TRACKER SYSTEM AND METHOD
An actuator assembly system array. The actuator assembly system array comprises a plurality of separate actuator assembly systems arranged in a row, with each actuator assembly system of the plurality of separate actuator assembly systems comprising: an array of one or more solar panels; a plurality of fluidic actuator assemblies; and a plurality of posts respectively coupled to and extending from the plurality of fluidic actuator assemblies. The actuator assembly system array further includes a fluidic control system comprising a plurality of fluid lines extending between and fluidically coupling the plurality of separate actuator assembly systems in series.
This application is a continuation of U.S. patent application Ser. No. 16/818,346, filed Mar. 13, 2020, which is a continuation of U.S. patent application Ser. No. 16/134,844, filed Sep. 18, 2018, which is a continuation of U.S. patent application Ser. No. 15/012,715 filed Feb. 1, 2016, which is a non-provisional of and claims the benefit of U.S. provisional patent application 62/110,275 filed Jan. 30, 2015 entitled “FLUIDIC ACTUATOR SYSTEM AND METHOD,” each of which applications is hereby incorporated by reference in its entirety and for all purposes.
This application is also related to U.S. application Ser. Nos. 14/064,070 and 14/064,072, both filed Oct. 25, 2013, which claim the benefit of U.S. Provisional Application Nos. 61/719,313 and 61/719,314, both filed Oct. 26, 2012. All of these applications are hereby incorporated herein by reference in their entirety and for all purposes.
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCHThis invention was made with Government support under contract number DE-AR0000330 awarded by DOE, Office of ARPA-E. The Government has certain rights in this invention.
BACKGROUNDConventional solar panel arrays are static and unmoving or configured to track the sun throughout the day to provide optimal capture of solar energy. Static solar panel arrays are often undesirable because they are unable to move and accommodate the changing angle of the sun during the day and throughout the year.
On the other hand, conventional moving solar panel arrays are also often undesirable because of their high cost of installation, the complexity of the mechanisms that move the solar panels, and the relatively high energy cost associated with actuating the solar panels. For example, some systems include motors that move individual solar panels or groups of solar panels. Such motors and other complex moving parts are expensive to install and maintain.
In view of the foregoing, a need exists for an improved solar panel actuation system and method in an effort to overcome the aforementioned obstacles and deficiencies of conventional solar panel actuation systems.
It should be noted that the figures are not drawn to scale and that elements of similar structures or functions are generally represented by like reference numerals for illustrative purposes throughout the figures. It also should be noted that the figures are only intended to facilitate the description of the preferred embodiments. The figures do not illustrate every aspect of the described embodiments and do not limit the scope of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTSSince currently-available solar panel actuation systems are deficient, a fluidic actuation system as described herein can prove desirable and provide a basis for a wide range of applications, such as efficiently and cost-effectively moving solar panels about one or more axes. This result can be achieved, according to one embodiment disclosed herein, by a bellows 100 as illustrated in
Turning to
The bellows 100 can be made of any suitable material including polymers, copolymers, terpolymers, and polymer blends (both miscible and immiscible), thermoplastic elastomers, thermoset polymers, thermoplastics, block copolymers, graft copolymers, polymer composites, and the like. Specific examples include high-density polyethylene (HDPE), cross-linked polyethylene (PEX), polypropylene (PP), low-density polyethylene (LDPE), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polystyrene (PS), polyetherimide (PEI), polyphenylene ether (PPE), thermoplastic polyurethane (TPU), thermoplastic elastomers (TPE), polycarbonate, acrylic, nylon, and the like. In various embodiments the bellows 100 can be made of different materials defined by layers or additives. For example, one embodiment can comprise a bellows 100 having an external carbon-black doped HDPE layer for UV resistance, over a more rigid structural PET layer, and with a third inner-layer of HDPE, LDPE, or the like, which can act as a flexible internal bladder. In other embodiments, the bellows 100 can be made of two or more materials in sequence. For example, one embodiment may comprise a bellows with sequentially alternating HDPE and PP convolutions, or the like.
In some embodiments it may be desirable for the bellows 100 to comprise one or more ultra-violet (UV) stabilizer, UV-absorber, anti-oxidant, thermal stabilizer, carbon black, glass fill, fiber reinforcement, electrostatic dissipater, lubricant concentrate or the like. Materials of the bellows 100 can be selected based on a desired manufacturing technique, bellows strength, bellows durability, range of motion, compliance, sun-resistance, temperature resistance, wear resistance and the like. In some embodiments, where the bellows 100 is employed in a location that experiences sun exposure, it can be desirable to include a protective UV coating or UV stabilizer in the bellows 100. Alternatively, the bellows 100 can be covered in a shroud or other protective surrounding.
Bellows 100 can be made via any suitable manufacturing process, including extrusion blow-molding (EBM), injection stretch blow-molding (ISBM), multi-layer blow-molding, co-extrusion blow molding, co-injection blow molding, suction blow-molding, 3-D blow-molding, sequential co-extrusion blow-molding, vacuum forming, injection molding, thermoforming, rotational molding, process cooling, three-dimensional printing, dip modeling or the like.
Bellows 100 can be any suitable thickness in various portions including about between 0.002 inches and 0.125 inches, and about between 0.0005 inches and 0.25 inches. In various embodiments, the thickness of various portions of the bellows 100 can be selected based on a desired manufacturing technique, bellows strength, bellows durability, range of motion, compliance, sun-resistance, temperature resistance, and the like.
In various embodiments, the hollow bellows 100 can be configured to be inflated and/or deflated with a fluid (e.g., air, a liquid, or the like), which can cause the bellows 100 to change size, shape and/or configuration. Additionally, the bellows 100 can be deformable such that the bellows 100 can change size, shape and/or configuration. For example
The bellows 100 can change between the first and second configuration in various suitable ways. For example, the bellows 100 can naturally assume the first configuration (
Additionally, the bellows 100 can be in the second configuration (
In some embodiments, it may be desirable for the convolutions 110 to engage in a contacting and/or rolling manner in various configurations. For example,
Although certain example embodiments of bellows 100 are illustrated herein, these example embodiments should not be construed to be limiting on the wide variety of bellows shapes, sizes and geometries that are within the scope and spirit of the present invention, including bellows 100 illustrated in
Turning to
The flexure 350 may be captured by the washers 340 or support panels 330, thereby constraining them to constituent bellows 100 of the actuator assembly. For example,
In various embodiments, the top and bottom heads 116, 121 of the bellows 100 can reside within respective coupling-holes 311, 321 of the top and bottom plates 310, 320. In other words, the bottom-heads 116 of the bellows 100 can extend into and couple with bottom coupling-holes 311 of the bottom-plate 310 and the top-heads 121 of the bellows 100 can extend into and couple with top coupling-holes 321 of the top plate 320. In various embodiments, the truncations 117, 121 of the top and bottom heads 116, 121 can correspond to and couple with the shape of the coupling-holes 311, 321 so as to reduce or prevent rotation of the bellows within the coupling-holes 311, 321. Additionally, inflation of the bellows 100 can expand the top and bottom heads 116, 121 so that the top and bottom heads 116, 121 further engage and couple with the coupling-holes 311, 321. Retaining features may be formed into the bellows 100, including at the top and bottom heads 116, 121 to index or to engage with the top plate, manufacturing jig, test fixture or the like. (e.g.,
In various embodiments, the top and bottom plates 310, 320 can comprise any suitable material, including a polymer, metal, wood, composite material, a combination of materials, or the like. Additionally, although a specific configuration of the top and bottom plates 310, 320 is shown herein, further embodiments can include plates having any suitable configuration. For example, various suitable embodiments of the top and bottom plates 310, 320 can be configured to interface with the bellows 100 and also distribute a point load from the flexure 350. Plates 310, 320 can also comprise and leverage existing structures, such as mounting piles, spanning beams or the like.
Top and bottom plates 310, 320 can be made in any suitable way. For example, in one embodiment, a cold rolling process can be used in conjunction with metal stamping to create a C-channel plate with the appropriate interfacing features for the top and bottom plates 310, 320 as described herein. Plates 310, 320 may also be formed of standard hot and cold rolled sections. Plate features may be die cut, CNC punched, laser cut, waterjet cut, milled or any other suitable subtractive manufacturing method. A plate 310, 320 may also comprise multiple standard sections or custom formed parts. Plates of this nature may be bonded together with a variety of fasteners including rivets, nuts and bolts, welds or the like. For example, top and bottom plates 310, 320 in accordance with a further embodiment are illustrated in
In another embodiment, manufacture of the top and bottom plates 310, 320 can include the creation and processing of composite panels. For example, a composite top or bottom plate 310, 320 can comprise a multi-material sandwich plate that takes advantage of a light weight and inexpensive core material and the stiffness and strength of thinner sheets of skin material that can adhere to either side of the core substrate. Such composite paneling is often used as high stiffness, high strength, low weight, low cost flooring or construction material.
In some embodiments, a composite top or bottom plate 310, 320 can comprise a honeycombed polymer core that can take compressive and shear loads, sandwiched between two metal skins that can bear the high tensile stresses caused by bending. It is possible to bind the top or bottom plate 310, 320 with bolts, heated staked columns, ultrasonic welding, or the top or bottom plates 310, 320 can be assembled with an adhesive.
Utilizing metal stamping, top and bottom plates 310, 320 can be produced having multi-planar curvature stamped metal skins and an injection molded polymer core. The structure that such geometry creates can give greater stiffness to a top and bottom plate 310, 320 per the volume of material used and provides an opportunity to cut down on the expensive metal skin material. Stiffening features such as ribs, bosses, deep drawn pockets and webbing can also be incorporated into the design of top and bottom plates 310, 320 in some embodiments.
In some embodiments, the plates 310, 320 need not be single planar elements. For instance, the bottom plate 320 can be two individual surfaces each parallel to the two opposing flanges of the post 710 such that the bellow interfaces point 180 degrees away from one another rather than 0 degrees as in previous configurations. The body of each of the bellows 100 then would bend through 90 degrees to meet the top plate 310 when the actuator is level. In this case, the plate may not be a bending element, but instead be compressive. The plates 310, 320 may also take a V-shape with major angle dictated by the desired range of motion of the actuator.
For example,
In various embodiments, it can be desirable to constrain the bellows 100 from buckling and/or squirming as the bellows 100 are inflated and/or deflated within the actuator assembly 300 or as external loads are applied, and it may be desirable to constrain the bellows 100 in relation to adjacent bellows 100 and radially about the flexure 350. Accordingly, in some embodiments, the bellows 100 can be constrained with one or both of the constraint-panels 330 and washers 340. For example, as shown in
The washers 340 may be fixed in position about the neutral axis of the flexure as an alignment control measure. This may be accomplished with insert blocks, adhesives, features molded into the washers, flexure or plate. These items may be part of pre-produced sub assembly, or attached after shipping to the installation location. In some embodiments, these items may be designed to serve multiple purposes including: act as hard stops, limit lateral and transverse bending, bear dead and design loads for instances where bellows are unpressurized or under-pressurized. In one such embodiment, for a single axis configuration, blocks with flanges tapered to fit the range of motion of the actuator may be inserted between the constraining panels and capturing the central flexure. These blocks may be placed between two flexures in the single axis set up, or to the outside of them. These blocks may be made of polymer, solid or bent sheet metal, or any other suitable material and formed in any suitable manner. For example, one embodiment of a flexure spacer 3000 is illustrated in
Although the actuator assembly 300 of
In various embodiments, the flexure 350 can be a tensile flexure that bears antagonistic forces of the actuator assembly 300 as the bellows 100 are inflated and/or deflated, while also providing for bending or flexing in response to movement of the actuator assembly 300 as discussed in further detail herein. In some embodiments, the flexure 350 can comprise a flexible galvanized steel wire rope that is coupled to the top and bottom plates 310, 320 via crimped Nicopress fittings or any other suitable wire rope fitting. In further embodiments, the flexure 350 can comprise a universal ball joint, a fiberglass rod, a Spectra cord, a Dyneema cord, a spring steel flexure, a pivot flexure, a tetrahedral linkage, or the like. Additionally, there may be multiple flexures. For example, two tensile flexures are used in a single axis configuration.
In another embodiment, as shown in
An actuator assembly 300 can be assembled in various suitable ways. For example,
In block 513, constraints such as the constraint-panels 330 and/or washers 340 can be applied to the bellows 100, and in block 514 the top plate 320 is applied to the top end 120 of the bellows 100. For example, as discussed herein, the top-heads 121 of the bellows 100 can be inserted into respective coupling holes 321 of the top plate 320. In block 515, the bellows 100 are compressed and the flexure 350 is coupled with the top plate 320. For example, in some embodiments, the flexure 350 can be coupled via a Nicopress fitting, via swaging, via a Spelter socket, or the like.
An actuator assembly 300 can also comprise snap-in connections, twist-in connections, one way push-in barb connections, toggle locks or any other suitable mechanism or connection to facilitate quick and inexpensive assembly of an actuator assembly 300. For example, flexure coupling slots 2500, 2600, 2700, 2800 are illustrated respectively in
In another example, a swivel capture 3150 is illustrated in
In some embodiments, the actuator assembly 300 can be constructed with an automated assembly process. For example,
The method 520 includes an inner washer attachment step that includes interior washers being threaded over the crimp and onto the wire flexure 350. The flexure 350 is also twisted to lock the washers into place.
The method 520 includes a bellows integration step where outer washers are placed around the bellows 100 and heat staked to the interior bellows 100. The bellows 100 are now attached to each other and the tensile member via the constraining washers.
Turning to
The actuator assembly 300 can also assume example configurations B and C. In such configurations B, C, the top-plate 320 is in a configuration where the plane TO of the top-plate 320 is no longer parallel to the plane BA of the base plate 310. For example, in configuration B, a first bellows 100A is expanded compared to the configuration A, whereas a second bellows 100B is compressed compared to configuration A. The central axes CE of the first and second bellows 100A, 100B become curved. Accordingly, the relative expansion and compression of the first and second bellows 100A, 100B in configuration B rotates the plane TO of the top plate 320 to the right. In such a configuration, the first bellows 100A can be more inflated compared to the first configuration A, and the second bellows 100B can be less inflated compared to the first configuration A.
In contrast, in configuration C, the second bellows 100B is expanded compared to the configuration A, whereas the first bellows 100A is compressed compared to configuration A. The central axes CE of the first and second bellows 100A, 100B are curved. Accordingly, the relative expansion and compression of the first and second bellows 100A, 100B in configuration C rotates the plane TO of the top plate 320 to the left. In such a configuration, the second bellows 100B can be more inflated compared to the first configuration A, and the first bellows 100A can be less inflated compared to the first configuration A.
Accordingly, by selectively inflating and/or deflating the bellows 100 of the actuator assembly 300, the plane TO of the top-plate 320 can be moved to various desired positions. In embodiments having four bellows 100 as shown in
In one application, as illustrated in
In a second embodiment 700B, as shown in
Although various example embodiments herein describe use of an actuator assembly 300 with solar panels 705, in further embodiments, an actuator assembly 300 can be used to actuate or otherwise move any other suitable object, including concentrators, reflectors, refractors, and the like.
In further embodiments, the actuator assembly 300 can comprise one or more hard stop (not shown) that can be configured to prevent the actuator assembly 300 from over-extending. For example, in some embodiments, the actuator assembly 300 can comprise one or more tensile rope or webbing coupled to and extending between the top and bottom plates 310, 320. In another example, positive bosses can be provided as part of the actuator assembly 300 or proximate to the actuator assembly 300 such that contact with the bosses constrains the range of motion of the actuator assembly 300. In various embodiments, such hard stops can be beneficial for preventing damage to the actuator assembly 300 in high winds or exposure to other forces that might over-extend the actuator assembly 300. Pressurizing against a hard stop may also prevent excitation of destructive resonant frequencies induced by oscillatory loads (such as wind). In some embodiments, it can be beneficial to stow the actuator assembly 300 against a hard stop when exposure to undesirable forces is anticipated (e.g., during a storm, or the like). These hard stops can also have a locking feature in order to stop all movement of the tracker when hit. This can serve as a stow mechanism that will further prevent damage to the tracker in a high wind event.
In some embodiments, a two-axis actuator assembly 300 can include a number of hard stops, for example eight natural stops (e.g., at N, NE, E, SE, S, SW, W, NW). As discussed in more detail herein, a single axis actuator assembly 300 can include two hard stops at two maximums of its range of motion. In further embodiments, the actuator assembly 300 can be stowed by raising the pressure of all bellows 100 in the actuator assembly 300 to increase the overall stiffness of the actuator assembly 300. Hard stops can also be locking, so that the stopping mechanism restricts movement in any direction, in order to stow the tracker securely. The locking mechanism can be actively or passively activated when the tracker reaches the hard stops. The locking mechanism can be activated when the tracker is at the extreme of any direction of its motion, or when it is at an intermediate point, for example, when the actuator is flat.
In one example embodiment, as illustrated in
Stow, lockouts or hard stops can be provided in various suitable ways in accordance with further embodiments. For example, in one embodiment, there can be a separate actuator lockout for purposes of stow. For example, a separate small bellows can be used to actuate a locking mechanism that rigidly, or near rigidly, fixes and actuator assembly 300. In one embodiment, such a mechanism can comprise a pin that engages a corresponding hole or slot, or such a mechanism can comprise multiple pins or toothed arrangements that engage corresponding features enabling multiple locking positions. In another embodiment, such a mechanism can comprise corresponding brake pads that enable continuous locking independent of tracker position. Off-normal loading can also be used to engage a locking mechanism in accordance with some embodiments.
In some embodiments, a transverse plate tilt can be used for lock out, stow or the like. For example, using asymmetric application of springs on flexures, a transverse angle can be piloted by actuator force to engage a lockout for high load and/or low load situations. Collective bellows pressure above or below the corresponding flexure with spring force can thereby be used to engage a locking mechanism that fixes the tracker position for the purposes of stow. Off normal loading can also be used to engage the locking mechanism in accordance with some embodiments.
For example,
In further embodiments, a bar-linkage lockout can be used to stow or lock an actuator assembly 300. For example, in one embodiment, an actuator piloted four bar linkage can be used to lockout tracker motion. In such an embodiment, An over center four bar linkage between top and bottom plates 310, 320 can be used to fix the actuator assembly 300 position for the purpose of stow, and the like. Such a mechanism can be actuated by an external actuator, collective bellows pressure, off normal loading, or the like.
One example embodiment of a bar-linkage lockout mechanism 4300 is illustrated in
The shaft 4310 is illustrated in a first configuration in
In further embodiments, a flexure extension lock out 4500 as illustrated in
In addition to a two-axis actuator assembly 300 as illustrated in
Other methods of constraining the inner convolutions of the bellows 100 can be present in further embodiments. For example, the bellows 100 can be constrained with a flexible tensile rope, cord, or string that wraps around the inner convolutions of the bellows 100 and connects adjacent bellows 100, in lieu of or in addition to washers and constraint panels. For example,
Additionally, a flexure 350 can extend between the bottom and top plates 310, 320 and be coupled to the base plate 310 via heads 953. In some embodiments, the flexure 350 can extend between the bottom and top plates 310, 320 via two runs 952 on opposing sides of a crown portion 952 that extends along the top plate 320 as illustrated in
Still referring to
Additionally, the actuator assembly 300 can comprise a damper 905 as illustrated in
In further embodiments, the damper 905 can be configured in any suitable way. For example, the damper 905 can be coupled to the top and bottom plate 310, 320; the damper 905 can be coupled to the bottom plate 310 and the second support 922; or the like. In some embodiments, the damper 905 can comprise an air/gas spring, oil dashpot, or the like. In further embodiments, the bellows 100 can be filled with a fluid such as water, or the like, to generate a suitable damping effect. In some embodiments, specifically in some embodiments of friction-based pivot dampers, the dampening coefficient may be modulated by varying the collective force applied by the bellows. By increasing collective bellows pressure, the stiffness provided by the dampener may be increased, which may be desirable for high dynamic load cases. The damper can take both linear and rotary forms in accordance with various embodiments.
In further embodiments, a damper can be internally located or integrated directly into a compliant fluidic actuator or bellows 100. For example, the material of the actuator can have a high damping coefficient, the actuator can be partially filled with a compliant material with a high damping coefficient, a block of porous material can be inserted into the actuator that restricts the passage of fluids in an out of said material thereby achieving damping, a block of elastomeric material that changes volume in response to external pressure with a significant damping coefficient, the actuator can be wrapped in a damping elastomeric material, and so forth.
In further embodiments a damper can be integrated with the flexure or pivot system or between washers. For example, the flexure can be encased in an elastomeric damping material which might further serve to maintain separation of washers and endplates, or elastomeric damping blocks can be stacked between washer plates.
As discussed herein, the actuator assembly 300 can be coupled to the ground or other structure via a post 710. For example, the actuator assembly 300 can be associated with or comprise structures illustrated in
In some embodiments, one or more actuator assemblies 300 can be coupled together. For example as shown in
Although a specific embodiment of a flexure 350 is illustrated in
For example,
In accordance with further embodiments, actuator assemblies 300 can include various other suitable structures and assume various other suitable forms. For example,
In another embodiment, as illustrated in
In a further embodiment, as illustrated in
In a further embodiment, as illustrated in
In yet another embodiment, as illustrated in
In another embodiment, as illustrated in
A further embodiment, as illustrated in
As illustrated by the embodiments of
As discussed herein, in various embodiments one or more actuator assembly 300 can be configured to actuate a solar panel 705 (see, e.g.,
Although certain example embodiments of an actuator assembly 300 shown herein comprise a specific number of bellows 100 (e.g., four, two, one, zero), these examples should not be construed to be limiting on the wide variety of configurations of an actuator assembly 300 that are within the scope and spirit of the present invention. For example, various embodiments of an actuator assembly 300 can include any suitable plurality of bellows 100 (e.g., 3, 5, 6, 7, 8 or more); can include a single bellows 100; or bellows 100 can be absent. The orientation of the bellows 100 and the direction of the force they exert can also change. Rotational motion of an actuator assembly 300 can be accomplished with bellows 100 providing a force that is not parallel and in the same direction, as shown in
As shown in
Accordingly, each of the manifold output lines 1640 can be operably connected to an inlet valve 1650, which is operably connected to a channel-level accumulator 1660. The channel-level accumulator 1660 is operably connected to an outlet valve 1670, a pressure sensor 1680 and a plurality of bellows 100 that are respectively associated with a different actuator assembly 300. The elements 1600 that are operably coupled with the manifold output line 1640A can be configured to maintain substantially the same pressure and/or deflation/inflation state for each of the bellows 100 attached thereto. In various embodiments, this can alternatively be achieved with a bidirectional valve in lieu of an inlet and outlet valve.
In various embodiments of a two channel system, an additional cross-over valve may be desirable. Such a valve can permit flow between the two channels when activated. This can allow the system to move towards a flat position without requiring air from the compressor. This would allow half of all motions to occur without the use of the compressor and without the associated power consumption. For example,
In accordance with various embodiments, the bellows 100 connected to a given manifold output line 1640 are each in the same relative position within an actuator assembly 300. For example, as shown in
Referring to
For example, presume that that the first manifold output line 1640A is associated with the front-right bellows 100 of each actuator assembly 300A-D; second manifold output line 1640B is associated with the front-left bellows 100 of each actuator assembly 300A-D; third manifold output line 1640C is associated with the rear-right bellows 100 of each actuator assembly 300A-D; and fourth manifold output line 1640D is associated with the rear-left bellows 100 of each actuator assembly 300A-D. In such an embodiment, therefore, the actuator assemblies 300 of a panel array 1500 can be simultaneously actuated while also maintaining essentially the same orientation. In other words, by selectively varying the pressure applied by the manifold lines 1640A-D, the panel array 1500 can be configured to collectively track the sun, or otherwise move in unison for other purposes.
Additionally, the panel array 1500 of
As discussed herein, the relative relationship between pressures of bellows 100 in an actuator assembly 300 can be used to position a solar panel 705 coupled to the top plate 320 of the actuator assembly 300. Higher or lower overall pressures can be used with similar relative pressure differences between the bellows 100 being used to make the actuator assembly 300 assume various suitable configurations. Higher overall pressures can result in greater stiffness of the bellows 100, which can be desirable for dynamic loading conditions or the like. Lower overall pressures can result in reduced stiffness of the bellows 100 and can be beneficial to reduce strain on the panel array 1500 components. In some embodiments, overall pressure can be dynamically changed for various reasons, including eliminating dangerous resonance modes, adapting environmental conditions such as rain, snow or wind, or to reduce the power consumption of the panel array 1500 by lowering the overall operating pressure. Varying pressure in the bellows 100 may also serve to actuate a stow or other mechanism. For example, in one embodiment, high bellows pressures may compress a spring that is in line with the flexure, or integrated into the retaining plates. This action may activate a lockout feature for use in situations where high stiffness is desirable. Additionally, the spring may extend in when the bellows 100 are under-pressurized, also locking out the actuator assembly 300 for maintenance or fail safe modes. Stow mechanisms may be actively or passively actuated. Stow mechanisms may also be actuated from a separate control source (dedicated electrical signal) or from a pressure signal or combination of pressure signals already being used to control angle and stiffness of the actuator.
In various embodiments (e.g., as shown in
In some embodiments, one or more accumulators can be located in various suitable locations in the panel array 1500, including co-location with sensors, which can be beneficial for ensuring that control sensing is substantially unaffected by pressure inconsistencies, pressure normalization delays, or pressure drops or spikes due to a valve or other causes. Accordingly, control sensing can be insulated from dynamic events that are downstream from such accumulators. For example, if wind were to move actuator assemblies 300 in the panel array 1500 such that pressures in the panel array 1500 fluctuate, such pressure changes can be insulated from control sensors by the accumulators.
In further embodiments, scout-sensors can be used for control of actuator assemblies 300 in the panel array 1500. For example, in some embodiments, sensors such as a sun sensor, inclinometer, and/or the like can be positioned on one or more actuator assemblies 300 to monitor the position and configuration of the one or more actuator assemblies 300. In such embodiments, each actuator assembly 300 may not need to have sensors associated with it, and instead only a small subset of the actuator assemblies 300 need to be associated with sensors. In some embodiments, a control system can use feedback from inverter data or other energy production data to adjust the position of actuator assemblies 300.
Scout sensors can be desirable in various embodiments because such sampled sensing can adapt to changes in a panel array 1500 over time, including addition or removal of actuator assemblies 300 from the panel array 1500; settling or other movement of actuator assemblies 300 in the panel array 1500; deformation or other changes to materials in the panel array 1500, or the like.
Additionally, such scout sensing can be beneficial because it can sense dynamic loading conditions so that the system can adjust pressure and/or stiffness of the system. For example, if wind were to move actuator assemblies 300 in the panel array 1500 such that pressures in the panel array 1500 fluctuate, such scout sensors could detect the change and stiffen the panel array 1500 by increasing overall pressure to resist the environmental conditions causing the pressure fluctuations.
In various embodiments, the panel array 1500 can comprise a powered air compressor that is operable to introduce pressurized fluid into panel array 1500, which can be used to selectively actuate and/or inflate bellows 100. Such a compressor and other components of the panel array 1500 can be powered by a hardwired electrical connection, via battery, via solar power, or the like. In some embodiments, to accommodate instances where such power sources are lost or expended, or if the compressor fails, the panel array 1500 can comprise a backup of pressurized fluid that can be used in the panel array 1500. For instance, compressed air can be stored in a tank, accumulator or reservoir. Storage of compressed air can also allow the compressor-tank system to supply air at a rate greater than the compressor's capacity.
Although
Additionally, in various embodiments, bellows 100 can be inter-coupled in any suitable way, including more than one or a combination of the coupling examples shown and described herein. For example, some embodiments of a panel array 1500 can include a trunk-and-branch configuration, wherein primary lines 1510 have a larger diameter and secondary lines 1510 (e.g. extensions 1715 of
Lines 1510 can comprise any suitable material for containing a desired fluid. For example, in various embodiments, lines can be polyurethane, polyvinylchloride (PVC), high-density polyethylene (HDPE), cross-linked polyethylene (PEX), polyamide, steel, galvanized steel, iron, copper, aluminum, or the like. Lines 1510 can be flexible and/or rigid in some embodiments. In some embodiments, lines 1510 can be configured to serve as compliance in joints with deformable seals; the lines 1510 can provide sealing compliance and/or compliance can be external.
In various embodiments, a panel array 1500 can include one or more type of suitable line 1510 and joint material, and in some embodiments, a given portion of a line 1510 or joint can comprise a plurality of materials. For example, a metal core can be covered in a polymer to provide buckling support during flexing or for environmental protection. In further embodiments, lines 1510 can be fiber or braid reinforced. A polymeric tube may have a metal foil layer for creep resistance. A line may be covered with a secondary shroud to avoid excessive weather-related degradation, such as that from ultraviolet radiation. Selective use of such a shroud permits the use of a continuous line of non-weather-resistant material to be economically used through areas of intermittent protection, such as is the case bridging between co-linear solar arrays with gaps between arrays or between adjacent solar arrays.
Lines 1510 of the panel array 1500 can be coupled in various suitable ways. For example, connectors can interface with the inside and/or outside of respective lines 1510 or other components. In various embodiments, compressive connections, bonded connection, welded connections, adhesive connections, or the like can be used.
In various embodiments, it can be beneficial to use a flow-restriction device or structure at various positions in a panel array 1500. For example, as shown in
Use of flow-restriction devices or structures can limit the rate of flow into/out of the bellows 100 to inhibit undesirable pressure drops and/or pressure surges in the bellows 100, which can be beneficial for maintaining smooth actuation of the actuator assemblies 300 and making the panel array 1500 more tolerant of fluid leaks and/or ruptures in the panel array 1500.
For example, the system of interconnected bellows 100 of a panel array 1500 can maintain operation even when a failure occurs at a bellows 100, cap 1725, 1735, or the like, where a leak or rupture occurs downstream of a flow-restriction device.
Additionally, in some examples of a single axis configuration, where the tops of multiple actuators 300 are mechanically fixed to one another (e.g., as illustrated in
Alternatively, in further examples of a single axis configuration of an actuator 300 having two bellows 100, it can be advantageous to permit flow between mechanically linked actuators via the use of relatively large internal diameter lines. Restrictions can be used where the pneumatic connection for a group of mechanically linked actuators attaches to a pneumatic line supplying multiple actuator groups. Doing so can isolate the impact of leak failures to the single mechanically linked group, permitting the continued operation of other groups on the same line while avoiding significant stresses in, and potential damage to, mechanical structures.
For example,
In another example,
Restriction sizing can be selected based on maximizing the degree of restriction while maintaining sufficient flow capacity to move the actuator at the desired maximum speed during normal operation (e.g., leak-free and/or low leak rate). A greater degree of restriction can have the benefit of limiting the volumetric flow rate even in a severe leak case, permitting the compressor to compensate for leaked air and allowing the rest of the system to continue to operate.
Flow restriction devices can include any suitable device or structure. For example,
In further embodiments, a flow-restriction device or structure can comprise a metering orifice, which can include a small hole (e.g. 0.004-0.050″ in diameter) or other sized hole that is of smaller diameter that surrounding lines 1510, or the like. In further embodiments, lines 1510 can be configured to provide flow-restriction by sizing an inner diameter of the tubing over a length such that desired flow-resistance is achieved. In other words, lines 1510 can act as an extended, large-diameter, metering orifice.
In some embodiments, V-plate bulbous actuators can be antagonistically positioned in a V-configuration with a flexure or pivot at the turning point. Compliant cylinders can be inflated antagonistically so as to affect a strong pressure to position ratio. The cylinders can be constructed in multiple ways including blow molding, rotomolding, fabric tube with sealed ends, a sewn fabric envelope with separate impermeable bladder, and the like. Multiple bulbous actuators can be stacked for greater range of motion.
For example,
The spine 4025 is coupled to a portion of a plate 4020, which in this example is coupled at an approximately 90 degree angle from a face of the plate 4020 substantially at the center of the plate 4020. The sector body 4015 can maintain a fixed position relative to the ground (e.g., via a post or the like) and the plate 4020 can be rotated by selective inflation and/or deflation of one or both of the actuators 4005.
In the example configuration shown in
In a further embodiment, V-plate ball actuators can be antagonistically positioned in a V-configuration with a flexure or pivot at the turning point. Compliant balls can be inflated antagonistically and in one configuration cupped by hemispherical end plates, one of which can be concave, the other of which can be convex. Multiple ball actuators can be stacked for greater range of motion.
In yet another embodiment, V-plate bellows actuators can be antagonistically positioned in a V-configuration with a flexure or pivot at the turning point. Compliant bellows can be arranged in an arc around the approximate center of a pivot or flexure. Ribs can be used, like spokes on a wheel to constrain the motion of the bellows. Angled rib assemblies may couple corresponding bellows convolutions and actuator flexure or pivot.
Additionally, although various example pneumatic architectures have been illustrated in accordance with some example embodiments (e.g.,
Similarly,
In various embodiments storage of compressed air can be configured to prevent or reduce parasitic energy loss. For example, in some embodiments, a control system can communicate with air generation system to only run the compressor 1611 when there is DC over-generation (within certain limits). When the inverters are clipping, energy is being lost (not exported to the grid) so the energy used for compression is “free.” In such embodiments, it can be desirable to have large air storage capacity. Such embodiments can allow a tracker system to improve the overall energy yield of a solar array by only generating compressed air when there is excess power available from the solar array.
In a conventional solar implementation there can be a greater portion of DC power available compared to AC power. In this state, the excess DC generation is dissipated as heat. By operating the compressor only during these times, the cost of energy for the compressor 1611 is effectively negative because the energy consumed has no value (it cannot be exported) and consuming that energy will reduce the temperature of the solar modules thus reducing their degradation rate and extending their lifetime.
Additionally, in further embodiments, a system can comprise a plurality of compressors 1611 configured for air storage at different pressures. For example, in one embodiment, a system can comprise a high pressure compressor 1611 and a low pressure compressor 1611. The high pressure compressor 1611 can be configured for maximizing storage capacity for a given volume and the second low pressure compressor 1611 can be configured to increase system efficiency during normal low-demand tracking operation. Such embodiments can reduce the total energy used by the tracking system thus increasing effective solar yield.
The described embodiments are susceptible to various modifications and alternative forms, and specific examples thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the described embodiments are not to be limited to the particular forms or methods disclosed, but to the contrary, the present disclosure is to cover all modifications, equivalents, and alternatives.
Claims
1. An actuator assembly system array, the actuator assembly system array comprising:
- a plurality of separate actuator assembly systems arranged in a linearly aligned row on a portion of the ground, with each actuator assembly system of the plurality of separate actuator assembly systems comprising: an array of a plurality of solar panels of the same size disposed adjacent to each other in a common plane in only a single row, the array of the plurality of solar panels coupled together via a pair of linear support rails that extend along respective parallel axes that are parallel to the common plane of the plurality of solar panels, the array of the plurality of solar panels configured to collectively rotate in unison about no more than a single axis of rotation based on an angle or position of the sun; a plurality of fluidic actuator assemblies respectively extending between and coupled to the linear support rails, the fluidic actuator assemblies configured to collectively rotate the array of the plurality of solar panels in unison about the no more than the single axis of rotation based on the angle or position of the sun, with each respective fluidic actuator assembly of the plurality of fluidic actuator assemblies comprising: a V-shaped bottom plate; a planar top plate rotatably coupled to the V-shaped bottom plate, with the rotatable coupling configured for rotation about the single axis of rotation; and a first inflatable actuator and a second inflatable actuator disposed between the V-shaped bottom plate and the planar top plate on opposing sides of the rotatable coupling, the first and second inflatable actuator configured to be inflated and deflated to cause the array of the plurality of solar panels to rotate about the no more than the single axis of rotation; and a plurality of posts respectively coupled to and extending from the plurality of fluidic actuator assemblies along a respective parallel axis, with respective posts of the plurality of posts disposed in the ground to couple the actuator assembly system to the ground, with the length of the respective posts between the respective fluidic actuator assemblies to the ground being disposed in the ground at different lengths; and
- a fluidic control system comprising a plurality of fluid lines extending between and fluidically coupling the plurality of separate actuator assembly systems in series, the fluidic control system comprising: a first fluid channel with a first set of fluid lines, that fluidically couple the respective first inflatable actuators of the plurality of fluidic actuator assemblies in series, and a second fluid channel with a second set of fluid lines that are separate from the first set of fluid lines, the second set of fluid lines fluidically coupling the respective second inflatable actuators of the plurality of fluidic actuator assemblies in series, the fluidic control system configured to actuate, via a common shared fluid source, the plurality of separate actuator assembly systems of the actuator assembly system array in unison including causing the plurality of solar panels of the respective actuator assembly systems to rotate about the no more than the single axis of rotation of the respective actuator assembly systems in unison based on the angle or position of the sun.
2. The actuator assembly system array of claim 1, wherein actuation of the plurality of separate actuator assembly systems of the actuator assembly system array in unison includes:
- first inflation in unison or first deflation in unison of the respective first inflatable actuators of the plurality of fluidic actuator assemblies in series, the first inflation in unison or first deflation in unison being via the first set of fluid lines of the first fluid channel; and
- second inflation in unison or second deflation in unison of the respective second inflatable actuators of the plurality of fluidic actuator assemblies in series, the second inflation in unison or second deflation in unison being via the second set of fluid lines of the second fluid channel.
3. The actuator assembly system array of claim 1, wherein each of the respective actuator assembly systems has:
- no more and no less than two fluidic actuator assemblies; and
- no more than two posts and no less than two posts respectively extending from the two fluidic actuator assemblies into the ground.
4. The actuator assembly system array of claim 1, wherein each of the respective actuator assembly systems has:
- a plurality of separate actuator assembly systems arranged in a plurality of linearly aligned rows on a portion of the ground, wherein the plurality of linearly aligned rows are disposed in parallel to each other, and wherein each of the plurality of linearly aligned rows comprises a separate plurality of actuator assembly systems.
5. An actuator assembly system array, the actuator assembly system array comprising:
- a plurality of separate actuator assembly systems arranged in a linearly aligned row, with each actuator assembly system of the plurality of separate actuator assembly systems comprising: an array of one or more solar panels coupled to a pair of linear support rails that extend along respective parallel axes that are parallel to a plane of the one or more solar panels, the array of the one or more solar panels configured to rotate about no more than a single axis of rotation based on an angle or position of the sun; a plurality of fluidic actuator assemblies respectively extending between and coupled to the linear support rails, the fluidic actuator assemblies configured to rotate the array of the one or more solar panels about the no more than the single axis of rotation based on the angle or position of the sun; and a plurality of posts respectively coupled to and extending from the plurality of fluidic actuator assemblies along a respective parallel axis; and
- a fluidic control system comprising a plurality of fluid lines extending between and fluidically coupling the plurality of separate actuator assembly systems in series.
6. The actuator assembly system array of claim 5, wherein an array comprises a plurality of solar panels of the same size disposed adjacent to each other in a common plane in only a single row, the plurality of solar panels configured to collectively rotate in unison about no more than a single axis of rotation based on an angle or position of the sun.
7. The actuator assembly system array of claim 5, wherein respective posts between the respective fluidic actuator assemblies have different lengths.
8. The actuator assembly system array of claim 5, wherein the fluidic control system comprises:
- a first fluid channel with a first set of fluid lines, that fluidically couple respective first inflatable actuators of the plurality of fluidic actuator assemblies in series, and
- a second fluid channel with a second set of fluid lines that are separate from the first set of fluid lines, the second set of fluid lines fluidically coupling respective second inflatable actuators of the plurality of fluidic actuator assemblies in series,
- the fluidic control system configured to actuate the plurality of separate actuator assembly systems of the actuator assembly system array in unison including causing the one or more solar panels of the respective actuator assembly systems to rotate about the no more than the single axis of rotation of the respective actuator assembly systems in unison based on the angle or position of the sun.
9. The actuator assembly system array of claim 5, wherein each respective fluidic actuator assembly of the plurality of fluidic actuator assemblies comprises:
- a bottom plate;
- a planar top plate rotatably coupled to the bottom plate, with the rotatable coupling configured for rotation about the single axis of rotation; and
- a first inflatable actuator and a second inflatable actuator disposed between the bottom plate and the planar top plate on opposing sides of the rotatable coupling, the first and second inflatable actuator configured to be inflated and deflated to cause the array of the one or more solar panels to rotate about the no more than the single axis of rotation.
10. The actuator assembly system array of claim 5, wherein each of the respective actuator assembly systems has:
- no more and no less than two fluidic actuator assemblies; and
- no more than two posts and no less than two posts respectively extending from the two fluidic actuator assemblies into the ground.
11. An actuator assembly system array, the actuator assembly system array comprising:
- a plurality of separate actuator assembly systems arranged in a row, with each actuator assembly system of the plurality of separate actuator assembly systems comprising: an array of one or more solar panels; a plurality of fluidic actuator assemblies; and a plurality of posts respectively coupled to and extending from the plurality of fluidic actuator assemblies; and
- a fluidic control system comprising a plurality of fluid lines extending between and fluidically coupling the plurality of separate actuator assembly systems in series.
12. The actuator assembly system array of claim 11, wherein the plurality of separate actuator assembly systems are arranged linearly aligned in the row.
13. The actuator assembly system array of claim 11, wherein the array of the one or more solar panels are coupled to a pair of linear support rails that extend along respective parallel axes that are parallel to a plane of the one or more solar panels.
14. The actuator assembly system array of claim 13, wherein the plurality of fluidic actuator assemblies respectively extend between and are coupled to the linear support rails.
15. The actuator assembly system array of claim 11, wherein the array of the one or more solar panels are configured to rotate about no more than a single axis of rotation.
16. The actuator assembly system array of claim 11, wherein an array comprises a plurality of solar panels disposed adjacent to each other in a common plane in only a single row, the plurality of solar panels configured to collectively rotate in unison about no more than a single axis of rotation based on an angle or position of the sun.
17. The actuator assembly system array of claim 11, wherein respective posts between the respective fluidic actuator assemblies have different lengths.
18. The actuator assembly system array of claim 11, wherein the fluidic control system comprises:
- a first fluid channel with a first set of fluid lines, that fluidically couple respective first inflatable actuators of the plurality of fluidic actuator assemblies in series, and
- a second fluid channel with a second set of fluid lines that are separate from the first set of fluid lines, the second set of fluid lines fluidically coupling respective second inflatable actuators of the plurality of fluidic actuator assemblies in series.
19. The actuator assembly system array of claim 11, wherein each respective fluidic actuator assembly of the plurality of fluidic actuator assemblies comprises:
- a bottom plate;
- a top plate rotatably coupled to the bottom plate, with the rotatable coupling configured for rotation about only a single axis of rotation; and
- a first inflatable actuator and a second inflatable actuator disposed between the bottom plate and the top plate on opposing sides of the rotatable coupling, the first and second inflatable actuator configured to be inflated and deflated to cause the array of one or more solar panels to rotate about no more than the single axis of rotation.
20. The actuator assembly system array of claim 11, wherein each of the respective actuator assembly systems has:
- no more than two posts and no less than two posts respectively extending from two fluidic actuator assemblies into the ground.
Type: Application
Filed: May 30, 2023
Publication Date: Nov 2, 2023
Inventors: Leila Marcia MADRONE (San Francisco, CA), Kyle Douglas BETTS (San Francisco, CA), Peter Sturt LYNN (Oakland, CA), Louis Hong BASEL (Berkeley, CA), Brent RIDLEY (Huntington Beach, CA), Saul Thomas GRIFFITH (San Francisco, CA), James Dylan MCBRIDE (San Francisco, CA), Jeffrey LAMB (San Francisco, CA), Eric Preston Lien SUAN (Baltimore, MD), Erica LIN (Millbrae, CA), Joshua ERICKSON (Oakland, CA), Vincent Domenic ROMANIN (San Francisco, CA)
Application Number: 18/203,276