Design of a Software Controlled Two axis Automatic Solar tracking

system.

M.R. I. Sarker1, M. R.A Beg2, M.Z. Hossain3, M. T. Islam1 and M.RZaman2

1
Department of Mechanical Engineering, CUET, Bangladesh
2
Department of Mechanical Engineering, RUET, Bangladesh
3
Department of Electrical & Electronic Engineering, CUET, Bangladesh

Abstract: This paper presents the design of a Software Controlled Two axis Automatic
Solar tracking system to track Solar PV Panel according to the direction of beam
propagation of Sun’s radiation. The entire tracking system consists of sensor with
comparator, control circuits to motor drive with control software, and gearbox with supports
and mountings. The controlling motion for PV panel has been provided by discrete motion
of the motor. CMOS Integrated Circuits (ICs) with relays are used in the control circuits,
which generate pulses according to software feedback for rotation of the motor drive. For
resetting the position of the panel from end-of-day position to that for operation early the
next day a provision has been kept in the software in this system. The amount of receivable
solar insolation through two axis tracking is considered as 100% at all latitude and energy surplus
becomes about 57% without atmospheric influences. In case of seasonal changes of the Sun’s
position, it is possible only by changing software adjustment to reset position of PV Panel in
this system. Considering all above aspects of this tracking system it can be concluded that, it
is an flexible tracking system with least cost and high efficiency for trapping the Sun’s
incident energy.

Key Words: Tracking system, Solar PV Panel, CMOS Integrated Circuits, Control Circuits.

1. INTRODUCTION: Single Axis Tracking – panels are tracked on a

Sun is moving across the sky during the day. In the
case of fixed solar collectors the projection of the
collector area into the plane, which is perpendicular
to the radiation direction, is given by function
cosines of the angle of incidence (Fig-1). The
higher is the angle of incidence, the lower is the
power. The solar tracker, a device that keeps
photovoltaic or photo thermal panels in an optimum
position perpendicularly to the solar radiation
during daylight hours, can increase the collected
energy by up to 40%.
There are different types of photovoltaic solar
generation systems: Fixed panel, Single Axis
Tracking, and Dual Axis Tracking. As their name
implies, Fixed Panels remain stationary and convert
sunlight to electricity when sunshine falls on them.
Tracking panels follow the path of the sun to
maximize the exposure of the panels to solar
radiation in order to convert sunlight to energy.
single axis. Dual Axis Tracking systems move the
solar panels so that they continuously point towards
the sun, using both azimuth and elevation axial
movements.
Theoretical calculation of the energy surplus in the
case of tracking collectors is as follows: Assume,
the maximum radiation intensity is Ι = 1 100 W-m-2
falling on the area which is oriented perpendicularly
to the direction of radiation. It is assumed, the day
lengths t=12h=4300s as well as the night length and
it is compared, the tracking collector which is all
the time optimally oriented to the sun with the fixed
collector which is oriented perpendicularly to the
direction of radiation only at noon. Mark the
collector area S0.

Fig-1: Fixed PV array, one axis tracking
a) For fixed collector: The projection of this area on
the area, which is oriented perpendicularly to the
radiation direction, is equal S=S0.cosϕ and the
angle ϕ is changing in the interval ϕ∋[ π /2,− π/2]
during the day. The angular velocity of the sun
−5 −1
moving cross the sky is equal ω = 7,27.10 s and
the differential of the falling energy is equal
dW=I.S dt. When we don’t consider the atmosphere
influence, we can calculate the energy, which is
fallen on the collector area S0=1m2 during one day
+21600 +21600
sin ωt 
w = ∫ I .S 0 . cos ωtdt = I .S 0  
−21600  ω  −21600
2 I .S 0
= = 303 .10 7 W .s.......... ...... (1)
ω circuit. In this case, however, a computer is used to
(b) For the tracking collector which is all the time
optimally oriented to the sun we calculate: When it
isn’t considered the atmosphere influence, it can be
calculated the energy, which is fallen on the
collector area S0=1m2 during one
ϕ loop) Systems.
S0
One Axis Tracking
day
W = I .S 0 t = 475 .10 7 W .s ......... (2)
ο
(Sinceϕ = 0 )
Comparison Eq. (1) and Eq. (2) shows the energy
surplus 57% when it isn’t considered the
atmosphere influence. It would be really obtained
this surplus for example on the Moon surface.[1]
3. METHODOLOGIES OF AUTOMATIC
TRACKING SYSTEMS FOR PV PANEL:
Automatic tracking systems for PV Panel are of two
types: Program or Software based Systems and
Individual Hardware (without program) Systems.
Both systems can be designed on the basis of single
axis E-W tracking or Two-axis tracking.
3.1 Program or Software based Systems:
These systems of tracking use a computer program
which determine the proper orientation of panel
with PV cells. In its storage device or memory
chips, a year-round data of angles of Sun’s position
according to time of the day are stored. These data
are addressed by addressing chips and processed by
a microprocessor unit. The processed data are fed to
the port of the computer system. The port signals
are further fed to the driver circuits of stepper
motors. Stepper motors, unlike normal DC motors,
move in incremental steps, which are triggered by
digital pulses. Driver circuits are required for
supplying these pulses. The pulse frequency
determines the speed of rotation of the motor shaft.
Usually a timer IC is used in the average driver
generate the pulses, thus enabling speed and
direction control by a computer [2].These systems
are of two types:
• Online Tracking (close loop) Systems
• Rough Positioning with Database (open
3.2 Individual Hardware (without program)
systems:
In these systems some logic circuits with timers are
used to generate pulses, which are fed to a DC
motor for tracking of solar PV Panel. For
predetermined position of the panel, a disc is
indexed with contact points which are designed
according to the position of the sun with the time of
the day. The contact points and the timer & logic
circuits are combined to produce pulses for discrete
motion of the motor which control the panel
through control mechanism.
 Continuous mapping of Maximum
A/D Converter Power Point (MPP) of PV cells using
current (I) and Voltage (V) from PV
Solar PV Panel Panel by Microprocessor unit in
different time of the day

Control
Mechanism Stepper Motors Driver Circuits

Fig: 2. Block Diagram of Online Tracking (close loop) Systems.

4 DESIGN OF TWO AXIS AUTOMATIC
SOLAR TRACKING SYSTEM:
4.1 System description:
The designed tracking system have been used a
software based online tracking method as shown in
fig-2. The designed system components are
photovoltaic cell, sun sensor, interfacing component
with CPU, stepper motor driver circuit, stepper
motor and PV cell supporting metallic structure
with mechanical gear mechanism. Here to detect the
sun position servo system has been used.
Servo system is a photoelectric method, which is
used to find a deviation of the radiation incident
upon a concentrator. It operates the elevation and
azimuth driving systems to return the radiation
parallel to the optical axis. For detecting the
deviation an optical tube may be used, which is
fixed with as axis parallel to that of concentrator, in
which there is a small opening' at one and, through
which a beam of solar radiation is introduced.
This radiation is incident on four photoelectric
tubes at the other end of the tube. When imbalance
of the voltage between two tubes up and down
occurs, it effects the change of elevation and that
between two tubes right and left, the change of
azimuth. Another method uses four phototransistors
to detect deviation around a sun image.
sun sensor information as inputs to generate proper
motor commands to slew the collector. The PC base
controller contains database program based on sun's
position for every time of a definite day. When the
stepper motor gets the commands from the
controller, the motor starts to rotate at a definite
angle according to the controller command that
slew the collector. [3]
The basic philosophy of the control system is that a
predetermined desired rate is modified or trimmed
by actual position errors determined by the sun
sensor. The controller ensures that the tracking
collector is pointed toward the sun normally and
sends a "start track" command. The controller
constantly calculates the sun's rate for the two axis
(azimuth and elevation) of control during the day.
SOLAR
PANEL
SENSOR C
P
U
POWER
SUPPLY
DRIVER
GEAR
MOTOR CIRCUIT
DRIVE
Fig. 5- Block diagram of the designed tracking system

Fig-6.1 describes the general operations of the sun-
tracking system together with some of the most
important components. Sun sensor's detector
determines system misalignment (position error of
solar radiation collecting unit) and then sends a
signal to the controller (CPU's software). The
controller (CPU's software) uses the sun's rate and
4.2 Design of control circuit:
The main components of the control circuit are (1)
sensor LDR (Light Dependent Resistor) with
comparator (741IC) (2) stepper motor driver
(ULN2003 IC with zener diode) (3) parallel port
and software with CPU.There is no any signal
conditioner like ADC, because LDR output directly
can access to the parallel ports and comparator can
process this output of LDR within 5v.
4.2.1Sensor:
It is a device used to generate an equivalent
electrical signal, either in the form of voltage or
current, if a non-electrical physical quantity is
applied to it. Thus in the case of say an electrical
resistance temperature element, the quantity being
measured is temperature and the sensor transforms
an input of temperature into a change in resistance.
The possible sensors can be identified, taking into
account such factors as their range, accuracy,
linearity, speed of response, reliability,
maintainability, life power supply requirements,
ruggedness', availability, cost nature of the
measurement. The selection of sensors cannot be
taken in isolation from a consideration of the
form of output that is required from the system
after signal conditioning, and thus there has to be a
suitable marriage between sensor and signal
conditioner. Here a tube consisting LDR with small
opening is used as Sensor. LDR (light dependent
resistor) is a sensor the resistance changes if the light
intensity is changed. If LDR is connected with a
voltage source, the current will also changes. The
change of current will be in accordance with the
change of light intensity. Here a comparator is used
with the sensor to compare the sensor output with the
required output.
4.2.2 Driver circuit:
The ULN2003 as shown in fig-6 is a 7-bit 50V
500mA TTL-input NPN Darlington driver. This is
adequate to control a four phase unipolar stepper
motor which has been selected as stepper motor
driver circuit due to its low cost and greater
accuracy to control.
Fig 6-ULN2003 IC Diagram.
It is recommended to connect a 12v zener diode
between the power supply and VDD (Pin 9) on the
chip, to absorb reverse (or "back") EMF from the
magnetic field collapsing when motor coils are
switched off. It is recycled the power and motor
lead connectors from the TM100 Logic PCB. A
convenient source of 12v and 5v is an old IBM-PC
power supply unit. The 9-way D-type connector is
appropriate for the number of (parallel) control
lines needed in the cable.
4.3 Design of mechanical structure:
.Most photovoltaic systems are designed to last 20
years or longer. It is important to that the other
components in the system, including mechanical
components, have life time’s equivalent to those of
the pv modules. It is also important that the
mechanical design requirements of the system be
consistent with the performance requirements as
well as with the operational requirements. The
mechanical design of photovoltaic systems cuts
across a verity of discipline, most notably civil and
mechanical engineering and to a lesser extent
material science, aerospace engineering and
architecture. More specifically mechanical design
involves:
• Determining the mechanical forces acting
on the system.
• Selecting, sizing, and configuring
structural members to support these forces
with an adequate margin of safety.
• Selecting and configuring materials that
will not degrade or deteriorate
unacceptably over the life of the system.
• Locating, orienting and mounting the
photovoltaic array so that it has adequate
access to the sun’s radiation, produces the
required electrical output and operates
over acceptable PV cell temperature
range.
• Designing an array support structure that
is aesthetically appropriate for the site and
application and provides for ease of
installation and maintenance.
 Considering above criterion gears and holding TRACKING CONCENTRATORS.
mechanisms for the panel is selected.[4] info@solar-trackers.com
2. RAI G.D. "SOLAR ENERGY
5 DISCUSSIONS: UTILISATION "Third edition, KHANNA
PUBLISHERS DELHI-110006 (1987).
The tracking mechanism is capable of track the Sun
according to the time and it is possible to adjust the 3. Benjamin C.Kuo “AUTOMATIC
panel for accuracy of tracking adjustment is not CONTROL SYSTEM”7th Edition, Prentic
needed in the circuit which is needed only to the Hall India.
software if necessary. However due to the of axis
movement of any single axis tracker, It could not 4. Roger Massenger, Jerry Ventre
minimize the angle of incident to zero as what a two “PHOTOVOLTAIC SYSTEMS
axis tracker could do. So the amount of receivable ENGINEERING” ISBN0-8493-2017-
solar insolation through two axis tracking is 8, CRS Press, New York.
considered as 100% at all latitude and comparison of
equation (1) and equation (2) shows the energy
surplus 57% without considering the atmosphere
influence in this case which is the most important
factor.

The power consumption by the system is very low

because of low energy consumption devices are used
like as COMS digital IC's and other electronic
components. Moreover the motor also consumes a
small amount of energy because it rotates only for a
fraction of a minute at every interval of time. It is
possible to face the panel always perpendicular to the
Sun's incident rays by the software control circuit. So,
it has greater flexibility and accuracy.

6 CONCLUSIONS:

It is simple to operate and maintenance is easier due

to absence of circuit complexity. There is a provision
in the software for adjustment of the system in case
of seasonal variation. The system performance can
be improved by using high capacity panel, so that it
will need no battery and it can be operated with self
power generation. This tracking system is more
compact and easier than any other tracking system
with minimum cost because only simple sensor
(LDR) and driver circuit IC (ULN2003) are used
which are available with low in cost. So considering
all above aspects of this tracking system, it is
simple, cost effective & highly efficient for trapping
the Sun's abundant free energy.

7 REFERENCES:

1. Vladislav1 MartinPoulek2 NEW

BENIFACIAL SOLAR TRACKERS AND