The document describes a new solar tracker concept called Titan Tracker. It summarizes key advantages of Titan Tracker over conventional mounted-pole systems, including greater reliability, accuracy above 0.01 degrees, and profitability through dual-axis tracking from a 10 degree elevation. Titan Tracker uses a 3D truss structure, independent driving and support systems, continuous movement, and other design features to achieve these benefits for concentrating photovoltaic installations.

1. ( Área reservada a imagen )
TITAN TRACKER:
the new concept
CPV Summit USA 2009
Hotel Sheraton Mission Valley – San Diego Carlos García García
February 3rd – 4th, 2009
Engineer
Manager - TITAN TRACKER

2. A CHANGE IN CONCEPT
In 1968 Dick Fosbury invented a new
way to do the high jump.
He was the first athlete who used
this new technique which led to him
winning the gold medal in the Mexico
Olympics
In this way, he beat Russian athletes
who had been improving the
conventional technique during
previous years.
Nowadays, all the athletes use the
“Fosbury” technique.
2

3. CONTENTS
1. BACKGROUND
2. RELIABILITY
3. ACCURACY
4. PROFITABILITY
5. BUSINESS MODEL
6. REFERENCES
3

4. 1. BACKGROUND
1.1. Evolution
At first, solar parks used FIXED systems
Gradually, different systems appeared,
with TRACKING:
1-AXIS tracking •Mounted-pole
1-AXIS polar tracking
2-AXIS tracking (mounted-pole)
2-AXIS tracking (TITAN TRACKER)
Mounted-pole system is the most
common one but lacks reliability
because of its own conceptual
characteristics •TITAN TRACKER
Due to inertia and a lack of alternatives,
despite its shortcomings, which were
even more obvious for CPV, an attempt
was made to use mounted-pole systems
in CPV
4

5. 1. BACKGROUND
1.2. What would the ideal tracker be for CPV?
Solar trackers are critical element
for CPV installations. CPV
technology needs trackers and
vice versa.
Nowadays, modules are being
made that are adapted to the
precision of the trackers and not
the other way round.
So what would the ideal tracker
be like?
RELIABLE
ACCURATE
COST-EFFECTIVE
TITAN TRACKER MOUNTED-POLE
TITAN TRACKER fulfils these ACCURACY > 0.01º < 0.1º
requirements. RELIABILITY ≈ FIXED << FIXED
COST << >>
5

6. 2. RELIABILITY
2.1. The concept of TITAN TRACKER
What sort of structures have
demonstrated reliability during the history The Eiffel tower was built in
of engineering in the long term? 1889 during the Expo, with a
weight of 7,300 tons and 300 m
of height and was considered
Eiffel tower the tallest construction of its
time
Electrical pylons
Many examples
All these constructions have been made
using 3D truss using screws, exactly as is
done in TITAN TRACKER
This manufacturing technique and the
geometry of the design mean that TITAN
TRACKER is practically as reliable as a
fixed structure
6

7. 2. RELIABILITY
2.2 Structure based on 3D truss
3D truss based on cold-formed sections
The support structure is based on a
3D truss using mainly cold-formed
sections of steel:
Cold-formed and rolled
Normalized and standardized
Screwed
Hot galvanized
These cold-formed sections have a
perfectly tabulated and tested “C”-type cold-formed section
behavior under extreme loads
7

8. 2. RELIABILITY
2.3 Structure using screws
Detail of different joint elements
Structure based on screws, no
welding, except when strictly
necessary
In this way, the following problems,
which are usual in welding, can be
avoided:
Early corrosion
Residual strain
Specialized staff
Discontinuous galvanizing
X-raying of welding
Screws, flanges and rivets
TITAN TRACKER MOUNTED-POLE
STRUCTURE USES SCREWS WELDED
8

9. 2. RELIABILITY
2.4 Five supports
B
It is an obvious but crucial issue to
assure reliability: Five supports
1 fixed support in the center (A)
2 non-driven rolling supports (B)
2 driven rolling supports (C)
C A Fixed support C
“Driven” support
TITAN TRACKER MOUNTED-POLE
SUPPORTS 5 1 B “Non-driven” support
9

10. 2. RELIABILITY
2.5 No bending moments or embedding
The structure works without bending If we assume the presence of a load, q
moments, only compressions on the (wind effect) applied on the panel board in
ground on the rolling supports and a vertical position, that load is transmitted
to the ground through the structure and
compressions, traction and cutting shared at the supports as the following
in the centre types of stress:
There is no embedding
Horizontal cutting on support C
TITAN TRACKER MOUNTED-POLE
Compression on support A
BENDING MOM. NO YES Traction on support C
EMBEDDING NO YES
FOOTPRINT << >>
Decomposition of the wind effect Equivalent System
WIND (q)
•<>
A C B A C B
10

11. 2. RELIABILITY
2.6 Minimal deformations in the structure
Horizontal bar
The panel board is tightly secured to
the structure:
On the top bar of non-deformable truss
At one point (pusher- spindle)
For this reason, with TITAN
TRACKER all possible deformations Point- pusher (spindle)
are less than about l2, where l would
be a characteristic dimension. TITAN TRACKER support elements: one line and one point
In the mounted-pole, the panel board
is supported only at two points
situated on a projecting beam and
one of those points is also a Point
mechanism.
TITAN TRACKER MOUNTED-POLE
PANEL SUPPORT BAR + POINT POINT
DEFORMATIONS < l2 l3
ONE-SUPPORT FAMILY support elements: only one point
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12. 2. RELIABILITY
2.7. Structural calculations
Structural calculations of TITAN TRACKER
Structural calculations with wind
coefficients according to the
standard NBE-EA-95, Basic Standard
for Steel Structures in Buildings,
much stricter than the EU Machines
Directive:
Calculations under unbalanced conditions in
vertical from wind loads
Calculations under unbalanced conditions in
horizontal from wind load
Calculated for the static loads in any
position under the following wind
speeds :
125 Km/h (78 Mph) for FPV
122 Km/h (76 Mph) for CPV.
12

13. 2. RELIABILITY
2.8 High structural resistance
High structural resistance, at any
position of the panel boards, even
in vertical.
(1) Elevation angle formed by the panel (modules) and
the vertical plane (see drawing) That way, we consider
different positions 80º, 45º and 10º (the most unfavorable
case)
(2) Component is the part of the tracker considered for
the calculations: the board (modules) and the body
(support structure of the boards)
(3) Average static wind load calculated for each m2 of the
module in Kg/m2
(4) Vertical imbalance in wind load considered in Kg/m2
(5) Horizontal imbalance in wind load considered in
Kg/m2
(6) Horizontal static wind in km/h generating the average
load give on each m2 of the solar module with the
indicated inclination (based on wind coefficients of the
Spanish standard NBE-EA-95)
≈ means that the data are only extrapolated from other
detailed calculations. (*) With the board in the indicated position, it would support this static wind and also
the structure would support it
(**) With the board in the indicated position, a static wind of 216 Km/h would
exhaust it
13

14. 2. RELIABILITY
2.9. High structural resistance
High structural resistance, with any
position of the panel boards, even
Horizontal unbalanced wind load
vertical.
Vertical unbalanced wind loads
Horizontal unbalanced wind loads
Vertical unbalanced wind load
14

15. 2. RELIABILITY
2.10 Independent driving and structure
Support Support Driving
The driving and structure are
completely independent.
Support
In this case, with TITAN TRACKER
each element fulfils its function, the
driving system just moves and the
structure just supports.
Driving Support Support
In the mounted-pole systems, the
driving system also acts as a TITAN TRACKER: driving and structure are INDEPENDENT
support and it is even the joining
element between the panel board and
the structure.
TITAN TRACKER MOUNTED-POLE Driving and
support
DRIVING and STRUCTURE INDEPENDENT DEPENDENT
STRESS << >>
Stress in the driving
MOUNTED-POLE: driving and structure are DEPENDENT
15

16. 2. RELIABILITY
2.11 No hydraulic driving
Azimuth driving: pinion toothed-wheel
The TITAN TRACKER driving is made
using no hydraulics:
Elevation: 2 electrical motor gears 120 W and
pinion-toothed wheel with spindle (CPV)
Azimuth: 2 electrical motor gears 90 W and
pinion-toothed wheel. 1 drive-wheel is also an
option.
This prevents the typical problems
with hydraulic elements such as:
Loss of pressure Elevation driving: pinion toothed-wheel with spindle
Loss of oil
Replacement of elements
Continuous maintenance
Low temperatures
TITAN TRACKER MOUNTED-POLE
HYDRAULICS NO YES
16

17. 2. RELIABILITY
2.12 High resistance rolling supports
Detail of a non-drive-wheel
TITAN TRACKER uses high- Steel cores
resistance technical wheels:
Core made of steel
Coating of high-resistance polyurethane
Maximum capacity
High resistance to abrasion
Minimum deformations under compression
High stock availability
Global suppliers
Detail of a drive-wheel
17

18. 3. ACCURACY
3.1 General issues
The accuracy of TITAN TRACKER is
determined by the effect of the:
Control system
Geometry of the driving
Structure
TITAN TRACKER is designed to
achieve extremely high accuracy,
greater than 0.01º.
TITAN TRACKER MOUNTED-POLE
ACCURACY > 0.01º < 0.1º
18

19. 3. ACCURACY
3.2 Control system
The control system sends orders to Optical sensor
the motor gears at any time.
TITAN TRACKER uses a control
solution specific for its typology:
closed loop strategy based on
algorithm and optical sensor
The control system has a
characteristic accuracy of:
0.010º on cloudy days (analytical calculation)
0.006º on sunny days (optical sensor)
19

20. 3. ACCURACY
3.3 Control system
The Master control transmits to each The concept of TITAN TRACKER and
tracker the results of the solar its structural geometry and driving
positioning calculations based on the system allow for easy self-calibration
data of latitude, longitude and solar of the system according to parameters
time. that are customized by the user
The Slave control of each tracker The accuracy and other parameters are
analyses the information and takes the also easily customized by the user
appropriate decisions based on the
solar radiation measured by the optical Valid for any latitude
sensor:
If low (cloudy day) the sun is tracked based on the
master control data
If high (sunny day) it automatically tracks the sun
based on the work of its optical sensor
20

21. 3. ACCURACY
3.4 Driving with a long lever arm
Accuracy of the driving in azimuth
The driving system (azimuth) has a
lever arm length of 10,000 mm
(motor-gears on the outer sides) in
the case of TITAN TRACKER
The concept of mounted-pole
systems uses only a lever arm length
of about 200 mm. (50 times less)
The accuracy is directly proportional
to the length of the lever arm.
Motor-gear
Motor-gear
TITAN TRACKER MOUNTED-POLE
LEVER ARM LENGTH 10,000 mm. 200 mm.
Length of lever arm 10,170 mm
21

22. 3. ACCURACY
3.5 Continuous movement
TITAN TRACKER movement in azimuth (sun at 15º/h)
With TITAN TRACKER, the long lever
arm makes it possible to make a
CONTINUOUS movement (azimuth)
with only one start and stop every
day Deviation (º)
In the case of mounted-pole systems
the movement is DISCONTINUOUS,
with thousands of starts and stops
every day. This leads to great stress
in the mechanisms and seriously
compromises its reliability.
TITAN TRACKER is totally electrical
and requires minimum power since it
operates from the outer sides.
22

23. 3. PRECISION
3.6 Comparative tracking
Deviation (º)
TITAN TRACKER movement azimuth/elevation MOUNTED-POLE movement azimuth/elevation
TITAN TRACKER MOUNTED-POLE
MOVEMENT CONTINUOUS DISCONTINUOUS
CYCLES/DAY (*) 1 12,000
•(*) Cycles / day in azimuth with an accuracy of 0.01 at 40º latitude
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24. 3. ACCURACY
3.7 High structural stability
High structural stability: Illustration of the TITAN TRACKER structure
Structure based on 3D truss with high
rigidity which allows minimal deformations
Under static wind speed of about 80 Km/h
(50 Mph) the structure has a maximum
deformation of about 10 mm in the corner
of the panel boards, which is equivalent to
a deviation of only around 0.05º
Mounted-pole systems do not work under
conditions of wind speed higher than 35-
40 Km/h (22 Mph)
TITAN TRACKER MOUNTED-POLE
STOW POSITION Adjustable 40 Km/h
24

25. 4. PROFITABILITY
4.1 Dual-axis tracking (flat-plate)
TITAN TRACKER can obtain up to α=10º
45% more energy than fixed
systems, 40ºN latitude (Spain)
Complete dual-axis tracking
Minimum zenithal angle of 10º (1º in CPV)
Most mounted-pole systems (flat- TITAN TRACKER: Starts from an elevation of 10º
plate) have only partial dual-axis
tracking since in most cases they
start from an elevation of 30/35º
TITAN TRACKER MOUNTED-POLE
α=30º/35º
ELEVATION from (flat-plate) 10º 30/35º
2-AXIS TRACKING (flat-plate) COMPLETE PARTIAL
MOUNTED-POLE: Starts from an elevation of 30/35º
25

26. 4. PROFITABILITY
4.2. Low-cost foundation
Anchor bolts
Since the foundation does not
operate with bending moments, it is
very small, and there are therefore
important savings in material.
Formworks are not needed, and
thereby, it is not necessary to have
specialized staff.
Concrete Steel
Track 9’60 m3 147 Kg Consumption of materials
Footprint 3’90 m3 50 Kg Mod. 122-219 ATR PRECISION
Total 13’50 m3 197 kg
TITAN TRACKER MOUNTED-POLE
STEEL 1 Kg/m2 PV 5,5 Kg/m2 PV
CONCRETE 60 liters/m2 PV 95 liters/m2 PV
Detail of the foundation
26

27. 4. PROFITABILITY
4.3. Low-cost foundation
The plot does not require any
excavation work (no ditches) and it is
formed directly on the ground.
It is possible to an uneven surface in
the raceway (drops in level)
± 20 mm. (flat-plate)
± 10 mm. (CPV)
Plot preparation
27

28. 4. PROFITABILITY
4.4 Capacity and use of the land
High capacity:
211 m2 (flat-plate) expandable to 219 m2
219 m2 (CPV)
Optimal balance between width and
height (flat-plate) to make better use
of the land with no shade In latitude
40º N and with α=11,5º E-W and
Detail of the separation between trackers
α=16,5º N-S the recommended
separation between trackers is:
44 m E-W direction and
31 m N-S direction
For flat photovoltaic plates, in
latitude 40º N, the ratio for land use
is 6.46 m2 land/m2 panel, which is
optimum for complete dual-axis
tracking
28

29. 4. PROFITABILITY
4.5 Structure made by CNC
CNC machine in operation
TITAN TRACKER has been designed
to be manufactured mainly by CNC
machines. For instance, cold-formed
sections alone represent more than
70% of the total weight.
CNC manufacturing provides a very
high and flexible capacity, and even
more traceability in the process
Any metalworking firm can
manufacture TITAN TRACKER with
standard facilities and without
specialized staff.
TITAN TRACKER MOUNTED-POLE
STRUCTURE USES SCREWS WELDED
MANUFACTURING CNC ?
29

30. 4. PROFITABILITY
4.6 Pre-mounted structure
Pre-assembly of TITAN TRACKER in the plant
TITAN TRACKER is usually supplied
in the form of pre-mounted (panels
already joined by screws in the plant)
This makes transport easier and
reduces assembly time on the site
For assembly, only two non-specialized
operators are required, assisted by a standard
crane
The transport ratio is between 1 and 2 trackers
by standard truck
On-site assembly of TITAN TRACKER
30

31. 4. PROFITABILITY
4.7 Screw-less module installation (flat-plate)
Modular installation of TITAN TRACKER
TITAN TRACKER uses any kind of PV
module technology, brand and
dimensions
The installation of the modules
requires no screws in the case of a
flat-plate. It is done on belts that are
anchored with sliding staples, of the
necessary width for the plate to be
assembled.
Since it requires no screws,
assembly costs are reduced as well
as the possibility of accidents to
operators.
31

32. 4. PROFITABILITY
4.8 Standard supply and maintenance-free
The rest of the components are
standard and low cost with a
tested and fully guaranteed
performance:
Machined parts (pinion-toothed wheels,
spindle, etc)
Cables, screws, rivets
Electrical panel
Moreover, maintenance-free
components are used at the
friction points (bearings, flanges,
etc.)
All these components are easily
accessible and can quickly be
replaced if necessary, since the
driving and structure are
completely independent.
32

33. 4. PROFITABILITY
4.9 Summary
More energy production: complete elevation
with start from 10 degrees (flat-plate) up to
45% more than fixed systems (40º latitude)
More stiffness: five supports, supporting
static wind speeds of up to 125 km/h (78 Mph)
in any position
More Reliability: using screws and galvanized
3D structure, no hydraulics
Independence between structure and driving
system: crucial for reliability
High capacity: 219 m2 of net surface for cpv
modules
Low-cost foundation: savings in materials
(80% in steel and 35% in concrete)
Easy & quick installation: screw-less module
installation (flat-plate)
Reduced maintenance: using technical
materials maintenance-free
Extreme accuracy, greater than 0.01 degrees
(CPV)
33

34. 5. BUSINESS MODEL
5.1 General issues
Licensing agreements:
For construction or projects
For territory/country
Direct supply:
Supply of solar trackers EX WORKS
Transport to the site
Installation (*) as an option
•(*) It can also be installed by the client itself
34

35. 5. BUSINESS MODEL
5.2 Licensing agreement
Our business model is based mainly on
licensing agreements, the most cost-
effective option in order to develop a
pipeline of solar projects.
General issues of the agreement:
Non exclusive right to manufacture, use and sell
Territory or specific project
Valid for 5 years, with an extension option
Cost model:
Fixed initial payment
Royalty per tracker
If you are interested, please ask for
further details of the “Basis of
Agreement”
“Basis of Agreement” document
35

36. 6. REFERENCES
The TITAN TRACKER concept was
created in October 2006
Nowadays, solar installations exist
that use TITAN TRACKER with more
than 15 MW in operation.
TITAN TRACKER has just completed
a CPV project in the ISFOC
installation www.isfoc.com
Solar Park in Eruela, Pedro Muñoz (Ciudad Real) Spain
36

37. The value of technology
•Carlos García
•Sales Manager
•cgarcia@titantracker.es
•+34 608 23 25 50
New website: www.titantracker.com
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