Solaroptimus increases solar energy by 30 per cent
An
Igus UK product story
Edited by the Engineeringtalk editorial team
Nov 5, 2008
The Solaroptimus tracking systems on the latest Conergy photovoltaic systems have been designed to ensure they are always at the correct angle to the sun.
To enable the systems to run maintenance-free over longer periods, even under extreme weather conditions, Conergy decided to use Igus components for all plain bearing applications and rod end bearings and linear units.
Igus suggested fitting all bearing points on the Solaroptimus with Igus products.
The Solaroptimus uses twin-axis tracking systems to constantly optimise the alignment of photovoltaic generators, increasing energy production by more than 30 per cent in some cases.
In north Europe, optimum position detection always moves to the brightest spot in cloudy conditions.
In south Europe, where the sky is often bright and cloudless, a system that keeps the photovoltaic modules at a right angle to sunray incidence on the basis of astronomical data is more effective; the Solaroptimus was developed for this region.
During development, the focus was on durability and maintenance freedom, since the systems are often set up in remote areas without on-site personnel.
This is why the developers decided against complex drive systems, preferring instead to use components with straightforward designs.
This requirement applied to motors and bearings.
Set-up locations for solar systems are often very dry, with high levels of sand and fine dust.
Another factor to be taken into account was the wide temperature spectrum the bearings had to work across.
Igus suggested fitting all bearing points on the Solaroptimus with Igus products.
On the 20-metre-long main axes of the frame systems, Iglidur plastic bearings ensure low-friction and maintenance-free operation.
The built-in solid lubricant of the polymer eliminates the need for lubricants.
Iglidur G bearings are suitable for pivoting and rotary movements at low to medium speed.
The Iglidur G bearings can also operate in dirty and dusty conditions.
Conergy engineers used Drylin linear plain bearings in the adjustment systems to reduce strain on the drive systems.
These bearings guarantee the exact linear motion of the axes.
The Drylin W bearings slide on a hard anodised aluminium rail profile, giving low-friction running without stick/slip effects.
Sand and dust do not effect this linear bearing: any debris is pushed away by a snowplough effect without affecting the gliding properties.
Conergy decided to use Igubal rod end bearings for the couplings which link the solar module carriers.
These connecting parts absorb high forces, have good damping properties and weigh five times less then conventional metallic bearings.
The rod end bearings remain maintenance-free, even in the presence of fine or coarse dust.
The integrated solid lubricants ensure low friction with maximum abrasion resistance.
The drives of the module frames, which are responsible for the north-south alignment, apply a force of 6,800N, while the drives of the main frames for east-west tracking apply a force of 10,000N.
The drive is moved through a maximum of one full revolution per day with a maximum speed of 4mm/s Igus had abrasive sand flown in from southern Spain to test its systems.
The test demonstrated that bearings did not have to be replaced over the calculated service life of the Solaroptimus.
The test also demonstrated the UV resistance of the plastic and resistance to the temperature range and humidity.
The first Solaroptimus systems have recently been installed in southern Spain.
Eight-hundred movable systems will eventually produce solar energy at this location.
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