Project Paper
Volume 2
April 2015
Issue 8
International Journal of Informative & Futuristic Research
ISSN (Online): 2347-1697
Tracking Of Solar Panel By
Hydraulic System
Paper ID
Key Words
IJIFR/ V2/ E8/ 090
Page No.
2856-2881
Research Area
Mechanical
Engineering
Design and Development, Solar Tracking System, Hydraulic System
Prof. Kusekar S. K 1
Ajinkya Patil
Sachin B. Patil 2
Prasad B. Rajmane 3
Akshay B. Bhosale 4
Professor, Department Of Mechanical Engineering
A G. Patil Institute of Technology,
Solapur, Maharashtra- India
B.E. Student ,Department Of Mechanical Engineering
A G. Patil Institute of Technology,
Solapur, Maharashtra- India
B.E. Student ,Department Of Mechanical Engineering
A G. Patil Institute of Technology,
Solapur, Maharashtra- India
B.E. Student , Department Of Mechanical Engineering
A G. Patil Institute of Technology,
Solapur, Maharashtra- India
B.E. Student ,Department Of Mechanical Engineering
A G. Patil Institute of Technology,
Solapur, Maharashtra- India
Abstract
In this project work, with the title Tracking of Solar Panel by Hydraulic System,
we were planning for design and developing a solar tracking system which will
utilize mechanical energies for the tracking operation. At present, the solar
tracking system use electrical energy for tracking operations and this electrical
energy for operations is supplied by same solar panels or by external electrical
storage or supply lines, this reduces efficiency of the solar panels. Using
mechanical energy for tracking will increase the output of solar panels and
remove the constraint on the location of the tracking system.
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Copyright © IJIFR 2015
2856
ISSN (Online): 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
1. Introduction
1.1 Solar Energy
Energy from the sun travels to the earth in the form of electromagnetic radiation similar to
radio waves, but in a different frequency range called solar energy. Solar power is the conversion of
received solar radiation into usable energy. It is a process that consists of harnessing the sun's
present emissions of heat or light. This heat and light are the effects of the sun's constant nuclear
fusion of hydrogen nuclei. The process of fusion produces helium nuclei as well as large amounts of
energy.
Available solar energy is often expressed in units of energy per time per unit area, such as
watts per square meter (W/m2). The amount of energy available from the sun outside the earth’s
atmosphere is approximately 1367 W/m2. Some of the solar energy is absorbed as it passes through
the Earth’s atmosphere. As a result, on a clear day the amount of solar energy available at the
Earth’s surface in the direction of the sun is typically 1000 W/m2. The level of solar radiation a
region receives depends on latitude and local weather conditions.
1.2 Solar Tracking
Solar tracking is the process of varying the angle of solar panels, to take advantage of the
full amount of the sun`s energy. In remote places sun is the cheap source of electricity. The output
from solar panel depends on the intensity of sunlight falling on it and also on the angle of incidence.
It means to get maximum efficiency; the solar panel must remain in front of sun during the whole
day. But due the rotation of earth the panel can’t maintain their position always in front of sun. Thus
to get maximum and a constant output, a system is required which should be capable to constantly
rotate the solar panel. Initial tests in industry suggest that this process can increase the efficiency of a
solar power system by up to 50%. Given those gains, it is an attractive way to enhance an existing
solar power system.
1.3 Solar Panels
Solar Panels are the devices for capturing the energy in sunlight. Solar photovoltaic panels
contain arrays of solar cells that convert light into electricity. The solar cells sometimes called
photovoltaic cells, photovoltaic meaning literally .light-electricity. Solar cells or PV cells rely on the
photovoltaic effect to absorb the energy of the sun and cause current to flow between two oppositely
charged layers. Crystalline silicon and Gallium arsenide are typical choices of materials for solar
cells. When exposed to sunlight, a 6 cm diameter silicon cell can produce a current of about 0.5 A at
0.5 V. Gallium arsenide is more efficient than Crystalline silicon.
A solar panel is a collection of solar cells. Solar panels are constructed of these cells cut into
appropriate shapes, protected from radiation and handling damage on the front surface by bonding
on a cover glass, and cemented onto a substrate (either a rigid panel or a flexible blanket). Electrical
connections are made in series-parallel to determine total output voltage. The cement and the
substrate must be thermally conductive, because the cells heat up from absorbing infrared energy
that is not converted to electricity. Since cell heating reduces the operating efficiency it is desirable
to minimize the heating. The resulting assemblies are called solar panels or solar arrays.
1.4 Electrical Solar Tracking Systems
The most of today’s Solar tracking systems are electrical systems. Elements of these systems
are an electric servo drive and an electronic control system. The electric servo drive includes a
stepper motor, which rotates the solar panels with a pre-set angular displacement. The control
S. K. Kusekar, Ajinkya Patil, Sachin Patil, Prasad Rajmane, Akshay
Bhosale:: Tracking of Solar Panel by Hydraulic System
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ISSN (Online): 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
system gives an input signal to servo drive system to drive the stepper motor with the help of sensor
and electronic counters.
In these systems, the major portion of energy produced by the solar panel is utilized for
tracking operation. If not, these systems should have a battery storage unit or should be connected to
power supply grid or the combination of both.
1.5 Mechanical Solar Tracking Systems
Mechanical engineering is one of the largest, broadest and oldest engineering disciplines and
uses principles of energy, materials, and mechanics to design and manufacture machines and devices
of all types. Mechanics, energy and heat, mathematics, engineering sciences, design and
manufacturing form the foundation of mechanical engineering.
Fundamentally, mechanical engineering involves with the mechanics of motion and the
transfer of energy from one form to another or one place to another.
The various fields of application of mechanical engineering are,
 Energy conversion
 Energy resource
 Environment and Transportation
 Engineering and Technology management
 Manufacturing
 Materials and Structures
 Systems and Design
In above fields the Solar Engineering falls in the category of Energy resource. Mechanical
engineers are effectively involved in solar energy in finding new ways to produce mechanical and
electrical power for heating, refrigeration and water purification and also in the design of devices
and structure to collect solar energy.
Mechanical solar tracking systems are the systems which use the mechanical energy for
operation and involve the fundamental concepts of various fields, related to mechanical engineering.
The tracking of solar panels can be effectively done with mechanical systems. These systems are
robust in design and are very less sensitive to seasonal changes. Mechanical systems, built with high
precision are well suited for tracking operation.
2. Problem Definitions And Identification
The position of the sun keeps on changing every day. Solar panels as we know are entirely
dependent on the sun. The more the sun rays fall on the panels the more outcomes we get and it serves
our purpose of installing a solar panel. The challenge nowadays is to keep a track of the position of the
sun so that we get the maximum output from the panels. We hope to achieve this with a Mechanical
tracking system.
2.1 Identification
i.
There are many problems associated with conventional solar panel because they are fixed in one
direction.
ii.
The positions of the sun keeps on changing every day, along with the sun, solar panel have to move
in same direction.
iii.
The other system also used for solar tracking but they consumes most of the energy produced by
solar panels for tracking, which effects the efficiency of solar panel.
S. K. Kusekar, Ajinkya Patil, Sachin Patil, Prasad Rajmane, Akshay
Bhosale:: Tracking of Solar Panel by Hydraulic System
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ISSN (Online): 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
To rectify these above problems the solar panel should be such that it always receives maximum
intensity of light. For existing solar panels, which are without any control systems typical level of
efficiency varies from 10% to 4% - a level that should improve measurably if the present interest
continues.
3. Literature Review





One-Axis Trackers – Improved Reliability, Durability, Performance, and Cost Reduction Final Subcontract Technical Status Report - 2 May 2006 – 31 August 2007 by J. Shingleton
Shingleton Design, LLC Auburn, New York – page 7:
The work effort focused on reducing the total cost of electricity generated by single-axis
tracking solar energy systems for utility and other large-scale commercial applications.
Developing a factory assembled, modular tracker, while building on the strengths of the
existing technology, resulted in improved performance and reliability and reduced
installation time, cost, and environmental impact.
Low cost tracker by Marliyani Binti Omar This thesis is submitted as partial fulfillment of
the requirements for the award of the Bachelor of Electrical Engineering - Faculty of
Electrical & Electronics Engineering University Malaysia Pahang -MAY, 2009 - page5
Solar tracker is invented because solar panel disables to move toward the sunlight when the
sun moves from east to west. In order to produce maximum power output, solar tracker is
design with motor so that the solar panel will move toward the position of sun.
Atlas solar tracking by Mechatronics Company manual:-Atlas system can achieve up to
40% more output power than fixed tilt systems. It ensures that the PV panels are
optimally orientated towards the sun, converting efficiently direct and indirect solar
radiation into electricity.
Hawe hydraulics manual :- HAWE Hydraulics offers compact positioning systems, which
consist of a hydraulic power pack with a control system that is directly attached. The electric
motor and pump in this closed system is submerged for protection against rain,
condensation, and dirt. HAWE’s modular products mean we can easily adjust power and
movement speeds according to customers’ requirements, as well as provide easier access for
maintenance. With various product sizes, low friction, and minimized stick or slip effect,
tracking movements can be controlled reliably and accurately. Dampened over-center valves
ensure smooth movements, which protects the entire structure.
Rockwell automations solar tracking application manual book:-Concentrated applications
like concentrated photovoltaic panels (CPV) or concentrated solar power (CSP) require a
high degree of accuracy to ensure the sunlight is directed precisely at the focal point of the
reflector or lens. Non-concentrating applications don’t require tracking but using a tracker
can improve the total power produced by the system. Photovoltaic systems using high
efficiency panels with trackers can be very effective. There are many types of solar trackers,
of varying costs, sophistication, and performance. The two basic categories of trackers are
single axis and dual axis.
4. Scope Of Work
We search for project related to solar power related, and we got some points to study from that we
select the solar tracker.
S. K. Kusekar, Ajinkya Patil, Sachin Patil, Prasad Rajmane, Akshay
Bhosale:: Tracking of Solar Panel by Hydraulic System
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ISSN (Online): 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
To study about solar energy and its efficiency.
To study about PV cells
To study on the PV plate and its overall structure, like its power output, setting angle (the
angle at which solar panel is going to fit), sun light intensity in day hours, etc.
To study on sun tracker systems like electrical solar tracker, mechanical tracker and
hydraulic tracker.
To study on hydraulic tracker and how to implement it in tracking system project.
Study related to fluid mechanics which is we are going to use in this project.
To study on hydraulic system and its components mainly piston, control valves, check
valves and hydraulic oil.
Study on structural design of hydraulic solar tracker.
5. Objective
The need for mechanical systems for tracking operation can be better explained with the drawbacks associated with electrical tracking systems. Those are,
i. The present Electrical tracking systems consumes most of the energy produced by solar panels
which serves as a demerit for the Solar system.
ii. We plan to totally neglect the wastage of electricity generated by the panels. In other words
we hope to increase the output of the solar panels.
iii. The minimum power required for operation may not be available at all times o the day due to
change in atmosphere. Tracking will help solve this problem.
iv. Mechanical systems can work in any environment. Dust and humidity have no ill-effects on
the system.
v. To simplify the system and avoid any complexity in design.
vi. We try to make the entire system compact So that there is no issue when it comes to moving
the system.
vii. The energy required for operation will increase with the increased size of solar Panel.
6. Methodology
The methodology of design for the design of mechanical tracking system is explained by following
steps,
i.
Determining sunray orientation and time range to which the panel has to be tracked.
ii.
Calculating the required angular velocity of the panel.
iii.
Calculating the system pressure and cylinder (actuator) discharge.
iv.
calculating the weight/force required to create the required pressure.
v.
Selecting cylinder of suitable diameter and stroke length.
vi.
Selecting the suitable grade of hydraulic oil.
vii.
Calculating the capacity of reservoir.
viii.
Designing the hydraulic circuit with QUICK RETURN facility to reduce the time required
for bringing the panel to its original position.
ix.
Selecting required mechanical components of suitable dimensions and material.
x.
Preparing production drawings and fabrication of mechanical elements.
xi.
Assembly of the device.
xii.
Demonstration.
S. K. Kusekar, Ajinkya Patil, Sachin Patil, Prasad Rajmane, Akshay
Bhosale:: Tracking of Solar Panel by Hydraulic System
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ISSN (Online): 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
6.1 Hydraulic System Design
6.1.1 Introduction to Fluid Power Systems
The basic source in industries comes from three kinds of sources. These are,
1. Electrical Systems
- These systems use electrical prime movers like electrical motors.
2. Mechanical Systems
- These systems use mechanical prime movers like I.C Engines and in olden days the Steam engines
were used.
3. Fluid Power Systems
- The third common source of power that is widely used in modern industries is the fluid power.
6.1.2 Fluid Power Systems
Fluid power refers to the branch of engineering that deals with the use of high pressure fluids (gases
or liquids) within confined areas (like hoses, cylinders) to generate, control and transmit power.
In fluid power systems high pressure fluid both liquid and gases, can be used to transmit
power from the point of source to the point of utilization, which can be used to produce rotary and
linear motions. A fluid is substance which is capable of flowing. Fluid power systems that use
liquids as the working medium are called Hydraulic systems. Fluid power systems that use gases
(commonly air or Nitrogen) are commonly known as Pneumatic systems.
The some of the drawbacks of the Pneumatic system, which resist from using them for
tracking operation are:
 Compressibility: Due the higher compressibility of working medium, the calculated
displacement of actuator cannot be obtained.
 Precision: Precision of pneumatic systems is less than hydraulic systems.
 Operating temperature: Pneumatic systems are high sensitive to operating
 Temperature, compared to hydraulic systems.
The two important aspects of the fluid power system are,
1. Power transmission
The power from input point to output point is transmitted without any change in the
magnitude and with the same amount of displacement.
2. Power multiplication
Similar to levers, in fluid power systems, the force at input point can be multiplied to a
greater extent at the output point. Such power multiplication is possible with the use of large output
piston that the input piston. The multiplication process is associated with the change in magnitude of
displacement.
Figure 6.1: Structure Of Hydraulic Power System
S. K. Kusekar, Ajinkya Patil, Sachin Patil, Prasad Rajmane, Akshay
Bhosale:: Tracking of Solar Panel by Hydraulic System
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ISSN (Online): 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
The schematic arrangement of a hydraulic power system is illustrated by the figure
Notations:
 Pump with electric motor
 Flow control valves
 Pressure regulating valve
 Reservoirs
 Pressure gauges
 Cylinder with load
The system consists of three main segments (i) Power supply, (ii) Control system and (iii)
Output. All these are connected through a closed loop with suitable hydraulic lines. The hydraulic
line with a filter at the end, running from the reservoir through pump till the output point is called
the pressure line (A). The fluid line running from the output point back to the reservoir is termed the
return line (B), which carries the low pressure fluid, back to the reservoir.
Reservoir or sump is an oil container, whose capacity depends on the capacity of oil
required for the fluid power system, with enough reserve oil to cater for leakage loss and continuous
operation.
i) Power Supply
The power supply segment comprises the prime mover, and the pump. The fluid from pump
passes through a filter, where foreign particles are removed. The pump supplies the input power to
fluid to convert it into hydraulic power.
ii) Control System
The control unit is intermediate but most important part between the power supply and
output segments. Control unit comprises different valves for various purposes. A typical control unit
includes the types of valves,
a. Directional control valves: to control the direction of actuator movement.
b. Pressure control valves: to control the fluid pressure, this in turn controls the output force.
c. Flow control valves: to control the flow rate of the fluid, to regulate the speed of the actuator
iii) Output
The output segment of hydraulic system includes the actuator and the load. The function of
actuator is to convert the fluid power back to mechanical power. Depending upon the end use the
actuator can be either linear type (hydraulic cylinder) or rotary type (hydraulic motor).
Examples of fluid system
Following devices are the common examples of the fluid systems,
i.
Hydraulic press
ii.
Hydraulic accumulator
iii.
Hydraulic intensifier
iv.
Hydraulic ram
v.
Hydraulic lift
vi.
Hydraulic crane
vii.
Fluid or hydraulic coupling
viii.
Fluid or hydraulic torque converter
ix.
Air lift pump
x.
Gear wheel pump
S. K. Kusekar, Ajinkya Patil, Sachin Patil, Prasad Rajmane, Akshay
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International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
6.1.3
Fundamentals of Fluid Mechanics:
Fluid mechanics is that branch of science which deals with the behavior of fluids (liquids or
gases) at rest as well as in motion. Thus this branch of science which deals with the static,
kinematics and dynamic aspects of the fluids. The design of a hydraulic system involves the basic
concepts and principles of the fluid mechanics. The study of fluids at rest is called fluid static’s. The
study of fluid in motion, where pressure forces are not considered, is called fluid kinematics and if
the pressure forces are also considered for the fluids in motion, that branch of science is called fluid
dynamics.
6.1.4 Fluid properties:
Following are some of important fluid properties which are to be considered while designing
the hydraulic system.
01. Mass density: It is the mass per unit volume whereas weight density (or Specific weight) is the
weight per unit volume at the standard temperature and pressure.
02. Specific gravity: It is the ratio of the specific weight of the liquid to the specific weight of
standard fluid. It is a dimensionless quantity.
03. Viscosity: It is the property of fluid which determines its resistance to shearing stresses.
04. Compressibility: It is the property by virtue of which fluids undergo a change in volume under
the action of external pressure. It is the inverse of bulk modulus.
05. Pressure: Pressure is defined as the force exerted on the unit area. The pressure on a fluid is
measured in two different systems. In one system, it is measured above the absolute zero or
complete vacuum and it is called absolute pressure and in other system pressure is measured above
the atmospheric pressure it is called gauge pressure.
6.1.5 Pascal’s Law:
The basic principle underlying all the fluid power applications is the Pascal's law this law
deals with a hydrostatics, the subject related to the transmission of power through a confined fluid
under pressure. In fact, it is the fundamental principle based on which all the fluid power systems
work.
Referring to figure the Pascal's law can be stated as;
The pressure exerted on to a confine fluid is transmitted undiminished in all directions, and
acts uniformly at the right angle to the containing surfaces.
6.1.6 Continuity equation
The equation is based on conservation of mass is called continuity equation. Thus for a fluid
flowing through the pipe at all the cross-section, the quantity of fluid per second is constant.
Consider two cross-sections of a pipe, as in figure
Figure 6.2:- Continuity Equation
S. K. Kusekar, Ajinkya Patil, Sachin Patil, Prasad Rajmane, Akshay
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ISSN (Online): 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
Continuity equation
Let,
V1 = Average velocity at cross-section 1-1
r1 = Density at section 1-1
A1 = Area of pipe at section 1-1
And V2, r2, A2 are corresponding values at section 2-2.
Then the rate of flow at section 1-1 = r1A1V1
And rate of flow at section 2-2 = r2A2V2
According to law of conservation of mass,
Rate of flow at section 1-1 = Rate of flow at section 2-2
r1A1V1=r2A2V2
The above equation is applicable to the compressible as well as incompressible fluids and is called
continuity equation. If the fluid is incompressible (e.g. Hydraulic oils), then
r1= r2
and the above continuity equation reduces to
A1V1= A2V2
6.1.7 Bernoulli’s equation and its applications
Statement: It states that in a steady, ideal flow of an incompressible fluid, the total energy at any
point of the fluid is constant. The total energy consists of pressure energy, kinetic energy and
potential energy or datum energy.
These energies are,
Pressure energy = p/rg in m of fluid
Kinetic energy = v2/2g in m of fluid
Datum energy = z in m of fluid
Thus mathematically, Bernoulli's theorem is written as,
p/w + v2/2g + z = Constant - - - - - - - - - - - - (here w = rg)
Applications: Bernoulli's equation is applied in all problem of incompressible fluid flow where
energy considerations are involved. The sum of common applications of Bernoulli's theorem is,
1. Venturimeter - for measuring the rate of fluid flow
2. Orifice meter - for measuring the rate of fluid flow
3. Pitot tube - for measuring velocity of fluid flow
Orifice:
Orifice is a small opening of any cross-section, through which a fluid is flowing.
Orifice may be of any cross-section such as circular, triangular, rectangular etc.
Classification of orifice:
Orifice are classified based on,
 Size: Small orifice and large orifice
 Cross-sectional areas: Circular orifice, triangular orifice, rectangular orifice & square orifice
 Shape of upstream edge: Sharpe-edged orifice and bell-mouthed orifice
 Nature of discharge: Free discharging orifice and drowned or sub-merged orifices
Co-efficient of discharge for orifice:
It is defined as the ratio of actual discharge from an orifice to theoretical discharge. It is denoted by
Cd.
Cd = Actual velocity
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Bhosale:: Tracking of Solar Panel by Hydraulic System
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International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
Theoretical velocity
And Theoretical velocity is given by the equation,
v2 = 2gH m/s
Where,
v = velocity of fluid flowing through the orifice in m/s
g = acceleration due to gravity in m2/s
H = head in m
- Discharge through orifice:
The rate of discharge from orifice is expressed by the equation,
Q = Cd A (2gH)0.5m3/s
Where A = cross-sectional area of orifice in m2
6.1.8 Characteristics of Hydraulic systems
01. High forces (torques) with compact size.
02. Step less change (control or regulation) of speed.
03. Suitable for heavy duty operations.
04. Suitable for heavy load applications.
05. Simple overload protection.
06. Higher response time.
07. Hydraulic means of transferring energy are usually slower when compared to
pneumatics or
electrics.
08. Suitable for controlling fast movement process and for high precision movement.
09. High capital cost.
10. Flexibility may not be as good as pneumatics or electrics.
11. Unavoidable leakages, due to higher system pressure.
12. Prone to fire hazards.
6.2 Mechanical Design
This section of design includes the details of hardware elements used in the tracking system
and also the design analysis of those elements
6.2.1 Machine Design
Machine design is the creation of new and better machines and improving the existing once.
A new machine is one which is more economical in the overall cost of production and operation.
Classifications of machine design:
a. Adaptive design
b. Development design
c. New design
6.2.2 Mechanics
Mechanics may be defined as that science which describes and predicts the conditions of
rest or motion of bodies under the action of forces. Mechanics is a physical science, since it deals
with the study of physical phenomenon. The three divisions of mechanics and their sub-divisions are
given as below,
a. Mechanics of rigid bodies
I. Static’s
II. Dynamics
b. Mechanics of deformable bodies
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20th Edition, Page No: 2856- 2881
c. Mechanics of fluids
I. study of compressible fluids
II. Study of incompressible fluids (Hydraulics)
6.2.3 Space, time, mass and force
These are basic concepts of the mechanics. These concepts are not truly defined; they should
be accepted on the basis of our intuition and experience and used as mental frame of reference of our
study. The concept of space is associated with the notation of the position of a point P. the position
of P may be defined by three lengths measured from a certain reference point, or origin, given in
three directions. These lengths are known as co-ordinate of P. To define an event, it is not sufficient
to indicate its position in space. The time of the event should also be given. The concept of mass
used to characterize and compare the bodies on the basis of certain fundamental mechanical
experiments. Two bodies of same mass, for example, will be attracted by earth in the same manner;
they will also offer the same resistance to a change in translational motion. A force represents the
action of one body on another. It may be excreted by actual contact or at a distance, as in the case
gravitational forces and magnetic forces. A force is characterized by its point of application, its
magnitude and direction. A force is represented by a vector.
6.2.4 Energy and Power
Energy may be defined as capacity to do work. The energy exists in many forms e.g.
mechanical, electrical, chemical etc. The three types of mechanical energies are Potential energy,
Kinetic energy and Strain energy. The S.I unit of energy is Joule (J) and the symbol is E. Power may
be defined as rate of doing work per unit time. The S.I unit of power is watt (W) and the symbol is
P.
6.2.5 Tracking mechanism
The mechanism selected for tracking system is based on lever principle. The type of lever
used manipulate the required load is Second type lever. Basically, a lever is rod or bar capable of
turning about a fixed point called fulcrum. It is used as a machine to lift / transmit a load by the
application of small effort. The ratio of load lifted to the effort applied is called mechanical
advantage. A lever may be Straight or curved and the forces applied on the lever (or by the lever)
may be parallel or inclined to one another.
6.3 Application Of Levers In Engineering Practice
The load (W) and the effort (P) may be applied to the lever in three different ways. The
Fulcrum is denoted by F and direction of reaction is indicated by an arrow mark.
6.3.1 First type/First class lever
In the first type of levers, the fulcrum is in between load and effort. These levers are
commonly used in railway signalling, rocker arms, hand pumps, foot levers etc.
Figure 6.3:-First Type Of Lever
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6.3.2 Second type/Second class lever
In this type, the load is in between the fulcrum and effort. The application of such type of
lever is found in levers of loaded safety valves.
Figure 6.4:- Second Type Of Lever
6.3.3 Third type/Third class levers
In this type of levers, the effort is in between the fulcrum and load. The use of such type of
levers is not recommended in engineering practice. However a pair of tongs, the treadle of sewing
machine is the examples of this type of lever.
Figure 6.5:- Third Type Of Lever
6.4 Schematic Diagram
The arrangement of the hydraulic components and other mechanical elements are illustrated
by the following schematic diagram.
The components of the system are,
i. Panel seat
ii. Column
iii. Base
iv. Weight
v. Weight holder
vi. Double acting cylinder
vii. Check valve
viii. Flow control valve
ix. Reservoir
x. Filter
xi. Rod end mounting
xii. Piston end hinge
xiii. Handle
xiv. Counter weight platform
xv. Connecting hose
xvi. T-Connector
xvii. Stopper
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Figure 6.6:-Schematic Diagram Of Tracking Of Solar Panel
6.4.1 Working procedure
Working procedure of the designed tracking system is explained by the hydraulic circuit
diagram and by the schematic diagrams. Each duty cycle of the system contains two steps, those are,
6.4.2 Tracking
As the tracking weight acts on the piston through piston rod, it pushes the oil out of the
cylinder and the oil flows towards reservoir. While, due to the restricted cross sectional area at flow
control valve the piston moves with the velocity equal to calculated tracking velocity. During this
action the check valve remains closed, hence oil is allowed to flow only through flow control valve.
At the rod end of the cylinder, the oil is sucked into cylinder due to the vacuum pressure created by
the applied weight.
Figure 6.7: Tracking
6.4.3 Return
As the tracking time finishes, the panel seat has to be rotated by applying the torque,
manually, to bring back into initial position. The vacuum pressure is created at piston end chamber
and oil from reservoir rushes towards cylinder. As soon as the system pressure exceeds the cracking
pressure of check valve, check valve opens and allowing full flow of oil from it, reducing the time
required for repositioning operation.
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The flow control valve also allows the oil to flow from it, increasing rate of flow and reduced panel
repositioning time. At rod end of cylinder the piston forces the oil. The oil pressure increases and oil
flows out of the cylinder. Oil returns to reservoir through a filter placed in the return line.
Figure 6.8:- Return
The lever mechanism used for the current tracking system is illustrated by the figure
Figure 6.9: Lever Mechanism
6.4.4 Tracking mechanism
Here, the load is the resistance offered by the cylinder for displacement, which while
depends on the rate of flow from the cylinder. The weight of the disc is the applied driving force,
hence it is the effort applied on the system to perform the desired operation. The weight is applied
through a weight holder. Comparing with the types of lever systems, as the load is between fulcrum
and effort point, this is a system with second type lever system. The arrow on the points shows the
direction of force.
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6.5 Hydraulic Circuit Design
Hydraulic circuit is representation of various components of the hydraulic system by using
graphic symbols. The design of hydraulic circuit which precedes the design of actual components,
does not really involve any calculations as it is the mere representation of the system using different
graphic symbols.
Figure 6.10: Hydraulic Circuit Diagram
6.6 Hydraulic Circuit Diagram:
Hydraulic circuit diagram for the mechanical solar tracking system is illustrated by the
figure 6.11,
6.7 Symbol Representation
In the design of hydraulic systems, it is not possible to draw the construction details of the
component on drawing. To make it convenient for representation of different components, various
graphic symbols were developed.
6.7.1 Rules for symbol usage:
The following are the rules for the using graphic symbols,
I. A graphic symbol represents function only. It does not describe any construction features.
II. A circuit diagram with graphic symbol is functional only. It only shows the sequence in which
various components are connected.
III. Valves are essentially drawn in their unactuated position.
IV. The orientation of the symbol on the drawing in no way indicates the actual orientation of the
component in the actual system. The orientation shown has no functional meaning for symbol.
Elements of Hydraulic system.
The components of the hydraulic circuit and their functions are,
 Hydraulic actuator (Hydraulic Cylinder)
The actuators are used in hydraulic systems to convert the fluid energy (i.e. fluid with high
pressure) back into mechanical energy by reducing the pressure of fluid. The power developed by
the actuator depends on,
a. Flow rate
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Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
b. Pressure drop across the actuator
c. Efficiency of actuator
There are three types of hydraulic actuators,
1. Linear actuators
2. Rotary actuators (Continuous)
3. Rotary actuators (Limited angle)
Linear actuators are nothing but hydraulic cylinders, which produce straight line motion.
The linear motion achieved in a hydraulic cylinder depends on the stroke length. These actuators are
generally termed hydraulic cylinders. Other specific terms like rams and jacks are also used for
hydraulic actuators, depending on their end use. The term ram is used for single acting cylinder that
causes linear motion in horizontal plane and the term jack refers to a hydraulic cylinder that is used
to lift the loads.
The common types of linear actuators are,
a. Single acting cylinder
b. Double acting cylinder
c. Displacement cylinder

Double acting cylinder: Double acting cylinder produces linear motion in two directions.
Hydraulic power is applied on either side of the piston. The construction of double acting
cylinder is similar to single acting cylinder except that rod end of the cylinder also has oil port.
The constructional details of the double acting cylinder is as shown in fig,Constructional details
of double acting cylinder
Figure 6.11-Constructional Details Of Double Acting Cylinder
Double acting cylinder has a hollow cylinder (barrel), piston and piston rod. Both the ends are sealed
with the end caps, which are either threaded or welded to the main cylinder. In some designs, the
end caps are held with the cylinder by tie rods. The piston is provided with a piston seal, commonly
used are piston rings to protect the leakage of oil. The rod is provided with seal to protect the
leakage, a bearing to carry the radial loads, a wiper to protect the foreign particles like dust entering
into cylinder. Oil ports are provided on either side of the piston, so that the fluid pressure can be
applied alternatively on both the sides.
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
Graphical symbol:
I.
Flow control valve (FCV)
The function of flow control valve is to regulate the flow rate of fluid in a hydraulic system.
This in turn used to control the speed of actuator/s. These valves are basically variable area orifices,
in which increasing the area of orifice increases the flow rate and decreasing the area of orifice
reduces the flow rate.
The common types of FCVs are,
1. Simple needle valve
2. Needle valve with integral check
3. Pressure compensated FCV

Graphical Symbol:
II.
Check Valve
Check valves are also known as directional control valves. The function of check valve is to
direct the free flow in only one direction, and block any flow in reverse direction. These are similar
in operational analogy of electronic diodes.
The three types of check valves are generally used.
a. Ball type valve
b. Poppet type valve
c. Pilot operated check valve
A spring operated direction valve requires a small pressure to open, which is
called as cracking pressure. Due to this it can work like low pressure relief valve to some extent.
 Graphical symbol:
III.
Filter
Filters are used in hydraulic systems to remove both the solid and liquid contaminants. Filter
is a device that consist of an element (called filter element) having the openings. When the
contaminated oil passes through the filter element, the particles remain/get filtered, while the clean
fluid passes out of the element. Filter elements are available in sizes as small as 1 micron, which
mean even a dust particle of size 1 micron gets filtered through this filter element.
The three common types of filter elements used in hydraulic systems are,
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Volume - 2, Issue - 8, April 2015
20th Edition, Page No: 2856- 2881
a. Mechanical elements
b. Absorbent elements
c. Adsorbent elements
The types of filters are,
a. Full-flow filter
b. Proportional-flow filter
 Graphical symbol:
IV.
Hydraulic oil
The working fluid in all hydraulic systems is a fluid. Various oil based fluids which had the
desirable properties were developed for the use in hydraulic systems.
The functions of the hydraulic fluid are,
a. To transmit power, this is the primary function.
b. To lubricate various moving parts, so as to avoid metal-to-metal contact, and reduce wear and
noise.
c. To carry the heat generated in the system due to friction between moving parts and moving fluid,
and to dissipate to the environment either through a suitable heat exchanger or through the reservoir.
V.
Desirable properties of hydraulic fluids:
For the fluid to perform efficiently, it must possess certain properties. Certain additives are
added to achieve/preserve the desirable properties. The various properties required for an ideal
hydraulic fluid are as follows,
a. Viscosity
The most basic desirable property of hydraulic fluid is the optimum viscosity. Viscosity
refers to the resistance of a fluid to flow. A low viscous fluid is a thin and can flow easily, but causes
leakages and a very high viscous fluid is thick and doesn't flow easily. In practice, ideal hydraulic oil
should have optimum viscosity.
b. Lubrication
The other major requirement of hydraulic oil is the lubricating ability. A thin film of
lubrication should present to avoid direct contact between two mating surfaces; else both surfaces
rub with each other resulting in high wear rates. The extent to which direct metal-to-metal contact is
avoided depends on the strength of the fluid film which is a function of the viscosity of the fluid. In
hydraulic systems, the fluids themselves act as lubricating medium.
c. Chemical and environmental stability
For a good hydraulic fluid, a good chemical and environmental stability is desirable. Most
fluids are vulnerable to oxidization, as they come in contact with oxygen in air. The oxidation
products are highly soluble in oil, and being acidic in nature, they can easily corrode the metallic
parts. Oxidation leads to deterioration in the chemical nature of the fluid, which may form some
chemical sludge’s, gum or varnish at low velocity or stagnation points in the system. These chemical
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products increase the viscosity of the fluid. Rust is the formation of iron oxide by the chemical
reaction between steel and oxygen. Corrosion is another chemical phenomenon, occurring between
any metal part and acid. These problems can be minimized by adding certain chemical additives to
the fluid, that inhibit oxidation, within the fluid, or that form a thin chemical layer on the metal parts
and avoid direct contact, and hence reduce rusting and corrosion problems.
d. Incompressibility
The incompressibility of a fluid is measure of its stiffness, and given by its bulk modulus
(B). The compressibility of a fluid has influence on the system response, and makes it susceptible to
shock waves. In normal hydraulic systems its effect on system response is not considered, while the
compression values are used to avoid shock wave problems.
e. Fire resistance
Fire resistance is one important property required for applications in aircraft engines, steel
mills, foundries and mines, where the working environment are hot. Through petroleum based oils
are suitable and have many desirable characteristics, they are highly vulnerable to fire hazards. In
such cases fire resistant fluids are used. Fire resistance of a hydraulic fluid measured by some of the
characteristics, those are flash point, fire point and autogenously temperature.
f. Foam resistance
Dissolved air reacts with the fluid to form acidic products which in turn cause corrosion and
sludge problems. The presence of foam in the fluid causes serious operational problems. Certain
additives are added to fluid, which act as foam-depressants.
VI.
Reservoir
Reservoirs are basically storage tanks for the hydraulic oil. The functions of a hydraulic
reservoir are,
a. To act as a storage tank.
b. To provide heat exchange, thus cooling the oil.
c. To allow entrained air to escape from fluid.
d. To allow fluid contaminations to settle down.
e. To make-up any leakages in the system.
f. To provide filling point for the system.
The reservoir design should be optimum. A smaller size reservoir then required causes
problems like overheating, increased contamination, higher wear and tear. An over sized reservoir
will increase the cost of tank and longer warming period.
VII.
Hydraulic System Design
Hydraulic system design includes the determination force required for the cylinder and
system pressure. The details of calculation steps for the hydraulic system design are given as below,
6.6 Nomenclature
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
D = Cylinder diameter in m
A = Cross sectional area of cylinder in m2
L = Length of stroke in m
d = Diameter of orifice in m
Cd = Co-efficient of discharge for orifice
Vp = Velocity of piston in m/s
Vo = Velocity of oil at orifice in m/s
Qc = Cylinder discharge in m3/s
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ix.
x.
xi.
xii.
xiii.
xiv.
xv.
Qo = Orifice discharge in m3/s
P = System pressure in N/m2
F = Force in N
W = Weight in N
r = Density of hydraulic oil in kg/m3
a = Distance from rod end to panel hinge in m
b = Distance from loading point to panel hinge in m
Available data:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
Time range = 8 AM to 4 PM (8 Hrs)
Pressure drop across the check valve = 50.8 mm Hg = 6772.77 N/m2
Pressure drop across the filters = 1 inch of Hg = 3386.38 N/m2
Size of the panel (L x B x H) = 1 m x 0.5 m x 0.025 m
Selected Hydraulic oil = SAE20 W40
r = 880 kg/m3
D = 0.05 m and A = 0.00196 m2
L = 0.21 m
d = 0.001 m
Cd = 0.62
6.7 Calculations
I.
Velocity of piston
Vp = Stroke length / Time range
= 0.21 / 28800
Vp = 7.29E-6 m/s
II.
Cylinder discharge
Qc = Cross-sectional area A x Velocity of piston Vp
= 1.963E-3 x 7.29E-6
Qc = 1.43E-8 m3/s
III.
Velocity of oil at orifice
By the relation for discharge from orifice,
Qo = Cd x a x Vo
1.43E-8 = 0.62 x 7.85E-7 x Vo
Vo = 0.029 m/s
IV.
System pressure
2 x P = Vo x r - - - - - - - (by V = (2gH)0.5 & P = rgH)
2 x P = 0.0292 x 880
P = 0.37 Pa or N/m2
And also considering the pressure drop across the filters = 3386.68 Pa
(Note: As check valve is closed during tracking operation, pressure drop across check valve is not
considered.)
The Total system pressure,
P = 0.37 + 3386.38
i.e. P = 3386.75 Pa
V.
Force required,
F=PxA
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= 3386.75 x 1.963E-3
F = 6.64 N
The force required on the cylinder for tracking = 6.64 N
VI.
Reservoir Design
Reservoir design is essential to determine the capacity of tank, hence to assure proper
functionality. Some of the common rules to be followed in reservoir design are as follows,
a. The minimum size of the reservoir should be at least twice the pump delivery per minute.
b. Its capacity should be adequate enough to hold all the oil from the system that might drain into
tank.
c. It should have oil level much above the intake strainer, so that no whirling effect will occur.
d. Its capacity should enough to allow for thermal expansion.
Calculations:
Displacement of cylinder,
Vc = (3.142/4) x D2 x L
= (3.142/4) x 0.052 x 0.21
Vc = 0.000412 m3
Volume of oil in hoses and other accessories,
Va = (3.142/4) x 0.012 x 0.6
Va = 0.0000471 m3
Theoretical volume of tank,
Vt = Vc + Va
= 0.000412 + 0.0000471
Vt = 0.00046 m3
As per optimum design practices, the actual volume of tank should be at least twice the theoretical
volume of tank.
Hence,
Minimum Volume of tank = 2 x Vt
= 2 x 0.00046
i.e. Minimum volume of tank = 0.00092 m3 or 0.92 Liter
VII.
Force and Energy Calculation
Due the application of lever principle the effort required for the tracking operation is
different from the calculated value of force in the hydraulic system calculation.
(Note: All dimensions are in mm)
The force required is different for both steps of operation and they are calculated as below.
Step 1: Tracking
Referring to the mechanism and by the lever principles, taking reaction at fulcrum point,
We have,
Load x 0.13 m = Effort x 0.5 m
13.295 N x 0.13 m = W x 0.5 m - - -( F = 13.295 N )
i.e.
W = 3.456 N
Load required for the tracking operation = 3.456 N
and energy consumed for tracking,
Energy = Force x Distance (Cylinder displacement)
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= 3.456 x 0.21
i.e. E = 0.725 J
Energy required for tracking operation = 0.725 J
Step 2: Return
The force applied for return operation is manual. Assuming a normal person can exert 5 kg
of force against gravity, then
Force required for return operation = 49.05 N
Energy consumed for the return operation = Force x Angular displacement
= 5 x 9.81 x (π/180) x 0.5 x 120
i.e. E = 51.36 J
Energy consumed for return operation = 51.36 J
6.8 Assembly
I. Column and base
This is the load bearing structure of machine which takes all forces acting on the system.
The column and base are welded together to provide more strength and to carry the solar panels of
larger sizes than designed. It also includes two stoppers to restrict the displacement of panel seat to
the required position. These are plates of 4mm thickness and welded to the column.
II.
Panel seat
Panel seat is a fabricated frame on which solar panel is mounted. It is fabricated element and
sufficient numbers of holes are provided to facilitate the mounting of solar panel. It also supports the
weight holder and transmits tracking force to cylinder. A provision also made on the frame to mount
the counter weight, for flexibility in selection of weight disc/s. A handle is provided with the frame
to facilitate the lifting the panel seat for return operation.
III.
Weight holder and weight disc
The function of weight holder is to hold the weight disc in its place. Another important
function of weight holder is to provide proper moment to overcome static friction of cylinder at the
beginning of tracking operation. The static friction is very high at the beginning of tracking
operation. Weight disc is a molded disc which is mounted on weight holder to exert driving torque
for tracking operation. Multiple discs can be used according to their unit weight and requirement.
FLUID FLOW
CONTROL VALVE
CHECK VALVE
Figure 6.12 : Control Valve And Check Valve
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WEIGHT AND WEIGHT HOLDER
Figure 6.13: Weight And Weight Holder
PANNEL SET
Figure 6.14: Panel Set
PANNEL SET SUPPORTING HINGE
PISTON END HINGE
DOUBLE ACTING
CYLINDER
Figure 6.15: Showing Hinges And Double Acting Cylinder
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Figure 6.16: Overall Assembly Of Hydraulic Solar Tracker
7 Advantages, Disadvantages and Limitations
7.1 Advantages
1. Hydraulic solar tracker is easy to design and manufacture compare to other tracker system.
2. Increased reliability and robustness of hydraulic control system compared with other solar
tracker.
3. Hydraulic solar trackers generate more energy than other tracking system like electric solar
tracker.
4. Lubrication of system is not necessary due to less moving parts.
5. Compare to other tracking system hydraulic tracking system cost is less.
6. Important reduction of whole life maintenance cost of solar tracker .
7.2 Disadvantages
1. Structurally less rigid then permanent mounts and hence can be vulnerable to storm damage.
2. More chances to leakage of hydraulic oil.
3. Required manual power to pump the oil in cylinder.
7.3 Limitation
The Track Rack begins the day facing west as the morning sun rises in the east we need to
pump the oil in cylinder with the help of manual power.
8. Bill Of Materials
Table 8.1: Bill Of Materials
Sr No.
1.
2.
3.
4.
5.
Part Code
TPSH -1
TPSH -2
TPSH -3
TPSH -4
TPSH -5
Description
PANEL SEAT
COLUMN
BASE
WEIGHT
WEIGHT HOLDER
Qty
01
01
01
01
01
Material
MS
MS
MS
MS
MS
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6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
TPSH -6
TPSH -7
TPSH –8
TPSH –9
TPSH –10
TPSH –11
TPSH –12
TPSH –13
TPSH –14
TPSH –15
TPSH –16
DOUBLE ACTING CYLINDER
CHECK VALVE
FLOW CONTROL VALVE
RESERVOIR
ROD END MOUNTING
PISTON END HINGE
CONNECTOR HOSE
COUNTERWEIGHT PLATFORM
T-CONNECTORS
HOSE CLIPS
CONNECTOR NOZZLES
01
01
01
01
01
01
01
01
02
20
08
STD
STD
STD
MS
MS
MS
STD
MS
STD
STD
STD
9. Result
The results obtained after the detailed calculations are given as below,
i.
Velocity of piston = Vp = 7.29E-6 m/s
ii.
Cylinder = Qc = 1.43E-8 m3/s
iii.
Velocity of oil at orifice = Vo = 0.029 m/s
iv.
System pressure = P = 3386.75 Pa
v.
The force required on the cylinder for tracking = F = 6.64 N
vi.
Considering mechanism for tracking, weight required for tracking,
i. W = 3.456 N
vii.
Energy required for tracking operation = 0.725 J
viii.
Force required for return operation = 49.05 N
ix.
Energy consumed for return operation = 51.36 J
x.
Minimum volume of tank = 0.00092 m3 or 0.92 Liter
xi.
Increased power output and returns = 87.6 kW-hr worth of Rs.403 /solar panel of area 0.456 m2 and analysis period of 1 year)
------
(Considering a
10. Conclusion
It is observed that the designed mechanical tracking system is a system, which consumes no energy
for operation and contributing towards increasing the productivity of the solar panels. This is the
first attempt made towards utilizing the gravitational energy as a driving force for solar tracking
systems and also in providing a suitable tracking system for the remote places. In view of increasing
demand for the electrical power, this tracking system can contribute a little (around 87.6 kW-hr per
year) in the fulfilment this demand
11. Future Scope
Further research work will be suggested towards reducing the material cost, towards implementation
of suitable sensors to assure ease in operations and towards obtaining the preferred essential
requirements. Some of the preferred essentials and the guidelines associated with design and
development of this tracking device are;
I.
A sensor with electronic counter, which will provide input signal to a buzzer, to indicate the
start of tracking cycle. On basis of this, the panel is tilted by means of handle to perform
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II.
III.
return operation. The electronic system, if used, should consume very little electric energy,
making the device suitable for remote applications by providing small & long lasting
batteries.
Use of multiple panels on panel seat, to increase the returns from tracking system.
System can be modified to suite other solar applications like solar air heating and solar
water heaters.
References
PUBLISHED PAPER REFERANCE
[1] One-Axis Trackers – Improved Reliability, Durability, Performance, and Cost Reduction - Final
Subcontract Technical Status Report - 2 May 2006 – 31 August 2007 by J. Shingleton Shingleton
Design, LLC Auburn, New York
[2] Low cost tracker by Marliyani Binti Omar This thesis is submitted as partial fulfillment of the
requirements for the award of the Bachelor of Electrical Engineering - Faculty of Electrical &
Electronics Engineering University Malaysia Pahang -MAY, 2009
[3] A review of principle and sun-tracking methods for maximizing solar systems output by Hossein
Mousazadeh, Alireza Keyhani, Arzhang Javadi, Hossein Mobli Karen Abrinia, Ahmad Sharifi Department of Agricultural Machinery Engineering, University of Tehran, Iran
BOOK REFERANCE
[1] Fluid mechanics and Hydraulic machines by R.K.Bansal.
[2] Basic hydraulics and hydraulic plumbing US army division.
[3] Machine design by R.S.Khurmi and J.K Gupta.
[4] Vector mechanics for engineers by F.B Beer.
[5] Atlas solar tracking by mechatron company manual.
WEB REFERENCE
We have followed several links on the internet’s which are as follows:
[1] http://www.canren.gc.ca/tech_appl/about solar energy.htm.
[2] http://www.palmdalewater.org/alternative solarenergy.htm.
[3] http://www.careercornerstone.org/careers for mechanical engineers
[4] http://www.burkoil.com.
[5] http://www.bull-electrical.com/solar panels, electrical and water, controllers, panels, solar
shargers.htm.
S. K. Kusekar, Ajinkya Patil, Sachin Patil, Prasad Rajmane, Akshay
Bhosale:: Tracking of Solar Panel by Hydraulic System
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