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Key Words Design and Development, Solar Tracking System, Hydraulic System
Abstract
In this project work, with the title Tracking of Solar Panel by Hydraulic System,
we were planning for design and developing a solar tracking system which will
utilize mechanical energies for the tracking operation. At present, the solar
tracking system use electrical energy for tracking operations and this electrical
energy for operations is supplied by same solar panels or by external electrical
storage or supply lines, this reduces efficiency of the solar panels. Using
mechanical energy for tracking will increase the output of solar panels and
remove the constraint on the location of the tracking system.
www.ijifr.com
Copyright © IJIFR 2015 2856
ISSN (Online): 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
1. Introduction
system gives an input signal to servo drive system to drive the stepper motor with the help of sensor
and electronic counters.
In these systems, the major portion of energy produced by the solar panel is utilized for
tracking operation. If not, these systems should have a battery storage unit or should be connected to
power supply grid or the combination of both.
1.5 Mechanical Solar Tracking Systems
Mechanical engineering is one of the largest, broadest and oldest engineering disciplines and
uses principles of energy, materials, and mechanics to design and manufacture machines and devices
of all types. Mechanics, energy and heat, mathematics, engineering sciences, design and
manufacturing form the foundation of mechanical engineering.
Fundamentally, mechanical engineering involves with the mechanics of motion and the
transfer of energy from one form to another or one place to another.
The various fields of application of mechanical engineering are,
Energy conversion
Energy resource
Environment and Transportation
Engineering and Technology management
Manufacturing
Materials and Structures
Systems and Design
In above fields the Solar Engineering falls in the category of Energy resource. Mechanical
engineers are effectively involved in solar energy in finding new ways to produce mechanical and
electrical power for heating, refrigeration and water purification and also in the design of devices
and structure to collect solar energy.
Mechanical solar tracking systems are the systems which use the mechanical energy for
operation and involve the fundamental concepts of various fields, related to mechanical engineering.
The tracking of solar panels can be effectively done with mechanical systems. These systems are
robust in design and are very less sensitive to seasonal changes. Mechanical systems, built with high
precision are well suited for tracking operation.
2.1 Identification
i. There are many problems associated with conventional solar panel because they are fixed in one
direction.
ii. The positions of the sun keeps on changing every day, along with the sun, solar panel have to move
in same direction.
iii. The other system also used for solar tracking but they consumes most of the energy produced by
solar panels for tracking, which effects the efficiency of solar panel.
To rectify these above problems the solar panel should be such that it always receives maximum
intensity of light. For existing solar panels, which are without any control systems typical level of
efficiency varies from 10% to 4% - a level that should improve measurably if the present interest
continues.
3. Literature Review
One-Axis Trackers – Improved Reliability, Durability, Performance, and Cost Reduction -
Final Subcontract Technical Status Report - 2 May 2006 – 31 August 2007 by J. Shingleton
Shingleton Design, LLC Auburn, New York – page 7:
The work effort focused on reducing the total cost of electricity generated by single-axis
tracking solar energy systems for utility and other large-scale commercial applications.
Developing a factory assembled, modular tracker, while building on the strengths of the
existing technology, resulted in improved performance and reliability and reduced
installation time, cost, and environmental impact.
Low cost tracker by Marliyani Binti Omar This thesis is submitted as partial fulfillment of
the requirements for the award of the Bachelor of Electrical Engineering - Faculty of
Electrical & Electronics Engineering University Malaysia Pahang -MAY, 2009 - page5
Solar tracker is invented because solar panel disables to move toward the sunlight when the
sun moves from east to west. In order to produce maximum power output, solar tracker is
design with motor so that the solar panel will move toward the position of sun.
Atlas solar tracking by Mechatronics Company manual:-Atlas system can achieve up to
40% more output power than fixed tilt systems. It ensures that the PV panels are
optimally orientated towards the sun, converting efficiently direct and indirect solar
radiation into electricity.
Hawe hydraulics manual :- HAWE Hydraulics offers compact positioning systems, which
consist of a hydraulic power pack with a control system that is directly attached. The electric
motor and pump in this closed system is submerged for protection against rain,
condensation, and dirt. HAWE’s modular products mean we can easily adjust power and
movement speeds according to customers’ requirements, as well as provide easier access for
maintenance. With various product sizes, low friction, and minimized stick or slip effect,
tracking movements can be controlled reliably and accurately. Dampened over-center valves
ensure smooth movements, which protects the entire structure.
Rockwell automations solar tracking application manual book:-Concentrated applications
like concentrated photovoltaic panels (CPV) or concentrated solar power (CSP) require a
high degree of accuracy to ensure the sunlight is directed precisely at the focal point of the
reflector or lens. Non-concentrating applications don’t require tracking but using a tracker
can improve the total power produced by the system. Photovoltaic systems using high
efficiency panels with trackers can be very effective. There are many types of solar trackers,
of varying costs, sophistication, and performance. The two basic categories of trackers are
single axis and dual axis.
4. Scope Of Work
We search for project related to solar power related, and we got some points to study from that we
select the solar tracker.
5. Objective
The need for mechanical systems for tracking operation can be better explained with the draw-
backs associated with electrical tracking systems. Those are,
i. The present Electrical tracking systems consumes most of the energy produced by solar panels
which serves as a demerit for the Solar system.
ii. We plan to totally neglect the wastage of electricity generated by the panels. In other words
we hope to increase the output of the solar panels.
iii. The minimum power required for operation may not be available at all times o the day due to
change in atmosphere. Tracking will help solve this problem.
iv. Mechanical systems can work in any environment. Dust and humidity have no ill-effects on
the system.
v. To simplify the system and avoid any complexity in design.
vi. We try to make the entire system compact So that there is no issue when it comes to moving
the system.
vii. The energy required for operation will increase with the increased size of solar Panel.
6. Methodology
The methodology of design for the design of mechanical tracking system is explained by following
steps,
i. Determining sunray orientation and time range to which the panel has to be tracked.
ii. Calculating the required angular velocity of the panel.
iii. Calculating the system pressure and cylinder (actuator) discharge.
iv. calculating the weight/force required to create the required pressure.
v. Selecting cylinder of suitable diameter and stroke length.
vi. Selecting the suitable grade of hydraulic oil.
vii. Calculating the capacity of reservoir.
viii. Designing the hydraulic circuit with QUICK RETURN facility to reduce the time required
for bringing the panel to its original position.
ix. Selecting required mechanical components of suitable dimensions and material.
x. Preparing production drawings and fabrication of mechanical elements.
xi. Assembly of the device.
xii. Demonstration.
Continuity equation
Let,
V1 = Average velocity at cross-section 1-1
r1 = Density at section 1-1
A1 = Area of pipe at section 1-1
And V2, r2, A2 are corresponding values at section 2-2.
Then the rate of flow at section 1-1 = r1A1V1
And rate of flow at section 2-2 = r2A2V2
According to law of conservation of mass,
Rate of flow at section 1-1 = Rate of flow at section 2-2
r1A1V1=r2A2V2
The above equation is applicable to the compressible as well as incompressible fluids and is called
continuity equation. If the fluid is incompressible (e.g. Hydraulic oils), then
r1= r2
and the above continuity equation reduces to
A1V1= A2V2
6.1.7 Bernoulli’s equation and its applications
Statement: It states that in a steady, ideal flow of an incompressible fluid, the total energy at any
point of the fluid is constant. The total energy consists of pressure energy, kinetic energy and
potential energy or datum energy.
These energies are,
Pressure energy = p/rg in m of fluid
Kinetic energy = v2/2g in m of fluid
Datum energy = z in m of fluid
Thus mathematically, Bernoulli's theorem is written as,
p/w + v2/2g + z = Constant - - - - - - - - - - - - (here w = rg)
Applications: Bernoulli's equation is applied in all problem of incompressible fluid flow where
energy considerations are involved. The sum of common applications of Bernoulli's theorem is,
1. Venturimeter - for measuring the rate of fluid flow
2. Orifice meter - for measuring the rate of fluid flow
3. Pitot tube - for measuring velocity of fluid flow
Orifice:
Orifice is a small opening of any cross-section, through which a fluid is flowing.
Orifice may be of any cross-section such as circular, triangular, rectangular etc.
Classification of orifice:
Orifice are classified based on,
Size: Small orifice and large orifice
Cross-sectional areas: Circular orifice, triangular orifice, rectangular orifice & square orifice
Shape of upstream edge: Sharpe-edged orifice and bell-mouthed orifice
Nature of discharge: Free discharging orifice and drowned or sub-merged orifices
Co-efficient of discharge for orifice:
It is defined as the ratio of actual discharge from an orifice to theoretical discharge. It is denoted by
Cd.
Cd = Actual velocity
Theoretical velocity
And Theoretical velocity is given by the equation,
v2 = 2gH m/s
Where,
v = velocity of fluid flowing through the orifice in m/s
g = acceleration due to gravity in m2/s
H = head in m
- Discharge through orifice:
The rate of discharge from orifice is expressed by the equation,
Q = Cd A (2gH)0.5m3/s
Where A = cross-sectional area of orifice in m2
6.1.8 Characteristics of Hydraulic systems
01. High forces (torques) with compact size.
02. Step less change (control or regulation) of speed.
03. Suitable for heavy duty operations.
04. Suitable for heavy load applications.
05. Simple overload protection.
06. Higher response time.
07. Hydraulic means of transferring energy are usually slower when compared to pneumatics or
electrics.
08. Suitable for controlling fast movement process and for high precision movement.
09. High capital cost.
10. Flexibility may not be as good as pneumatics or electrics.
11. Unavoidable leakages, due to higher system pressure.
12. Prone to fire hazards.
c. Mechanics of fluids
I. study of compressible fluids
II. Study of incompressible fluids (Hydraulics)
6.2.3 Space, time, mass and force
These are basic concepts of the mechanics. These concepts are not truly defined; they should
be accepted on the basis of our intuition and experience and used as mental frame of reference of our
study. The concept of space is associated with the notation of the position of a point P. the position
of P may be defined by three lengths measured from a certain reference point, or origin, given in
three directions. These lengths are known as co-ordinate of P. To define an event, it is not sufficient
to indicate its position in space. The time of the event should also be given. The concept of mass
used to characterize and compare the bodies on the basis of certain fundamental mechanical
experiments. Two bodies of same mass, for example, will be attracted by earth in the same manner;
they will also offer the same resistance to a change in translational motion. A force represents the
action of one body on another. It may be excreted by actual contact or at a distance, as in the case
gravitational forces and magnetic forces. A force is characterized by its point of application, its
magnitude and direction. A force is represented by a vector.
6.2.4 Energy and Power
Energy may be defined as capacity to do work. The energy exists in many forms e.g.
mechanical, electrical, chemical etc. The three types of mechanical energies are Potential energy,
Kinetic energy and Strain energy. The S.I unit of energy is Joule (J) and the symbol is E. Power may
be defined as rate of doing work per unit time. The S.I unit of power is watt (W) and the symbol is
P.
6.2.5 Tracking mechanism
The mechanism selected for tracking system is based on lever principle. The type of lever
used manipulate the required load is Second type lever. Basically, a lever is rod or bar capable of
turning about a fixed point called fulcrum. It is used as a machine to lift / transmit a load by the
application of small effort. The ratio of load lifted to the effort applied is called mechanical
advantage. A lever may be Straight or curved and the forces applied on the lever (or by the lever)
may be parallel or inclined to one another.
6.4.2 Tracking
As the tracking weight acts on the piston through piston rod, it pushes the oil out of the
cylinder and the oil flows towards reservoir. While, due to the restricted cross sectional area at flow
control valve the piston moves with the velocity equal to calculated tracking velocity. During this
action the check valve remains closed, hence oil is allowed to flow only through flow control valve.
At the rod end of the cylinder, the oil is sucked into cylinder due to the vacuum pressure created by
the applied weight.
The flow control valve also allows the oil to flow from it, increasing rate of flow and reduced panel
repositioning time. At rod end of cylinder the piston forces the oil. The oil pressure increases and oil
flows out of the cylinder. Oil returns to reservoir through a filter placed in the return line.
The lever mechanism used for the current tracking system is illustrated by the figure
Double acting cylinder: Double acting cylinder produces linear motion in two directions.
Hydraulic power is applied on either side of the piston. The construction of double acting
cylinder is similar to single acting cylinder except that rod end of the cylinder also has oil port.
The constructional details of the double acting cylinder is as shown in fig,Constructional details
of double acting cylinder
Graphical symbol:
Graphical Symbol:
III. Filter
Filters are used in hydraulic systems to remove both the solid and liquid contaminants. Filter
is a device that consist of an element (called filter element) having the openings. When the
contaminated oil passes through the filter element, the particles remain/get filtered, while the clean
fluid passes out of the element. Filter elements are available in sizes as small as 1 micron, which
mean even a dust particle of size 1 micron gets filtered through this filter element.
The three common types of filter elements used in hydraulic systems are,
a. Mechanical elements
b. Absorbent elements
c. Adsorbent elements
products increase the viscosity of the fluid. Rust is the formation of iron oxide by the chemical
reaction between steel and oxygen. Corrosion is another chemical phenomenon, occurring between
any metal part and acid. These problems can be minimized by adding certain chemical additives to
the fluid, that inhibit oxidation, within the fluid, or that form a thin chemical layer on the metal parts
and avoid direct contact, and hence reduce rusting and corrosion problems.
d. Incompressibility
The incompressibility of a fluid is measure of its stiffness, and given by its bulk modulus
(B). The compressibility of a fluid has influence on the system response, and makes it susceptible to
shock waves. In normal hydraulic systems its effect on system response is not considered, while the
compression values are used to avoid shock wave problems.
e. Fire resistance
Fire resistance is one important property required for applications in aircraft engines, steel
mills, foundries and mines, where the working environment are hot. Through petroleum based oils
are suitable and have many desirable characteristics, they are highly vulnerable to fire hazards. In
such cases fire resistant fluids are used. Fire resistance of a hydraulic fluid measured by some of the
characteristics, those are flash point, fire point and autogenously temperature.
f. Foam resistance
Dissolved air reacts with the fluid to form acidic products which in turn cause corrosion and
sludge problems. The presence of foam in the fluid causes serious operational problems. Certain
additives are added to fluid, which act as foam-depressants.
VI. Reservoir
Reservoirs are basically storage tanks for the hydraulic oil. The functions of a hydraulic
reservoir are,
a. To act as a storage tank.
b. To provide heat exchange, thus cooling the oil.
c. To allow entrained air to escape from fluid.
d. To allow fluid contaminations to settle down.
e. To make-up any leakages in the system.
f. To provide filling point for the system.
The reservoir design should be optimum. A smaller size reservoir then required causes
problems like overheating, increased contamination, higher wear and tear. An over sized reservoir
will increase the cost of tank and longer warming period.
VII. Hydraulic System Design
Hydraulic system design includes the determination force required for the cylinder and
system pressure. The details of calculation steps for the hydraulic system design are given as below,
6.6 Nomenclature
i. D = Cylinder diameter in m
ii. A = Cross sectional area of cylinder in m2
iii. L = Length of stroke in m
iv. d = Diameter of orifice in m
v. Cd = Co-efficient of discharge for orifice
vi. Vp = Velocity of piston in m/s
vii. Vo = Velocity of oil at orifice in m/s
viii. Qc = Cylinder discharge in m3/s
6.7 Calculations
I. Velocity of piston
Vp = Stroke length / Time range
= 0.21 / 28800
Vp = 7.29E-6 m/s
II. Cylinder discharge
Qc = Cross-sectional area A x Velocity of piston Vp
= 1.963E-3 x 7.29E-6
Qc = 1.43E-8 m3/s
III. Velocity of oil at orifice
By the relation for discharge from orifice,
Qo = Cd x a x Vo
1.43E-8 = 0.62 x 7.85E-7 x Vo
Vo = 0.029 m/s
IV. System pressure
2 x P = Vo x r - - - - - - - (by V = (2gH)0.5 & P = rgH)
2 x P = 0.0292 x 880
P = 0.37 Pa or N/m2
And also considering the pressure drop across the filters = 3386.68 Pa
(Note: As check valve is closed during tracking operation, pressure drop across check valve is not
considered.)
The Total system pressure,
P = 0.37 + 3386.38
i.e. P = 3386.75 Pa
V. Force required,
F=PxA
= 3386.75 x 1.963E-3
F = 6.64 N
The force required on the cylinder for tracking = 6.64 N
= 3.456 x 0.21
i.e. E = 0.725 J
Energy required for tracking operation = 0.725 J
Step 2: Return
The force applied for return operation is manual. Assuming a normal person can exert 5 kg
of force against gravity, then
Force required for return operation = 49.05 N
Energy consumed for the return operation = Force x Angular displacement
= 5 x 9.81 x (π/180) x 0.5 x 120
i.e. E = 51.36 J
Energy consumed for return operation = 51.36 J
6.8 Assembly
I. Column and base
This is the load bearing structure of machine which takes all forces acting on the system.
The column and base are welded together to provide more strength and to carry the solar panels of
larger sizes than designed. It also includes two stoppers to restrict the displacement of panel seat to
the required position. These are plates of 4mm thickness and welded to the column.
II. Panel seat
Panel seat is a fabricated frame on which solar panel is mounted. It is fabricated element and
sufficient numbers of holes are provided to facilitate the mounting of solar panel. It also supports the
weight holder and transmits tracking force to cylinder. A provision also made on the frame to mount
the counter weight, for flexibility in selection of weight disc/s. A handle is provided with the frame
to facilitate the lifting the panel seat for return operation.
III. Weight holder and weight disc
The function of weight holder is to hold the weight disc in its place. Another important
function of weight holder is to provide proper moment to overcome static friction of cylinder at the
beginning of tracking operation. The static friction is very high at the beginning of tracking
operation. Weight disc is a molded disc which is mounted on weight holder to exert driving torque
for tracking operation. Multiple discs can be used according to their unit weight and requirement.
FLUID FLOW
CONTROL VALVE
CHECK VALVE
PANNEL SET
DOUBLE ACTING
CYLINDER
7.1 Advantages
1. Hydraulic solar tracker is easy to design and manufacture compare to other tracker system.
2. Increased reliability and robustness of hydraulic control system compared with other solar
tracker.
3. Hydraulic solar trackers generate more energy than other tracking system like electric solar
tracker.
4. Lubrication of system is not necessary due to less moving parts.
5. Compare to other tracking system hydraulic tracking system cost is less.
6. Important reduction of whole life maintenance cost of solar tracker .
7.2 Disadvantages
1. Structurally less rigid then permanent mounts and hence can be vulnerable to storm damage.
2. More chances to leakage of hydraulic oil.
3. Required manual power to pump the oil in cylinder.
7.3 Limitation
The Track Rack begins the day facing west as the morning sun rises in the east we need to
pump the oil in cylinder with the help of manual power.
8. Bill Of Materials
Table 8.1: Bill Of Materials
Sr No. Part Code Description Qty Material
1. TPSH -1 PANEL SEAT 01 MS
2. TPSH -2 COLUMN 01 MS
3. TPSH -3 BASE 01 MS
4. TPSH -4 WEIGHT 01 MS
5. TPSH -5 WEIGHT HOLDER 01 MS
9. Result
The results obtained after the detailed calculations are given as below,
i. Velocity of piston = Vp = 7.29E-6 m/s
ii. Cylinder = Qc = 1.43E-8 m3/s
iii. Velocity of oil at orifice = Vo = 0.029 m/s
iv. System pressure = P = 3386.75 Pa
v. The force required on the cylinder for tracking = F = 6.64 N
vi. Considering mechanism for tracking, weight required for tracking,
i. W = 3.456 N
vii. Energy required for tracking operation = 0.725 J
viii. Force required for return operation = 49.05 N
ix. Energy consumed for return operation = 51.36 J
x. Minimum volume of tank = 0.00092 m3 or 0.92 Liter
xi. Increased power output and returns = 87.6 kW-hr worth of Rs.403 /- ------ (Considering a
solar panel of area 0.456 m2 and analysis period of 1 year)
10. Conclusion
It is observed that the designed mechanical tracking system is a system, which consumes no energy
for operation and contributing towards increasing the productivity of the solar panels. This is the
first attempt made towards utilizing the gravitational energy as a driving force for solar tracking
systems and also in providing a suitable tracking system for the remote places. In view of increasing
demand for the electrical power, this tracking system can contribute a little (around 87.6 kW-hr per
year) in the fulfilment this demand
return operation. The electronic system, if used, should consume very little electric energy,
making the device suitable for remote applications by providing small & long lasting
batteries.
II. Use of multiple panels on panel seat, to increase the returns from tracking system.
III. System can be modified to suite other solar applications like solar air heating and solar
water heaters.
References
PUBLISHED PAPER REFERANCE
[1] One-Axis Trackers – Improved Reliability, Durability, Performance, and Cost Reduction - Final
Subcontract Technical Status Report - 2 May 2006 – 31 August 2007 by J. Shingleton Shingleton
Design, LLC Auburn, New York
[2] Low cost tracker by Marliyani Binti Omar This thesis is submitted as partial fulfillment of the
requirements for the award of the Bachelor of Electrical Engineering - Faculty of Electrical &
Electronics Engineering University Malaysia Pahang -MAY, 2009
[3] A review of principle and sun-tracking methods for maximizing solar systems output by Hossein
Mousazadeh, Alireza Keyhani, Arzhang Javadi, Hossein Mobli Karen Abrinia, Ahmad Sharifi -
Department of Agricultural Machinery Engineering, University of Tehran, Iran
BOOK REFERANCE
[1] Fluid mechanics and Hydraulic machines by R.K.Bansal.
[2] Basic hydraulics and hydraulic plumbing US army division.
[3] Machine design by R.S.Khurmi and J.K Gupta.
[4] Vector mechanics for engineers by F.B Beer.
[5] Atlas solar tracking by mechatron company manual.
WEB REFERENCE
We have followed several links on the internet’s which are as follows:
[1] http://www.canren.gc.ca/tech_appl/about solar energy.htm.
[2] http://www.palmdalewater.org/alternative solarenergy.htm.
[3] http://www.careercornerstone.org/careers for mechanical engineers
[4] http://www.burkoil.com.
[5] http://www.bull-electrical.com/solar panels, electrical and water, controllers, panels, solar
shargers.htm.