Dimensioned designs and solar tracker construction procedure
Size and description of the parts, sequence of the realization of the DIY pieces, tips
The structure as detailed visible in the images we define it to "H" inclined on top of which is mounted a bar square section to which will be fixed by brackets the solar panel. This bar has the possibility to rotate thanks to the pins made of stainless steel screws M10 x 55mm connected to the structure by self-made iron "L" brackets.
The dimensions without solar panel are 1250mm - 80mm - 60mm L x H x W with the inclination of the plane to which the solar panel will be fixed of 30 degrees (Tilt) and rotation capacity (Pan) of about + and - 40 degrees.
The terms Tilt and Pan are used in a partially improper way as they are usually heard in solar trackers with double axis of rotation while in our Tilt is fixed inclination.
[ Photos with numbered references to the main parts ]
Construction Procedure :You can start by cutting the 30 x 30 mm square section pipe pieces, part (1) 965mm - part (2) 830mm - part (3) 355mm at the longest point - part (4) 878mm - part (5) 600mm
With 25 x 3 mm iron plate made of 2 squares (6-7) to "L" of 40 x 50mm that serve to connect through the screws M10 that act as a pin the bar to which the solar panel will be fixed, 1 square (8) 100 x 65mm that serves to connect the linear telescopic piston to the bar (part 1) to which the solar panel is fixed, are also needed 2 pieces drilled with different wheelbases (9-10) 60mm, these two parts serve to allow greater tightening of the screws without causing the crushing of the square section pipe.
The next step is the tracing of the various parts according to the interaxes that you can find in the drawings on this page, since you do not need a high precision you can use a meter, a calibrated square ruler or a gauge. In any case, after marking the point to be drilled with a fine marker, it is advisable to make a punching in order to create a small recess that will serve during the drilling to position the tip so that the hole is made exactly where traced.
[ Drawing with reference numbering main parts and part size with drilling distance ]
NOTES: (1) made the holes on the self-made squares only after having folded (2) made the holes on the bar to which the solar panel will be mounted (part 1) only after assembling for test the rest of the structure including the brackets that act as a pin,in this way you can draw holes for fixing screws without worrying about the inevitable tolerances of realization.
Before moving on to painting you have to finish the test assembly by adding the brackets and the linear actuator and power supply made some rotations up to the bottom so as to ensure that everything moves correctly.
For the painting we proceeded by applying adhesive tape on the holes and on the end of the square section tube ,in this way it was possible to pour the bottom paint inside the tube and making it rotate to adhere the protective paint on all the walls. The excess paint can be poured into the container for use in other pieces, the same operation must be repeated for the finishing paint.
[ Some phases of painting ]
Once the painting is finished, it will be possible to assemble the various parts, keeping the bar to which the solar panel will be fixed as part of the structure last.
At this point you can mount the "L" shaped bracket part (8) to the newly assembled mobile bar, on it using M6 screws you will also need to place one of the two brackets that are supplied when purchasing the linear actuator which in our case we remember must have a stroke of 150mm, these brackets already have 6mm diameter holes suitable for fixing the actuator at its ends with pins, the second bracket will always be positioned with M6 screws but longer to the structure part (2) through the holes already made (340mm center distance to the first hole, refer to the drawing with dimensions) we strongly recommend making slots of a few mm on the second bracket so as to be able to adjust it because almost certainly with the tolerances of a DIY construction plus the tolerances of the piston itself you will not have the same inclination of the panel in the two end stops; our example, although declared with a 150mm stroke, actually extended by 158mm before stopping. With the possibility of adjustment you will be able to center the inclination of the solar panel in the same way both with the actuator fully retracted and extended.
In our project of DIY solar tracker to support the relays, the timer and a charging circuit we used a plastic cutout 300 x 200mm connected by zippers to keep it always perpendicular to the ground, the position as high and central as possible was chosen to take advantage of the weather protection given by the solar panel above, the remaining space on the panel is to mount a battery charging control unit.
Although not essential since it is a mobile solar tracker we thought to equip it with wheels to facilitate the movement.
[ Fully assembled solar tracker ]
