Solar Tracker Report Example

8/10/2019 Solar Tracker Report Example

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Mechanical/Electrical/Software

TeamDesignandPrototyping

fora

SunTrackingSolarEnergyCollector

System

ForMechanicalEngineering4B03

Authors:

TylerKenyon

YajieJiang

AllanD.Spence

August2010


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TableofContents

1.Introduction................................................................................................................................ 1

2.

Fixed

vs.

Tracking

Solar

Panels

....................................................................................................

1

3.OrbitalMechanicsReview.......................................................................................................... 2

4.SystemRequirementsSummary................................................................................................. 3

5.ComponentsandEquipment...................................................................................................... 4

6.ConceptualMechanicalDesign................................................................................................... 7

6.1AzimuthTrackingBase.......................................................................................................... 8

6.2ZenithTrackingUpperStage................................................................................................. 9

7.

CAD

Detail

Design

and

Assembly

..............................................................................................

14

7.1AzimuthTrackingBase........................................................................................................ 14

7.2ZenithTrackingTop............................................................................................................. 14

9.PhysicalModelRealizationfromCAD....................................................................................... 18

10.Summary................................................................................................................................. 18

Acknowledgements....................................................................................................................... 18

11.Appendix................................................................................................................................. 19

Appendix

A1

Electrical

Implementation

.................................................................................

19

AppendixA2ArduinoSoftwareTutorial................................................................................ 32

AppendixA3SoftwareImplementation................................................................................. 37

AppendixA4CADDrawings.................................................................................................... 38

AppendixA5RapidPrototypedComponentCosts................................................................ 39

References.................................................................................................................................... 40


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1.IntroductionHarnessingsolarphotovoltaicenergyisapromisinggreenenergytechnology. Toensure

highestenergy collectionefficiency, it isproposed thatanautomatic sun tracking systembe

developed to continuously align the collector surface normalwith the instantaneous solarvector(thedirectionfromthecollectortowardsthesun. Anexampleofafullscalesystemis

showninFig.1. Thefocusofthisprojectistwofold:

1. Mechanicaldesignandprototyping

2. Electronicandsoftwaredesignandimplementation

Forconsistencywithestablished industryandscientificstandards, thesystemwill trackusing

AzimuthandZenithangles (Fig.2) [1].Theprojectdeliverablesaredesigndocumentsandan

actual scale model prototype that faithfully represents the design required for a full size

system. CoordinatedteameffortofstudentsinbothMechanicalandMechatronicsEngineeringismandatory.

TheCADdesignforthesolartrackingsystemwascreatedusingAutodeskInventor2010

[2].PrototypeplasticcomponentswereproducedusingaDimensionBST[3]rapidprototyping

machine. The software and electronics are based on an Arduino Duemilanove [4]

microcontroller.

2.Fixedvs.TrackingSolarPanelsSmall solarpanelsare frequently installedata fixedorientation,whereas larger installations

typicallytrackthesolarvectorusing2axisAzimuth/Zenithaxes. Thereturnoninvestmentfor

theaddedexpenseoftrackingcanbeestimatedbyreferringto insolationdataavailablefrom

[7]. ForCanada, the preferred fixedorientation is adue South facingAzimuth,with Zenith

angle corresponding to the latitude. Using Hamilton as an example, selected mean daily

insolation values [8] are reproduced inTable1. DuringDecemberdays,when thedays are

short and the sun is predominantly towards the South, there is a limited gain from 2axis

tracking. During the long days of June and July, the 2axis advantage is 8.9 kWh/m2 / 5.5

kWh/m2=62percent. Thereasonforthe2axisadvantageisthegreaterAzimuthrangeinthe

summer. Recognizingthattheextremeweathersummerairconditioningloadcausesagreater

electricityloadthanwinterheating[9],harnessingtheextraenergyfromsolartrackingonhot

summerdaysisattractive. Itisabalancebetweeninitialcapitalcost,extramaintenance,and

powerconsumedfortrackingvs.extraenergycollectedessentiallyaneconomyofscale. This

optimizationisanessentialengineeringdesignissueforfullscaleimplementation. Forthescale

model project in this course, it is sufficient to recognize the significant potential gain for


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tracking, but limit activity to demonstrate application of the course product design and

developmentconcepts.

3.OrbitalMechanicsReview

Thesunchangespositionintheskybecauseoftwoeffects(Fig.3):

1. DailyrotationoftheEarth

2. Seasonalvariationdueto23.5degreerotationaxistilt

Thesunposition(orsolarvector)hasbeenobservedforthousandsofyears,and isknownto

highaccuracy. Usingalmanactablesoronlinesoftware[6],sunriseandsunsetinformationfor

specific latitudesand longitudescanbeobtained. Forexample (Fig.4),on June21,2010at

Toronto,Ontario,thesunrisesat5:36amEDTatanAzimuthof56degreesEastofNorth. Itsets

at 9:03pm at anAzimuthof304degrees. Atnoon theAltitude angle is69.8degrees. The

Zenithangleis9069.8=20.2degrees. BecausethelatitudeofTorontois43.7degreesNorth,

andtheaxistiltis23.5degrees,aZenithangleof43.723.5=20.2degreesisexpected.

Thefactthat,duringtheNorthernsummer,thesunrisesandsetsNorthofEast/West, isalso

duetotheaxistilt. SeeFig.5foranillustration. At43.7degreesNorthlatitude,themorningis

longerby24.49degrees. Since15degreesisonehour,thiscorrespondstoalongermorningby

1.63hoursor1hourand38minutes. Theeveningissimilarlylengthenedforatotaldaylength

of12+3.26hours=15.26hours=15hours16minutes. Actuallengthofdayisslightlylonger

thanthisduetoatmosphericrefraction(about7minutesintotalattheequator).

Attimesotherthansunrise,noon,orsunset,thesolarvectorcanbecalculatedusingpublished

algorithms [1]. Thisparticularalgorithmacceptsas inputthe location latitudeand longitude,

andthetimeofdayexpressedinCoordinatedUniversalTime(UTC),themeansolartimeatthe

prime longitudemeridianpassing through theRoyalObservatoryatGrenwich,England. This

informationisavailableusingaGlobalPositioningSystem(GPS)receiver. Forafixedposition,

the latitude and longitude are constant, and a realtime clock is sufficient. The algorithm

outputisthesolarvectorAzimuthangleandZenithangle,asdefinedinFig.2.


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4.SystemRequirementsSummaryForthisreport,theprototypesolartrackeristobeascalemodelofaproposedfullsizedesign

withthefollowingrequirements:

Figure1. ExampleFullScaleSunTrackingSolarPhotovoltaicEnergyCollectionSystem(photo

byA.Spence)

Table1.MeanDailyInsolation(inkWh/m2)forHamilton,Ontario(summarizedfrom[8])

South-facingvertical

(tilt=90)

South-facing,tilt=latitude

South-facing,tilt=latitude+15

South-facing,tilt=latitude-

15

Two-axissun-

tracking

Horizontal(tilt=0)

January 2.8 2.8 2.9 2.5 3.3 1.6

June 2.6 5.4 4.7 6.0 8.8 6.2

July 2.7 5.5 4.8 6.1 8.9 6.3

December 2.2 2.2 2.3 2.0 2.6 1.2

Annual 2.9 4.2 4.0 4.3 5.9 3.7


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ItisintendedforuseinCanadaatlatitudesbetween40and60degreesNorth.

Sofarasispossible,itistoutilizethecomponentsandequipmentdescribedherein.

Itistocalculateazimuth/zenithanglesusingthecurrenttimeobtainedfromtherealtime

clock.

Itisassumedthattherealtimeclockremainspoweredupfromitsbackupbatteryandisalwaysreliable,evenifpowerislosttotheArduinoandsteppermotors. Uponpowerup

(includingafterapowerfailure),thesystemmustrecoverinawaythatavoidsovertravel

orwindupofeithertheazimuthorzenithstage.

Powerwillbeprovidedusingawalltransformersupplying9VDC1000mAtotal.

Duringdaylighthours,thesystemmusttracktowithin1degree. Afterdarkthesystem

istoparkwithazimuthSouthandZenithanglezero(upwards). Apinholeorothermeans

toverifytrackingfidelitymustbeincluded.

Theprototypemustbereasonablysafetooperatewithlowriskofinjurytooperators,or

damagetoequipment.

5.ComponentsandEquipment

Components

The project involves mechanical/electrical/software (mechatronic) product development.

Emphasis ison themechanicalaspects,withjudiciouschoiceofelectrical/software interface.

Thefollowinglistdescribesthesuppliedcomponentsavailabletocompletetheproject.

ArduinoDuemilanove

microcontroller:

This microcontroller provides a very simple programmable interface to the electrical

switches,motor,clock,etc. Forcommunicationandcustomization, it isconnectedtoa

Windows/MacOScomputerusingastandardUSBcable. Theassociatedprogramming

softwareisavailableatnocharge. Implementationofthecurrenttimetoazimuth/zenith

angleconversionprogram[1]isprovidedforyoutouse. RefertoAppendixA1fordetails.

ArduinoDuemilanovecustomexpansionshield:

Toprovide a standard interface for theproject, an expansion shield is provided. This

custommade

shield

includes

(see

below)

aDS

1307

real

time

clock,

two

MC

3479

stepper

motor drivers, and support components for themechanical limit and optical homing

switches. RefertoAppendixA2fordetails.

ElectroMechanicalComponents:

Autodesk InventorCADdrawingsareprovided inAppendixA3,andcomputer readable

modelfilesareavailableonthecoursewebsite.


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o JapanServoKP35FM2035StepperMotors

Thesemotorshaveafullstepresolutionof1.8degrees(200stepsperrevolution).

Maximumtorqueis700gcmoftorqueat24VDC/500mA. Installedconditionsare

9VDC,andhenceamaximumtorqueof250gcmisrealistic.

o MechanicalLimit

Switch

Amechanical limit switch isused. On theprovidedprototype, the switchwillbe

triggeredwhen the azimuth stage approachesNorth, and can be sensed by the

microcontroller. Together with the optical homing switches, checking for

unintended azimuthwindup after power loss can be programmatically detected

andrecoveredfrom.

o OpticalHomingSwitches

Optical switchesareused to sense,withhigh repeatability,both theazimuthand

zenithhomepositions. ByinterruptingtheLEDlightbeam,theprovidedprototype

homestheazimuthat90degrees(East),andtheZenithat90degrees(horizon).

SignificantMechanicalHardware:

o AzimuthStageLazySusanBearing:

Thechosen3 inchDiameterLazySusanbearing(LeeValleyToolsSKU12K01.01) is

usedtotakethegravityweightthrustloadfortheAzimuthrotationalstageonthe

prototype. This bearing is quite loose, and a higher quality choice would be

requiredforafullsizeimplementation.

o MountingHardware:

Unlessstatedotherwise,thethreadedfastenersare#632threadinstalledin4mm

diameterclearanceholes. Forsnugness,pivotsusemetricM40.7thread. Alength

of#1032threadedbrassrod,withcorrespondingnuts,wasusedfortheprototype

Zenithstageleadscrew.

o SheetPlastic:

Smallquantitiesof0.125 inchand0.250 inchthickclearsheetplasticareavailable

fromtheMechanicalEngineeringTechnicalServicesstafflocatedatJHE205.

Equipment

DigitalMultimeterCircuitTestKit:

TheelectricalcomponentsareprewiredforconnectiontotheArduinocustomexpansion

shield. For convenience,minor circuit testingcanbeaccomplishedusing theCanadian

Tirekit#52-0064-4 digital multimeter, wire strippers, and pliers.


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SmallWrenches,ElectricDrills,etc.:

Smallwrenchesforsecuringfasteners,etc.areavailablewiththemultimeterkits. Electric

drills fordrilling sheetplastic are available from theMechanical Engineering Technical

ServicesstafflocatedatJHE205. Successfulcompletionofashopsafetytrainingcourse

at

the

beginning

of

the

term

is

required

before

using

powered

equipment.

RapidPrototypingPrinter:

RapidPrototypingservicesareprovidedbyMechanicalEngineeringTechnicalServicesfor

afeeof$12percubicinchofpartmaterial. TheDimensionBST768maximumbuildsize

is 8 inches (~200mm) 8 inches (~200mm) 12 inches (~300mm). The printing

resolution is0.010 inches (~0.25mm). Supportmaterialwillautomaticallybeaddedby

theDimensionCatalystsoftware. Thereisnochargeforsupportmaterial,butyoushould

considertheneedtomanuallyremovethesupportmaterialinyourdesign.

TheprinterusesABSplastic,amaterialwithapproximatematerialproperties:

Youngsmodulus=2.89GPa PoissonsRatio=0.38

YieldStrength=40MPa Density=1.06g/cm3

Becausethematerialisnottrulysolid,itisrecommendthatyourdesignassumestiffness

and strengthvalues thatare50%of solidABS. Usingawall thicknessno thinner than

0.060 inches(1.5mm)toavoidrapidprototyping layerdelamination. Tomostfaithfully

emulateplasticinjectionmoulding,constantwallthicknessesshouldbeused.

ComputerAidedDesignSoftware:

The facultyhasnow standardizedonAutodesk Inventor forgeneralCADuse. Allwork

submittedforgradingmustbecreatedusingInventor(noexceptions). Itisexpectedthata kinematically correct mechanism solution will be completed before physical

prototyping. Finiteelement analysis isnotessential,but reasonablejudgmentofpart

stiffnessisexpected.

Whensavingparts inSTL format for rapidprototyping,select theoption tousehighest

resolution. Designswillbereviewedbytheinstructor/TAs/TechnicalServicesstaffbefore

printing. Advice to revisedesignsareprovided toavoidwastedprinting,and the final

decisionwhenandiftoprintanypartrestssolelywiththeinstructionalteam.


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6.ConceptualMechanicalDesignInordertofullytrackingthesunfromsunrisetosunsetusingthesuppliedrealtimeclockand

Azimuth/Zenith calculation algorithm, the preferred mechanical design should employ

matchingrotaryaxes. Foramaximumlatitudeof60degreesNorth(suchasnearYellowknife,NWT),atthesummersolsticethesunrisesat27degrees(measuredEastfromNorth),andsets

at333degrees. At40degreesNorth(suchasnearWindsor,ON),theZenithstage,onwhich

thesolarpanelismounted,mustcoverarangefrom90degrees(horizon)to16.5degreesfrom

overhead.

Figure2. SolarVectorAngleDefinitions(from[1]). TheAzimuthangle()ismeasuredfrom

True North towards True East. Therefore True North corresponds to 0 , True East

corresponds to 90 degrees,TrueSouth corresponds to 180 degrees,andTrueWest

correspondsto 270 degrees. TheZenithangle( Z ) ismeasuredfromdirectlyoverhead.

Hence 0Z means that the sun isdirectlyoverhead,castingno shadow. Thisoccurs, forexample, at local solar noon on the equator on an Equinox (approximatelyMarch 20 or

September22).


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Toavoiddependenceonelectricmotor torque tomaintainpositionagainstwindandgravity

forces,goodbalancingand selflockinggear reduction shouldbeused. For rotarymotion,a

wormgearcanbeused. For linearmotion,a leadscrewcanbeused. For learningpurposes,

theprototypedescribedinthisreportusesawormgearfortheAzimuthstageandaleadscrew

fortheZenithstage. Thisisnotnecessarilyoptimal,andyouareexpectedtocriticallyevaluate

choices foryourteamdesignbasedonspecificrequirementsannounced forthecurrentyear

courseoffering.

6.1Azimuth-TrackingBaseForlearningpurposes,andtopermitcustomization,theAzimuthwormgeardrivewasdesigned

using theDesignAcceleratorwithinAutodesk Inventor. Sizeswere approximated to fit the

supplied steppermotors, switches,and LazySusanbearing. Forademonstrationprototype,

this is somewhatabestjudgmentapproach. Full sizedesignsmust includeoptimization for

technicalcapability,attractiveness,environmentalcompatibility,cost,etc. Aworm(thescrew

likegearthatattachestothesteppermotor)pitchdiameterof20mmwaschosen. Thecenter

distance (from thecenterof theworm/motoraxis to thecenterof the largewormgearaxis

(alignedwiththeAzimuthaxis)wassetto82mm(Fig.6).

A coarse approximation for the ABS dry coefficient of friction is 0.5fc . For the chosen

lead/helix angle 11.3 degrees, tan 11.3 0.2 0.5 fc and hence self locking is

assured.

Withthechosenratioof36,themotor/wormwillrevolve36timesforeachrevolutionofthe

larger(LazySusanaxis)wormgear. Eachmotorrevolutionequals10wormgeardegrees,and

hencewith200fullstepspermotorrevolution,theresolutionis10degrees/200steps=0.05

degreesperstep.

Atpowerup,themicrocontrollerhasnoinformationonthecurrentAzimuthangle,andhence

an initialization procedure is needed. After initial installation, a properly operating system

shouldneverbeoutsideofthe27to333degreeAzimuthrange,evenifpowerislost. Hencea

powerupmotion that turns theAzimuth stageEastward toan initializationpositionof22.5

degreesshouldalwayssucceed. Intheprototype,thisisaccomplishedusingasmallscrewthat

protrudesdownward from theAzimuthwormgearand interrupts theopticalhoming switchLED light beam. Themicrocontroller senses the change in switch status, stops the stepper

motor, and initializes its internal Azimuth angle counter to correspond to an angle of 22.5

degrees. If,foranyreason,theopticalswitchsensingprocedurefails,motionwillcontinueuntil

anangleof zerodegrees (dueNorth) is reached. At thispointa second,upwardprotruding

screwwillcontactthemechanicalrollerleverlimitsafetyswitch,disconnectingsteppermotor

power independentofthemicrocontroller. Thisisconsideredtobeafaultconditionthatcan


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onlybeclearedbydepressingtheoverride limitswitchandcommandingthesteppermotor

to move the Azimuth stage Westward, or by manually moving the Azimuth worm gear

Westwardbeyond22.5degreeswhilethesteppermotorisunpowered.

6.2

Zenith-

Tracking

Upper

Stage

TheZenithtrackingstagesimilarlymustbeselflockingtoavoiduncontrolledmovementinthe

eventofelectricalpowerloss,highwinds,andthegravityforceduetothesolarpanelmass. A

wormgeardrivesimilartothatusedfortheAzimuthstagemaybethebestchoiceforpractical

implementation. Foracademic illustration,theprototypedescribedhereinusesaselflocking

leadscrewimplementation. ThekinematicconceptisshownasaCADsketchinFig.7. Allunits

areinmillimetersanddegrees. Theleadscrewnutpivotislocatedatpoint ,0A X ,where

0X whenthepivot is locatedatpoint D . Asthesteppermotorturnsthe leadscrew,the

nut pivot is constrained to travel along the horizontal lead screw bounded by points

24,0M and 88,0N . ThesolarpanelpivotsarelocatedatpointsB andC.

Usingtrigonometry,thenonlinearkinematicrelationshipbetweenthelinearmotionofthenut

pivot A andtheZenithangle (theta)canbeexpressedusingthesystemofequations

cos cos 180

cos cos

0 15 sin sin 180

15 sin sin

X BC AB

BC AB

BC AB

BC AB

ForadesiredZenithangle,iterativeNewtonRaphsonzerofindingtechniquescanbeusedto

solve for the corresponding nut pivot position ,0A X . Details are presented in the

softwarealgorithmimplementation(AppendixA1).

The lead screw used has a #1032 thread (32 threads per inch), and hence the nut pivot

advancesby1/ 32*25.4 0.79375 mm perrevolutionor0.79375 / 200 0.004 mm perstep.


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Figure3. EarthOrbitandAxisTiltEffectonSeasons(from[5])


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Figure4. SunriseandSunsetDataforJune21,2010atToronto,Ontario(from[6])

(a) (b)

Figure5. SummerSolsticeGeometryatToronto,Ontario. Theearthaxistiltis23.45degrees.

Thelatitudeis43.7degreesnorth. Thesliceofearth(inthechestnutbrowncolour)isfrom90

degreeseastback towhere theday/nightboundary ison June21. (a)Ata latitudeof43.7

degrees,thislengthensthemorningby24.49degreesoflongitude,or1hourand38minutes.

The

evening

length

increases

by

an

equal

amount,

for

a

total

of

3

hours

and

16

minutes,

makingthegeometricdaylength15hoursand16minutes. TheextratimeshowninFigure4

isduetorefractionnearthehorizon(upto7minutesneartheequator). (b)Toanobserveron

thesurfaceoftheearthatToronto,thesunappearsatthedawnhorizon56.6degreesnorth

ofeast.


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Figure6. AzimuthStageAutodeskInventorDesignAcceleratorWormGearParameters


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(a)

(b) (c)

Figure7. LeadscrewZenithTrackingStageKinematicConceptSketch: (a) pointandangle

labels; (b) geometryatZenithangleof90degrees; (c) geometryatZenithangleof0

degrees.


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7.CADDetailDesignandAssemblyComputer Aided Design of all major system components was performed using Autodesk

Inventor,withassembliesandkinematicmechanismconstraintsusedtoverifycorrectmotion.

Asbefore, theCADdesign is separated into theAzimuthandZenith tracking stages. Abrief

summaryispresentedhere. DetaileddrawingsarecontainedinAppendixA3.

7.1Azimuth-TrackingBaseFig.8(a)showsthegeneralCADdesignoftheazimuthtrackingbaseanditsassemblysituation.

Otherthanpurchasedhardware,thedetaildesignedcomponentsincludeanacrylicbaseplate,

arapidprototypedwormwheelgearring,theworm,andamotorbracket.Thebaseplate#632

clearancemountingholesweremadeusingaworkshopdrillpress/millingmachine. Therapid

prototypedsteppermotorbracket ismountedtothebaseplateandadjustedsothatcorrect

gearengagement isachieved. The Lazy Susanbearing ispositioned10mm above theplateusingspacersandlonger#632screws,washers,andnuts.Thewormgearisdesignedasaring

shapetoreducerapidprototypingmaterialconsumption.Acorrespondingholepatternmates

to the topplateof theLazySusanbearing.Theopticalswitch isusedtohomethesystemat

powerup. AlimitswitchmustbeaddedtoyourdesigntoavoidAzimuthwindup.

Fig.8(b) shows thedesignofwormandmotor shaft coupling.Theworm isdesignedwitha

centralshaftdiameterhole.Twoholesaredrilledandtapped90aparttoaccept#632plastic

screws.Theplasticscrewsprotectthemotorshaftfromdamage.

7.2Zenith-TrackingTopInadditiontohardwarecomponents,theZenithtrackingtopassembly(Fig.9(a))consistsofan

acrylicsupportplate,motorhub,motorbracket,leadscrewslidebridge,slidingnutandpivot,

crank, front pivot, pinhole sun locator, solarpanel plate, homing optical switchmount, and

homingtab. Thecrankframeisdesignedina'C'shapewithstrengtheningcornerribs. The

pinholesunlocatorisinstalledabovethepanelusinglong#632screwsandnuts,andisusedto

verify the system performance. If the tracking system performs well the pinhole will aim

sunlightontothecentermarkonthesolarpanel.Thetwothroughholesintwouppercornersof thepanel canbeused to install analog LightDependentResistors foroptimal solarpanel

operationoncloudydays,andtotakeadvantageofgroundsnowreflection. Thisoptimization

isbeyondthescopeofthecourse.


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Thehomingopticalswitchismountedontothefrontsideofthepivot(Fig.9(b)). Anextension

tab,mountedon thesolarpanelplate, interrupts theopticalswitchat the90degreeZenith

homeposition. Clearanceslotsareincludedtoaccommodateelectricalwirerouting.

(a)

(b)

Figure8.AzimuthTrackingStage: (a)BaseDesignandAssembly; (b)WormGearCoupler


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The rapidprototypednuthousinghasaxial#1032hexagonaldepressions toaccept the lead

screwnut.Thepivotaxishasdepressionstoaccept#632nutsforthecrankjoint. Thebridge

hasaslottoallowtheslidingmotionalongtherail(Fig.10).8.KinematicSimulation

(a)

(b)

Figure9.(a) ZenithTrackingTopAssembly; (b)OpticalSwitchDetails


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To simultaneously simulate the Azimuth and Zenith trackingmotion, the Autodesk Inventor

AssemblyStudioapplicationwasused.First, thejointconstraintsweredefined, including the

positional constraint for the slider, the gear ratio constraintbetweenworm andworm gear

ring,andtherotationalangularconstraintforthe leadscrewrod.Foreachoftheconstraints,

thecorrespondingmotionspeedsaresetupaccordingtothesystemkinematicproperties.

Figure10. LeadScrewDetails

(a) (b)

Figure11. Final(a)CAD;and(b)PhysicalModels


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11.Appendix

AppendixA1ElectricalImplementation

ArduinoDuemilanove

To improve the efficiency of a solar energy collector, an active tracker that continuously

accommodatesthevaryingpositionofthesun isnecessary.Tomeettheserequirements,the

ArduinoDuemilanove [4]microcontrollerboard is responsible forcalculating thesolarvector

andcontrollingthesteppermotors.TheArduinoDuemilanoveisbasedontheAVRATmega328

andincludes14digitalinput/outputpinsand6analoginputs(FigA11).

FigureA11.AcircuitschematicsymbolfortheArduinoDuemilanovedemonstratingthedevice

pinout.


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RealTimeClock

ForthepurposeofZenithandAzimuthanglecalculations,thesolartrackerrequiresanaccurate

estimation of the current Coordinate Universal Time (UTC). The DS1307 Real Time Clock

integratedcircuit isused toprovideprecisetimekeeping (Fig.A12).TheDS1307requiresa5

voltsupplywiredtopin8,anda32.768kHzcrystaloscillatorconnectedbetweenpins1and2.

Toutilizethe I2Cserial interfacesupportedbytheArduinoDuemilanove,theSerialDataLine

and Serial Clock Line from the DS1307must bewired to analog input pins 4 and 5 of the

Arduino,respectively.TheDS1307chipalsousesanexternalbatterythatcanprovideover10

yearsofbackuppowerintheeventofpowerfailure.

External components such as resistors or capacitors are not required for the supporting

circuitryoftheDS1307.However,a32.768kHzcrystaloscillatorisrequiredtogenerateaclock

signal.

Figure A12. The circuit schematic illustrates the Arduino Duemilanove interfaced with the

DS1307RealTimeClock


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StepperMotorDriver

TocontroltheAzimuthandZenithsteppermotors,anMC3479steppermotordriver(Fig.A13)

wasused.

FigureA13.TheMC3479StepperMotorDriverconfiguredforusewiththesolartrackerdesign.

Thesteppermotordriverusesfour inputpinstoconfiguretheoperationofasteppermotor.

For thepurposeof this solarcollectordesign,only twopins from theArduinocontrollerare

required.Digitaloutputpin6oftheArduinoDuemilanoveiswiredtoCW/CCWofthedriverto

control the clockwise/counterclockwise direction of the motor. Arduino digital pin 5 is

connectedtotheCLKpinoftheMC3479totriggereachmotorstep.MC3479pins8and9are


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tiedtogroundtorestrictoperationtohighimpedanceandfullsteppingmode,respectively.A

seconddriverisusedtocontrolthesolarZenithtrackingstage.Arduinodigitaloutputpin7 is

connectedtoCW/CCWanddigitaloutputpin8isconnectedtoCLK.Controlandconfiguration

oftheMC3479driverissummarizedinTableA11.

TableA11.FourpinsoftheMC3479driverareusedtoconfiguretheoperationofthestepper

motor.

The supporting circuitry for each stepper motor driver includes a 1N5221A Zener diode

connectedbetweenVmandVdtopreventdamagefromvoltagespikesduringcurrentswitching

in themotor coils. There also exists4 groundpinsoneachMC3479driver to improveheat

dissipationwithintheintegratedcircuitfromthemotorcoils.Thebias/setresistor,RB,iswired

between Bias (pin 6) and ground. The resistor valuewas selected to encourage low power

operation.Bylimitingthebiascurrent,IBS,thebiasresistorreducestheoutput(motor)current

andtherebyreducespowerconsumption.FromtheformulaforRbias,thevalueischosentobe

51.1k.

1000 0.86

0.7

Pin Name Input Description

7 CLK PositiveEdgeTriggered Themotor takesa step foreach risingedgeof

theinputsignal.

8 OIC GND OutputImpedanceControlonlypertainstohalf

steppingoperation.

9_______________

FULL/HALF GND A logic low (ground) input signal enables full

stepping.

10____________

CW/CCW DigitalSignal Thelogicleveloftheinputsignaldeterminesthe

directionof rotation.The rotor stepsclockwise

if the input signal is logic low (ground) orcounterclockwiseiftheinputislogichigh(+5V).


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LimitSwitches

Toensurerobustoperation,thesolarenergycollectorisfittedwithlimitswitchestopreventa

stepper motor from exceeding the angular bounds of the design. A micro roller switch

mountedonthebaseofthesolarenergycollectorpreventsmultiplerevolutionwindupofthe

Azimuthtrackingstage.ThesolarcollectoralsoincludestwomorelimitswitchesontheZenith

trackingstagetopreventovertraveldamagetotheleadscrewmechanism.Eachswitchisrated

upto2Aat30VDC

FigureA14.LimitSwitchescontributetofailsafeoperationofthesolarcollector.

The limitswitchesareconnected inserieswiththepowersupply line(Fig.A14)andoperate

completelyindependent

of

the

Arduino

Duemilanove.

The

switches

are

organized

inthis

way

to

immediatelycutpowertothemotordrivers intheeventoffailure.Assoonaseachswitch is

triggered,thecircuitisopenedandunabletosupplypower.

Afterthesourceofthefaulthasbeencorrected,onecancontinueoperationofthesolarenergy

collector. To resume supplying power to the motors, a jumper shunt can be applied

momentarily to a pair of header pins marked RESET_MTR on the printed circuit board.

A full scale implementation would require relays and additional software to automatically

correctthepositionuponfaultcorrection.


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24

OpticalHomingSensor

Twoopticalslotsensorsareusedtodetectwhenthesolarenergycollectorhasbeenoriented

inthehomeposition.Ahomingsensormountedonthebaseofthesolartrackeristriggeredby

a#256screw.Thescrew isdesignedtopassthroughtheslotsensorastheAzimuthtracking

stageofthecollectorpositions itselfforsunriseat22.5degreesEastofNorth.Asecondslot

sensor detectswhen the Zenithtracking stage is oriented directly towards the horizon (90

fromZenith).

FigureA15.Anopticalslotsensorisusedtohomethedevice.

The optical slot sensors are connected to the printed circuit board through a polarized

connector.Eachhomingsensorrequiresa5Vandgroundconnection.Thesensoroutputsare

wired todigital inputpins 2 and 3on theArduinoDuemilanove (Fig.A15).A 10k pullup

resistorwiredtoeachdigitalinputpinensuresthatthesensoroutputavoidsanindeterminate

digital logic state.Uponactivation,each individualoptical slot sensorproducesa logical low

signal(0V).Otherwise,thesensoroutputsalogicalhighsignal(+5V).


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25

PrintedCircuitBoard

The PCB consists of several core logical components (Fig. A16). The Arduino Duemilanove

controlstheoperationofthesteppermotordriversandrequiressensorinputfromtheslotted

homingsensorsandtherealtimeclock.

Fig.A16.Hierarchyofcoresolarenergycollectorcomponents.

CircuitSchematic

First,thecircuitschematicdiagramwasdesignedanddrawnwiththeCadSoftEAGLESchematic

Editor(Fig.A17)[10].


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26

Fig.A17.SolarTrackerv4.4completecircuitschematic.


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27

PCBPrototype

Usingasolderlessbreadboard,aprototypeofthefinaldesignwasconstructedandtestedusing

adigitalmultimeter,andbyobservingsensorsandmotorresponses(Fig.A18).

FigureA18.Eachaspectofthedesignwastestedwiththeuseofasolderlessbreadboard.

PCBFabrication

The printed circuit board layout was designed using CadSoft EAGLE Layout Editor. The

dimensionsoftheprintedcircuitboard(PCB)weredesignedtocorrespondwiththestandard

Arduinodimensions so that itcouldbeeasilymountedabove theArduinoDuemilanove (Fig.

A19). To interfacewith the Arduino,male header pins from the printed circuit board are

matched tomatewith femaleheaderson theArduinoDuemilanove.Three0.125diameter

holesaredrilledforthepurposeofmountingthePCB.


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28

FigureA1

8.The

PCB

measures

2.4

x2.1.

Theboarddesignconsistsofa topandbottomcopper layer.Extracopperareasareused to

reducenoiseandensureallcomponentsshareacommongroundpotential.Componentsare

useathroughholemountingscheme.Forthepurposeofsolderingcomponentstotheboard,

eachthroughholeontheprintedcircuitboardisdrilled0.019largerthanthediameterofthe

componentleadandplatedwithcoppertoprovideanelectricallyconductivesurface.Polarized

connectorsandsocketsareusedextensivelythroughoutthedesigntopreventincorrectwiring

duringinstallation.Aswell,connectors,jumpersandotherrelevantcomponentsarelabeledon

thesurfaceoftheprintedcircuitboardbymeansofsilkscreenprinting(Fig.A110).


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29

FigureA110a.ThetoplayeroftheSolarTrackerv4.4.

FigureA110b.ThebottomlayerofSolarTrackerv4.4.


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30

ThefinallayoutoftheprintedcircuitboardwasbrandedSolarTrackerv4.4(Fig.A112).ACAM

processorintegratedwithEAGLEwasusedtoproduceanindustrystandardfileformatforPCB

manufacturingmachines,GerberRS274X.

FigureA112.SolarTrackerv4.4fabricated.

FigureA113.Thefinalproductoftheprintedcircuitboardafterassembly.


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31

BillofMaterials

Allmaterialsarethroughholemountedwith2.54mmspacing.

1xSolarTrackerv4.4PrintedCircuitBoard2xMC3479StepperMotorDriver

2xDIPSocketSolderTail 16Pin

3x4PinMolexSLSeriesHeaderSocket

2x0.1FElectrolyticCapacitors

2x1N5221AZenerDiode

1x330 Resistor

2x51.1k Resistor

1x10k Resistor

2xKP35FM22PhaseBipolarStepperMotor2xOpticalSlotHomingSensors

3xNormallyClosedLimit(roller)Switches

4x40PinMaleHeaderPins

1x6PinFemaleWiretoBoardconnector

1x2PinJumperShunt

1xDIPSocketSolderTail 8Pin

1xDS1307RealTimeClockIC

1x32.768kHzCrystalOscillator 12.5pFInternalCapacitance

1x3V48mAh12mmBR1225LithiumCoinCellBattery1x12mmCoinCellBatteryHolder


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32

AppendixA2ArduinoSoftwareTutorial

ArduinoInstallationandTestProcedure

Tosetupand familiarizeyourselfwith theArduinoDuemilanove,youcan tryblinkingtheon

boardLED(connectedtopin13)onandoff.Thestepsbelowoutlinetheprocedure:

1. DownloadtheArduinointegrateddevelopmentenvironment(IDE)fromthemain

Arduinowebsitehttp://arduino.cc/en/Main/Software.Arduinoprovidesdistributions

forWindows,MacOSX,andLinux.Forthiscourse,theinstallationontheJHE219A

computers(WindowsXP)isofficiallysupported.Instructionsbelowcanbeusedifyou

wishtotestwithyourpersonalcomputer.

2. ConnecttheArduinoDuemilanovetoyourcomputerwithastandardUSBcable.

3. InstallthenecessarydriversforUSBserialconversion.Ifthedriversarenot

automaticallyinstalled,followthedirectionsofthewizardtosearchforUSBserial

converterdrivers.FTDIUSBDriverscanbefoundinthedriversfolderoftheArduino

distribution.

4. ConfirmthataUSBSerialPorthasbeensuccessfullyinstalled.InWindows,openthe

DeviceManager(ControlPanel>System>Hardware>DeviceManager)andnotethe

nameoftheserialportused(e.g.COM3).


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5. LaunchtheArduinoapplication.

6. Changethesettingstoworkwithyourconfiguration.Selecttheserialporttobe

programmed(Tools>SerialPort>YourPort).Next,ensurethattheArduino

environmentisconfiguredtoprogramtheArduinoDuemilanove(Tools>Board>

ArduinoDuemilanoveorNanow/ATmega328).RefertoAppendixA1formoredetail

regarding

the

Arduino

Duemilanove.

7. OpentheBlinkexample(File>Examples>Digital>Blink).

8. Click tocompilethecode.

9. Click touploadthesoftwaretotheArduinoboard.Executionwillautomaticallystart

afewsecondsafterthesoftwarehasfinisheduploading.


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34

ArduinoProgrammingTutorial

Software iswritten using the C/C++ based Arduino programming language. Each software

program written using the Arduino platform is called a sketch. Sketches do not include a

mai n( ) functionbutinsteadusefunctionsset up( ) andl oop( ) workinginconjunctiontoperform similar functionality. The set up( ) functionwill run only once at the beginning of

execution. Itmaybeusedto initializeserialportsettingsorconfigure input/outputports, for

example. Any local variables defined within set up( ) cannot be used in l oop( ) . The

l oop( ) functionwillexecuterepeatedlyuntiltheArduinoisreset.

TheArduinoplatformprovides itsown IntegratedDevelopmentEnvironment(IDE)todevelop

software, upload programs, and communicate with Arduino hardware (Fig. A21). The

developmentenvironmentcontainsatexteditorforwritingcode,aconsoleforerrormessages,

andatoolbar(TableA21).Aswell,thereareanumberofprojecttemplatesandotherfeaturesthatcanbeaccessedfromthedropdownmenus.

FigureA21.


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35

Verify/Compile Checkssoftwareforerrorsandcompilescode.

Stop Stopstheserialmonitor.

New Createsanewsketch.

Open Presentsamenuofallthesketchesinyoursketchbook.Clickingonewillopenit

withinthecurrentwindow.

Save Savesyoursketch.

UploadtoI/OBoard CompilesyourcodeanduploadsittotheArduinoI/Oboard.

SerialMonitor Openstheserialmonitor.

TableA21.

TheSerialMonitorrecordsallactivityovertheserialportanddisplaysitonscreen.Thistoolis

particularly useful for debugging your software because it can verify all input/output. After

openingtheSerialMonitor,adjustthebaudratesothatitcorrespondswiththebaudratethat

wasselectedduringinitializationoftheconnection.

AtutorialontheArduino languageanddevelopmentenvironmentfollowsbelow.Thetutorial

willintroduceserialcommunicationwiththeDS1307RealTimeClock.

RealTime

Clock

Communication

TheDS1307 isaRealTimeClockwithcalendarfunctionalitywhichtracksthesecond,minute,

hour,date,andyearinanindependenttimekeepingregister. Settingtheindividualparameters

ofthetimekeepingregistersorretrievingthecurrenttimefromtheRealTimeClockrequires

communicationusingInterIntegratedCircuit(I2C)serialcommunicationprotocol.

TheI2Ccommunicationprotocoloperatesinamaster/slaveconfigurationandrequiresonlythe

SDA (SerialData)andSCL (SerialClock) lines forbidirectionaldata transmission.TheArduino

Duemilanoveoperatesas themasterdevice,which supplies the clock line (SCL)and initiatesdatatransfers.TheslaveDS1307respondstothemasterArduinorequests.A7bitaddressing

systemisusedtodifferentiatebetweeneachindividualslavedeviceontheI2Cbus.TheDS1307

address(assignedbyindustrystandard)ishexadecimal0x68.

TheArduinoDuemilanovehardwarenativelysupportstheintegratedI2Cinterfacefoundonthe

ATmega328microcontroller.TheArduinoarchitectureassignsSDAandSCLtoanaloginputpins


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4and5respectively.Associated20k pullupresistorsarebuiltintotheArduinohardware,as

requiredforcorrect I2Coperation.TheArduinoWireLibrary(Wire.h) isusedtosimplifyserial

communicationwithI2Cdevices.

SettingParameters

For theDS1307, the contents of each clock and calendar register are encodedwith Binary

Coded Decimal (BCD). BCD represents each decimal digit with a halfbyte (4 bits) binary

sequence.Sinceonlytwodecimaldigitsarerequiredtorepresenteachunitoftime,1byte(8

bits) can store each timekeeper register. This facilitates data transmission since theWire.h

librarycansendandreceive individualbytessequentially.Becauseahexadecimaldigit isalso

encodedusingahalfbyte,wecansimplywritehexadecimalvaluestothetimekeeperregisters

insteadofworryingaboutconvertingtoBCD.

ThefirstbyteofanI2Ctransmissionincludestheslavedeviceaddressanddatadirection(7bits

areused forthedeviceaddress followedby1bittodesignatethereadorwritedirection). If

thedirectionbitisazero,themasterwillwritetotheDS1307.Ifthedirectionbitisaone

themasterwillreadfromtheDS1307.

TosetthedateandtimeforSaturday,March14,2022,at1:59AMUTC,forexample:

Wi r e. begi n( ) ; / / J oi n I 2C Bus

Wi r e. begi nTr ansmi ssi on( 0x68) ; / / Sl ave addr ess byt e f or DS1307Wi r e. send( 0) ; / / Set r egi st er poi nt er

Wi r e. send( 0x26) ; / / Second 00- 59

Wi r e. send( 0x59) ; / / Mi nut e 00- 59

Wi r e. send( 0x01) ; / / Hour 00- 23

Wi r e. send( 0x07) ; / / Day of week 01- 07

Wi r e. send( 0x14) ; / / Dat e 01- 31

Wi r e. send( 0x03) ; / / Mont h 01- 12

Wi r e. send( 0x22) ; / / Year 00- 99

Wi r e. send( 0x10) ; / * Cont r ol r egi st er def i nes squar e wave

oper at i on on pi n 7 */Wi r e. endTr ansmi ssi on( ) ;


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37

AppendixA3SoftwareImplementation


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/ / The Sol ar Vect or t r acki ng code i s f r omt he j our nal paper/ / "Computi ng t he Sol ar Vector "/ / Sol ar Energy 70( 5) , 431-441, 2001/ / aut hor s M. Bl anco- Mur i el , D. C. Al arcon- Padi l l a, T. Lopez- Moratal l a, and M. Lar a-Coi r a

/ / I mpl ement ati on of t he Newt on al gor i t hmi n C/ / htt p: / / deadl i ne. 3x. r o/newt oncode. ht ml

/ / i nst r uct or demonst r at i on Azi mut h / Zeni t h

#i ncl ude

#i ncl ude#i ncl ude#i ncl ude

#def i ne ASCI I ZERO 48 / / ' 0' = 48#def i ne pi 3. 1415926535897932384#def i ne t woPI ( 2. 0*pi )#def i ne r ad ( pi / 180. 0)#def i ne dEar t hRadi us 6371. 01 / / i n km#def i ne dAst r oUni t 149597890 / / i n km#def i ne OPTOPI NAZ 2#def i ne OPTOPI NZE 3#def i ne MOTZECWCCW 5#def i ne MOTZECLK 4#def i ne MOTAZCWCCW 7#def i ne MOTAZCLK 6

#def i ne MAXAZHOMESTEP 6250#def i ne MAXZEHOMESTEP 10000 / / ZE home max subj ect t o revi si on#def i ne STEPSAZHOME 1800 / / AZ home posi t i on = East = +90 degrees = 1800 st eps *** Update f or f i nal ver si#def i ne ANGLEZEHOME 90. 0 / / ZE home posi t i on = Hori zon = +90 degrees#def i ne STEPDLY 5

#def i ne ZENI THHOMENUTPOSI TI ON 24

#def i ne STEPSPERDEGAZ 20. 0 / / 1. 8 deg per st ep and 36:1 reduct i on worm gear s#def i ne STEPSPERMMZE 100 / / t empor ary demo

/ / Lat i t ude and Longi t ude f or McMaster ( J HE) = 43. 260181 ( N) , 79. 920892 ( W) . Lati t ude i s consi der ed posi t i ve t o the/ / Use deci mal f ormat ( Lat i t ude = 43 + 26. 0181/ 60 = 43. 434; Longi t ude = - 1 * ( 79 degr ees + 92. 0892/ 60) = - 80. 535; )const doubl e MCMASTERLATI TUDE = 43. 434;const doubl e MCMASTERLONGI TUDE = - 80. 535;

st r uct cTi me {

i nt i Year;i nt i Mont h;i nt i Day;doubl e dHour s;doubl e dMi nut es;doubl e dSeconds;

};

st r uct cLocat i on {doubl e dLongi t ude;doubl e dLat i t ude;

};

file://C:\Users\adspence\Documents\Courses20102011\MechEng4B03\SampleReport\Arduino\SolarTracker


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st r uct cSunCoor di nates {

doubl e dZeni t hAngl e;doubl e dAzi muth;

};

st r uct cTi me ut cTi me;st r uct cLocat i on ut cLocat i on;st r uct cSunCoor di nates utcSunCoor di nates;

i nt i Er rorAZFl ag; / / err or f l ag homi ng AZ

i nt i Er rorZEFl ag; / / err or f l ag homi ng ZE

i nt i St epsAZ = STEPSAZHOME;doubl e dAngl eZE = ANGLEZEHOME;doubl e dZeni t hNut Posi t i on = ZENI THHOMENUTPOSI TI ON;i nt i Curr ent ZEsteps = 8692;

/ / **************************************************************************************************************

voi d setup( ){/ / setup seri al communi cati onSeri al . begi n( 9600) ;Wi r e. begi n( ) ;Seri al . pr i nt l n( "Sol arTracker v4. 4" ) ;Seri al . pr i nt l n( "Ser i al Connecti on i ni t al i zed") ;Seri al . pr i nt l n( "" ) ;

pi nMode( MOTAZCWCCW, OUTPUT) ; / / AZ motor pi nMode( MOTAZCLK, OUTPUT) ;pi nMode( OPTOPI NAZ, I NPUT) ; / / opt o sl ot sensor AZdi gi ta l Wri te( MOTAZCWCCW, HI GH) ; / / al ways go home CCW = HI GHpi nMode( MOTZECWCCW, OUTPUT) ; / / EL motorpi nMode( MOTZECLK, OUTPUT) ;pi nMode( OPTOPI NZE, I NPUT) ; / / opt o sl ot sensor ZEdi gi ta l Wri te( MOTZECWCCW, HI GH) ; / / al ways go home CCW = HI GH

utcLocat i on. dLati t ude = MCMASTERLATI TUDE;utcLocat i on. dLongi t ude = MCMASTERLONGI TUDE;

Seri al . pr i nt l n( "Locat i on: McMaster Uni ver si t y, Hami l t on, ON") ;Seri al . pri nt ( "Lat i t ude ( Deci mal For mat) : ") ; Ser i al . pr i nt l n( ut cLocat i on. dLat i t ude) ;Seri al . pri nt ( "Longi t ude (Deci mal For mat) : ") ; Seri al . pr i nt l n( ut cLocat i on. dLongi t ude) ;Seri al . pr i nt l n( "" ) ;

/ / home the AZ st epper by l ooki ng f or bl ocked opto sl ot , when home = East = 90 degrees = 1800 st epshomeAzi muth( ) ;

/ / home t he Zeni t h st epper homeZeni t h() ;

} / / end set up( ) / / **************************************************************************************************************

voi d loop( ) {



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getCur r ent Ti me() ;begi nTr acki ng( ) ;

Seri al . pr i nt l n( "" ) ;del ay( 2000) ;

} / / end l oop( ) / / **************************************************************************************************************

voi d getCurr ent Ti me() {

Wi r e. begi nTr ansmi ssi on( 0x68) ;Wi r e. send(0) ; / / poi nt t o addr ess of t he ti mekeepi ng r egi st ersWi r e. endTr ansmi ssi on( ) ;

Wi r e. r equest From( 0x68, 7) ; / / r equest 7 bytes f r omDS1307utcTi me. dSeconds = convert HEX( Wi r e. r ecei ve( ) ) ;utcTi me. dMi nut es = conver t HEX( Wi r e. r ecei ve( ) ) ;utcTi me. dHour s = conver t HEX( Wi r e. r ecei ve( ) ) ;Wi r e. recei ve( ) ; / / di sr egard t he day of t he weekutcTi me. i Day = convert HEX( Wi r e. recei ve( ) ) ;utcTi me. i Mont h = conver t HEX( Wi r e. r ecei ve( ) ) ;ut cTi me. i Year = 2000 + conver t HEX( Wi r e. recei ve( ) ) ;

Seri al . pr i nt l n( "" ) ;Seri al . pr i nt l n( "Uni ver sal Coor di nat e Ti me") ;Seri al . pri nt ( "Ti me ( Hh: Mm: Ss) : ") ;i f ( ( i nt ) utcTi me. dHour s < 10) Seri al . pri nt ( "0") ;Seri al . pri nt ( ( i nt ) utcTi me. dHour s, DEC) ;Seri al . pri nt ( " : ") ;i f ( ( i nt ) utcTi me. dMi nutes < 10) Seri al . pri nt ( "0") ;Seri al . pri nt ( ( i nt ) utcTi me. dMi nutes, DEC) ;Seri al . pri nt ( " : ") ;i f ( utcTi me. dSeconds < 10) Seri al . pri nt ( "0") ;Seri al . pr i nt l n( ( i nt ) utcTi me. dSeconds, DEC) ;

Seri al . pri nt ( "Dat e (Dd/ Mm/ YYYY) ") ;i f ( ut cTi me. i Day < 10) Ser i al . pri nt ( "0") ;Seri al . pri nt ( ut cTi me. i Day, DEC) ;Seri al . pri nt ( " / ") ;i f (ut cTi me. i Mont h < 10) Ser i al . pri nt ( "0") ;Seri al . pri nt ( utcTi me. i Mont h, DEC) ;Seri al . pri nt ( " / ") ;i f ( ut cTi me. i Year < 10) Seri al . pri nt ( "0") ;Seri al . pr i nt l n( ut cTi me. i Year , DEC) ;Seri al . pr i nt l n( "" ) ;

} / / end getCur r ent Ti me() / / **************************************************************************************************************

voi d homeAzi muth( ) {

Seri al . pr i nt l n( "" ) ;Seri al . pr i nt l n( "Homi ng t he Azi muth- t r acki ng st age t o 90 degr ees East of Nort h") ;

/ / Home the AZ st epper by l ooki ng f or bl ocked opto sl ot . Home = East = 90 degrees = 1800 st eps



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i Err orAZFl ag = 0;i nt i Count ;i nt optoStateAZ;

f or ( i Count=0; i Count/ / shoul d be home i n 180 deg wort h of st epsopt oSt at eAZ = di gi t al Read( OPTOPI NAZ) ;i f ( opt oSt ateAZ == HI GH) { / / HI GH i s bl ocked (home)

br eak; / / now home} / / end i f

di gi ta l Wri te( MOTAZCLK, HI GH) ; / / STEP 1. 8 DEG ( wi t h 36 r educt i on = 0. 05 deg)

del ay( STEPDLY) ;

di gi ta l Wri te( MOTAZCLK, LOW) ;del ay( STEPDLY) ;

} / / end f or

i f ( i Count < MAXAZHOMESTEP) {/ / safel y homei Er rorAZFl ag = 0;i St epsAZ = STEPSAZHOME;

}el se {

/ / di dn' t get home i n 270 degi Er rorAZFl ag = 1;

} / / end i f

} / / end homeAzi muth( ) / / **************************************************************************************************************

voi d homeZeni t h( ) {

Seri al . pr i nt l n( "Homi ng t he Zeni t h- t r acki ng st age to +90 degrees ( Hori zon) ") ;Seri al . pr i nt l n( "" ) ;

/ / home t he Zeni t h st epper i Err orZEFl ag = 0;i nt i Count ;i nt optoSt ateZE;

f or ( i Count=0; i Count/ / shoul d be home i n 180 deg wort h of st epsopt oSt at eZE = di gi t al Read( OPTOPI NZE) ;i f ( opt oSt ateZE == HI GH) { / / HI GH i s bl ocked (home)

br eak; / / now home} / / end i f

di gi ta l Wri te( MOTZECLK, HI GH) ; / / STEP 1. 8 DEG ( document amount r at i o) del ay( STEPDLY) ;

di gi ta l Wri te( MOTZECLK, LOW) ;del ay( STEPDLY) ;

} / / end f or

i f ( i Count < MAXZEHOMESTEP) {/ / safel y homei Err orZEFl ag = 0;dAngl eZE = ANGLEZEHOME;

}



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el se {/ / di dn' t get homei Err orZEFl ag = 1;

} / / end i f

} / / end homeZeni t h() / / **************************************************************************************************************

voi d begi nTracki ng( ) {

Seri al . pr i nt l n( "Sol ar Tracki ng I ni tal i zed. " ) ;

Seri al . pr i nt l n( " - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - " ) ;

i nt i Del t aSt epsAZ, i Del t aSt epsZE;

GetSunPos( ut cTi me, utcLocat i on, &ut cSunCoor di nates) ; / / get t he curr ent sol ar vector Seri al . pri nt ( "Azi muth = ") ; Seri al . pr i nt l n( ut cSunCoor di nat es. dAzi muth) ;Seri al . pri nt ( "Zeni t h = ") ; Seri al . pr i nt l n( ut cSunCoor di nat es. dZeni t hAngl e);

Seri al . pri nt ( "Motor AZ= ") ; Seri al . pri nt ( ( doubl e) i St epsAZ/ ( doubl e) STEPSPERDEGAZ) ;Seri al . pri nt ( " Cur r ent i St epsAZ= ") ; Ser i al . pri nt ( i St epsAZ) ;i Del t aSt epsAZ = ( i nt ) ( utcSunCoordi nat es. dAzi muth*STEPSPERDEGAZ) - i StepsAZ;Seri al . pri nt ( " i Del t aSt epsAZ= ") ; Seri al . pr i nt l n( i Del t aSt epsAZ) ;MoveMotorAZ( i Del t aSt epsAZ) ;i St epsAZ = ( i nt ) ( utcSunCoordi nat es. dAzi muth*STEPSPERDEGAZ) ;

Seri al . pri nt ( "Motor ZE= ") ; Ser i al . pri nt ( dAngl eZE) ;Seri al . pri nt ( " Curr ent dAngl eZE= ") ; Ser i al . pr i nt l n( dAngl eZE);

Seri al . pri nt ( "ut cSunCoor di nates. dZeni t hAngl e = ") ;Seri al . pr i nt l n( ut cSunCoor di nat es. dZeni t hAngl e, DEC) ;

i f ( utcSunCoor di nat es. dZeni t hAngl e > 00. 1 && utcSunCoor di nat es. dZeni t hAngl e < 89. 9) {

i nt i Fut ur eZEsteps = get Zeni t hSteps( ut cSunCoor di nat es. dZeni t hAngl e);i nt del t aZeni t hSt eps = i Cur r ent ZEst eps - i Fut ur eZEst eps; / / store i n getZeni t h resul t i n vari abl e

MoveMotorZE( del t aZeni t hSt eps) ;

dAngl eZE = utcSunCoor di nat es. dZeni t hAngl e;i Cur r ent ZEst eps = i Fut ur eZEst eps;

}el se {

Ser i al . pr i nt l n( " The sun has set - no update" ) ;homeAzi muth( ) ;

homeZeni t h() ;} / / end i f

Ser i al . pr i nt l n( " - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ") ;} / / end begi nTr acki ng( )

/ / **************************************************************************************************************

voi d MoveMot or AZ( i nt i Del t aSt epsAZ) {i nt i Count ;

Seri al . pri nt ( "Movi ng Azi muth motor t hi s many st eps: ") ;Seri al . pr i nt l n( i Del t aSt epsAZ) ;



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i f ( i Del t aSt epsAZ == 0) {

return;} / / end i f i f ( i Del t aSt epsAZ > 0) {

di gi ta l Wri te( MOTAZCWCCW, LOW) ; / / posi t i ve CW= LOW }

el se {i Del t aSt epsAZ = - i Del t aSt epsAZ;di gi ta l Wri te( MOTAZCWCCW, HI GH) ; / / negati ve CCW = HI GH

} / / end i f

del ay(10);

i f ( i Er r orAZFl ag == 0) {f or ( i Count =0; i Count di gi t al Wr i t e(MOTAZCLK, HI GH) ; / / STEP 1. 8 DEG ( wi t h 36 r educt i on = 0. 05 deg)

del ay( STEPDLY) ;di gi ta l Wri te( MOTAZCLK, LOW) ;del ay( STEPDLY) ;

} / / end f or } / / end i f

} / / end MoveMotorAZ( ) / / **************************************************************************************************************

voi d MoveMot or ZE( i nt i Del t aSt epsZE) {i nt i Count ;

Ser i al . pri nt ( "Movi ng Zeni t h motor t hi s many st eps: ") ;Ser i al . pr i nt l n( i Del t aSt epsZE) ;

i f ( i Del t aSt epsZE == 0) {return;

} / / end i f i f ( i Del t aSt epsZE > 0) {

di gi ta l Wri te( MOTZECWCCW, HI GH) ; / / posi t i ve CW = LOW }

el se {i Del t aSt epsZE = - i Del t aSt epsZE;di gi ta l Wri te( MOTZECWCCW, LOW) ; / / negat i ve CCW = HI GH

} / / end i f del ay(10);

i f ( i Er r orZEFl ag == 0) {f or ( i Count =0; i Count di gi t al Wr i t e(MOTZECLK, HI GH) ; / / STEP 1. 8 DEG ( wi t h 36 r educt i on = 0. 05 deg)

del ay( STEPDLY) ;di gi ta l Wri te( MOTZECLK, LOW) ;del ay( STEPDLY) ;

} / / end f or

} / / end i f } / / end MoveMot orZE( ) / / **************************************************************************************************************

voi d GetSunPos(s t r uct cTi me ut cTi me, st r uct cLocati on ut cLocati on, st r uct cSunCoor di nat es *ut cSunCoor di nates){

/ / Mai n var i abl esdoubl e dEl apsedJ ul i anDays;doubl e dDeci mal Hour s;doubl e dEcl i pt i cLongi t ude;doubl e dEcl i pt i cObl i qui t y;doubl e dRi ght Ascensi on;doubl e dDecl i nat i on;



46/75

/ / Auxi l i ary vari abl esdoubl e dY;doubl e dX;

/ / Cal cul at e di f f erence i n days bet ween the cur r ent J ul i an Day/ / and J D 2451545. 0, whi ch i s noon 1 J anuar y 2000 Uni versal Ti me{

doubl e dJ ul i anDat e;l ong i nt l i Aux1;l ong i nt l i Aux2;

/ / Cal cul ate t i me of t he day i n UT deci mal hour sdDeci mal Hour s = utcTi me. dHour s + ( utcTi me. dMi nut es

+ ut cTi me. dSeconds / 60. 0 ) / 60. 0;/ / Cal cul at e cur rent J ul i an Dayl i Aux1 =( utcTi me. i Mont h-14) / 12;l i Aux2=( 1461*( ut cTi me. i Year + 4800 + l i Aux1) ) / 4 + ( 367*( ut cTi me. i Mont h

- 2-12*l i Aux1) ) / 12- ( 3*( ( ut cTi me. i Year + 4900+ l i Aux1)/ 100)) / 4+ut cTi me. i Day- 32075;dJ ul i anDate=( doubl e) ( l i Aux2) - 0. 5+dDeci mal Hour s/ 24. 0;/ / Cal cul ate di f f erence between cur r ent J ul i an Day and J D 2451545. 0dEl apsedJ ul i anDays = dJ ul i anDate- 2451545. 0;

}

/ / Cal cul at e ecl i pt i c coor di nat es (ecl i pt i c l ongi t ude and obl i qui t y of t he/ / ecl i pt i c i n r adi ans but wi t hout l i mi t i ng t he angl e to be l ess than 2*Pi/ / ( i . e. , t he resul t may be gr eat er t han 2*Pi ) {

doubl e dMeanLongi t ude;doubl e dMeanAnomal y;doubl e dOmega;dOmega=2. 1429- 0. 0010394594*dEl apsedJ ul i anDays;dMeanLongi t ude = 4. 8950630+ 0. 017202791698*dEl apsedJ ul i anDays; / / Radi ansdMeanAnomal y = 6. 2400600+ 0. 0172019699*dEl apsedJ ul i anDays;dEcl i pti cLongi t ude = dMeanLongi t ude + 0. 03341607*si n( dMeanAnomal y )

+ 0. 00034894*si n( 2*dMeanAnomal y ) - 0. 0001134- 0. 0000203*si n( dOmega);

dEcl i pt i cObl i qui t y = 0. 4090928 - 6. 2140e-9*dEl apsedJ ul i anDays+0. 0000396*cos( dOmega);

}

/ / Cal cul at e cel est i al coordi nat es ( ri ght ascensi on and decl i nat i on ) i n r adi ans/ / but wi t hout l i mi t i ng t he angl e t o be l ess t han 2*Pi ( i . e. , t he r esul t may be/ / great er t han 2*Pi ) {

doubl e dSi n_Ecl i pt i cLongi t ude;

dSi n_Ecl i pt i cLongi t ude= si n( dEcl i pti cLongi tude );dY = cos( dEcl i pti cObl i qui ty ) * dSi n_Ecl i pt i cLongi t ude;dX = cos( dEcl i pti cLongi t ude );dRi ght Ascensi on = atan2( dY, dX ) ;i f( dRi ght Ascensi on < 0. 0 ) dRi ght Ascensi on = dRi ght Ascensi on + t woPI ;dDecl i nati on = as i n( si n( dEcl i pt i cObl i qui ty ) *dSi n_Ecl i pti cLongi tude );

}

/ / Cal cul at e l ocal coor di nat es ( azi mut h and zeni t h angl e ) i n degr ees{

doubl e dGr eenwi chMeanSi der eal Ti me;doubl e dLocal MeanSi der eal Ti me;



47/75

doubl e dLat i t udeI nRadi ans;doubl e dHour Angl e;doubl e dCos_Lat i t ude;doubl e dSi n_Lat i t ude;doubl e dCos_Hour Angl e;doubl e dPar al l ax;dGr eenwi chMeanSi der eal Ti me = 6. 6974243242 +

0. 0657098283*dEl apsedJ ul i anDays+ dDeci mal Hour s;

dLocal MeanSi der eal Ti me = ( dGr eenwi chMeanSi der eal Ti me*15+ ut cLocat i on. dLongi t ude) *r ad;

dHour Angl e = dLocal MeanSi der eal Ti me - dRi ght Ascensi on;dLat i t udeI nRadi ans = ut cLocat i on. dLat i t ude*rad;dCos_Lat i t ude = cos( dLat i t udeI nRadi ans );dSi n_Lat i t ude = si n( dLat i t udeI nRadi ans );dCos_HourAngl e= cos( dHour Angl e );utcSunCoor di nat es- >dZeni t hAngl e = ( acos( dCos_Lat i t ude*dCos_Hour Angl e

*cos( dDecl i nat i on) + si n( dDecl i nat i on ) *dSi n_Lat i t ude) ) ;dY = - si n( dHour Angl e );dX = t an( dDecl i nati on ) *dCos_Lat i t ude - dSi n_Lat i t ude*dCos_Hour Angl e;utcSunCoordi nat es- >dAzi muth = atan2( dY, dX ) ;i f ( ut cSunCoor di nat es- >dAzi muth < 0. 0 )

utcSunCoor di nat es- >dAzi muth = utcSunCoor di nat es- >dAzi muth + t woPI ;utcSunCoor di nat es- >dAzi muth = utcSunCoor di nat es- >dAzi muth/ r ad;/ / Paral l ax Corr ecti ondParal l ax=( dEar t hRadi us/ dAst r oUni t )

*si n( utcSunCoor di nat es- >dZeni t hAngl e);utcSunCoor di nat es- >dZeni t hAngl e= ( utcSunCoor di nat es- >dZeni t hAngl e

+ dParal l ax)/ rad;}

} / / end GetSunPos( )

byt e convert HEX( byt e val ue) {/ / Thi s works f or deci mal 0- 99return ( ( val ue/ 16*10) + ( val ue%16) ) ;

} / / end convert HEX/ / **************************************************************************************************************

i nt get Zeni t hSt eps( doubl e t het a) {doubl e beta0; / / I ni t i al guessdoubl e beta; / / Appr oxi mate sol ut i ondoubl e epsi l on; / / Maxi mumer r ori nt maxI t er ati ons; / / Maxi mumnumber of i t erat i onsi nt i terat i ons; / / Act ual number of i t er ati ons

i nt converged; / / Whet her i t erat i on conver ged

doubl e t het aRAD = t het a * rad;

bet a0 = 0;epsi l on = 0. 00001;maxI t erat i ons = 10000;

doubl e nut Posi t i on =- 1;

/ / Fi nd t he f i rst posi t i ve sol ut i on. whi l e ( nut Posi t i on


48/75

beta = newt onsMethod(bet a0, epsi l on, maxI t erat i ons, &i t erat i ons, &conver ged, t hetaRAD) ;nut Posi t i on = 25*cos( t het aRAD) + 53*cos( t het aRAD+PI +beta) ;bet a0++;

}

i f ( conver ged) {Ser i al . pri nt ( "Newt on al gor i t hmconver ged af t er t hi s many st eps: ") ;Ser i al . pr i nt l n( i te rat i ons , DEC) ;Ser i al . pri nt ( " f ( ") ;Ser i al . pri nt ( beta, DEC) ;Ser i al . pri nt ( ") = ") ;

Ser i al . pr i nt l n( f ( t het aRAD, bet a) , DEC) ;}

el se {Ser i al . pr i nt l n( "Newt on' s method al gori t hm di dn' t conver ge") ;Ser i al . pri nt ( "The fi nal esti mate was: ") ;Ser i al . pr i nt l n( i te rat i ons , DEC) ;

}

/ / Ser i al . pr i nt l n( " " ) ; / / Seri al . pri nt ( "| AD| l engt h (mm): ") ; / / Seri al . pri nt l n( nut Posi ti on, DEC); / / Ser i al . pr i nt l n( " " ) ;

/ / cal cul ate and r eturn number of st eps/ / 0. 004mm per st epreturn ( ( i nt )( nut Posi t i on / 0. 004) );

} / / end getZeni t hSteps/ / **************************************************************************************************************

doubl e newt onsMet hod(doubl e beta0, doubl e epsi l on, i nt maxI t erati ons,i nt * i t erati ons_p, i nt * conver ged_p, doubl e t het aRAD ) {

doubl e beta = beta0;doubl e beta_prev;i nt i t er = 0;

do {i t er++;bet a_prev = bet a;bet a = bet a_pr ev - f ( t hetaRAD, bet a_pr ev) / f _pri me(t het aRAD, bet a_pr ev) ;

} whi l e ( f abs( bet a - bet a_pr ev) > epsi l on && i t er < maxI t er at i ons);

i f ( f abs( beta - bet a_pr ev)


49/75

doubl e f _pri me(doubl e thetaRAD, doubl e bet a) {

return - 53*cos( t hetaRAD + beta); / / t he deri vati ve} / / end f _pri me

/ / **************************************************************************************************************



50/75

38

AppendixA4CADDrawings


51/75


52/75


53/75

1

1

2

2

3

3

4

4SHEET1 OF1

DRAWN

CHECKED

QA

MFG

APPROVED

A. Dolgopolov 2/4/2010

DWG NO

SubassemblyPanel-Sunloc

TITLE

Subassembly Panel Sunloc

SIZE

CSCALE

McMaster University

PARTS LIST

DESCRIPTIONPART NUMBERQTYITEM

panel11

SensorBlockBracket12

sunlocVerif13

Plain Washer (Inch )Type A

and B

ANSI B18.22.1 - No. 8 -

narrow - Type B

74

Helical Spring Lock WashersANSI B18.21.1 - 0.13855

Hex Machine Screw NutANSI B18.6.3 - 6 - 32116

Square Recessed Pan Head

Machine Screw - Type III

ANSI B18.6.3 - 6-32 UNC -

1.25

27

foil18



ANSI B18.6.3 - 6-32 UNC -

0.75

29

7

1

1

6

4

3

8

5

2

9

1:1


54/75

DETAIL ASCALE 2 : 1

1

1

2

2

3

3

4

4

DRAWNA. DolgopolovCHECKED

QA

MFG

APPROVED

2/10/2010McMaster University

TITLE

Panel

SIZE

BSCALE

DWG NO

panel

SHEET1 OF1

A

38.00

30.00

70.00

62.00

6.00

94.00

45.30

55.10

100.00

6.0050.00

94.00100.00

5.00

15.00 30.0040.00

50.00

R2 TYP

4.172x

4 TYP

R4.59

1

R5.00

7.3

1:1

.15 AB

2.5

MATERIAL: BLACK ABS PROTOTYPE PLASTICUNLESS OTHERWISESTATED ALL DIMENSIONSIN MILLIMETERSTOLERANCES:LINEAR +0/-0.15

ANGULAR0.5

0AC

A


55/75

1

1

2

2


QA

MFG

APPROVED


TITLE

SunlocVerif

SIZE

ASCALE

DWG NO

SunlocVerif

SHEET1 OF1

30R

2.0AB2

A

4.23.62x THRU 6.55.5THRU

0AB

20 20

0A B

30

MATERIAL: BLACK ABS PROTOTYPE PLASTICUNLESS OTHERWISESTATED ALL DIMENSIONSIN MILLIMETERSTOLERANCES:LINEAR +0/-0.15ANGULAR 0.5

1:1


56/75

VIEW5SCALE 1 : 1

1

1

2

2


QA

MFG

APPROVED


TITLE

Sensor Block Bracket

SIZE

ASCALE

DWG NO

SensorBlockBracket

SHEET1 OF14:1

4.23.6THRU

4.23.6THRU

11

16

2.5

2.56.75

0A BC

0 B A C

B

10

A

11

5

5



57/75

VIEW4SCALE 1 : 1

1

1

2

2


QA

MFG

APPROVED


TITLE

Foil1

SIZE

ASCALE

DWG NO

Foil1

SHEET1 OF1

35

12

4.23.6THRU

0A BC

A

1

7

0.05AB

GH


10

10

PT G PT H

3:1


58/75


59/75

1

1

2

2

3

3

4

4SHEET1 OF1

DRAWN

CHECKED

QA

MFG

APPROVED


DWG NO

TopPlateBridgePivot

TITLE

Subassembly Top Plate Bridge Pivot

SIZE

CSCALE

McMaster University

PARTS LIST


Bridge11

TIL159Mount22

TIL15923

Slotted Pan Head Machine

Screw

ANSI B18.6.3 - 6 - 32 x 1

1/4 SP HMS

44

screwholder15

TopbasePlate16

Pivotversion217



and B

ANSI B18.22.1 - No. 8 -

narrow - Type B

89




ANSI B18.6.3 - 6-32 UNC -

0.6

411



ANSI B18.6.3 - 6-32 UNC -

1.25

312

6

6

12

11

8

10

9

1

12

7

3

2

4

7

5

5

1:1


60/75

1

1

2

2

SHEET1 OF1

DRAWN

CHECKED

QA

MFG

APPROVED

Jiang 11/1/2009

DWG NO

TopbasePlate

TITLE

Top Support Plate

SIZE

ASCALE

R

5.0025.00

30.00

42.00

47.00

67.0095.25

101.00

110.00130.00

5.

00

13.

00

14.

47

19.

00

24.

50

27.

00

32.

50

3

7.

00

47.

50

4.00 YP.

Scale: 1:1.5Unit: mmPlate Thickness: 5mm


61/75

1

1

2

2

3

3

4

4SHEET1 OF1

DRAWN

CHECKED

QA

MFG

APPROVED


DWG NO

Bridge

TITLE

Bridge

SIZE

BSCALE

McMaster University

1:1

A

4.23.64x

0AB

MATERIAL: BLACK ABS PROTOTYPE PLASTIC

UNLESS OTHERWISESTATED ALL DIMENSIONSIN MILLIMETERSTOLERANCES:LINEAR +0/-0.15

ANGULAR0.5

A1

A2 A3

A4

HOLE TABLEHOLE XDIM YDIM

A1 4.00 5.00

A2 4.00 35.00

A3 80.00 35.00

A4 80.00 5.00

15.924.1

40.0

8.0 76.0 84.0

4.0

11.4

10.0

13.0

27.0

30.0


62/75

SCALE 1 : 1

1

1

2

2

3

3

4

4


QA

MFG

APPROVED


TITLE

Pivot

SIZE

BSCALE

DWG NO

Pivotversion2-1

SHEET1 OF1

4

4.2

.15 A

.15 BC

0AB

MATERIAL: BLACK ABS PROTOTYPE PLASTICUNLESS OTHERWISESTATED ALL DIMENSIONSN MILLIMETERS

TOLERANCES:LINEAR +0/-0.15

ANGULAR 0.5

22

54

R4 TYP

R1 TYP

464

105

5.0

5.1

2

3

5

16.1

15

16

A 5

434

.15 C

2:1


63/75

VIEW2

SCALE 1 : 1

1

1

2

2


QA

MFG

APPROVED


TITLE

Screw Holder

SIZE

ASCALE

DWG NO

screwholder

SHEET1 OF12:1

4.23.62x

4.83

A

R3 TYP

0A

.15 CB

.15 AC

8

16.5

40


2.50 11.5

305

4

6

8


64/75


65/75

1

1

2

2

3

3

4

4SHEET1 OF1

DRAWN

CHECKED

QA

MFG

APPROVED


DWG NO

TopPlateMotorBracket

TITLE

Subassembly Top Plate Motor Bracket

SIZE

CSCALE

McMaster University

PARTS LIST


MotorBracket11

10-32thread12

MotorHub13

Slotted Pan Head Machine

Screw

ANSI B18.6.3 - 6 - 32 x 1

1/4 SP HMS

24

TopbasePlate15

JapanServoKP35FM2-03516

JapanServoKP35FM2-035Sh

aft

17

Cross Recessed Binding

Head Machine Screw - Type

I

ANSI B18.6.3 - No. 4 - 40 -

1 1/8

28



and B

ANSI B18.22.1 - No. 8 -

narrow - Type B

210




ANSI B18.6.3 - 6-32 UNC -

1.25

212


8 6

5

12

4

7

2

133

11

10

1

9

1:1


66/75

1

1

2

2


QA

MFG

APPROVEDA. Spence

11/6/2009

11/11/2009

McMaster University

TITLE

Solar Tracker Motor Bracket

SIZE

ASCALE

DWG NO

MotorBracket

SHEET1 OF1

14.013.5

40.039.5

2.01.5

12R

21

9

2x 3.54.3

2x 2.93.3

4.03.5

0 B A C

B

A

C

37.036.5

20

23

33

3.02.5

14

10

0.5ABC

0A B C

GH

36

11

G

H

1:1

6.5



67/75


68/75

1

1

2

2


QA

MFG

APPROVED


TITLE

SIZE

ASCALE

DWG NO

SubassemblyCrankRodScrewhold

SHEET1 OF1

PARTS LIST


10-32thread11

Hub#1Assem12

screwholder13Hex Machine Screw NutANSI B18.6.3 - 10 - 3274

Subassembly Slider & Nuts15

1:1

14

352


69/75

VIEW2

SCALE 1 : 1

1

1

2

2


QA

MFG

APPROVED


TITLE

Screw Holder

SIZE

ASCALE

DWG NO

screwholder

SHEET1 OF12:1

4.23.62x

4.83

A

R3 TYP

0A

.15 CB

.15 AC

8

16.5

40


2.50 11.5

305

4

6

8


70/75


71/75

SCALE 1 : 1

1

1

2

2


QA

MFG

APPROVED


TITLE

Slider and Nuts Subassembly

SIZE

ASCALE

DWG NO

SubassemblySlider&Nuts

SHEET1 OF1

PARTS LIST


slider11



Plain Washer (Inch )Type

and B

ANSI B18.22.1 - No. 8 -

narrow - Type B

244

2

1

3

2:1


72/75

SCALE 1 : 1

1

1

2

2


QA

MFG

APPROVED


TITLE

Slider

SIZE

ASCALE

DWG NO

slider

SHEET1 OF1

3.15.3

9.711.9

15

3.7 7.511.3

15

6

4

6

3.5

6.5

7

2.8

7.3

11.9

15

7.9

5.2

13.115.8

216.5

10.5


2:1

6

3


73/75

SECTION B-BSCALE 2 : 1

DETAIL ASCALE 4 : 1

SCALE 1 : 1

1

1

2

2

3

3

4

4


QA

MFG

APPROVED


TITLE

Crank

SIZE

BSCALE

DWG NO

crank

SHEET1 OF1

B B

A

4.173.51

.15AB

39.8

23.03

R3 TYP

R2 TYP

.53

9.12

3.32

4

6.62

122.5

5

MATERIAL: BLACK ABS PROTOTYPE PLASTICUNLESS OTHERWISESTATED ALL DIMENSIONSN MILLIMETERS

TOLERANCES:LINEAR +0/-0.15

ANGULAR 0.5

34.03

6.00

53 5

2

R5 TYP

32

2.00

A

2:1


74/75

39

AppendixA5RapidPrototypedComponentCosts

Cost of Rapid Prototype Parts

Part# RP Part Name # ofPieces ABS Material Used(inch^3) Support Material Used(inch^3) Cost(CAD) Total Cost(CAD)

1 Gear Ring 4 8.68 3.64 104.16

232.32

2 Worm Gear 4 4.88 1.36 58.56

3 Bridge Rail 1 0.45 0.89 5.4

4 Crank Arm 1 0.38 0.24 4.56

5Motor Shaft

Hub 1 0.23 0.11 2.76

6 Screw Holder 1 0.13 0.04 1.56

7 Pivot Stand 1 0.58 0.11 6.96

8 Slider 1 0.25 0.09 3

9 Panel 1 1.75 0.53 21

10 Motor Bracket 5 1.5 0.45 18

11Switch Block

Bracket 2 0.08 0.04 0.96

12Sun Beam

Locator 1 0.22 0.09 2.64

13 LDR Mount 2 0.12 0.08 1.44

14 TIL159 Mount 4 0.11 0.07 1.32


75/75

References[1] BlancoMuriel,M.,AlarcnPadilla,D.C.,LpezMoratalla,T.,andLaraCoira,M.,

ComputingtheSolarVector,SolarEnergy,70(5),431441,2001.

[2] AutodeskInc.,SanRafael,CA,www.autodesk.com.

[3] Dimension,Inc.,EdenPrairie,MN,www.dimensionprinting.com

[4] Banzi,M.,Cuartielles,D.,Igoe,T.,Martino,G.,andMellis,D.,ArduinoAlphav17,

www.arduino.cc

[5] Vogt,N.,Astronomy110G03LectureNotesFall2007,NewMexicoStateUniversity,

http://astronomy.nmsu.edu/nicole/teaching/astr110.

[6] www.timeanddate.com

[7] CANMETSolarPaper,http://canmetenergycanmetenergie.nrcan

rncan.gc.ca/eng/renewables/standalone_pv/publications/2006046.html

[8] PhotovoltaicPotentialandSolarResourceMapsofCanada,NaturalResourcesCanada,

https://glfc.cfsnet.nfis.org/mapserver/pv/index_e.php[9] OntarioIndependentElectricitySystemOperator,OntarioDemandForecast: 18Month

OutlookfromApril2007toSeptember2008,

http://www.ieso.ca/imoweb/pubs/marketReports/18Month_ODF_2007mar.pdf

[10] EagleLayoutEditor,http://www.cadsoftusa.com/