Abstract The main objective of this paper is to design

the mechanism of active tracking dual-axis mode

Sensorless heliostat and produce power using the
concentrated solar energy. The concentrated solar
energy is converted using Thermo Electric Generators
TEGs! which convert the thermal energy of the sun
directly into electricity. The accuracy and stability of
tracking system will be analy"ed for future development
usage. The paper aims to provide a prototype design for
future large scale power production to mitigate energy
crisis.
The sensor less tracking of sun and movement of the
system is governed by complex astronomical calculations
which give us the location of the sun at a particular
latitude# longitude and time. The system employs
accurate gear assemblies and feedback control system to
achieve precise and smooth motion re$uired for
tracking. %aintenance free Software of the system needs
only to be configured once. &t only has one time
manufacturing cost and its maintenance cost is negligible
with respect to output of the system.
Index Terms Feedback Control System, Parabolic
Reflector, Sensorless Sun tracking, Thermoelectric
!enerators
I. INTRODUCTION
Even in todays world market, with all of the vast
technoloy advancements and im!rovements, there are still
!eo!le who live in darkness at niht and "se candle liht or
kerosene lam!s to st"dy. These !eo!le have the knowlede
that electricity e#ists$ however, the area in which they reside
lacks the infrastr"ct"re and reso"rces for s"ch an amenity.
%lso, thro"ho"t the world, the demand for "sea&le enery
is increasin ra!idly, with electricity &ein the enery of
choice. This electricity !rod"ction, however, does not come
free. There is cost associated with the infrastr"ct"re for
settin "! new !ower !rod"ction facilities and the risin
cost and lack of nat"ral reso"rces s"ch as oil, coal, and
nat"ral as. One sol"tion is to steer away from conventional
methods and look for novel, alternative, renewa&le enery
reso"rces, s"ch as solar enery. The s"n is an e#cellent
so"rce of radiant enery, and is the worlds most a&"ndant
so"rce of enery. It emits electromanetic radiation with an
averae irradiance of '()( *+m, on the earths s"rface -',
,.. The solar radiation incident on the Earths s"rface is
com!rised of two ty!es of radiation / &eam and diff"se,
ranin in the wavelenths
from the "ltraviolet to the infrared
0(11 to ,11 nm2, which is characteri3ed &y an averae solar
s"rface tem!erat"re of a!!ro#imately 411156 -'1.. The
amo"nt of this solar enery that is interce!ted is )111 times
reater than the s"m of all other in!"ts / terrestrial n"clear,
eothermal and ravitational eneries, and l"nar
ravitational enery -'.. To !"t this into !ers!ective, if the
enery !rod"ced &y ,) acres of the s"rface of the s"n were
harvested, there wo"ld &e eno"h enery to s"!!ly the
c"rrent enery demand of the world.
7eliostat is a device consistin of an assem&ly
which revolves slowly occ"!yin a trackin mechanism so
as to convere s"nliht at a fi#ed foc"s. The concentrated
s"nliht at the foc"s !rovides &etter solar enery
concentration "sae.
In order to maintain their hih !erformance in concentratin
solar !ower systems, a concentratin &ody has most cr"cial
im!ortance amon all !arts as any irre"larity in
concentrator sha!e can make the foc"s !oint ar&itrary and
non effective. 8or this reard 9h"ai et al. -(. !ro!osed new
desins for concentrator+cavity receiver systems "sin the
:onte;Carlo ray;tracin method. In the st"dy, the radiation
fl"# distri&"tion inside the receiver was calc"lated, and, &y
!erformin ray;tracin analysis for different eometry of
receivers, they !ro!osed the <"!side;down !ear cavity= as
Umar 8aroo>
'
, :"hammad 9alman Tahir
,
, Na"man 7aider
(
, 7afi3 :"hammad Ishtia> %wan
?
,
:"33amil @anA"a
)
De!artment of Electrical Enineerin
University Of The B"nAa&, )?)C1
Dahore, Bakistan.
'
enr."marfaroo>Eyahoo.com,
,
s"!er&salmanEhotmail.com, (na"manFhaiderEhotmail.com,
?
ishtia>Fawan'CG)Ehotmail.com,
)
AAF?F"Ehotmail.com
Desin and Im!lementation of a Dow Cost D"al;%#is
7eliostat :irror 9ystem for Bower Brod"ction B"r!oses
the cavity receiver that !resents the most sta&le enery fl"#
thro"h its a!ert"re.
7eliostats have &een "sed to concentrate solar enery for
many years. %mon the challenes to &e overcome are
enery losses and s"n trackin. Chen et al. -?. !ro!osed a
fi#ed asymmetric c"rvat"re with the s!innin;elevation
trackin method. This restriction was intended to e>"ali3e
the man"fact"re cost of the new heliostat with that of
traditional heliostats with a3im"th;elevation trackin and
s!herical c"rvat"re. The res"lts showed that the new
heliostat desin co"ld red"ce the receiver s!illae loss &y
'1/(1H, and !rovided ood "niform !erformance witho"t
lare variations with time of day. Instead of !erformin
trackin motions in discrete ste!s as it is done in most
heliostat systems, 6ri&"s et al. -). !ro!osed a contin"o"s
trackin methodoloy. % sinificant red"ction of trackin
error &y smooth contin"o"s trackin was achieved.
:eas"rements of heliostat motion showed that aimin error
d"e to trackin intervals was !ractically eliminated.
In order to avoid shadin of the dish &y the
receiver, 6ri&"s and Ries -4. !ro!osed a new concentrator
desin for small systems with a constraint of limited
mo&ility of the receiver which is accom!lished &y "sin a
first !olar a#is and a second a#is that is alined with the
normal to the ecli!tic !lane. The new desin feat"res
res"lted in limited motion of the receiver$ off;a#is reflector
to eliminate shadin$ constant rotation s!eed in &oth a#es$
and constant fl"# distri&"tion on the receiver.
% heliostat m"st track the s"n !osition with a hih
deree of acc"racy so vario"s forms of trackin
mechanisms, varyin from sim!le to com!le# have &een
!ro!osed. They are mainly mechanical or electric+electronic
system. Ienerally, the electronic system can e#hi&it &etter
relia&ility and trackin acc"racy. These incl"de motors
controlled electronically &y vario"s sensors, which detect
the manit"de of solar ill"mination. %nother a!!roach
which is "sed in this research is to calc"late the !osition of
s"n "sin astronomical calc"lations which !rovides hih
acc"racy to the system. % com!le# trackin system
enerally "se controlled motors with feed&ack system.
Conventionally, a d"al a#is a3im"th;elevation
trackin mode heliostat is more common.
In the early history of heliostats develo!ment, it was mostly
"sed in astronomy field for solar o&servation. It was also
"sed to st"dy other celestial &odies and for s!acecraft
instr"ment cali&ration. In solar enery research field,
heliostat has &een a!!lied mostly in the hih tem!erat"re
solar f"rnace, solar !ower station and stirlin enine &ased
solar concentrators. 7y&rid systems for solar 0renewa&le2
enery "tili3ation have attracted considera&le attention from
scientists and enineers d"rin the last decade &eca"se of
their hiher efficiency and sta&ility of !erformance in
com!arison to individ"al solar devices -J.. They make "se
of waste heat and solar enery for eneration of electricity,
or even for direct a!!lications s"ch as heatin of water,
refrieration or air conditionin.
9ince solar enery in!"t is only availa&le d"rin the day,
solar systems re>"ire the "se of some thermal storae
stratey for later enery re"se. :"ch research has &een
cond"cted on thermal acc"m"lation systems, for many ty!es
of systems that have an interr"!ted enery in!"t 0e..,
clo"ds, niht !eriods2. 8or the sake of &revity, and as
e#am!les of solar enery thermal storae systems, two
recent st"dies &y 9alomoni et al. -G. and Kaiv"dh et al. -C.
can &e cited for &etter handlin of heat storae !lants.
II. 9L9TE: %RC7ITECTURE
A. Master Controller
%KR %T:EI%(, is "sed as master controller. It is "sed
&eca"se of its hih s!eed and memory which makes it ideal
to !erform astronomical calc"lations. %lso, it !rovides %DC
channels which are "tili3ed to im!lement feed&ack control
system. U9%RT comm"nication is "sed to interface it with
the slave controller. It is also res!onsi&le for controllin
motors in t"rn achievin !recise trackin of s"n.
B. Slave Controller
%tmel %TGC9), is "sed as a slave controller. It !rovides
&"ilt in m"lti!le#ed address+data &"s which is "sed to
interface it with RTC. It reads time from the RTC and sends
the time to the master controller thro"h U9%RT. It is also
res!onsi&le for DCD and 6ey!ad o!eration for &etter "ser
interface with the system.
C. RTC
D9',GGJ is "sed as a Real Time Clock 0RTC2 for the
system. It has a m"lti!le#ed address+data &"s thro"h which
it can &e interfaced with microcontroller.
D. Position Controller
Bosition controller is im!lemented inside master controller
i.e. %T:EI%(,. It takes the !osition of the s"n which is
calc"lated and forwards it to the ste!!er controller. 8or
acc"rate trackin, feed&ack system is also em!loyed. It
takes the feed&ack from the BOTs which are installed at the
&oth a#is of motion of the system.
E. Stepper Controller
9te!!er Controller is res!onsi&le for drivin the motors as
directed &y the !osition controller. It takes the !osition of
the s"n from the !osition controller and moves the system to
the desired !osition.
9ystem %rchitect"re
III. :EC7%NIC%D 9L9TE: DE9IIN
9ystem mechanical desin is mainly com!osed of fo"r
!arts which incl"desM
A. Parabolic Reflector
Bara&olic Reflector is "sed to convere s"nliht at the foc"s.
The si3e and the de!th of the reflector are chosen accordin
to the desired o"t!"t and desin of the system. *e desined
a !ara&olic reflector to convere s"nliht at the foc"s and
"tili3e it for !rod"cin !ower. The si3e of the !ara&olic
reflector is chosen to &e ? ft. for o"r !rototy!e. The reflector
is desined to have its foc"s at , ft. 8or reflection, mirror
coated acrylic sheet is "sed which !rovides e#cellent
reflectivity and achieves desired res"lts >"ite comforta&ly.
The Reflector area is ''.)4 8t.
,
which !rovides "s with
eno"h solar enery to achieve o"r oals.
Bara&olic Reflector
B. Fork Assembly
8ork %ssem&ly is res!onsi&le for the elevation
motion. It com!rises of a fork sha!ed frame which holds the
!ara&olic reflector frame, ste!!er motor and a harmonic ear
drive which is "sed with the ste!!er motor to achieve &etter
acc"racy. 9te!!er motor "sed is of ,11 ste!s+rev. 7armonic
drive !rovides a ratio of G1M' which !rovides system with
smooth elevation movement.
8ork %ssem&ly
C. Base assembly
Nase %ssem&ly incl"des worm ear assem&ly
which is res!onsi&le for a3im"th motion. *orm ear ratio is
'M',1. 8ork assem&ly is mo"nted thro"h thr"st &earin on
this &ase assem&ly.
Nase %ssem&ly
D. Power Pro!ction "nit
Thermoelectric enerators are devices which
convert heat 0tem!erat"re differences2 directly into electrical
enery, "sin a !henomenon called the O9ee&eck effectO 0or
Othermoelectric effectO2. Their ty!ical efficiencies are
aro"nd );'1H. Older 9ee&eck;&ased devices "sed &imetallic
A"nctions and were &"lky while more recent devices "se
&ism"th tell"ride 0Ni,Te(2 semicond"ctor !;n A"nctions and
can have thicknesses in the millimeter rane.
TE#s Set!p
Thermoelectric enerators are s"ch devices which
"ses the thermoelectric or see&eck effect to !rod"ce
electrical enery. % s!ecial enerator assem&ly is desined
to !rovide the !ro!er environment for TEIs to o!erate. It
nearly re>"ires a difference tem!erat"re of aro"nd ')1
o
C
&etween its two s"rfaces. One TEI cell !rod"ces "! to )*
of !ower de!endin "!on the intensity of heat. 9o a hy&rid
serial;!arallel com&ination is "sed in which ? TEIs series
ro"! is connected in !arallel with the other to enhance
c"rrent ratin.
%ll TEIs 0as clearly can &e seen in followin
fi"re2 are !laced on a flat s"rface of al"min"m sheet with a
thermal rease &etween their s"rfaces to !rovide contin"al
access of heat from heated sheet to the TEI cell s"rface.
TEIs 9et"!
%fter !lacin and wirin of the cells another
al"min"m sheet is !laced over them with thermal rease in
&etween sheet and cell s"rfaces to seal TEIs in with
!olyester foam in &etween sheets. It is ill"strated in a
followin fi"re.
9ealed TEIs
$eat Sinks
% heat sink is a term for a com!onent or assem&ly
that transfers heat enerated within a solid material to a fl"id
medi"m, s"ch as air or a li>"id. E#am!les of heat sinks are
the heat e#chaners "sed in refrieration and air
conditionin systems and the radiator 0also a heat
e#chaner2 in a car. 7eat sinks also hel! to cool electronic
and o!toelectronic devices, s"ch as hiher;!ower lasers and
liht emittin diodes 0DEDs2.
7eat sinks are "sed to remove heat from another side of
thermoelectric enerators so that a see&eck effect can take
!lace. 9o they are !laced over the "!!er al"min"m s"rface
with thermal rease in &etween s"rface contacts.
7eat sink 9et"!
Sealin% Acrylic Bo&
8"lly sealed acrylic sheet &o# is "sed to seal the
whole heat sinks so that a coolant can &e easily introd"ced
witho"t any leakae which controls heat sinks tem!erat"re
to shoot.
9ealin No#
$eat Removin% 'il
Transformer oil or heat removin oil is "s"ally a
hihly;refined mineral oil that is sta&le at hih tem!erat"res
and has e#cellent electrical ins"latin !ro!erties. It is "sed
in oil;filled transformers, some ty!es of hih voltae
ca!acitors, fl"orescent lam! &allasts, and some ty!es of hih
voltae switches and circ"it &reakers. Its f"nctions are to
ins"late, s"!!ress corona and arcin, and to serve as a
coolant.
Ins"latin oil is introd"ced to the sealed cham&er where it
hel!s cool the 7eat sinks &eca"se it serves as a very efficient
coolant and shows ood characteristics as a coolant.
Com!leted TEI %ssem&ly
(ooen Bo&
% ',' s>. inch wooden &o# is made to !revent the
TEI assem&ly to the direct e#!osition to s"nliht. 8irst of
all a heat ins"lator thermo!ole sheet is !laced and l"ed
over all entire &o# and then com!leted assem&ly is !laced in
it. 9o that to et the desired !ower eneration &o# as shown
in fi"re &elow.

8ront P Nack Kiew of Bower !rod"ction No#
Com!leted :echanical 9ystem
IK. EDECTRIC%D 9L9TE: DE9IIN
The main !"r!ose of the electrical system is to drive the
mechanical assem&ly and !erform acc"rate trackin of the
s"n. The main f"nctions of the set"! are to !erform a3im"th
and elevation calc"lations, drive motors, interface with real
time clock, interface with DCD P 6ey!ad for "ser
interaction.
%KR %T:EI%(, is "sed to !erform the calc"lations
&eca"se it o!erates at G :IB9, so it can also e#ec"te the
control alorithms and drive the ste!!er motors accordinly.
%TGC9), is "sed to interface with Real Time Clock
0D9',GJJ2 which !rovides the c"rrent time for calc"lations.
DCD P 6ey!ad are interfaced with %TGC9), for "ser
interaction and &oth controllers comm"nicate thro"h serial
!ort.
9ystem 9chematic
:otor Drivin Circ"it
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K. 9EN9ORDE99 TR%C6INI :ET7ODODOIL
A. Trackin% E)!ations
Derivation work is already done on trackin e>"ations.
Trackin e>"ations are "sed in reference from the work
done &y Beter;D"ffett 9mith -''..
B. Trackin% Al%orit*m
D;%;: %DIORIT7: 0 2
' INITI%DIQE;9ERI%D;TR%N9:I99ION 0 2
, 'E R Elevation %nle
( '( R %3im"th %nle
? '()* R %cknowledement
) '(+ R %nle Data
4 'Eo R S
J '(o R S
G ,ait for 9erial Interr"!t
C while D%L
'1 if '(+ re>"est from slave controller
'' 9END;9ERI%D '(+
', ,ait "ntil '()*
'( do 'E R 9UN;BO9ITION 0 2
'? '( R 9UN;BO9ITION 0 2
') while '( T '(o
'4 do
'J '(o R '(
'G ')( R C"rrent %3im"th %nle
'C do
,1 ')( R 9EN9OR;BO9ITION 0 2
,' while ')( - '(o
,, do
,( DRIKE;%QI:UT7;:OTOR 0 2
,? ')( R 9EN9OR;BO9ITION 0 2
,) while UE T UEo
,4 do
,J 'Eo . 'E
,G ')E R C"rrent Elevation %nle
,C do
(1 ')E R 9EN9OR;BO9ITION 0 2
(' while ')E - 'Eo
(, do
(( DRIKE;EDEK%TION;:OTOR 0 2
(? ')E R 9EN9OR;BO9ITION 0 2
C. Controller Flowc*arts
:aster Controller 8low chart
9lave Controller 8low chart
D. Slave Controller Al%orit*m
9;C %DIORIT7: 0 2
' INITI%DIQE;9ERI%D;TR%N9:I99ION 0 2
, INITI%DIQE;DCD 0 2
( INITI%DIQE;RTC 0 2
? 'E R Elevation %nle
) '( R %3im"th %nle
4 'T R Time
J '()* R %cknowledement
G '(+ R %nle Data
C while D%L
'1 '(+ R S
'' 'T R RE%D;RTC 0 2
', DI9BD%L;DCD 0 'T 2
'( if 'T V '1 9EC
'? then
') 9END;TI:E;D%T% 0 2
'4 ,ait "ntil '()*
'J '(+ R REWUE9T;%NIDE;D%T% 0 2
'G if '(+ - S
'C then
,1 9END '()* for received data
,' DI9BD%L;DCD 0 'E 2
,, DI9BD%L;DCD 0 '( 2
,( else
,? '(+ R REWUE9T;%NIDE;D%T% 0 2
,) else
,4 ,ait for )11ms
KI. 9L9TE: %N%DL9I9 P OBTI:IQ%TION
9L9TE: 9T%NIDITL
8or every system, 9ta&ility is the !arameter on
which the o!eration of whole system relies. The !rimary
f"nction of the system is directly affected &y the system
sta&ility which in this case is !ower !rod"ction.
Co"nter weihts are "sed to achieve hiher rank of sta&ility
of the system mechanical str"ct"re. Two co"nter weihts are
"sed to make &oth the a#is of elevation and a3im"th sta&le.
The elevation co"nter weihts s"!!ort the weiht of the
!ower !rod"ction assem&ly and introd"ce a co"nter;tor>"e
to s"!!ort the fork assem&ly which in t"rn enhances the
system sta&ility in reat deal.
8eed&ack control system is im!lemented to make
the software !art aware of the mechanical system !osition at
all times. This information then hel!s the software to make
decisions to achieve &etter sta&ility in the trackin system.
9ta&ility of the system ens"res the &etter workin of system
and make it desira&le dist"r&ance tolera&le. Noise
introd"ced d"rin trackin s"ch that a !"sh or !"ll thro"h
any "ndesired so"rce is firstly mitiated &y the system
mechanical and then in t"rn sta&ility is f"rther enhanced &y
the efficient alorithm im!lementation.
It can &e concl"ded that the system is sta&le in terms of
o!eratin mechanism. This is d"e to the fact that the
!ositions of the mechanical !arts are fi#ed and therefore not
m"ch !arameter chanes other than the intensity of the
s"nliht and s"rro"ndin effects.
9L9TE: %CCUR%CL
9ystem acc"racy ives the meas"re of the a&ility of
the system to !erform the !rimary f"nction accordin to the
desired s!ecification witho"t any erroneo"s workin. %s the
system tracks the s"n witho"t any sensors "sin com!le#
astronomical e>"ations, so a hih level of acc"racy is
re>"ired.
The system has a tolerance of aro"nd ,
o
;(
o
i.e. the
!ower !rod"ction ca!a&ility is not affected &y this m"ch
error. Let the system achieved an acc"racy of X 1.,)
o
reardless of the atmos!heric conditions and chane of
seasons.
9L9TE: 9EN9ITIKITL
9ystem sensitivity is the meas"re of the chane in
o"t!"t of the system when the in!"t is varied &y a small
amo"nt. In this system, the in!"t is the !osition of the s"n in
the sky in form of two anles and o"t!"t is the movement of
the mechanical assem&ly of the system which tracks the s"n.
The system showed hih sensitivity as it res!onded to very
small chanes in the anles characteri3in the !osition of the
s"n. The O"t!"t i.e. the movement of mechanical system
was o&served to follow the !osition of the s"n accordin to
the chanes in the characteri3in !arameters. The system is
fo"nd to &e so sensitive that it detects and mitiate any
"ndesira&le anles chanes in the o"t!"t of the system to
sto! the system to do erroneo"s trackin of the s"n.
9EN9ITIKITL P 9T%NIDITL UNDER 9EKERE %T:O9B7ERIC
CONDITION9
9evere atmos!heric conditions force the system to
deviate from its normal o!eratin characteristics. To
mitiate these effects, feed&ack control system is made
efficient eno"h to tackle these conditions to some e#tent.
If the e#ternal forces are small and "nder a certain
threshold, the system mechanical ear assem&lies toether
with the efficiently im!lemented alorithms ens"re the
normal o!eration of the system. On the other hand, if these
e#ternal forces are reater eno"h to do harm to the system
while it is in o!eration, a s!ecial detection system is
installed to move the system in slee! mode. In slee! mode,
the system &ecomes com!act eno"h &y facin downward to
&ecome more ro&"st and tackle these severe conditions.
%lso, in heavy rains and e#treme windy environments the
system electrical s"!!lies are c"t;off to !revent any s!arkin
or ha3ardo"s damae to the system.
9BEED O8 RE%CTION
*hile trackin, the s!eed of reaction of heliostat is
considered fast as it res!onds almost instantaneo"sly when
the anles characteri3in the !osition of s"n are chaned.
%lso, when the system is restored from slee! mode, it tracks
the s"n instantly. The system reacts very fast to move the
system &ack to its oriinal !osition when e#ternal forces
ca"se it to deviate from its desired !osition.
9L9TE: E88ICIENCL
9ystem efficiency is the ratio of the !ower
!rod"ced to the in!"t !ower. In this case, the in!"t is the
!ower received from the s"n and the o"t!"t is the electrical
!ower !rod"ced.
The system !rod"ced the !eak !ower of ?1*
d"rin o!eration when the tem!erat"re difference of ')1
o
C
was achieved. The e#!erimental res"lts are shown &elow.
Table /0 System 1utput 2esults
Temperat
ure
+ifference

o
)!
3oltage )urrents
(mps!
4ower
,atts!
J) G.? ,.,G 'C.,
'11 '1.1? ,.G, ,G.('
')1 ',.G? (.'4 ?1.)J
The system received ma#im"m in!"t solar !ower
of a!!ro#imately '6*. The system !rod"ced !ower of ?1
watt at ma#im"m in!"t. The efficiency of the system can &e
iven &y

The system achieved an acc"racy of ?H. The
efficiency of the system can &e increased &y "sin &etter
coolin sol"tion for the TEIs. The system has the ca!a&ility
to im!rove !ower !rod"ction to '11 watts &y minor chanes
in the desin.
KII. CONCDU9ION
The desin and im!lementation of a low cost d"al a#is
heliostat mirror system for !ower !rod"ction is !resented.
The oal of desinin this system was to make a low cost
system which can achieve lower cost !er watt. The system
achieved a cost of Rs. J)1+watt which is very low for a
!rototy!e systems where as !ast !rototy!es cost
Rs.'(,1+watt 0''Y+watt2. %lso the cost of the system can &e
reatly red"ced &y mass !rod"ction makin it com!etitive
and s"ita&le for commercial !"r!oses.
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rd
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