CPV Summit USA 2009

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


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


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


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


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


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.


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


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


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)


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


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.


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

Business

CPV Summit USA 2009