Volume 2
April 2015
Issue 8
Page No.
2856-2881
Research Area
Mechanical
Engineering
Prof. Kusekar S. K 1
Ajinkya Patil
Sachin B. Patil 2
Prasad B. Rajmane 3
Akshay B. Bhosale 4
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.
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1. Introduction
1.1 Solar Energy
Energy from the sun travels to the earth in the form of electromagnetic radiation similar to
radio waves, but in a different frequency range called solar energy. Solar power is the conversion of
received solar radiation into usable energy. It is a process that consists of harnessing the sun's
present emissions of heat or light. This heat and light are the effects of the sun's constant nuclear
fusion of hydrogen nuclei. The process of fusion produces helium nuclei as well as large amounts of
energy.
Available solar energy is often expressed in units of energy per time per unit area, such as
watts per square meter (W/m2). The amount of energy available from the sun outside the earths
atmosphere is approximately 1367 W/m2. Some of the solar energy is absorbed as it passes through
the Earths atmosphere. As a result, on a clear day the amount of solar energy available at the
Earths surface in the direction of the sun is typically 1000 W/m2. The level of solar radiation a
region receives depends on latitude and local weather conditions.
1.2 Solar Tracking
Solar tracking is the process of varying the angle of solar panels, to take advantage of the
full amount of the sun`s energy. In remote places sun is the cheap source of electricity. The output
from solar panel depends on the intensity of sunlight falling on it and also on the angle of incidence.
It means to get maximum efficiency; the solar panel must remain in front of sun during the whole
day. But due the rotation of earth the panel cant maintain their position always in front of sun. Thus
to get maximum and a constant output, a system is required which should be capable to constantly
rotate the solar panel. Initial tests in industry suggest that this process can increase the efficiency of a
solar power system by up to 50%. Given those gains, it is an attractive way to enhance an existing
solar power system.
1.3 Solar Panels
Solar Panels are the devices for capturing the energy in sunlight. Solar photovoltaic panels
contain arrays of solar cells that convert light into electricity. The solar cells sometimes called
photovoltaic cells, photovoltaic meaning literally .light-electricity. Solar cells or PV cells rely on the
photovoltaic effect to absorb the energy of the sun and cause current to flow between two oppositely
charged layers. Crystalline silicon and Gallium arsenide are typical choices of materials for solar
cells. When exposed to sunlight, a 6 cm diameter silicon cell can produce a current of about 0.5 A at
0.5 V. Gallium arsenide is more efficient than Crystalline silicon.
A solar panel is a collection of solar cells. Solar panels are constructed of these cells cut into
appropriate shapes, protected from radiation and handling damage on the front surface by bonding
on a cover glass, and cemented onto a substrate (either a rigid panel or a flexible blanket). Electrical
connections are made in series-parallel to determine total output voltage. The cement and the
substrate must be thermally conductive, because the cells heat up from absorbing infrared energy
that is not converted to electricity. Since cell heating reduces the operating efficiency it is desirable
to minimize the heating. The resulting assemblies are called solar panels or solar arrays.
1.4 Electrical Solar Tracking Systems
The most of todays Solar tracking systems are electrical systems. Elements of these systems
are an electric servo drive and an electronic control system. The electric servo drive includes a
stepper motor, which rotates the solar panels with a pre-set angular displacement. The control
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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. HAWEs 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 dont 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.
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5. Objective
The need for mechanical systems for tracking operation can be better explained with the drawbacks 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.
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6.4.3 Return
As the tracking time finishes, the panel seat has to be rotated by applying the torque,
manually, to bring back into initial position. The vacuum pressure is created at piston end chamber
and oil from reservoir rushes towards cylinder. As soon as the system pressure exceeds the cracking
pressure of check valve, check valve opens and allowing full flow of oil from it, reducing the time
required for repositioning operation.
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The lever mechanism used for the current tracking system is illustrated by the figure
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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
Double acting cylinder has a hollow cylinder (barrel), piston and piston rod. Both the ends are sealed
with the end caps, which are either threaded or welded to the main cylinder. In some designs, the
end caps are held with the cylinder by tie rods. The piston is provided with a piston seal, commonly
used are piston rings to protect the leakage of oil. The rod is provided with seal to protect the
leakage, a bearing to carry the radial loads, a wiper to protect the foreign particles like dust entering
into cylinder. Oil ports are provided on either side of the piston, so that the fluid pressure can be
applied alternatively on both the sides.
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Graphical symbol:
I.
Flow control valve (FCV)
The function of flow control valve is to regulate the flow rate of fluid in a hydraulic system.
This in turn used to control the speed of actuator/s. These valves are basically variable area orifices,
in which increasing the area of orifice increases the flow rate and decreasing the area of orifice
reduces the flow rate.
The common types of FCVs are,
1. Simple needle valve
2. Needle valve with integral check
3. Pressure compensated FCV
Graphical Symbol:
II.
Check Valve
Check valves are also known as directional control valves. The function of check valve is to
direct the free flow in only one direction, and block any flow in reverse direction. These are similar
in operational analogy of electronic diodes.
The three types of check valves are generally used.
a. Ball type valve
b. Poppet type valve
c. Pilot operated check valve
A spring operated direction valve requires a small pressure to open, which is
called as cracking pressure. Due to this it can work like low pressure relief valve to some extent.
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,
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IV.
Hydraulic oil
The working fluid in all hydraulic systems is a fluid. Various oil based fluids which had the
desirable properties were developed for the use in hydraulic systems.
The functions of the hydraulic fluid are,
a. To transmit power, this is the primary function.
b. To lubricate various moving parts, so as to avoid metal-to-metal contact, and reduce wear and
noise.
c. To carry the heat generated in the system due to friction between moving parts and moving fluid,
and to dissipate to the environment either through a suitable heat exchanger or through the reservoir.
V.
Desirable properties of hydraulic fluids:
For the fluid to perform efficiently, it must possess certain properties. Certain additives are
added to achieve/preserve the desirable properties. The various properties required for an ideal
hydraulic fluid are as follows,
a. Viscosity
The most basic desirable property of hydraulic fluid is the optimum viscosity. Viscosity
refers to the resistance of a fluid to flow. A low viscous fluid is a thin and can flow easily, but causes
leakages and a very high viscous fluid is thick and doesn't flow easily. In practice, ideal hydraulic oil
should have optimum viscosity.
b. Lubrication
The other major requirement of hydraulic oil is the lubricating ability. A thin film of
lubrication should present to avoid direct contact between two mating surfaces; else both surfaces
rub with each other resulting in high wear rates. The extent to which direct metal-to-metal contact is
avoided depends on the strength of the fluid film which is a function of the viscosity of the fluid. In
hydraulic systems, the fluids themselves act as lubricating medium.
c. Chemical and environmental stability
For a good hydraulic fluid, a good chemical and environmental stability is desirable. Most
fluids are vulnerable to oxidization, as they come in contact with oxygen in air. The oxidation
products are highly soluble in oil, and being acidic in nature, they can easily corrode the metallic
parts. Oxidation leads to deterioration in the chemical nature of the fluid, which may form some
chemical sludges, gum or varnish at low velocity or stagnation points in the system. These chemical
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D = Cylinder diameter in m
A = Cross sectional area of cylinder in m2
L = Length of stroke in m
d = Diameter of orifice in m
Cd = Co-efficient of discharge for orifice
Vp = Velocity of piston in m/s
Vo = Velocity of oil at orifice in m/s
Qc = Cylinder discharge in m3/s
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Available data:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
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
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VI.
Reservoir Design
Reservoir design is essential to determine the capacity of tank, hence to assure proper
functionality. Some of the common rules to be followed in reservoir design are as follows,
a. The minimum size of the reservoir should be at least twice the pump delivery per minute.
b. Its capacity should be adequate enough to hold all the oil from the system that might drain into
tank.
c. It should have oil level much above the intake strainer, so that no whirling effect will occur.
d. Its capacity should enough to allow for thermal expansion.
Calculations:
Displacement of cylinder,
Vc = (3.142/4) x D2 x L
= (3.142/4) x 0.052 x 0.21
Vc = 0.000412 m3
Volume of oil in hoses and other accessories,
Va = (3.142/4) x 0.012 x 0.6
Va = 0.0000471 m3
Theoretical volume of tank,
Vt = Vc + Va
= 0.000412 + 0.0000471
Vt = 0.00046 m3
As per optimum design practices, the actual volume of tank should be at least twice the theoretical
volume of tank.
Hence,
Minimum Volume of tank = 2 x Vt
= 2 x 0.00046
i.e. Minimum volume of tank = 0.00092 m3 or 0.92 Liter
VII.
Force and Energy Calculation
Due the application of lever principle the effort required for the tracking operation is
different from the calculated value of force in the hydraulic system calculation.
(Note: All dimensions are in mm)
The force required is different for both steps of operation and they are calculated as below.
Step 1: Tracking
Referring to the mechanism and by the lever principles, taking reaction at fulcrum point,
We have,
Load x 0.13 m = Effort x 0.5 m
13.295 N x 0.13 m = W x 0.5 m - - -( F = 13.295 N )
i.e.
W = 3.456 N
Load required for the tracking operation = 3.456 N
and energy consumed for tracking,
Energy = Force x Distance (Cylinder displacement)
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FLUID FLOW
CONTROL VALVE
CHECK VALVE
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PANNEL SET
DOUBLE ACTING
CYLINDER
Figure 6.15: Showing Hinges And Double Acting Cylinder
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8. Bill Of Materials
Table 8.1: Bill Of Materials
Sr No.
1.
2.
3.
4.
5.
Part Code
TPSH -1
TPSH -2
TPSH -3
TPSH -4
TPSH -5
Description
PANEL SEAT
COLUMN
BASE
WEIGHT
WEIGHT HOLDER
Qty
01
01
01
01
01
Material
MS
MS
MS
MS
MS
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TPSH -6
TPSH -7
TPSH 8
TPSH 9
TPSH 10
TPSH 11
TPSH 12
TPSH 13
TPSH 14
TPSH 15
TPSH 16
01
01
01
01
01
01
01
01
02
20
08
STD
STD
STD
MS
MS
MS
STD
MS
STD
STD
STD
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 /solar panel of area 0.456 m2 and analysis period of 1 year)
------
(Considering a
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
11. Future Scope
Further research work will be suggested towards reducing the material cost, towards implementation
of suitable sensors to assure ease in operations and towards obtaining the preferred essential
requirements. Some of the preferred essentials and the guidelines associated with design and
development of this tracking device are;
I.
A sensor with electronic counter, which will provide input signal to a buzzer, to indicate the
start of tracking cycle. On basis of this, the panel is tilted by means of handle to perform
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II.
III.
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.
Use of multiple panels on panel seat, to increase the returns from tracking system.
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 internets 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.
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