260 detailed design review
TRANSCRIPT
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
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.
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
Team Member ContributionsJose: Team LeaderJustin: DesignPeter: CommunicationZack: SolidWorksColin: ResearchTerrence: PresentationBradley: Economics