. The solar tracker of claim 1, wherein the relative motion is along the first rotation axis.
14. The solar tracker of claim 1, comprising a second solar panel support configured to support a second solar panel assembly, wherein: the first bearing assembly supports a first end of the second solar panel support on an opposite side of the first bearing assembly from the first solar panel support, enables rotation of the second solar panel support around a second rotation axis that is arranged in line with the first rotation axis, and couples the first solar panel support to the second solar panel support so that that rotation of the first solar panel support causes rotation of the second solar panel support.
15. The solar tracker of claim 14, wherein the first bearing assembly comprises a first shaft coupled to the first solar panel support, a second shaft coupled to the second solar panel support, a torque coupler into which the first shaft and the second shaft are inserted from opposite ends, a first plurality of shear pins each of which engages a complementary slot on the first shaft and a complementary slot on an internal surface of the torque coupler, and a second plurality of shear pins each of which engages a complementary slot on the second shaft and a complementary slot on the internal surface of the torque coupler.
16. The solar tracker of any of claim 1, wherein the first rotation axis is adjustably oriented at an angle greater than 90 degrees with respect to a long axis of the first support post.
17. The solar tracker of claim 1, wherein the first bearing assembly is a modular bearing assembly selected from the group consisting of row end bearing assemblies and straight through bearing assemblies.
18. The solar tracker of claim 17, wherein the row end bearing assemblies and straight through bearing assemblies each include one or more identical or substantially identical components adapted to interchangeably mount the bearing assemblies to the first support post.
19. The solar tracker of claim 1, wherein the first bearing assembly comprises a cradle and a clamp, wherein the cradle supports the first end of the first solar panel support, and the clamp retains the first end of the first solar panel support in the cradle.
20. The solar tracker of claim 19, wherein a cam mechanism provided by a feature on the torque tube clamp engages features on the cradle to increase a positive clamping force retaining the first solar panel support in the cradle.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0012]
[0013]
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[0015]
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[0020]
[0021]
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DETAILED DESCRIPTION
[0023] The following detailed description should be read with reference to the drawings, in which identical reference numbers refer to like elements throughout the different figures. The drawings, which are not necessarily to scale, depict selective embodiments and are not intended to limit the scope of the invention. The detailed description illustrates by way of example, not by way of limitation, the principles of the invention. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention.
[0024] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly indicates otherwise. Also, the term “parallel” is intended to mean “substantially parallel” and to encompass minor deviations from parallel geometries. The term “vertical” refers to a direction parallel to the force of the earth's gravity. The term “horizontal” refers to a direction perpendicular to “vertical”.
[0025] This specification discloses solar trackers that may be advantageously employed on sloped and/or variable terrain to rotate solar panels to track motion of the sun across the sky. As described in more detail below, these solar trackers may include, for example, various combinations of articulated joints, slip joints, and thrust bearings to address mechanical challenges posed by sloped and/or variable terrain that might otherwise prevent or complicate use of solar trackers on such terrain.
[0026] Referring to
[0027]
[0028] More generally, depending on the terrain variability different connection joints may be used between sections of a variable terrain solar tracker as disclosed herein. Along relatively planar sloping terrain straight-through bearing assemblies as described below may be used. Straight-through bearing assemblies maintain a straight driveline through the post connection but include thrust bearings to isolate the slope load from a section of the tracker. Along relatively planar horizontal terrain conventional pass-through bearing assemblies lacking thrust bearings may be used. When a change in the terrain slope angle occurs an articulating bearing assembly as described below may be used to link two rotation axes oriented at different angles to the horizontal. Articulating bearing assemblies may include thrust bearings to isolate slope load. Rotation of the tracker may be driven by a slew drive located at an end of the tracker, or at an intermediate position along the tracker.
[0029]
[0030] Other variations of the variable terrain solar tracker 200 may include other combinations of bearing assemblies 205, 210, 215, and 220 arranged to accommodate one, two, or more linked rotational axes arranged along terrain exhibiting one or more sloped portions and optionally one or more horizontal (flat) portions. Two or more such trackers may be arranged, for example next to each other in rows, to efficiently fill a parcel of sloped and/or uneven terrain with electricity-generating single axis tracking solar panels.
[0031] Referring again to
[0032]
[0033] Forked yokes 300 and cross and bearing 305 are enclosed in and supported by two pivoting vertical bearing supports 315. Splined shaft portions 300S on yokes 300 extend through openings 320 in respective pivoting vertical bearing supports 315 along corresponding rotation axes to engage complementary shaped and sized splined openings 325 in attachment plates 330 on torque tube supports 310. Torque tube supports 310 are retained on shaft portions 300S of yokes 300 by retaining rings 335. A splined shaft portion 300S of a yoke 300 in combination with a splined opening 325 in an attachment plate 330 forms a slip joint that transmits torque between shaft portion 300S and torque tube support 310 while allowing relative motion of the torque tube support 310 and shaft portion 300 along the rotation axis.
[0034] Rotation bearings 340 fitting over shaft portions 300S of yokes 300 are retained in sleeves 345 of pivoting vertical bearing supports 315 to provide vertical support for yokes 300 while allowing rotation of the yokes about their respective rotation axes.
[0035] As shown in
[0036] Referring again to
[0037] Other arrangements incorporating thrust bearings and/or slip joints with an articulating joint may also be used, as suitable. Such variations may include any suitable number or arrangement of torque transmitting drives that allows for translational motion.
[0038]
[0039] Rotation bearings 435 fitting over shafts 410 are retained in sleeves 440 of bearing support 400 to provide vertical support for shafts 410 while allowing rotation of the shafts about their shared rotation axis. Each shaft 410 is retained in position by a retaining ring 443 which engages one or the other of a pair of retaining ring grooves 445 on the shaft.
[0040] Bearing assembly 210 further includes two torque tube supports 450 each of which is attached to one of the shafts 410. A torque tube or equivalent longitudinal support (not shown) aligned parallel with and optionally displaced from the rotation axis of shafts 410 may be attached to one torque tube support 450, and another torque tube aligned parallel with and optionally displaced from the rotation axis of shafts 410 may be attached to the other torque tube support 450. In the illustrated example, when attached to bearing assembly 210 the torque tubes (or equivalent longitudinal supports) are aligned parallel with but displaced downward from the rotation axis when the panels they support are oriented horizontally. This configuration allows the rotation axis to lie in or close to the plane of the panels and/or in or close to the center of mass of the tracker, which can simplify operation of the tracker. Axial slots 455 in torque tube supports 450, by which a torque tube may be attached to the torque tube support, provide tolerance in the axial direction for support post placement.
[0041] As shown in
[0042] Referring again to
[0043] Other arrangements incorporating thrust bearings and/or slip joints with a straight-through joint may also be used, as suitable.
[0044]
[0045] A torque tube or equivalent longitudinal support (not shown) aligned parallel with and optionally displaced from the rotation axis may be attached to torque tube support 505 using axial slots 520, which provide tolerance for support post placement along the direction of the rotation axis. In the illustrated example, when attached to the row end bearing assembly the torque tube (or equivalent longitudinal support) is aligned parallel with but displaced downward from the rotation axis when the panels it supports are oriented horizontally. This configuration allows the rotation axis to lie in or close to the plane of the panels and/or in or close to the center of mass of the tracker, which can simplify operation of the tracker.
[0046]
[0047] Slew drive assembly 225 includes a slew drive 600 supported by a slew drive base 605, shafts 610 attached to and driven by slew drive 600 to rotate around a shared rotation axis, and torque tube supports 615 attached to drive shafts 610. Slots 620 in slew drive base 605 by which slew drive base 605 may be attached to support post 110 allow the orientation of slew drive assembly 225 to be adjusted to align the slew drive rotation axis with neighboring bearing assemblies. The angle between the rotation axis and the horizontal may be, for example, ≥0 degrees, ≥5 degrees, ≥10 degrees, ≥15 degrees, ≥20 degrees, ≥25 degrees, ≥30 degrees, ≥35 degrees, ≥40 degrees, ≥45 degrees, ≥50 degrees, ≥55 degrees, ≥60 degrees, ≥65 degrees, ≥70 degrees, ≥75 degrees, ≥80 degrees, ≥85 degrees, or up to 90 degrees. These examples refer to the magnitude of the angle between the rotation axis and the horizontal. The angles may be positive or negative with respect to the horizontal.
[0048] A torque tube or equivalent longitudinal support (not shown) aligned parallel with and optionally displaced from the rotation axis of shafts 610 may be attached to one torque tube support 615, and another torque tube aligned parallel with and optionally displaced from the rotation axis of shafts 610 may be attached to the other torque tube support 615. In the illustrated example, when attached to slew drive assembly 225 the torque tubes (or equivalent longitudinal supports) are aligned parallel with but displaced downward from the rotation axis when the panels they support are oriented horizontally. This configuration allows the rotation axis to lie in or close to the plane of the panels and/or in or close to the center of mass of the tracker, which can simplify operation of the tracker. Axial slots 625 in torque tube supports 615 by which a torque tube may be attached to the torque tube support, provide tolerance in the axial direction for support post placement.
[0049] The example bearing assemblies and the slew drive assembly described above may optionally be adapted to replace their torque tube supports (e.g., 310, 450, 505, and 615) with a torque tube cradle and clamp mechanism. Referring to
[0050] Side panels 710 of torque tube cradle 700 have upper edges that slope backward and upward from bottom panel 705, from the front toward the rear of the cradle. A bracket 730 projects outward from the sloping upper edge of each side panel 710, perpendicularly to the side panel. The plane of bracket 730 slopes backward and upward from the front toward the rear of the cradle.
[0051] As shown in
[0052] In use (e.g.,
[0053] As another example, referring now to
[0054] Torque tube cradle 800 is similar in structure to torque tube cradle 700 described above, except for lacking brackets 715 and including bent tabs 805 attached to rear portions of side walls 710 near their tops and projecting forward inside the cradle. Bracket 720 of torque tube cradle 800 is dimensioned and configured to attach to a rotating component of articulating joint bearing assembly 220 via bolts or other fasteners, for example, passing through holes or slots in the brackets. Bent tabs 805 may also be dimensioned and configured for attaching to bearing assembly 220 via bolts or other fasteners, for example, through holes or slots in the bent tabs.
[0055] Torque tube clamp 835 is similar in structure to torque tube clamp 735 described above. In use (e.g.,
[0056] Torque tube cradle 800 and torque tube clamp 835 may be similarly employed in variations of end bearing assembly 205 and straight-through bearing assembly 210.
[0057] Use of the torque tube cradle and clamp mechanisms described above can streamline torque tube installation and simplify torque tube manufacturing. These mechanisms allow use of a simple torque tube section precut to length with no features or penetrations in the tube wall, allow the torque tube to be inserted in a direction most ergonomically advantageous (e.g., from above) as determined by the construction crew, and may accommodate pre-assembly of torque tube sections with modules and clamps before being connected to the post foundations. Bearing assemblies may be rotated in place on top of a support post to allow alternative installation orientations.
[0058] In the examples described above, row end bearing assembly 205, straight-through bearing assembly 210, and articulating joint bearing assembly 220 are modular (e.g., have a standardized and similar size and shape) and include identical or substantially identical components (e.g., side plates 355, 460, and 510) adapted to mount the bearing assembly onto a support post. This makes these bearing assemblies easily interchangeable on a support post, which facilitates assembly in the field and adaptation of tracker geometry to the underlying terrain. Non-modular designs for these bearing assemblies may also be employed, as suitable.
[0059] The bearing assemblies described above, when installed in a tracker, may passively damp torsional and bending mode vibrations in the tracker in a frequency range of, for example, 1 Hz-10 Hz.
[0060] The bearing assemblies described above may provide a high allowance for installation tolerance along the rotation axis as well as along two axes perpendicular to the rotation axis and to each other.
[0061] Some functional features of the bearing assemblies described above may instead or additionally be integrated into the support post. For example, slip joints and/or axial load bearing surfaces may be integrated into the support posts.
[0062] This disclosure is illustrative and not limiting. Further modifications will be apparent to one skilled in the art in light of this disclosure and are intended to fall within the scope of the appended claims.