cpv summit usa 2009
TRANSCRIPT
TITAN TRACKER: the new concept
CPV Summit USA 2009
Carlos García García
EngineerManager - TITAN TRACKER
Hotel Sheraton Mission Valley – San DiegoFebruary 3rd – 4th, 2009
( Área reservada a imagen )
A CHANGE IN CONCEPT
� In 1968 Dick Fosbury invented a new way to do the high jump.
� He was the first athlete who used this new technique which led to him winning the gold medal in the Mexico Olympics
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winning the gold medal in the Mexico Olympics
� In this way, he beat Russian athletes who had been improving the conventional technique during previous years.
� Nowadays, all the athletes use the “Fosbury” technique.
CONTENTS
1. BACKGROUND
2. RELIABILITY
3. ACCURACY
4. PROFITABILITY
5. BUSINESS MODEL5. BUSINESS MODEL
6. REFERENCES
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1. BACKGROUND1.1. Evolution
� At first, solar parks used FIXED systems
� Gradually, different systems appeared, with TRACKING:
� 1-AXIS tracking� 1-AXIS polar tracking� 2-AXIS tracking (mounted-pole)� 2-AXIS tracking (TITAN TRACKER)
•Mounted-pole
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� 2-AXIS tracking (TITAN TRACKER)
� Mounted-pole system is the most common one but lacks reliability because of its own conceptual characteristics
� Due to inertia and a lack of alternatives, despite its shortcomings, which were even more obvious for CPV, an attempt was made to use mounted-pole systems in CPV
•TITAN TRACKER
1. BACKGROUND1.2. What would the ideal tracker be for CPV?
� Solar trackers are critical elementfor CPV installations. CPVtechnology needs trackers andvice versa.
� Nowadays, modules are beingmade that are adapted to theprecision of the trackers and notthe other way round.
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the other way round.
� So what would the ideal trackerbe like?
RELIABLE
ACCURATE
COST-EFFECTIVE
� TITAN TRACKER fulfils theserequirements.
TITAN TRACKER MOUNTED-POLE
ACCURACY > 0.01º < 0.1º
RELIABILITY ≈ FIXED << FIXED
COST << >>
2. RELIABILITY2.1. The concept of TITAN TRACKER
� What sort of structures have demonstrated reliability during the history of engineering in the long term?
� Eiffel tower
� Electrical pylons
� Many examples
The Eiffel tower was built in
1889 during the Expo, with a
weight of 7,300 tons and 300 m
of height and was considered
the tallest construction of its
time
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� All these constructions have been made using 3D truss using screws, exactly as is done in TITAN TRACKER
� This manufacturing technique and the geometry of the design mean that TITAN TRACKER is practically as reliable as a fixed structure
2. RELIABILITY2.2 Structure based on 3D truss
� The support structure is based on a 3D truss using mainly cold-formed sections of steel:
� Cold-formed and rolled
� Normalized and standardized
� Screwed
3D truss based on cold-formed sections
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� Screwed
� Hot galvanized
� These cold-formed sections have a perfectly tabulated and tested behavior under extreme loads
“C”-type cold-formed section
2. RELIABILITY2.3 Structure using screws
� Structure based on screws, no welding, except when strictly necessary
� In this way, the following problems, which are usual in welding, can be avoided:
� Early corrosion� Residual strain
Detail of different joint elements
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� Residual strain� Specialized staff� Discontinuous galvanizing� X-raying of welding
TITAN TRACKER MOUNTED-POLE
STRUCTURE USES SCREWS WELDED
Screws, flanges and rivets
2. RELIABILITY2.4 Five supports
� It is an obvious but crucial issue to assure reliability: Five supports
� 1 fixed support in the center (A)
� 2 non-driven rolling supports (B)
� 2 driven rolling supports (C)
Fixed supportA C
B
C
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Fixed supportA
B
“Driven” support
CC
“Non-driven” supportTITAN TRACKER MOUNTED-POLE
SUPPORTS 5 1
2. RELIABILITY2.5 No bending moments or embedding
� The structure works without bendingmoments, only compressions on theground on the rolling supports andcompressions, traction and cuttingin the centre
� There is no embedding
� If we assume the presence of a load, q(wind effect) applied on the panel board ina vertical position, that load is transmittedto the ground through the structure andshared at the supports as the followingtypes of stress:
� Horizontal cutting on support C
� Compression on support A
� Traction on support C
TITAN TRACKER MOUNTED-POLE
BENDING MOM. NO YES
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WIND (q)
A C B A C B
Decomposition of the wind effect Equivalent System
� Traction on support CEMBEDDING NO YES
FOOTPRINT << >>
•<>
2. RELIABILITY2.6 Minimal deformations in the structure
� The panel board is tightly secured to the structure:
� On the top bar of non-deformable truss
� At one point (pusher- spindle)
� For this reason, with TITAN TRACKER all possible deformations are less than about llll2, where llll would be a characteristic dimension.
Horizontal bar
Point- pusher (spindle)
TITAN TRACKER support elements: one line and one point
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be a characteristic dimension.
� In the mounted-pole, the panel board is supported only at two points situated on a projecting beam and one of those points is also a mechanism.
Point
TITAN TRACKER MOUNTED-POLE
PANEL SUPPORT BAR + POINT POINT
DEFORMATIONS < llll2 llll 3
ONE-SUPPORT FAMILY support elements: only one point
TITAN TRACKER support elements: one line and one point
2. RELIABILITY 2.7. Structural calculations
� Structural calculations with windcoefficients according to thestandard NBE-EA-95, Basic Standardfor Steel Structures in Buildings,much stricter than the EU MachinesDirective:
� Calculations under unbalanced conditions in
Structural calculations of TITAN TRACKER
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� Calculations under unbalanced conditions invertical from wind loads
� Calculations under unbalanced conditions inhorizontal from wind load
� Calculated for the static loads in anyposition under the following windspeeds :
� 125 Km/h (78 Mph) for FPV
� 122 Km/h (76 Mph) for CPV.
2. RELIABILITY2.8 High structural resistance
� High structural resistance, at any position of the panel boards, even in vertical.
� (1) Elevation angle formed by the panel (modules) and the vertical plane (see drawing) That way, we consider different positions 80º, 45º and 10º (the most unfavorable case)
� (2) Component is the part of the tracker considered for the calculations: the board (modules) and the body
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the calculations: the board (modules) and the body (support structure of the boards)
� (3) Average static wind load calculated for each m2 of the module in Kg/m2
� (4) Vertical imbalance in wind load considered in Kg/m2
� (5) Horizontal imbalance in wind load considered in Kg/m2
� (6) Horizontal static wind in km/h generating the average load give on each m2 of the solar module with the indicated inclination (based on wind coefficients of the Spanish standard NBE-EA-95)
� ≈ means that the data are only extrapolated from other detailed calculations. (*) With the board in the indicated position, it would support this static wind and also
the structure would support it
(**) With the board in the indicated position, a static wind of 216 Km/h would
exhaust it
2. RELIABILITY2.9. High structural resistance
� High structural resistance, with any position of the panel boards, even vertical.
� Vertical unbalanced wind loads
� Horizontal unbalanced wind loads
Horizontal unbalanced wind load
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Vertical unbalanced wind load
2. RELIABILITY2.10 Independent driving and structure
� The driving and structure are completely independent.
� In this case, with TITAN TRACKER each element fulfils its function, the driving system just moves and the structure just supports.
Support
SupportDriving
Support Driving
Support
Support
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� In the mounted-pole systems, the driving system also acts as a support and it is even the joining element between the panel board and the structure.
Support
Driving and
support
Driving
Stress in the driving
Support
TITAN TRACKER MOUNTED-POLE
DRIVING and STRUCTURE INDEPENDENT DEPENDENT
STRESS << >>
MOUNTED-POLE: driving and structure are DEPENDENT
TITAN TRACKER: driving and structure are INDEPENDENT
2. RELIABILITY2.11 No hydraulic driving
� The TITAN TRACKER driving is made using no hydraulics:
� Elevation: 2 electrical motor gears 120 W and pinion-toothed wheel with spindle (CPV)
� Azimuth: 2 electrical motor gears 90 W and pinion-toothed wheel. 1 drive-wheel is also an option.
�
Azimuth driving: pinion toothed-wheel
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� This prevents the typical problems with hydraulic elements such as:
� Loss of pressure� Loss of oil� Replacement of elements� Continuous maintenance� Low temperatures
Elevation driving: pinion toothed-wheel with spindle
TITAN TRACKER MOUNTED-POLE
HYDRAULICS NO YES
2. RELIABILITY2.12 High resistance rolling supports
� TITAN TRACKER uses high-resistance technical wheels:
� Core made of steel
� Coating of high-resistance polyurethane
� Maximum capacity
Detail of a non-drive-wheel
Steel cores
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� Maximum capacity
� High resistance to abrasion
� Minimum deformations under compression
� High stock availability
� Global suppliers
Detail of a drive-wheel
3. ACCURACY3.1 General issues
� The accuracy of TITAN TRACKER is determined by the effect of the:
� Control system
� Geometry of the driving
� Structure
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� TITAN TRACKER is designed to achieve extremely high accuracy, greater than 0.01º.
TITAN TRACKER MOUNTED-POLE
ACCURACY > 0.01º < 0.1º
3. ACCURACY3.2 Control system
� The control system sends orders to the motor gears at any time.
� TITAN TRACKER uses a control solution specific for its typology: closed loop strategy based on algorithm and optical sensor
Optical sensor
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algorithm and optical sensor
� The control system has a characteristic accuracy of:
� 0.010º on cloudy days (analytical calculation)
� 0.006º on sunny days (optical sensor)
3. ACCURACY3.3 Control system
� The Master control transmits to each tracker the results of the solar positioning calculations based on the data of latitude, longitude and solar time.
� The Slave control of each tracker analyses the information and takes the
� The concept of TITAN TRACKER and its structural geometry and driving system allow for easy self-calibration of the system according to parameters that are customized by the user
� The accuracy and other parameters are also easily customized by the user
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analyses the information and takes the appropriate decisions based on the solar radiation measured by the optical sensor:
� If low (cloudy day) the sun is tracked based on the master control data
� If high (sunny day) it automatically tracks the sun based on the work of its optical sensor
also easily customized by the user
� Valid for any latitude
3. ACCURACY3.4 Driving with a long lever arm
� The driving system (azimuth) has a lever arm length of 10,000 mm (motor-gears on the outer sides) in the case of TITAN TRACKER
� The concept of mounted-pole systems uses only a lever arm length of about 200 mm. (50 times less)
�
Accuracy of the driving in azimuth
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� The accuracy is directly proportional to the length of the lever arm.
Length of lever arm 10,170 mm
Motor-gear
Motor-gear
TITAN TRACKER MOUNTED-POLE
LEVER ARM LENGTH 10,000 mm. 200 mm.
3. ACCURACY3.5 Continuous movement
� With TITAN TRACKER, the long lever arm makes it possible to make a CONTINUOUS movement (azimuth) with only one start and stop every day
� In the case of mounted-pole systems the movement is DISCONTINUOUS, with thousands of starts and stops
TITAN TRACKER movement in azimuth (sun at 15º/h)
Deviation (º)
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with thousands of starts and stops every day. This leads to great stress in the mechanisms and seriously compromises its reliability.
� TITAN TRACKER is totally electrical and requires minimum power since it operates from the outer sides.
3. PRECISION3.6 Comparative tracking
Deviation (º)
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TITAN TRACKER movement azimuth/elevation MOUNTED-POLE movement azimuth/elevation
TITAN TRACKER MOUNTED-POLE
MOVEMENT CONTINUOUS DISCONTINUOUS
CYCLES/DAY (*) 1 12,000
•(*) Cycles / day in azimuth with an accuracy of 0.01 at 40º latitude
3. ACCURACY3.7 High structural stability
� High structural stability:
� Structure based on 3D truss with high rigidity which allows minimal deformations
� Under static wind speed of about 80 Km/h(50 Mph) the structure has a maximum deformation of about 10 mm in the corner
Illustration of the TITAN TRACKER structure
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deformation of about 10 mm in the corner of the panel boards, which is equivalent to a deviation of only around 0.05º
� Mounted-pole systems do not work under conditions of wind speed higher than 35-40 Km/h (22 Mph)
TITAN TRACKER MOUNTED-POLE
STOW POSITION Adjustable 40 Km/h
4. PROFITABILITY 4.1 Dual-axis tracking (flat-plate)
� TITAN TRACKER can obtain up to 45% more energy than fixed systems, 40ºN latitude (Spain)
� Complete dual-axis tracking
� Minimum zenithal angle of 10º (1º in CPV)
� TITAN TRACKER: Starts from an elevation of 10º
αααα=10º
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� Most mounted-pole systems (flat-plate) have only partial dual-axis tracking since in most cases they start from an elevation of 30/35º
TITAN TRACKER: Starts from an elevation of 10º
MOUNTED-POLE: Starts from an elevation of 30/35º
αααα=30º/35ºTITAN TRACKER MOUNTED-POLE
ELEVATION from (flat-plate) 10º 30/35º
2-AXIS TRACKING (flat-plate) COMPLETE PARTIAL
4. PROFITABILITY 4.2. Low-cost foundation
� Since the foundation does not operate with bending moments, it is very small, and there are therefore important savings in material.
� Formworks are not needed, and thereby, it is not necessary to have specialized staff.
Anchor bolts
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Detail of the foundation
TITAN TRACKER MOUNTED-POLE
STEEL 1 Kg/m2 PV 5,5 Kg/m2 PV
CONCRETE 60 liters/m2 PV 95 liters/m2 PV
Consumption of materials
Mod. 122-219 ATR PRECISION
Concrete Steel
Track 9’60 m3 147 Kg
Footprint 3’90 m3 50 Kg
Total 13’50 m3 197 kg
4. PROFITABILITY 4.3. Low-cost foundation
� The plot does not require any excavation work (no ditches) and it is formed directly on the ground.
� It is possible to an uneven surface in the raceway (drops in level)
� ± 20 mm. (flat-plate)
� ± 10 mm. (CPV)
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� ± 10 mm. (CPV)
Plot preparation
4. PROFITABILITY 4.4 Capacity and use of the land
� High capacity:
� 211 m2 (flat-plate) expandable to 219 m2
� 219 m2 (CPV)
� Optimal balance between width and height (flat-plate) to make better use of the land with no shade In latitude 40º N and with αααα=11,5º E-W and
Detail of the separation between trackers
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40º N and with αααα=11,5º E-W and αααα=16,5º N-S the recommended separation between trackers is:
� 44 m E-W direction and� 31 m N-S direction
� For flat photovoltaic plates, in latitude 40º N, the ratio for land use is 6.46 m2 land/m2 panel, which is optimum for complete dual-axis tracking
Detail of the separation between trackers
4. PROFITABILITY4.5 Structure made by CNC
� TITAN TRACKER has been designed to be manufactured mainly by CNC machines. For instance, cold-formed sections alone represent more than 70% of the total weight.
� CNC manufacturing provides a very high and flexible capacity, and even more traceability in the process
CNC machine in operation
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� Any metalworking firm can manufacture TITAN TRACKER with standard facilities and without specialized staff.
TITAN TRACKER MOUNTED-POLE
STRUCTURE USES SCREWS WELDED
MANUFACTURING CNC ?
4. PROFITABILITY4.6 Pre-mounted structure
� TITAN TRACKER is usually supplied in the form of pre-mounted (panels already joined by screws in the plant)
� This makes transport easier and reduces assembly time on the site
� For assembly, only two non-specialized operators are required, assisted by a standard crane
Pre-assembly of TITAN TRACKER in the plant
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crane� The transport ratio is between 1 and 2 trackers
by standard truckOn-site assembly of TITAN TRACKER
4. PROFITABILITY4.7 Screw-less module installation (flat-plate)
� TITAN TRACKER uses any kind of PV module technology, brand and dimensions
� The installation of the modules requires no screws in the case of a flat-plate. It is done on belts that are anchored with sliding staples, of the
Modular installation of TITAN TRACKER
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anchored with sliding staples, of the necessary width for the plate to be assembled.
� Since it requires no screws, assembly costs are reduced as well as the possibility of accidents to operators.
4. PROFITABILITY 4.8 Standard supply and maintenance-free
� The rest of the components are standard and low cost with a tested and fully guaranteed performance:
� Machined parts (pinion-toothed wheels, spindle, etc)
� Cables, screws, rivets� Electrical panel
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� Electrical panel
� Moreover, maintenance-free components are used at the friction points (bearings, flanges, etc.)
� All these components are easily accessible and can quickly be replaced if necessary, since the driving and structure are completely independent.
4. PROFITABILITY 4.9 Summary
� More energy production: complete elevation with start from 10 degrees (flat-plate) up to 45% more than fixed systems (40º latitude)
� More stiffness: five supports, supporting static wind speeds of up to 125 km/h (78 Mph) in any position
� More Reliability: using screws and galvanized 3D structure, no hydraulics
� Independence between structure and driving � Independence between structure and driving system: crucial for reliability
� High capacity: 219 m2 of net surface for cpvmodules
� Low-cost foundation: savings in materials (80% in steel and 35% in concrete)
� Easy & quick installation: screw-less module installation (flat-plate)
� Reduced maintenance: using technical materials maintenance-free
� Extreme accuracy, greater than 0.01 degrees (CPV)
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5. BUSINESS MODEL5.1 General issues
� Licensing agreements:
�For construction or projects
�For territory/country
�
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� Direct supply:
� Supply of solar trackers EX WORKS
� Transport to the site
� Installation (*) as an option
•(*) It can also be installed by the client itself
5. BUSINESS MODEL5.2 Licensing agreement
� Our business model is based mainly on licensing agreements, the most cost-effective option in order to develop a pipeline of solar projects.
� General issues of the agreement:
� Non exclusive right to manufacture, use and sell
� Territory or specific project
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� Territory or specific project
� Valid for 5 years, with an extension option
� Cost model:� Fixed initial payment
� Royalty per tracker
� If you are interested, please ask for further details of the “Basis of Agreement”
“Basis of Agreement” document
6. REFERENCES
� The TITAN TRACKER concept was created in October 2006
� Nowadays, solar installations exist that use TITAN TRACKER with more than 15 MW in operation.
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� TITAN TRACKER has just completed a CPV project in the ISFOC installation www.isfoc.com
Solar Park in Eruela, Pedro Muñoz (Ciudad Real) Spain
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The value of technology
•Carlos García•Sales Manager •[email protected]•+34 608 23 25 50
New website: www.titantracker.com