GoPV 1sttraining Tracker Design 1st Part
GoPV 1sttraining Tracker Design 1st Part
Oct. 28th
PV Tracker – Design and Control
INTRODUCTION
(10:00-12:00)
PV TRACKER – DESIGN & CONTROL - Convert Italia -
Specific Topics:
1. Introduction to Tracker System for PV plant
Speaker:
Giuseppe Demofonti, Convert Italia
Time: 10 minutes
GoPV Project | 1st TRAINING COURSES
TECHNICAL FOCUS ON FUTURE SOLAR PV SYSTEMS
• The productivity of PV modules depends, in general, on their inclination with respect to the sun.
• From the beginning of PV technology, many efforts have been spent to develop devices able to change the
TRACKER orientation of the module surface.
• Single or double axis trackers have been developed instead of fixed oriented structures.
Steel structure
Driving devices
/ Actuator
Control board /
Power system
GoPV Project | 1st TRAINING COURSES
TECHNICAL FOCUS ON FUTURE SOLAR PV SYSTEMS
The new horizontal single axis tracker for bifacial modules should ensure a significant contribution of reflected
light on the back of the PV module.
A new architecture of the tracker is needed: from single module to double module in portrait configuration
The overall height of the tracker is more than doubled, with consequent greater effect of external loads on
the stability of the tracker, in particular wind loads.
CONCEPT DESIGN
✓ 2 modules portrait
TRACKER
✓ Total number of modules: 26
CONFIGURATION ✓ Dimension: ≈ 4 m x 14 m
✓ Tracking angle: ± 55°
✓ Improve Wired Communication Control Board and Drive to reduce the length of cables
ELECTRONICS ✓ Develop a “new” Tracker Wireless Control System: SCADA 2° level
✓ Improve a Self-Power System to supply locally and independently groups of trackers
PV TRACKER – DESIGN & CONTROL
Convert Italia
General Topics Speaker Time
Introduction to Tracker Device for PV plant.
Mono axial tracker Concept Design: G. Demofonti 10 min
performances vs reliability
Oct. 28th
PV Tracker – Design and Control
STRUCTURAL DESIGN
(10:00-12:00)
Structural Design of Mono Axial Tracker
Specific Topics:
1. Design Inputs – Approaches - Restrictions
2. Main Codes
3. GOPV project: Goals concerning Tracker Design
Speaker:
Andrea Ricci, Convert
Time: 20 minutes
GoPV Project | 1st TRAINING COURSES
TECHNICAL FOCUS ON FUTURE SOLAR PV SYSTEMS
→ Except for particular cases, in common applications Wind Loads govern the tracker design.
15
Design General Restrictions
General Consideration
Trackers have to be considered as common steel structures and be compliant with civil
regulations such for example EN1993 – Eurocode 3.
➢ Main structures calculation requirement in terms of deformations and resistance have to be
respected.
Aiming error
In all service ranges no plastic deformations are permitted:
➢ Tracking accuracy must be guaranteed in the range of a few degrees (usually around 1° or 2°) of error
throughout the expected life of the project
Module Deflection
➢ PV-Modules have to be considered as independent elements, which do not produce any structural
resistance improvement and which may have their own rotations/displacements.
➢ Commonly it is considered the L/150 limit as a deflection restriction prescribe to prevent failures among
the connection's points (bolts, rivet, clamps, etc).
➢ Piles are one of the most variable elements in tracker designing, since it is affected by all soil-mechanical-
characteristics possible changings.
➢ Currently more and more detailed models for embedded length calculation are requested and eventually
confirmed with pull-out tests.
➢ This is turning out to be a consolidated practice given the uncertainty about the soil properties definition on
large sites.
➢ Omega (Ω) sections maximize the contact surface with the soil, reducing embedment lengths.
➢ Concrete foundations in general are not used.
➢ One of the main standard components scope is to be easily manufactured worldwide and easily adaptable to
different situations.
➢ As for example, the module rails have been developed to be suitable in both configurations: frame and
frameless module installation (currently both available in the market).
→ Same omega shape profiles for both configurations GoPV Project | 1st TRAINING COURSES
TECHNICAL FOCUS ON FUTURE SOLAR PV SYSTEMS
➢ Most of connections are bolted joint, assembled directly in field, whereas welds are realized only into
manufacturing workshop and on small single tracker components (mainly mechanical components).
➢ Due to their complexity (geometrical and in terms of loading condition), many times finite element
analysis and lab testing are required to make reliable calculation and a cost-effective design.
➢ All mechanical elements (KIT) needs a specific design, mainly based on:
✓ the load inputs coming from standard component design (defined by the codes),
✓ Installation and maintenance requirements
✓ Movement and mechanical performances granted along the project life.
➢ Due to their complexity (geometrical and in terms of loading condition), many times finite element analysis
and lab testing are required to make reliable calculation and a cost-effective design.
Since trackers are considered as civil structures, in general a Structural Calculation Report of
tacker for each PV plant must be carried out .
General overview
➢ A dedicated design code focused on tracker don’t exist.
➢ Two main international standards approaches exist dedicated to steel structure and building:
✓ Eurocode
✓ ASCE 7-16
➢ In both code “physics described” always remains the same, they difference, in terms of:
✓ loads and load combinations,
✓ return time of each characteristic variables loads (50 years vs hundreds of years),
✓ difference between the “Service Limits” and “Ultimate Limits”.
▪ Tracker must be designed according to the local regulations, since trackers are considered as civil structures.
▪ Additional requirements coming from the customer must be meet.
o Assumptions too conservative could make a project no-economically favourable: generally studies to derogate single
standard aspects must be made.
o A comprehensive regulation focus on monoaxial tracker is being developed in the IEC–WG9: at the moment, it is only
focused on people safety.
GoPV Project | 1st TRAINING COURSES
TECHNICAL FOCUS ON FUTURE SOLAR PV SYSTEMS
Main issues 1P → 2P
✓ More accurate models for wind loads: Wind tunnel tests and CFD simulation.
NEEDS
✓ Development of a more performing actuator.
25
Design Input – GOPV 2-P Tracker
Oct. 28th
PV Tracker – Design and Control
WIND LOADS and AERODYNAMIC DESIGN
(10:00-12:00)
Structural Design of Mono Axial Tracker:
Wind Loads and Aerodynamic Design
Specific Topics:
1. Wind loads Base Knowledge
2. Wind Loads: Main Codes approach
3. Wind loads evaluation: technical needs & available approaches
4. Wind Loads and Aerodynamic Design: GOPV Project
✓ Wind tunnel – Static tests & Aeroelastic tests
✓ CFD Simulations / Analysis
Speaker:
Andrea Ricci, Convert
Drag D and Lift L forces are defined as function of the airflow velocity and surface width:
𝒄 ∙ 𝟏Τ𝟐 𝝆𝒗𝟐 ∙ 𝑩,
where c represents a coefficient obtained for several angle of attack α in wind tunnel tests;
Drag D and Lift L forces can be considered simultaneously determining force F, perpendicularly to the surface:
𝑭 = 𝒄𝒑 ∙ 𝟏Τ𝟐 𝝆𝒗𝟐 ∙ 𝑩,
Where cp is the “wind pressure coefficient” which changes as a function of the attack angle α. GoPV Project | 1st TRAINING COURSES
TECHNICAL FOCUS ON FUTURE SOLAR PV SYSTEMS
Describing the same phenomenon both approaches depend mainly by the same parameters (such as terrain
topography, roughness,…) and lead both to the calculation of the Peak Pressure.
➢ A code procedure does not adequately describe the wind interaction among
tracker and air flow and represents a conservative approach;
➢ CFD and Wind Tunnel tests are the only way to “fill this gap of knowledge”.
WIND LOADS
WIND TUNNEL TESTS CFD Simulations GoPV Project | 1st TRAINING COURSES
TECHNICAL FOCUS ON FUTURE SOLAR PV SYSTEMS
GOPV Approach:
➢ Wind Tunnel Test, using the “Politecnico di Milano” Wind Laboratory - GVPM,
➢ CFD – Simulations, using ANSY-CFX Software
➢ Collaboration with University of Rome “La Sapienza” and Enginesoft
GoPV Project | 1st TRAINING COURSES
TECHNICAL FOCUS ON FUTURE SOLAR PV SYSTEMS
The University of Rome “La Sapienza” and Enginesoft were involved to support Convert in the develop
CDF studies concerning wind-tracker interaction, especially focused on:
✓ the role of the gap on a two-portrait-modules tracker has on wind loads actions,
✓ how to the wind loads acting on surfaces may change due to for to different angles of attack.
Wind
The wind pressure reduction is around 35% starting from the third row
Wind loads
CFD Simulations - Influence of a multiple tracker array
➢ The influence of a tracker arrays on internal structures it is affected by the GCR (Ground Cover Ratio)
➢ Lower is the row spacing higher is the sheltering effect: positive effect on the pressure on modules
8,50 m – GCR=0,50
Wind Tunnel Test – Wind Static Loads
Wind tunnel laboratory can provide wind pressure coefficients, distinguish among different tracker position, for
different tilt angles and for different wind directions.
Measured parameters
✓ Pressure and moment coefficient vs orientation of modules α,
Results
➢ The WT result is allowing a more accurate plant design, distinguishing among internal and external rows.
➢ Internal rows are around 80 - 85% of the overall structures: the optimization of their design assure a cost reduction.
➢ Nowadays tracker design is heavily focused on aerodynamic instability, especially for the windward rows.
➢ This turns to be the main and more restrictive design issue.
M
Torsional static
instability (Divergence)
α
Galloping
Flutter
Wind Tunnel Test - Aeroelastic instability
Results:
➢ As long as the tracker-flow ensemble can have an overall damping
higher than the forcing in play, the system is in equilibrium.
(*) Note: velocity are referred to 10minutes averaged values measured at 10m height above ground.
To scale at gust factor a multiplier x 1,46 is suggested
GOPV 44
Wind Tunnel Test - Aerodynamic
➢ Mass ratio,
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