IT’S ALWAYS SUNИY IN ONTARIO

Peter Meyerhofer, Zack Rooker, Jose Nazario, Colin Kenley, Terrence Mathis, Bradley Lai, Justin Bronstein

Goals and ObjectivesThe goal of our project is to design the mechanical assembly of a dual-axis solar tracker that can be used to improve the efficiency of solar panels used in flat, rural areas of southern Ontario.

10°-350°

7°-85°

85”

120”

Figure 1: Our dual-axis solar tracker.

Customer and Derived RequirementsCustomer Requirements Derived Requirements Satisfied

Operate over two axes during spring, summer and fall

Have 70 degrees of altitude range yes (78 degrees of range)

Have 230 degrees of azimuth range yes (340 degrees range)

Hold 4 50-lb solar panels yes

Be able to operate for 7 years with little to no maintenance

Maximum one maintenance per year yes

Withstand environmental conditions without corrosion

Be able to withstand rain up to 4in/hour and operate at temperatures from -30 to 100F and wind speeds up to 80 mph

yes

Minimize cost Less than other dual-axis trackers yes

Design ConceptOur design consists of a pole and mounting system onto which four solar panels can be mounted. Two linear actuators allow rotation about the azimuthal and altitudinal axes. The structural components will be made from 6061 aluminum and their dimensions have been calculated to ensure the system’s structural integrity under the required conditions.

Make/Buy Decisions1: favor buying10: favor manufacturing

PartManufacturability (30%) Availability (30%) Cost (40%)

Total DecisionRaw Weighted R W R W

Faceplate 9 2.7 7 2.1 9 3.6 8.4 make

Solar panel 1 0.3 1 0.3 1 0.4 1 buy

0.75” clevis pins 3 0.9 2 0.6 3 1.2 2.7 buy

120” cross support 3 0.9 3 0.9 3 1.2 3

modify (cut to length)

Linear actuator 1 0.3 1 0.3 1 0.4 1 buy

Drawings

Drawings

Technical InformationThe fastest rate of rotation is 230 degrees in 10 minutes.The standard wind load, 30 lb/ft^2, comes out to 2310 lb.At 4000 lb of wind load and half the yield stress of aluminum, the column size should be 7-in OD, 6-in ID.An actuator positioned 0.5 meters off-center would have to exert 1.5 lb (+200% tolerance) for 3 times the fastest rotation (not including structural support). Since our actuator has 1250 lb, this is no problem.

Bill of MaterialsITEM NO. PART NUMBER DESCRIPTION Part Supplier QTY. Cost per part Total Purchasing Number

1 P-001-IASIO 6ft pole MetalsDepot 1 $275.46 $275.46 T36

2 P-002-IASIO .5 in Clevis McMaster Carr 9 $5.98 $53.82 92390A944

3 O-003-IASIO 3x1.5 6061 Al Channel LA Support MetalsDepot 1 $5.13 $5.13 LA support bar hz

4 M-004-IASIO LA Support Lower MetalsDepot 1 $1.68 $1.68 T334

5 M-005-IASIO LA support bracket MetalsDepot 2 $0.42 $0.84 S211

6 P-006-IASIO Linear actuator Windy Nation 2 $170.00 $340.00 LIN-ACHD-24

7 M-007-IASIO 36in main support MetalsDepot 1 $12.96 $12.96 T3218

8 M-008-IASIO Bottom Plate MetalsDepot 1 $35.28 $35.28 P312T6

9 M-009-IASIO Faceplate MetalsDepot 2 $20.16 $40.32 P312T6

10 P-010-IASIO .75 in Clevis McMaster Carr 1 $16.99 $16.99 97245A759

11 M-011-IASIO main support LA bracket MetalsDepot 3 $0.42 $1.26 S211

12 O-012-IASIO 36in main support no hole MetalsDepot 1 $12.96 $12.96 T3218

13 O-013-IASIO 120in cross support MetalsDepot 2 $44.28 $88.56 T311218-6061

14 O-014-IASIO 85in cross support MetalsDepot 4 $29.52 $118.08 T311218-6061

15 M-015-IASIO 2x2 bracket MetalsDepot 2 $0.35 $0.70 S211

16 M-016-IASIO 2x2 holder MetalsDepot 2 $0.67 $1.34 S211

17 P-017-IASIO 1.25 Steel Cap Screw McMaster Carr 4 $0.87 $3.46 91286A368

18 P-018-IASIO .5"-20 Hex Locknut McMaster Carr 4 $0.45 $1.81 97135A255

19 P-019-IASIO Solar panel Wholesale Solar 4 $240.00 $960.00 1970255

20 M-020-IASIO photocell bottom support MetalsDepot 1 $0.39 $0.39

21 M-021-IASIO photocell top support MetalsDepot 2 $0.32 $0.63

22 P-022-IASIO Solar Super Cell Edmund Scientifics 2 $8.95 $17.90 3081621

23 P-023-IASIO 6-32 .5" Pan Head Screw McMaster Carr 2 $0.06 $0.12 90604A148

24 P-024-IASIO 6-32 Hex Locknut McMaster Carr 2 $0.03 $0.05 90631A007

25 P-025-IASIO Square U-Bolt McMaster Carr 16 $2.87 $45.92 3060T45

26 M-026-IASIO clamp MetalsDepot 32 $0.14 $4.38 S211

27 P-027-IASIO screw clamp McMaster Carr 16 $0.12 $1.98 9434T18

Total 104 $2,040.06

ITEM NO.

PART NUMBER Description Part Supplier Qty. COST PER PART

TOTAL PURCHASING NUMBER

1 P-001-IASIO 6ft pole MetalsDepot 1 $275.46 $275.46 T36

6 P-006-IASIO Linear actuator Windy Nation 2 $170.00 $340.00 LIN-ACHD-24

9 M-009-IASIO Faceplate MetalsDepot 1 $20.16 $20.16 P312T6

13 O-013-IASIO 120in cross support

MetalsDepot 2 $44.28 $88.56 T311218-6061

19 P-019-IASIO Solar panel Wholesale Solar 4 $240.00 $960.00 1970255

22 P-022-IASIO Solar Super Cell

Edmund Scientifics 2 $8.95 $17.90 3081621

26 M-026-IASIO clamp MetalsDepot 32 $0.14 $4.38 S211

TOTAL 104 $2040.06

Materials/ManufacturingCriteria Weight (%) Steel A36 (DATUM) 6061 Aluminum Stainless Steel

Light Weight 10 S + S

Weather Resistant 40 S + +

Strength 20 S - S

Low Cost 20 S - -

Welding 10 S S -

TOTAL 100

Sum of + 0 50 40

Sum of S 100 10 30

Sum of - 0 40 30

Aluminum 6061 is the primary material: lightweight and corrosion-resistant.

Milling and stamping out of stock aluminum and stainless steel sheeting.

Failure Mode and Effects AnalysisItem Function Failure

Mode Cause of Fail Effect of Fail S O D RPN Corrective Action

Linear Actuators Rotates the solar panels

Fails to Operate

Electronic Failure solar panel doesn't rotate

2 3 2 12 Buy higher quality linear actuator

Column Supports the weight of the solar panels

Buckling Buckles under weight Stand collapses 5 1 3 15 Change column

Square Tubes Forms the rack for solar panels

Deforms under stress

Buckles under weight Bad news bears 4 1 3 12 Use larger bracket

Clevis Pins Holds key elements together and allows

for rotation

Shear Weight, Wear Solar panel rack falls, linear

actuators fall

5 2 5 50 Use larger pins

Clamps Holds the solar panel in place

Loosening, Corrosion

Basic Operation Solar panel falls out of position

1 4 4 16 Buy materials with corrosive resistant

coatings

Photocells Tracks the sun Fails to Operate

Electric Failure Solar panel cannot track the

sun

2 4 2 16 Buy higher quality photocells

Theory of OperationsThe linear actuators rotate the panels throughout the day, in short bursts. The small photocells help measure where the Sun is coming from and the actuators are positioned to keep the panels normal to the Sun. As the Sun starts to set, the panels will rotate back to a horizontal position so that they are able to detect sunrise the next day and begin tracking again. Maintenance will be performed once per summer. The system will be inspected to proactively detect failing parts. It will be positioned vertically during winter, covered by a tarp, to reduce snow buildup.

Fixed vs. Tracking12 hours a day9 months a year12c/kWh38.7% increase in efficiency

Cost Breakdown AnalysisCost of materials $2040.06Manufacturing requirements: Milling, Stamping, WeldingTime requirements:

Milling: 4 hrsStamping: 0.5 hrsWelding: 5 hrs

Total Labor Cost: 9.5 hrs x $19/hr = $180.50Total Cost: $2220.56Selling Price: $2600

Fixed vs.Tracking Price Comparison

Fixed Tracking

Cost $1879.00 $2600

Revenue $403.92/year $560.24/year

Breakeven Point 4.65 years 4.64 years

Maturity Point 4.61 years

Profit $921.60 $1258.29

Updated Gantt Chart

Team Member ContributionsJose: Team LeaderJustin: DesignPeter: CommunicationZack: SolidWorksColin: ResearchTerrence: PresentationBradley: Economics

Questions?