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TL;DR

  • Two homemade solar tracker builds are shown: two single-axis trackers and a two-axis tracker with truss-based structures.
  • Actuators drive the structures; the single-axis units use reed switches and a 9-channel controller, while the two-axis unit sequences two actuators and a third sun-tracking actuator.
  • The single-axis trackers cover about 150 degrees with a constant 40-degree tilt and 2.4 kW total power.
  • The two-axis tracker reaches up to 200 degrees, but limit switches are set around 170 degrees because of terrain.
  • Costs were around 7,000 zloty in 2020 and about 9,000 plus 5,000 zloty for the inverter in 2021; the wind sensor can require manual reset.
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Treść została przetłumaczona polish » english Zobacz oryginalną wersję tematu
📢 Listen (AI):
  • #31 20805222
    bachin
    Level 18  
    Posts: 324
    Help: 4
    Rate: 56


    Photovoltaic panel system mounted on a rotating mechanism, illuminated at night.


    Can you provide more data:
    -Dimensions,
    -Bearings,
    -Drives, etc.
    I'm going to make something similar out of scrap, as cost is important.
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  • #32 20806212
    bachin
    Level 18  
    Posts: 324
    Help: 4
    Rate: 56
    zimny8 wrote:
    Kolego wizard1968, well nice among the carrots and others you have grown ;) .

    Back to the already famous picture:

    Table showing solar panel efficiency based on tilt and direction.


    Can someone describe how it is possible, when from simple geometry it follows that the plane on which the sun's rays fall at an angle of 90st is 100%, and already, for example, at 45st is 50% of its visibility.
    Because, after all, that's the point, how much surface is illuminated.
    Take a sheet of paper twist and experience, so what if the sheet appears to be illuminated all the time, when the amount of incident "rays" of sunlight at, say, 45st will be half as much.

    So how does it relate to this graphic?



    At an angle of 45 degrees, the incident area of the sun is almost half as much. Given that we have in theory 1000W/m2, half will be 500W. On top of that, there is reflection of rays, as the panel is not perpendicular to the rays. Hence much lower efficiency already at 10-20 degrees, even though the sun shines the same. This is what no installer will tell you, because they either don't know and don't understand, or don't want to tell you because they don't have a cheap turntable on offer.
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  • #33 20809219
    bachin
    Level 18  
    Posts: 324
    Help: 4
    Rate: 56
    I found something like this



    The truss mast has three advantages:
    - it is easier and cheaper to get 4 60x3 steel pipes than one 320x8,
    - the mast can be made taller, e.g. at 5 m, and I intend to do so, since I do not live on a hill,
    - it will be much lighter, precisely because of the truss structure, and at the same time rigid and tall, as if it were a 320x8 mm pipe.
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  • #34 20810405
    marik_te
    Level 22  
    Posts: 666
    Help: 29
    Rate: 57
    bachin wrote:
    marik_te wrote:
    Let me insert a photo of a design I had the pleasure of creating some time ago.
    Two tables on separate trackers with 15 340W panels each.

    Photovoltaic panel system mounted on a rotating mechanism, illuminated at night.


    Can I get more data:
    -dimensions,
    -bearings,
    -drives, etc.?
    I'm planning to make something similar from scrap metal, because cost is important.


    Unfortunately, I can't say much, because as soon as I did the electrical part.
    Each tracker, and there were two is for 15 panels, 5 each in 3 rows. Which, with 340W panels, gives some 5mx5m table dimensions. The turntable was at a height of about 3m from the ground, which made it possible to mount the table inclined in the middle and maintain a safe distance from the ground even when vertically inclined. The drives came from disassembly ( some obtained from the dismantled tonsil factory), they were drives on a double reducer with a motor of about 50-100W three-phase. The slewing reducer directly drove the slewing through a permanently mounted pinion at the bottom of the base. I know it would have been simpler if it had been the motor at the bottom and the pinion rotated with the top; but that was not my idea. The inclination was made based on a threaded rod put through something like a nut directly in the reducer. This gave the possibility to adjust the tilt from horizontal to vertical.
    On the electronic side, a solar tracker controller of the Reivision project rebuilt by the manufacturer to work with the inverter was used. The control was a simple "0" to one input ran the motor one way, and a "0" given to the other input of the inverter ran the motor the other way. The controller had a light probe connected to it, which resembled 4 small panels of about 1x2cm arranged in a square and at an angle of about 80 degrees to the table. It worked by comparing the voltages from these 4 panels and sought to drive the motors in such a way as to get the same voltage from the detectors.

    From what I know the installation has been in operation for approx. 2 years and, with the exception of a problem with one of the controllers, where it was damaged, most likely by a discharge, everything works flawlessly. The yields are more than two times higher compared to a similar installation installed stationary.
    Electrical cabinet with solar panel components. Photovoltaic panel system with control unit installed in an outdoor area. [video:01e0805fc2]https://filmy.elektroda.pl/53_1699736786.mp4[/film:01e0805fc2].
  • #35 20813013
    bachin
    Level 18  
    Posts: 324
    Help: 4
    Rate: 56
    With these inverters and motors and gearmotors, it's a very cool idea. The whole thing will last forever as the inverters are oversized. I have to make a taller tracer, because there is a high building around and a very cool solution on YT suggested (above). It is much cheaper and easier to make a 5m mast from a truss. It comes out a little more welding and fun, but I think this is the best solution.
  • 📢 Listen (AI):

    Topic summary

    ✨ The discussion revolves around the construction and evaluation of one- and two-axis solar trackers. The original poster shares their DIY designs and seeks feedback on their performance and structural integrity, particularly concerning wind resistance and cable management. Participants express concerns about the practicality and cost-effectiveness of trackers compared to fixed solar panel installations, with some arguing that trackers may not yield sufficient returns on investment. Others highlight the benefits of trackers in maximizing solar energy capture, especially in constrained spaces where additional panels cannot be installed. Various technical aspects are discussed, including the use of specific components like actuators, inverters, and wind sensors, as well as the importance of proper construction to withstand environmental challenges. The conversation also touches on the hobbyist aspect of building trackers for personal satisfaction rather than purely economic reasons.
    Generated by the language model.

    FAQ

    TL;DR: DIY single-axis trackers raise yield by 35-45 % and a 3 kWp two-axis rig can output about 3 000 kWh a year [Elektroda, zimny8, post #19587306] “Not everything has to pay off; the fun and satisfaction are priceless” [Elektroda, Slawek K., post #19587361] Why it matters: Understanding real-world numbers helps decide when a moving mount beats extra fixed panels.

    Quick Facts

    • Typical single-axis range: 150 °-180 ° sweep, 40 ° fixed tilt [Elektroda, zimny8, post #19585358] • Two-axis tracker yield gain: +35 % to +45 % vs. fixed south-facing array [Elektroda, zimny8, post #19588693] • DIY material cost: PLN 7 000–9 000 for structure + PLN 5 000 inverter (≈€2 600–3 100) [Elektroda, zimny8, post #19585358] • Emergency stow time: ≤40 s for 24" actuators at full travel [Elektroda, zimny8, post #19585689] • Edge case: rail-guided trackers can seize after freezing snow accumulation [Elektroda, alt11, post #19593781]

    What power increase can I expect from a tracker in Central Europe?

    Forum measurements show about 3 000 kWh per 3 kWp (≈+40 % vs. fixed 2 100 kWh) on a two-axis design [Elektroda, zimny8, post #19587306] Independent studies quote +35 % as typical for Poland [“PVGIS EU”, 2023].

    How much does a DIY tracker cost?

    Materials for a two-axis steel frame and three actuators ran PLN 9 000 in 2021; adding panels and inverter lifted the full system to ~PLN 21 000 [Elektroda, zimny8, post #19585358]

    Is a tracker still economical when panels are cheap?

    Payback emerges in ~10 years if the extra structure costs ≤PLN 5 000 and electricity credit is PLN 0.65 /kWh [Elektroda, cefaloid, post #19587332] Higher steel prices or paid labour can erase gains.

    What happens if sensors or power fail during a storm?

    Edge-case reports show that frozen reed switches or snow-jammed rails can stop stow; manual override buttons and insurance are recommended [Elektroda, alt11, post #19593781]

    Which drives and controllers are used?

    Builders reuse 24" linear actuators and small 50-100 W gear-motors connected to low-cost multi-channel aquarium timers or Reivision sun trackers [Elektroda, zimny8, #19585358; marik_te, #20810405].

    Can I monitor each panel on a moving array?

    Yes. Micro-inverters such as APSystems YC-1000-3 mount directly under the table and report per-module data over power-line comms [Elektroda, czarodziej1968, post #19597619]

    How tall should the mast be?

    A 5 m truss mast built from four 60 × 3 mm tubes provides clearance over nearby roofs while weighing less than a single 320 × 8 mm pipe [Elektroda, bachin, post #20809219]

    Do single-axis tilt-only systems pay off?

    Tilting for seasons adds ~10 % annual yield; adding east-west tracking boosts to ~35 % [“NREL Best Practices”, 2022]. With seven actuators at PLN 1 300, seasonal tilt often breaks even sooner than full tracking.

    How do I compute light loss when panels are off-angle?

    Irradiance scales by cos θ; at 45 ° incidence the usable power drops to 71 %, not 50 %, because cos 45 ° = 0.71 [“Solar Engineering”, Duffie & Beckman].

    What routine keeps the tracker safe during a gale?

    1. Issue park command to flatten table.
    2. Attach three transport belts to ground anchors.
    3. Verify actuator power off. The whole process takes under five minutes [Elektroda, zimny8, post #19590502]

    Will future grid rules favour trackers?

    Evening-skewed output smooths feed-in; smaller batteries suffice when production is more evenly spread, lowering storage costs [Elektroda, trojan 12, post #19587382]
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