Periodic Reporting for period 1 - IDeCAST (Innovative design and control methodologies for large scale solar tracker)
Okres sprawozdawczy: 2021-07-01 do 2023-06-30
This project tackles a critical engineering challenge in the field of renewable energy: design and control methodologies for next-generation solar tracking systems in terms of both energy-efficient and structurally robust. Traditional solar trackers used in photovoltaic (PV) and concentrated solar power (CSP) systems typically suffer from several technical limitations—most notably, high energy consumption due to large actuation torques, low stiffness under wind loads, and limited tracking accuracy caused by friction and mechanical backlash. These issues not only increase operational costs and maintenance requirements but also limit the long-term reliability and scalability of solar farms.
Given the urgent global need to reduce carbon emissions and transition toward sustainable energy systems, improving the efficiency and cost-effectiveness of solar tracking technologies is of great societal importance. Solar trackers can increase energy capture by up to 25–30% compared to fixed systems, making them vital for maximizing the return on investment in solar installations. However, for these technologies to become more widespread—especially in large-scale solar farms—new approaches are needed to reduce energy input, enhance durability, and maintain precision tracking in harsh environmental conditions such as wind and dust.
The overall objective of this project is to develop and validate innovative design and control methodologies for a new type of solar tracker with superior mechanical and tracking performance.
Given the urgent global need to reduce carbon emissions and transition toward sustainable energy systems, improving the efficiency and cost-effectiveness of solar tracking technologies is of great societal importance. Solar trackers can increase energy capture by up to 25–30% compared to fixed systems, making them vital for maximizing the return on investment in solar installations. However, for these technologies to become more widespread—especially in large-scale solar farms—new approaches are needed to reduce energy input, enhance durability, and maintain precision tracking in harsh environmental conditions such as wind and dust.
The overall objective of this project is to develop and validate innovative design and control methodologies for a new type of solar tracker with superior mechanical and tracking performance.
Since the project began, significant progress has been made toward developing an innovative solar tracker with low energy consumption, high structural stiffness, and improved tracking accuracy. The project has delivered key theoretical advances and practical outcomes, laying a solid foundation for the next generation of intelligent, efficient solar tracking systems.
The core innovation involved designing a novel solar tracker inspired by the motion of ancient stone mills. Using Grassmann Line Geometry, a unique parallel pushing mechanism was developed, allowing wide-angle solar tracking (±90° azimuth, 0–90° elevation) with minimal torque from a single driving joint. This design improves compactness, stiffness, and dynamic performance.
A comprehensive performance evaluation framework was built, visualizing key metrics such as workspace, stiffness, and energy efficiency in performance atlases. Using a two-step optimization method, the team achieved a 25% reduction in energy use and a 50% increase in structural stiffness compared with traditional trackers.
Dynamic analysis was conducted to address environmental disturbances such as wind and friction. The Stribeck friction model helped understand stick-slip effects, and aerodynamic modeling supported by wind tunnel data quantified wind loads. These studies showed the need for robust control strategies.
To meet this requirement, a control system combining feedforward friction compensation, wind disturbance observation, and sliding mode control was developed. This improved the tracker’s accuracy and stability under real-world conditions.
A key milestone was the successful construction and testing of a prototype. It included a CNC-based platform integrating the new mechanism and control algorithms. Experiments validated the design and confirmed wide motion range, low energy use, and high tracking precision.
The project’s results were published in five open-access papers and shared at international events, enhancing visibility and knowledge transfer. With strong project management and all milestones achieved on time, the project met its scientific and technical objectives. It holds promising commercialization potential and will support future research and applications in renewable energy.
The core innovation involved designing a novel solar tracker inspired by the motion of ancient stone mills. Using Grassmann Line Geometry, a unique parallel pushing mechanism was developed, allowing wide-angle solar tracking (±90° azimuth, 0–90° elevation) with minimal torque from a single driving joint. This design improves compactness, stiffness, and dynamic performance.
A comprehensive performance evaluation framework was built, visualizing key metrics such as workspace, stiffness, and energy efficiency in performance atlases. Using a two-step optimization method, the team achieved a 25% reduction in energy use and a 50% increase in structural stiffness compared with traditional trackers.
Dynamic analysis was conducted to address environmental disturbances such as wind and friction. The Stribeck friction model helped understand stick-slip effects, and aerodynamic modeling supported by wind tunnel data quantified wind loads. These studies showed the need for robust control strategies.
To meet this requirement, a control system combining feedforward friction compensation, wind disturbance observation, and sliding mode control was developed. This improved the tracker’s accuracy and stability under real-world conditions.
A key milestone was the successful construction and testing of a prototype. It included a CNC-based platform integrating the new mechanism and control algorithms. Experiments validated the design and confirmed wide motion range, low energy use, and high tracking precision.
The project’s results were published in five open-access papers and shared at international events, enhancing visibility and knowledge transfer. With strong project management and all milestones achieved on time, the project met its scientific and technical objectives. It holds promising commercialization potential and will support future research and applications in renewable energy.
The project has made significant progress beyond the current state of the art in both the design and control methodologies for solar trackers. Traditionally, solar trackers rely on heavy and complex drive systems that result in high energy consumption and limited stiffness, especially under external disturbances like wind loads. This project introduces an innovative type synthesis and optimization framework based on Grassmann geometry, allowing the creation of a novel parallel pushing mechanism. This design enables efficient sun-tracking with only one active joint and minimal driving torque, dramatically reducing power consumption while enhancing mechanical stiffness and workspace.
Compared with existing industrial solar trackers, the proposed system reduces energy usage, which allows better resilience against environmental disturbances and lower maintenance costs. These advancements are achieved through the combination of type synthesis theory, performance atlas analysis, wind-load simulation, and modern nonlinear control strategies including friction feedforward compensation and sliding mode control.
By the end of the project, we expect to deliver a fully validated prototype of the solar tracker, tested under real-world conditions. The final system will demonstrate superior performance in energy efficiency, tracking accuracy, and operational stability. Over five high-quality journal publications will have disseminated the findings to both academic and industrial audiences. The complete open-access data and models will ensure knowledge transfer and global collaboration.
In terms of socio-economic effects, the proposed solar tracker has the potential to lower the capital and operational costs of solar power plants, making renewable energy more accessible and economically viable. This contributes directly to global efforts to reduce carbon emissions and dependence on fossil fuels. Furthermore, by improving the efficiency and lifespan of solar systems, this technology supports sustainable infrastructure development, especially in remote or resource-limited regions.
Societally, this project promotes the uptake of advanced engineering and clean energy technologies through academic-industrial collaboration, open science dissemination, and training of early-stage researchers. It also provides a strong demonstration of how interdisciplinary knowledge—from robotics and control to mechanical design and environmental modeling - can be integrated to solve real-world problems. The success of the project may inspire further innovations in solar energy utilization, and potentially influence policy and investment decisions in the renewable energy sector at both national and international levels.
In conclusion, the project contributes cutting-edge technologies to solar tracking, demonstrates measurable improvements over current systems, and provides high-impact benefits to science, industry, and society.
Compared with existing industrial solar trackers, the proposed system reduces energy usage, which allows better resilience against environmental disturbances and lower maintenance costs. These advancements are achieved through the combination of type synthesis theory, performance atlas analysis, wind-load simulation, and modern nonlinear control strategies including friction feedforward compensation and sliding mode control.
By the end of the project, we expect to deliver a fully validated prototype of the solar tracker, tested under real-world conditions. The final system will demonstrate superior performance in energy efficiency, tracking accuracy, and operational stability. Over five high-quality journal publications will have disseminated the findings to both academic and industrial audiences. The complete open-access data and models will ensure knowledge transfer and global collaboration.
In terms of socio-economic effects, the proposed solar tracker has the potential to lower the capital and operational costs of solar power plants, making renewable energy more accessible and economically viable. This contributes directly to global efforts to reduce carbon emissions and dependence on fossil fuels. Furthermore, by improving the efficiency and lifespan of solar systems, this technology supports sustainable infrastructure development, especially in remote or resource-limited regions.
Societally, this project promotes the uptake of advanced engineering and clean energy technologies through academic-industrial collaboration, open science dissemination, and training of early-stage researchers. It also provides a strong demonstration of how interdisciplinary knowledge—from robotics and control to mechanical design and environmental modeling - can be integrated to solve real-world problems. The success of the project may inspire further innovations in solar energy utilization, and potentially influence policy and investment decisions in the renewable energy sector at both national and international levels.
In conclusion, the project contributes cutting-edge technologies to solar tracking, demonstrates measurable improvements over current systems, and provides high-impact benefits to science, industry, and society.