U.S. patent application number 14/671921 was filed with the patent office on 2016-07-07 for solar tracker drive mount.
The applicant listed for this patent is SunPower Corporation. Invention is credited to Tyler Grushkowitz, Matthew Lambert, Vicent Ripoll Agullo, Brian S. Wares.
Application Number | 20160195303 14/671921 |
Document ID | / |
Family ID | 56286293 |
Filed Date | 2016-07-07 |
United States Patent
Application |
20160195303 |
Kind Code |
A1 |
Lambert; Matthew ; et
al. |
July 7, 2016 |
SOLAR TRACKER DRIVE MOUNT
Abstract
A sun-tracking solar drive of a solar energy system can include
mounting hardware supporting the solar drive with support
components of the same type of that used for supporting other
components of system. The support components can be in the form of
pile driven members, which optionally can be connected together for
sharing the loads associated with the solar drive. The solar drive
can be mounted to the support components with an adjustable mount
member, configured to allow an orientation of the solar drive to be
adjusted.
Inventors: |
Lambert; Matthew; (Oakland,
CA) ; Wares; Brian S.; (Berkeley, CA) ; Ripoll
Agullo; Vicent; (San Francisco, CA) ; Grushkowitz;
Tyler; (Hayward, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SunPower Corporation |
San Jose |
CA |
US |
|
|
Family ID: |
56286293 |
Appl. No.: |
14/671921 |
Filed: |
March 27, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62099978 |
Jan 5, 2015 |
|
|
|
Current U.S.
Class: |
126/605 |
Current CPC
Class: |
F24S 25/70 20180501;
F24S 25/15 20180501; Y02E 10/47 20130101; F24S 2030/136 20180501;
F24S 25/12 20180501; F24S 30/425 20180501 |
International
Class: |
F24J 2/38 20060101
F24J002/38; F24J 2/54 20060101 F24J002/54; F24J 2/52 20060101
F24J002/52 |
Claims
1. A solar energy collection system comprising: a first array of
solar energy collection devices mounted so as to be movable between
first and second positions, the first array of solar energy
collection devices mounted to a first rotational member assembly
supported above the ground by a first plurality of support members
which are fixed to the ground; a second array of solar energy
collection devices spaced from the first array, the second array of
solar energy collection devices mounted to a second rotational
member assembly supported above the ground by a second plurality of
support members; a drive system comprising an actuator, a drive
link assembly connecting the actuator with the first and second
arrays; an actuator support supporting the actuator above the
ground, the actuator support comprising a third plurality of
support members fixed to the ground and connected together.
2. The solar energy collection system according to claim 1, wherein
the third support members are the same type of member as the first
and second plurality of support members.
3. The solar energy collection system according to claim 1, wherein
the third plurality of support members are substantially the same
as the first and second plurality of support members.
4. The solar energy collection system according to claim 1, wherein
the first, second, and third plurality of support members are
piles.
5. The solar energy collection system according to claim 4, wherein
the first, second, and third plurality of support members are
structural c-channel members pile-driven into the ground.
6. The solar energy collection system according to claim 1, wherein
the actuator support comprises an actuator mounting fixture having
an actuator mounting surface connected to the actuator and first
and second mounting surfaces, the first mounting surface connected
to at least one of the third plurality of support members and the
second mounting surface connected to at least a second of the third
plurality of support members.
7. The solar energy collection system according to claim 6, wherein
the actuator mounting surface comprises an arrangement of fastening
features configured for fixation to the actuator in a plurality of
different orientations.
8. The solar energy collection system according to claim 1, wherein
the actuator support comprises an actuator mounting fixture having
an actuator mounting surface configured for fixation to the
actuator in a plurality of different orientations, the actuator
support being connected to at least first and second support
members of the third plurality of support members.
9. The solar energy collection system according to claim 1, wherein
the third plurality of support members comprises at least four
piles, pile driven into the ground.
10. A solar energy collection system comprising: a first array of
solar energy collection devices mounted so as to be movable between
first and second positions, the first array of solar energy
collection devices mounted to a first rotational member assembly; a
second array of solar energy collection devices spaced from the
first array, the second array of solar energy collection devices
mounted to a second rotational member assembly; a drive system
comprising an actuator, a drive link assembly connecting the
actuator with the first and second arrays; an actuator support
supporting the actuator above the ground, the actuator support
configured to allow an orientation of the actuator to be adjusted
between a plurality of different orientations relative to the first
and second arrays of solar energy collection devices.
11. The solar energy collection system according to claim 10, the
actuator support comprises a mounting member fixed to the ground
and a mounting plate fixed to the actuator and adjustably mounted
to the mounting member.
12. The solar energy collection system according to claim 10,
wherein the first and second rotational members pivot about first
and second pivot axes, respectively, and wherein the actuator
support is configured to allow the actuator to be angularly
adjusted about an axis that is transverse to the first and second
pivot axes.
13. The solar energy collection system according to claim 10,
wherein the actuator support comprises a first member fixed
relative to the ground and a second member adjustably connected to
the first member, the second member being fixable to the first
member and a plurality of different orientations over an angular
range of at least about 5.degree. about an adjustment axis which is
perpendicular to a rotational axis of the first and second
rotational member assemblies.
14. The solar energy collection system according to claim 10,
wherein the first and second rotational assemblies are supported
above the ground with a first type of support member, the actuator
support comprising the first type of support member.
15. The solar energy collection system according to claim 10,
wherein the first and second rotational assemblies are supported
above the ground with piles driven into the ground, the actuator
support comprising piles driven into the ground.
16. The solar energy collection system according to claim 10,
wherein the first rotational member assembly is supported above the
ground of a first plurality of support members, the actuator
support comprising a second plurality of support members, the first
and second pluralities of support members being connected together
with at least a first structural member.
17. The solar energy collection system according to claim 16,
wherein the actuator support comprises an actuator mount directly
connected to the actuator, the mount connected to and supported by
the first structural member.
18. The solar energy collection system according to claim 17,
wherein the actuator mount comprises a first member fixed to the
first structural member, a second member fixed to the actuator, the
first and second members being adjustably connected to each
other.
19. The solar energy collection system according to claim 10,
wherein the actuator support comprises a truss having a central
portion and extending in a longitudinal direction between a first
end of the truss and a second end of the truss, the longitudinal
direction being generally parallel to a rotational axis of the
first rotational member assembly, the first and second ends of the
truss being fixed relative to the ground, the central portion of
the trust being fixed to the actuator.
20. A solar energy collection system comprising: a first array of
solar energy collection devices mounted so as to be movable between
first and second positions, the first array of solar energy
collection devices mounted to a first rotational member assembly
supported above the ground with a first plurality of support
members; a second array of solar energy collection devices spaced
from the first array, the second array of solar energy collection
devices mounted to a second rotational member assembly supported
above the ground with a second plurality of support members; a
drive system comprising an actuator, a drive link assembly
connecting the actuator with the first and second arrays; means for
adjustably supporting the actuator above the ground with the same
type of support members of the first plurality of support members.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/099,978 filed Jan. 5, 2015, entitled "Solar
Tracker Drive" by Lambert et al., the entire contents of which are
hereby incorporated by reference.
TECHNICAL FIELD
[0002] Embodiments of the subject matter described herein relate
generally to solar energy systems which include drive systems for
sun-tracking, solar energy collecting devices.
BACKGROUND
[0003] Some larger solar collector installations include arrays of
sun-tracking, solar power collector assemblies. Such assemblies can
be used in conjunction with photovoltaic modules, concentrated
photovoltaic modules, as well as concentrated thermal solar
collector devices.
[0004] Sun-tracking solar energy systems include hardware for
automatically adjusting the position of the collector devices to
track the sun as it moves across the sky. Some known systems
include parallel rows of solar energy collection devices supported
on pivoting shafts, known as "torque tubes." The torque tubes are
pivoted to tilt the solar energy collection devices so as to track
the movement of the sun.
[0005] Further, some systems (a.k.a. "ganged" systems) include a
reduced number of drive devices, for example, where each drive
device is connected to a plurality of parallel torque tubes. Such
systems can benefit from the cost reduction of using fewer drives,
which can include expensive electric motors, control circuitry, and
other hardware.
BRIEF SUMMARY
[0006] An aspect of at least one of the inventions disclosed herein
includes the realization that some types of solar tracking systems,
such as those including a plurality of parallel rows of solar
energy collectors driven with a common drive, can benefit from
reduced labor and hardware costs by utilizing certain common
components for various different applications within a system
having a plurality of connected ground based supports for
supporting a drive unit of a "ganged" sun-tracking solar power
system.
[0007] For example, "ganged" sun-tracking solar power systems
include a series of drive links extending from a drive actuator, to
pivoting connections at each of a number of parallel torque tubes.
Such pivoting connections can include bearings or simple pin-hole
connections. Such connections are also connected to a torque arm
associated with each torque tube. Thus, as the drive links are
moved by the drive actuator, the torque tubes are pivoted. However,
due to the nature of "ganged" systems, the total loads imparted to
the sun-tracking drive system can be quite large.
[0008] For example, some known solar power systems which have 18
parallel torque tubes can generate loads of 30,000-50,000 lbs. of
force, for example, when snow-loaded or subject to high winds.
Thus, some known solar system designs include large, heavy and
expensive drive mounts to withstand the maximum load design
parameters of such systems.
[0009] An aspect of at least one of the embodiments disclosed
herein includes the realization that certain components for
supporting parallel torque tubes can also be used for supporting a
drive used for moving the torque tubes in a sun tracking movement.
For example, in some known designs, the torque tubes of such
systems are supported by a plurality of pile driven support
members. However, a single one of such pile driven support members
would not normally be sufficient for anchoring a drive used for
pivoting a plurality of torque tubes. Bus, an aspect of at least
one of the embodiments disclosed herein includes the realization
that a plurality of such pile driven supports can be used to
replace the large, heavy, expensive drive mounts typically used for
such systems.
[0010] Thus, in accordance with an embodiment, a sun tracking solar
power system including a plurality of parallel arrays of sun
tracking solar energy collection devices can comprise a plurality
of spaced apart support members supporting each of the plurality of
parallel arrays of sun tracking solar energy collection devices, a
sun tracking drive connected to the plurality of parallel arrays
and configured to drive the parallel arrays race on tracking
movement, and a plurality of the support members supporting and
fixing the sun tracking drive relative to the plurality of parallel
arrays.
[0011] In some embodiments, a solar energy collection system can
comprising a first array of solar energy collection devices mounted
so as to be movable between first and second positions, the first
array of solar energy collection devices can be mounted to a first
rotational member assembly supported above the ground by a first
plurality of support members which are fixed to the ground. A
second array of solar energy collection devices can be spaced from
the first array, the second array of solar energy collection
devices can be mounted to a second rotational member assembly
supported above the ground by a second plurality of support
members. A drive system can comprise an actuator, a drive link
assembly connecting the actuator with the first and second arrays.
An actuator support can supporting the actuator above the ground,
the actuator support comprising a third plurality of support
members fixed to the ground and connected together.
[0012] Additionally, in some embodiments, a solar energy collection
system can comprise a first array of solar energy collection
devices mounted so as to be movable between first and second
positions, the first array of solar energy collection devices can
be mounted to a first rotational member assembly. A second array of
solar energy collection devices can be spaced from the first array,
the second array of solar energy collection devices can be mounted
to a second rotational member assembly. A drive system can comprise
an actuator, a drive link assembly connecting the actuator with the
first and second arrays. An actuator support can support the
actuator above the ground, the actuator support can be configured
to allow an orientation of the actuator to be adjusted between a
plurality of different orientations relative to the first and
second arrays of solar energy collection devices.
[0013] This summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the detailed description. This summary is not intended to identify
key features or essential features of the claimed subject matter,
nor is it intended to be used as an aid in determining the scope of
the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A more complete understanding of the subject matter may be
derived by referring to the detailed description and claims when
considered in conjunction with the following figures, wherein like
reference numbers refer to similar elements throughout the
figures.
[0015] FIG. 1 is a schematic top plan view of a solar collector
system including a sun-tracking drive in accordance with an
embodiment;
[0016] FIG. 2 is a schematic diagram of the system illustrated in
FIG. 1 illustrating optional electrical connections of the
collector system with various electrical components;
[0017] FIG. 3 is a perspective view of the solar collection system
of FIG. 1, illustrating a plurality of piles mounted to the ground
and supporting a plurality of torque tubes with a sun-tracking
drive in accordance with an embodiment;
[0018] FIG. 4 is a schematic, southerly facing, elevational view of
four rows of a sun-tracking solar collection system in which the
four rows are tilted with a common drive;
[0019] FIG. 5 is a schematic view of the system of FIG. 4,
illustrating a backtracking movement of the system as the sun
rises, the initial position indicated in solid line, a subsequent
position illustrated in dotted line;
[0020] FIG. 6 is a schematic elevational view of the system of FIG.
5, illustrating a forward tracking movement of the system during
mid-day;
[0021] FIG. 7 is a schematic elevational view of the system of FIG.
6, illustrating a backtracking movement during a portion of the
evening;
[0022] FIG. 8 is a schematic elevational view of the system of FIG.
7, at sunset;
[0023] FIG. 9 is an enlarged perspective view of the mounting
arrangement of the drive assembly illustrated in FIG. 2;
[0024] FIG. 10 is a top plan view of the mounting arrangement
illustrated in FIG. 9;
[0025] FIG. 11 is a side elevational view of the mounting
arrangement illustrated in FIG. 10;
[0026] FIG. 12 is a rear, right, and top perspective view of a
drive mount member that can be used in conjunction with the drive
mount assembly illustrated in FIGS. 9-11;
[0027] FIG. 13 is a rear elevational view of the drive mount member
illustrated in FIG. 12;
[0028] FIG. 14 is a top plan view of the drive mount member
illustrated in FIG. 12;
[0029] FIG. 15 is a front elevational view of the drive mount
member illustrated in FIG. 12;
[0030] FIG. 16 is a bottom plan view of the drive mount member
illustrated in FIG. 12;
[0031] FIG. 17 is a cross-sectional view of the drive mount member
illustrated in FIG. 16, taken along line 17.-17.;
[0032] FIG. 18 is a bottom, rear, and right side perspective view
of the drive mount member of FIG. 12 mounted to the drive mount
arrangement of FIG. 9;
[0033] FIG. 19 is a rear, top, and right side partially exploded
view of the drive mount member of FIG. 12;
[0034] FIG. 20 is a rear elevational view of the drive mount
arrangement of FIG. 3 and illustrating a north south slope
installation;
[0035] FIG. 21 is an enlarged rear elevational view of the mounting
arrangement of FIG. 20;
[0036] FIG. 22 is a rear, top, and right side perspective view of
the mounting arrangement of FIG. 18 including a drive motor and
jackscrew mounted thereto and optional reinforcement members.
DETAILED DESCRIPTION
[0037] The following detailed description is merely illustrative in
nature and is not intended to limit the embodiments of the subject
matter or the application and uses of such embodiments. As used
herein, the word "exemplary" means "serving as an example,
instance, or illustration." Any implementation described herein as
exemplary is not necessarily to be construed as preferred or
advantageous over other implementations. Furthermore, there is no
intention to be bound by any expressed or implied theory presented
in the preceding technical field, background, brief summary or the
following detailed description.
[0038] This specification includes references to "one embodiment"
or "an embodiment." The appearances of the phrases "in one
embodiment" or "in an embodiment" do not necessarily refer to the
same embodiment. Particular features, structures, or
characteristics may be combined in any suitable manner consistent
with this disclosure.
[0039] Various units or components may be described or claimed as
"configured to" perform a task or tasks. In such contexts, the
phrase "configured to" is used to connote structure by indicating
that the units/components include structure that performs those
task or tasks during operation. As such, the unit/component can be
said to be configured to perform the task even when the specified
unit/component is not currently operational (e.g., is not
on/active). Reciting that a unit/circuit/component is "configured
to" perform one or more tasks is expressly intended not to invoke
35 U.S.C. .sctn.112, sixth paragraph, for that unit/component.
[0040] "First," "Second," etc. as used herein, these terms are used
as arbitrary labels for nouns that they precede, and do not imply
any type of ordering (e.g., spatial, temporal, logical, etc.). For
example, reference to a "first" solar module does not necessarily
imply that this solar module is the first solar module in a
sequence; instead the term "first" is used to differentiate this
solar module from another solar module (e.g., a "second" solar
module).
[0041] As used herein, the term "based on" describes one or more
factors that affect a determination. This term does not foreclose
additional factors that may affect a determination. That is, a
determination may be solely based on those factors or based, at
least in part, on those factors. Consider the phrase "determine A
based on B." While B may be a factor that affects the determination
of A, such a phrase does not foreclose the determination of A from
also being based on C. In other instances, A may be determined
based solely on B.
[0042] The following description refers to elements, nodes, or
features being "coupled" together. As used herein, unless expressly
stated otherwise, "coupled" means that one element/node/feature is
directly or indirectly joined to (or directly or indirectly
communicates with) another element/node/feature.
[0043] Some elements, components, and/or features are described as
being adjustable or adjusted. As used herein, unless expressly
stated otherwise, "adjust" means to position, modify, alter, or
dispose an element or component or portion thereof as suitable to
the circumstance and embodiment. In certain cases, the element or
component, or portion thereof, can remain in an unchanged position,
state, and/or condition as a result of adjustment, if appropriate
or desirable for the embodiment under the circumstances. In some
cases, the element or component can be altered, changed, or
modified to a new position, state, and/or condition as a result of
adjustment, if appropriate or desired.
[0044] In addition, certain terminology may also be used in the
following description for the purpose of reference only, and thus
are not intended to be limiting. For example, terms such as
"upper", "lower", "above", and "below" refer to directions in the
drawings to which reference is made. Terms such as "front", "back",
"rear", and "side" describe the orientation and/or location of
portions of the component within a consistent but arbitrary frame
of reference which is made clear by reference to the text and the
associated drawings describing the component under discussion. Such
terminology may include the words specifically mentioned above,
derivatives thereof, and words of similar import.
[0045] The inventions disclosed herein are described in the context
of non-concentrated photovoltaic arrays and modules. However, these
inventions can be used in other contexts as well, such as
concentrated photovoltaic systems, thermal solar systems,
concentrated thermal solar systems, etc.
[0046] In the description set forth below, a solar energy
collection system 10 is described in the context of a plurality of
solar collection modules, supported so as to be pivotally
adjustable for sun-tracking purposes. Each of the modules can
include a support arrangement supporting a plurality of solar
collection devices as well as wiring for connecting the various
solar collection devices to each other and to other modules. For
example, the solar collection system 10 of FIG. 1 can include a
controller 50 and/or other devices for controlling operation of the
drive 30 for sun-tracking operations or functionalities.
[0047] FIG. 1 illustrates the solar collection system 10, which can
be considered an electricity farm, and which includes an improved
drive mount assembly 30. FIGS. 1-8 generally describe the
environment of use of the drive mount assembly 30 in the context of
the sun-tracking solar collection system 10. A detailed description
of the drive assembly 30 is set forth below with reference to FIGS.
9-22.
[0048] The solar collection system 10 includes a solar collector
array 11 which includes a plurality of solar collection modules 12.
Each of the solar collection modules 12 can include a plurality of
solar collecting devices 14 (e.g., solar cells) incorporated into a
laminate and encircled by a peripheral frame. The modules 12 can be
supported by a drive shaft or torque tube 16.
[0049] Each of the torque tubes 16 are supported above the ground
by a support assembly 18. Each of the support assemblies 18 can
include a pile 22 and a bearing assembly 20. The piles 22 can be in
the form of any type of pile, for example, those types of piles
which can be "pile-driven" into the ground for providing structural
support. For example, but without limitation, the piles 22 can be
in the form of C-shaped channel structural steel, or other types of
piles.
[0050] With continued reference to FIG. 1, the system 10 can also
include a drive assembly 30 connected to the torque tube 16 and
configured to pivot the torque tube 16 so as to cause the modules
12, and thus the collector devices 14, to track the movement of the
sun. In the illustrated embodiment, the torque tubes 16 are
arranged generally horizontally and the modules 12 can be connected
to each other and the torque tubes 16, as more fully described in
U.S. patent application Ser. No. 13/176,276, filed Jul. 5, 2011,
the entire contents of which is hereby expressly incorporated by
reference. However, inventions disclosed herein can be used in the
context of other types of arrangements. For example, the system 10
can include a plurality of modules 12 that are arranged such that
the torque tubes 16 are inclined relative to horizontal, wherein
the torque tubes 16 are not connected in an end to end fashion,
such as the arrangement illustrated and disclosed in U.S. Patent
Publication No. 2008/0245360. The entire contents of the
2008/0245360 patent publication, as well as the entire contents of
the U.S. patent application Ser. No. 13/631,782 are hereby
expressly incorporated by reference. Further, the inventions
disclosed herein can be used in conjunction with the systems that
provide for controlled tilting about two axes, although not
illustrated herein.
[0051] Additionally, the solar collection devices 14 can be in the
form of thermal solar collection devices, concentrated photovoltaic
devices, or concentrated thermal solar collection devices. In the
illustrated embodiment, the solar collection devices 14 are solar
cells configured for non-concentrated photovoltaic modules 12.
[0052] With reference to FIG. 2, solar collection system 10 can
further include an electrical system 40 connected to the array 11.
For example, the electrical system 40 can include the array 11 as a
power source connected to a remote connection device 42 with power
lines 44. The electrical system 40 can also include a utility power
source, a meter, an electrical panel with a main disconnect, a
junction, electrical loads, and/or an inverter with the utility
power source monitor. The electrical system 40 can be configured
and can operate in accordance with the descriptions set forth in
U.S. Patent Publication No. 2010/0071744, the entire contents of
which is hereby expressly incorporated by reference.
[0053] FIG. 3 illustrates the array 11 with all but one of the
solar collection devices 14 removed. As shown in FIG. 3, each of
the support assemblies 18 includes the bearing 20 supported at the
upper end of a pile 22. The torque tube 16 can be of any length and
can be formed in one or more pieces. The spacing of the piles 22
relative to one another, can be determined based on the desired
limits on deflection of the torque tubes 16 between the support
structures 18, wind loads, shading, and other factors. The spacing
of the piles 22 is also a consideration for the spacing of the
torque tubes 16 and the spacing of the modules 12. The ratio of the
total area of all of the upper surfaces of the modules 12 (when in
a "noon" position) divided by the total area occupied by the
modules 12 (including all of the gaps) is known as the "Ground
Coverage Ratio" (GCR). Larger gaps between the modules 14 result in
a lower GCR, but also reduce inter-row shading and thus reduce the
amount of time during which backtracking is needed to avoid
inter-row shading.
[0054] The tilt drive 30 can include a drive strut 32 coupled with
the torque tube 16 in a way that pivots the torque tube 16 as the
drive strut 32 is moved axially along its length. The drive strut
32 can be connected with the torque tube 16 with torque arm
assemblies 34. In the illustrated embodiment, the torque arm
assemblies 34 disposed at an end of each of the torque tubes 16.
Additionally, the array 11 can include an electrical wire tray 60
supported by one or more of the piles 22, or by other means.
[0055] FIGS. 4-8 schematically illustrate sun-tracking movements of
the modules 12 over the course of the daylight portion of one day.
Specifically, FIG. 4 illustrates the system 10 oriented in a "noon"
position. However, as shown in FIG. 4, the sun 52 is on the
eastward horizon, i.e., sunrise. As the sun 52 rises, sunlight 54
from the sun 52 approaches the modules 12 along a direction
essentially parallel to the upper surfaces of the modules 12. The
modules 12, however, are maintained in a direction pointing
directly upward ("noon"), so as to avoid `the eastward module 56
from casting a shadow on the adjacent, westward positioned modules
12.
[0056] With reference to FIG. 5, as the sun 52 rises from the
sunrise position illustrated in solid line to a position later in
the morning, illustrated in dash line, the controller 50 operates
the drive 30 to tilt the modules 12 in a backtracking motion.
Specifically, during a backtracking motion in the morning, the
modules 12 are gradually tilted eastwardly, as the sun 52 rises
along a westerly trajectory.
[0057] The controller 50 performs calculations for controlling the
drive 30 so as to orient the modules 12 as closely as possible to
an orientation perpendicular to the sunlight 54, without casting a
shadow on adjacent modules 12. In other words, the controller 50
causes the modules 12 to rotate through a range of non-optimal
orientations, which produces less power than a perpendicular
orientation, so as to avoid casting shadows which have a greater
detrimental effect on total power output of the system 10.
[0058] With reference to FIG. 6, as the sun 52 moves to a position
at which shadows can no longer be cast by any of the modules 12
onto an adjacent module 14, the modules 12 are tilted through a
forward tracking movement, following the movement of the sun 52
such that the modules 12 face a direction as close as possible to
perpendicular to sunlight 54 from the sun 52.
[0059] With reference to FIG. 7, as the sun 52 continues to move
across the sky, it eventually reaches a position, illustrated in
FIG. 7, at which the westward modules, for example, module 56,
begins or will begin to cast shadows on the adjacent modules 12
positioned to the east. Thus, the controller 50 controls the
modules 12 to tilt through a backtracking movement, like that
described above with reference to FIG. 5. By the time of sunset, as
illustrated in FIG. 8, the modules 12 are eventually tilted to a
horizontal or "noon" position.
[0060] While the modules 12 are tilted in before noon orientations
(i.e., all positions when modules 12 are tilted eastwardly relative
to a "noon" position) and afternoon orientations (i.e., all
positions when modules 12 are tilted westwardly relative to a
"noon" position), gravity generates some torque on the torque tubes
16 which is transferred to the torque arms 34. The gravity-induced
torque is caused by the position of the center of gravity of the
array, which tends to be above the pivot axis of the torque tube
16, during before-noon positions of the modules 12.
[0061] The torque generated during before-noon orientations of the
modules 12, is transferred through the torque arm 34 to the drive
struts 32. The drive struts 32 can comprise a plurality of link
members connected in an end-to-end fashion and additionally
connected to an end of the torque arm 34. The torque thus generates
tension forces in the drive links. Similarly, when the modules 12
are oriented in after-noon orientations, the gravity-induced
torques are transferred through the torque arms 34 to the drive
struts 32 in the form of compressive forces which are resisted by
the drive assembly 30.
[0062] Additionally, loads created by other matter collecting on
the modules 12 can generate additional loads. For example,
significant amounts of snow can accumulate the upper surface of the
modules 12, thereby generating even higher torques and loads. Thus,
for some sizes of solar systems 10, such systems including 18 rows
of torque tubes 16, the drive assembly 30 can be subjected to axial
loads, in the form of tension and compression of the drive struts
32 as high as 30,000 to 50,000 pounds.
[0063] Using 50,000 pounds as an exemplary maximum design load
parameter for the drive assembly 30 establishes the drive assembly
30 as the component which is exposed to the highest loads in the
entire system 10, by a significant margin. Thus, known existing
systems similar to that illustrated in FIGS. 1 and 3 include
heavily ballasted mounting bases specifically designed for
supporting a drive assembly. For example, such known systems
include a large diameter hole filled with steel reinforced concrete
having sufficient size and weight for resisting the 50,000 pound
lateral load design parameter noted above.
[0064] An aspect of at least one of the inventions disclosed herein
includes the realization that significant amount of labor costs,
material costs and construction time can be avoided by forming a
drive mount base from a plurality of other support structures used
for supporting other parts of the solar system 10.
[0065] Thus, with reference to FIGS. 9-11, the drive assembly 30
can include a mounting base assembly 100 comprising a plurality of
structural support members used in other parts of the system 10,
connected together in such a way that loads imparted to the drive
assembly 30 are shared amongst the plurality of structural
members.
[0066] For example, in the illustrated embodiment, the mounting
base 100 includes a plurality 102 of piles 22 which are similar to
or the same as piles 22 illustrated in FIG. 3 above as supporting
torque tubes 16. Optionally, the piles used for the mounting base
100 can be of the same type of support member as the piles 22 used
to support the torque tubes 16. In some embodiments, the piles 22
of the mounting base can have different structures, thicknesses,
cross sections, yet be installable in the same fashion as the piles
22 supporting the torque tubes, for example, by pile-driving, and
thus be considered as being the same type of or substantially the
same support members as those used to support he torque tubes 16.
In the illustrated embodiment, the mounting base 100 includes six
(6) piles 22. Other numbers and types of piles 22 can also be
used.
[0067] With continued reference to FIG. 9, the piles 22 are
illustrated as having been pile-driven into the ground G with the
same or similar orientation to that of the piles 22 supporting the
torque tube 16. More specifically, for example, the piles 22 have
planar faces 23 a/k/a "webs", which extend generally perpendicular
to the pivot axis of the torque tube 16. In the illustrated
embodiment, the webs face towards north, as illustrated in FIG.
9.
[0068] As such, during construction of a system 10, the piles 22
forming the plurality of supports 102 can be installed into the
ground G at approximately the same time, for example, during the
same construction phase as that during which the piles 22
supporting the torque tube 16 are driven into the ground G.
[0069] The mounting base 100 can also include a load sharing
assembly 104. The load sharing assembly 104 can be configured to
interconnect two or more of the plurality of load support members
102 so as to spread loads amongst the plurality of support members.
Thus, in the illustrated embodiment, the load sharing assembly 104
includes interconnection member 106 and interconnection member 108,
each of which connect a plurality of the piles 22 together. In the
illustrated embodiment, the interconnection members 106 and 108 are
in the form of structural "angle steel". However, other
configurations of the interconnection members 106, 108 can also be
used.
[0070] Optionally, the interconnection members 106, 108 and the
associated piles 22 can include apertures for receiving fasteners,
such as threaded fasteners, to simplify assembly at a solar
facility site. In the illustrated embodiment, the apertures on the
piles 22 are formed on the webs 23 and the apertures on the
interconnection members 106, 108 are formed on the vertical
portions of those frame members, positioned for alignment with the
apertures on the webs 23. With such apertures attached, for
example, with threaded fasteners, parts of the interconnection
members 106, 108 each are oriented horizontally, referred to herein
as horizontally extending portions 110, 112.
[0071] Additionally, optionally, the interconnection members 106,
108 can extend to piles 22 supporting the torque tube 16. As such,
the interconnection members 106, 108 can also be attached to the
piles 22 supporting the torque tube 16. Additionally, such
connections can be facilitated with pre-drilled apertures for
receiving threaded fasteners. However, other techniques can also be
used.
[0072] Optionally, an alignment tool 114 can be used during
installation of the interconnection members 106, 108 to ensure
proper spacing between the upper surfaces 110, 112 and otherwise
proper alignment of the support frame members 106, 108.
[0073] With the plurality of support members 102 connected in a way
so as to share a load, the tensile loads acting in the direction of
arrow T (FIGS. 9-11), as well as the compressive loads which act in
the direction of arrow C transferred to a drive supported by the
drive mount base 100 can be shared amongst the plurality of support
members 102. As such, the plurality of support members 102 can
withstand tensile forces T and compressive forces C that are much
greater than the maximum forces which individual piles 22 could
withstand on their own.
[0074] Thus, for example, in a system 10 with a maximum load
parameter of 50,000 pounds compression or tension and based on the
height of the load sharing assembly 104, each individual pile 22
could withstand approximately 10,000 pounds of compression C or
tension T. However, combined with the load sharing assembly 104,
the plurality of support members 102 can withstand maximum loads up
to approximately 60,000 pounds of compression C or tension T. Thus,
depending on the design parameters of a particular system, the
number of piles 22 and/or types of support members used in the
plurality of support members 102 can be modified.
[0075] With reference to FIGS. 12-17, the drive assembly 30 can
also include an actuator mount member 120. The actuator mount
member 120 can be configured to be securely fixed to the drive
mount base 100 as well as to an actuator configured to apply
driving forces to the drive struts 32 during operation. The
actuator can be any type of actuator. Optionally, the actuator 122
(FIG. 22) can be in the form of an electric jackscrew drive.
[0076] For example, the jackscrew drive 122 can include an electric
motor, a worm gear-type transmission, and a jackscrew member 124
and can be configured to drive the jackscrew member 124 through a
reciprocating, east-west movements, for driving the drive struts 32
in the desired directions. Such actuators 122 can include an
annular or cylindrical mounting face extending around the jackscrew
124, for example, with a bolt hole pattern or other attachment
device configured to attach to a drive mount. Such actuators 122
are well known in the art and widely commercially available. Thus,
the actuator 122 is not described further.
[0077] With continued reference to FIGS. 12-17, the actuator mount
member 120 can include mounting portions for fixation to the mount
base 100 and for connection to the actuator 122.
[0078] For example, optionally, the actuator mount 120 can be
configured for fixation to the load sharing assembly 104 of the
mount base 100. In some embodiments, the actuator mount member 120
includes first and second mounting portions 140, 142 configured to
be fixable to the interconnecting members 106, 108, respectively.
For example, the mounting portions 140, 142 can be formed with
structural members, such as plate steel, or other members, and a
plurality of apertures for fixation to the frames 106, 108 with
fasteners, such as threaded fasteners. With continued reference to
FIGS. 12 and 16, the apertures can be enlarged or slotted to
provide for adjustable mounting to the frame members 106, 108.
[0079] With the continued reference to FIG. 12-17, the actuator
mount member 120 can also include a web portion 144 extending
between and connecting the mounting portions 140, 142. In the
illustrated embodiment, the web portion 144 is generally in the
form of a truss having a configuration designed to withstand the
forces associated with supporting the actuator 122 as well as
forces imposed onto the actuator 122 by way of compression C and
tension T forces (FIG. 9) transmitted to the jackscrew 124 (FIG.
22). In the illustrated embodiment, the web portion 144 is
constructed with the plurality of plate steel members welded
together, with weight-reducing/access apertures. However, other
configurations can also be used.
[0080] With reference to FIGS. 12, 13, 14, and 15, the actuator
mount member 120 can include an actuator mount face 150. The
actuator mount face 150 can include one or more features configured
for adjustable connection to the actuator 122.
[0081] For example, with continued reference to FIGS. 15, 16, and
17, the mounting face 150 can include a central aperture 152 to
accommodate reciprocal movement of the jackscrew 124 therethrough.
Optionally, the central aperture 152 can be significantly larger
than the jackscrew 124 so as to provide for multiple mounting
orientations and positions of the actuator 122 relative to the
mounting face 150. Additionally, optionally, the mounting face 150
can include a plurality of upper apertures 154 and a plurality of
lower apertures 156 extending above and below the central aperture
152, respectively. The upper and lower apertures 154, 156 can be
configured and arranged to provide for a plurality of different
mounting locations for the actuator 122. For example, the apertures
154, 156 provide for a plurality of different mounting positions of
the actuator 122 laterally spaced as viewed in FIG. 15, described
in greater detail below with reference to FIG. 21.
[0082] Optionally, with continued reference to FIGS. 13, 14, and
15, the actuator mount member 120 can include other mounting
surfaces, to provide additional means for withstanding the
compressive C and tensile T forces transmitted to the actuator 122.
For example, but without limitation, the actuator mount member 120
can include an intermediate mount portion 160 mounted in a location
generally between the mounting portions 140, 142. For example, as
in the top plan view of FIG. 14, the intermediate mount portion 160
is disposed between the mounting portions 140 and 142.
Additionally, as viewed in FIGS. 13 and 15, the intermediate mount
portion 160 is disposed above the central aperture 152 of the mount
face 150 and higher than the mounting portions 140, 142. The
intermediate mounting portion 160 can be configured to be
attachable to additional support structures, as desired. In the
illustrated embodiment, the intermediate support portion 160
includes apertures 162 for receiving fasteners, such as threaded
fasteners. However, other attachment techniques and devices can
also be used.
[0083] With continued reference to FIG. 19, the actuator mount
member 120 can also include an adjustable actuator mounting member
that is adjustably fixable to the actuator mount member 120. For
example, the adjustable actuator mount member 170 can be configured
to be fixable to the mounting face 150 in a plurality of different
orientations.
[0084] In some embodiments, the adjustable actuator mount member
170 includes a mounting face 172 and one or more actuator mounting
arms 174. The actuator mounting arms 174 can include one or more
apertures 176 configured to be fixable to the actuator 122. In the
illustrated embodiment, the arms 174 and apertures 176 are
configured to securely attach to a worm gear housing of the
actuator 122, because the actuator 122 is designed to be supported
by the worm gear casing. Other actuators can be supported with
other types of mounting arms 174 and/or apertures 176.
[0085] The mounting plate 172 also includes a central aperture 178
configured to accommodate the jackscrew 124 (FIG. 22). As such, the
central aperture 178 is disposed between the arms 174.
[0086] The mounting plate 172, as noted above, is configured to be
adjustably mountable to the mounting face 150. Thus, in some
embodiments, the mounting plate 172 includes a plurality of slotted
upper and lower apertures 180, 182 configured to be attachable to
the upper and lower apertures 154, 156 of the mounting face
150.
[0087] More specifically, with reference to FIGS. 15 and 19, the
upper apertures 180 of the mounting plate 172, due to their
elongated shape, can be aligned with the upper apertures 154 of the
mounting face 150 in a plurality of different positions and
orientations. Similarly, the lower apertures 182 can also be
variably aligned with the lower apertures 156 of the mounting face
150. Such adjustability provides for both lateral and rotational
adjustment of the adjustable actuator mounting member 170.
[0088] Optionally, in the illustrated embodiment, the upper and
lower apertures 180 are slotted and extend along arched paths. For
example, the curved slotted configurations of the upper and lower
apertures 180, 182 further facilitate rotational adjustment of the
member 170 relative to the mounting surface 150. Optionally, the
upper and lower apertures 180, 182 can extend along a radius of
curvatures centered approximately in the central aperture 178.
[0089] Additionally, in some embodiments, the mount assembly 120
can also include a clamping plate 190 configured to be attachable
to the member 170 with the mounting face 150 disposed there
between. Thus, the clamping plate 190 includes a central aperture
192 shaped and configured to be alignable with the central aperture
178 of the member 170 and the central aperture 152 of the mounting
face 150. Additionally, the clamping plate member 190 can also
include a plurality of apertures configured to be alignable with
the upper and lower apertures 180, 182 of the member 170 for
receiving fasteners, such as threaded fasteners. As such, the
clamping plate 190 and the member 170 can be secured together, with
the mounting face 150 clamped there between for secure fixation
thereto.
[0090] As noted above, the configuration of the upper and lower
apertures 180, 182 can provide for beneficial adjustment of the
member 170 relative to the face 150.
[0091] One example of an installation configuration is illustrated
in FIGS. 20 and 21. In this exemplary configuration, the ground G
is at a slope of approximately 5.degree. relative to horizontal.
The piles 22 are driven into the Ground so as to be vertical in
orientation. As such, the frame members 106, 108 are mounted such
that their upper faces 110, 112 are horizontal and lie
approximately in the same plane. As such, the actuator mount member
120 can be fixed to the frame members 106, 108 so as to extend in a
generally horizontal orientation. However, the torque tubes 16 are
mounted such that their pivot axis 17 extends parallel to the
ground G, as noted above, in this example, at an angle of
approximately 5.degree., relative to horizontal. Thus, in this
orientation of the torque tube 16, the torque arms 34 extend
downwardly at approximately 5.degree. relative to vertical.
Similarly, all of the drive struts 32 will be aligned along and
also rise and fall in accordance with the movement of the torque
arms 34, along a plane perpendicular to the torque tube 16. The
actuator 122 is mounted in accordance with the angular orientation
and movement of the drive struts 32 so that the jackscrew 124 can
move appropriately in a proper alignment with the drive struts
32.
[0092] Thus, as illustrated in FIG. 21, the adjustable actuator
mount 170 can be mounted at an angle skewed from the mounting face
150. In the illustrated embodiment, the offset alignment of the
adjustable actuator mount plate 170 is accommodated by the slotted
upper and lower apertures 180, 182 and their configuration and
alignment to be fixable with the upper and lower apertures 154, 156
of the mounting face 150.
[0093] With reference to FIG. 22, the drive assembly 30 can also
include reinforcing members 190, 192. For example, the reinforcing
members 190, 192 can be configured to be fixable to the apertures
162 on the upper or intermediate mount portion 160 and fixable to
the frames 106, 108, respectively. For example, the reinforcing
members 190, 192 can include apertures at their upper ends,
alignable with the apertures 162 of the actuator support member 120
and the apertures at their opposite ends for fastening with
apertures in the frames 106, 108. As such, the reinforcing members
190, 192 can assist in resisting torsional forces that can be
generated by the system 10, through the application of compressive
C and tensile T forces acting through the jackscrew 124 on the
actuator 122 and thus on the actuator mount member 120.
[0094] Although specific embodiments have been described above,
these embodiments are not intended to limit the scope of the
present disclosure, even where only a single embodiment is
described with respect to a particular feature. Examples of
features provided in the disclosure are intended to be illustrative
rather than restrictive unless stated otherwise. The above
description is intended to cover such alternatives, modifications,
and equivalents as would be apparent to a person skilled in the art
having the benefit of this disclosure.
[0095] The scope of the present disclosure includes any feature or
combination of features disclosed herein (either explicitly or
implicitly), or any generalization thereof, whether or not it
mitigates any or all of the problems addressed herein. Accordingly,
new claims may be formulated during prosecution of this application
(or an application claiming priority thereto) to any such
combination of features.
* * * * *