Professional Documents
Culture Documents
APPROVALS
Revision History
Table of Contents
1 PROJECT OVERVIEW
For off-grid campers, gas operated generators are the typical machine of choice for electrical
power generation. Electrical generators provide a portable power solution to provide creature comforts.
The downside to these generators is that they are noisy, difficult to transport, and they emit pollution.
Portable solar panels are a viable option for customers seeking to replace their generators. Solar panels
capture renewable energy without excessive noise and pollution. However, there is no portable solar
power system available on the market to achieve high-energy intake. Studies have shown that
compared to a fixed-position solar panel, there is an average energy-intake gain of 20-30% with solar
tracking technology.
PROJECT DEFINITION DEFN-MAE0162
2 PROJECT DETAIL
By March 16, 2018, we will create a complete set of design documentation to manufacture a portable,
easy-to-use solar panel mount. The mount will be adjustable to varying sizes of 100W solar panels.
Additionally, the mounting system will autonomously and periodically adjust its orientation towards the
sun to achieve optimal solar intake.
Kashif Laurie
Matthew Tsang Christopher Rocha Devin Frerichs Carlos Ayala Ryan Carter
Document
Team Member Safety Officer Team Member Purchasing Manager Project Manager
Manager
Name Est. Hours (Fall) Est. Hours (Winter) Rate ($/hr) Est. Total ($)
The solar tracking team will meet twice every week. The details of our weekly meetings are shown
below.
In-person Everyone Wednesday 1:00 PM On campus: UCI Student Center Jong Min Jung
1. Revision History
A Update communication plan and project team [1/10/18] Jong Min Jung
PROJECT DEFINITION DEFN-MAE0162
Table of Contents
2 PRODUCT DESCRIPTION
2.1 Product Value Proposition
The minimum viable product (MVP) features of our design were compared to the features of portable
solar panels from leading competitors on the market. A summary of our product value proposition is
shown below.
Must-Haves
• Utilize Solar Energy Yes Yes Yes Yes Yes
• Portable Yes Yes Yes Yes Yes
Performance Benefits
• Efficient Solar Tracking No No No No Yes
• Lightweight 26.1 lbs 29.8 lbs 28 lbs 25.9 lbs 40 lbs
• Weather Resistance Yes Yes Yes Yes Yes
Delighter
• Easy Setup/Storage Yes Yes Yes Yes Yes
Age 45
Gender Male
Education BA
Job Architect
Income $125,000
2.4 Assumptions
It is assumed that the end user of our product will be able to transport the solar tracking system to its
location of operation. The end user will possess a common socket wrench tool set to secure all hardware
during the setup process. The end user will be able to mount their solar panel (1) to the T-bracket (3).
Furthermore, once the solar panel has been mounted to the T-bracket (3), the end user must mount the
T-bracket to the elevation arm (4). The end user must also be able to connect all power cables, setup
their charge controller, and align the panel so that sunlight is incident on the face of the solar panel’s
photovoltaic cells.
2.5 Dependencies
The solar tracker system’s logic controller and motors will depend on energy from the end user’s
RV/camper batteries. This will be accomplished by a single power cable connected from said batteries to
an electrical port located on the solar tracking system. In total, there will be 4 conductors contained in
the power cable: 1 pair of conductors will be used to transfer the output electricity from the solar panel
to the end users batteries and the other pair will be used to transfer electricity from the end user’s
batteries to the solar tracking system.
PROJECT DEFINITION DEFN-MAE0162
3 PRODUCT REQUIREMENTS
3.1 Functional Performance Requirements
Metric Description Units Marginal Value Ideal Value
Max Operating Maximum ambient temperature Degrees 140 90
Temperature conditions for system’s operation (°F)
Min Operating Minimum ambient temperature Degrees -5 40
Temperature conditions for system’s operation (°F)
Maximum Load Maximum solar panel weight that can lbs 22 18
be supported
Maximum Panel length Maximum length of solar panel that in. 48 42
the system can support
Maximum Panel width Maximum width of solar panel that in. 29 26
the system can support
Maximum Panel height Maximum height of solar panel that in. 2.5 1.4
the system can support
Minimum Panel length Minimum length of solar panel that in. 39 42
the system can support
Minimum Panel width Minimum width of solar panel that in. 21 26
the system can support
Minimum Panel height Minimum height of solar panel that in. 1.1 1.4
the system can support
Electrical enclosure Degree of protection against the IP rating IP65 IP66
Protection intrusion of solid objects, dust,
accidental contact, and water in
electrical enclosures.
Maximum Wind Speed Maximum velocity of wind that panel mph 30 15
can sustain without tipping
PROJECT DEFINITION DEFN-MAE0162
4 APPENDIX
IP Ingress Protection (IP) code. This standard defines ratings for water and debris
protection.
Customer Persona
Name: Samuel Thompson
Age: 45
Gender: Male
Job: Architect
Income: $125,000
Needs/Goals:
- Average
- Figures out solutions on his own
- Owns a smartphone, iPad, and laptop
Technology Adoption Life Cycle Segment:
- Early Majority, he has to see the real need for an upgrade and is willing to do so if his
needs are met. Otherwise, what he has “does the job fine”.
Concept Generation
Seasonal Bracket
T-bracket
Legs
Azimuth Motor
Mount
Concept Selection
Every concept generated was discussed during our team
meetings to hear various opinions. The main considerations for us
were manufacturability and cost. Discussions were used to rule out
any ideas that were not feasible for us to manufacture or if it would be
too much for our budget of $700 per quarter. From the remaining
concepts, we used decision matrices to decide which idea to pursue.
T-bracket Mount
Specification Reference Phone Wire Thumb
Case Screw
Manufacturability 0 + + +
Cost 0 0 0 +
Ease of Use 0 + - +
Durability 0 + + +
Total 0 +3 +1 +4
Material
Specification Reference Steel Aluminum
Weight 0 - +
Heat Conductivity 0 - +
Corrosion 0 - +
Resistance
Elasticity 0 - +
Welding 0 0 +
Total 0 -4 +5
Axes of rotation
Specification Reference Uniaxial Biaxial
Power Output 0 0 0
Ease of Setup 0 0 0
Feasibility 0 + +
Number of Parts 0 + -
Total 0 +2 0
Leg Attachments
Specification Reference Hinge Quick Foldable
Release Tripod
Pins
Feasibility 0 - + 0
Ease of Use 0 + + +
Volume 0 + + +
Total +1 +3 +2
Customer Interaction
Specification Reference Handles Bag
Manufacturability 0 0 +
Cost 0 - +
Ease of Use 0 - +
Total 0 -2 +3
Proposed Solution
We claim:
A solar tracking mount that:
- Tracks the sun throughout the day with little to no cloud cover
with a gear system driven by a motor
- Has a sensor that uses LED to detect sunlight
- Fits all 100W panels with adjustable mounting arms
- Has foldable legs for easy storage
High Level Assembly – Exploded View
Base Assembly
Motor Assembly
Central Column Assembly
Gantt Chart
Tasks
Project Breakdown
Work Breakdown Structure
Analysis
Experiment #1: Sensor Error
NOTES:
Location: UCI blue tables between Engineering Gateway and McDonnell Douglas
Date: 26 Jan 2018
Time: 1:15 PM
Weather conditions: Sunny day with no clouds, 65°F
Purpose: Test the accuracy of the solar sensors
The misalignment angle was measured by recording the distance of the
Procedure: edge of the shadow from the edge of the aluminum angle.
The shadows were cast from a small piece of aluminum angle that was hot
glued to the elevation arm.
An aluminum angle was included on the prototype for each axis, elevation
and azimuth.
Each sensor was tested individually and then the tests were run again with
simultaneous sensor operation.
One small piece of paper was taped parallel to the surface of the elevation
arm on each side of the aluminum angles.
The shadow-edge line was marked on this paper for each trial.
To calculate the angle of error, the inverse tangent of the height of the
aluminum angle and the shadow distance edge was calculated.
Rotation direction for the azimuth movement is defined by looking down
towards the ground.
Rotation direction for the elevation movement is defined by looking from the
solar sensor towards to the elevation motor.
RESULTS:
Max Error (Azimuth only) 15.33°
Min Error (Azimuth only) 2.57°
Max Error (Elevation
only) 18.05°
Max Error (Elevation
only) 5.93°
Max Error
(Simultaneous-Azimuth) 26.8°
Min Error (Simultaneous-
Azimuth) 2.52°
Max Error
(Simultaneous-Elevation) 20.39°
Min Error (Simultaneous-
Elevation) 9.08°
Comments: It was noted that there may be small error in the angle between the sensor's
photodiodes. Additionally, there may be small error due to the
fact that the sensors are not perfectly perpendicular to the aluminum angles.
Care was taken to minimize this error by carefully aligning
the sensors with the elevation arm. However it is expected that
approximately 2-5° of error may be attributed due to this fact.
The power gain from dual axis given the error in our sensors from
experiment #1 is going to be minimal. Thus, we simplify our design to
uniaxial.
Experiment #3: Time Based Rotation
NOTES:
Location: AV
Date: 9 Mar 2018
Time: 12 PM
Weather
conditions: N/A
Purpose: Measure power gain for uniaxial vs biaxial setups
Piece of paper with 1° increments was taped to the top of Base-1. The motor and
timer were turned on simultaneously until the central column rotated the amount of
Procedure: degrees listed in the tables. The experiment was ran 5 times per experiment
Results:
With the solar panel mounted, the rotation rate is 17.7°/s
Without the panel mounted, the rotation rate is 18.7°/s
Circuit Diagram
Bill of Materials
Owner’s Manual
Table of Contents
Overview ................................................................................................................................................. xxiv
Exterior .................................................................................................................................................... xxiv
Set-Up...................................................................................................................................................... xxvi
Legs ..................................................................................................................................................... xxvi
T-Bracket............................................................................................................................................ xxvii
Seasonal Elevation Bracket ............................................................................................................xxviii
Operation ................................................................................................................................................ xxix
Technical Specifications ....................................................................................................................... xxix
Frequently Asked Questions ................................................................................................................. xxx
Troubleshooting ..................................................................................................................................... xxxi
Care/Maintenance .................................................................................................................................xxxii
Overview
The AceTrack system is a solar panel mount that
autonomously and periodically adjusts its orientation towards
the sun to achieve optimal solar intake. AceTrack has three
seasonal settings that allow it to achieve at least 20% more
power than a stationary solar panel.
Exterior
1. Extending Arms
2. T-Bracket
3. Seasonal Elevation Bracket
4. Central Column
5. Base
6. Leg Bracket
7. Leg
Interior
Technical Specifications
Frequently Asked Questions
1. What size panels can be used?
a. AceTrack can support most 100W panels
(maximum dimension capability: 48”x29”x2.5”)
I hear a squeaking sound coming from The squeaking sound it likely a result of
the base. insufficient lubrication. Please reference
the Care/Maintenance section
My solar panel is not securely attached Loosen the thumb screws on the T-
to the T-bracket. bracket. Slide in the extending arms
until the solar panel is securely
supported. Retighten the thumb screws
AceTrack will not turn on Power to the control system is obtained
from the junction box between the RV’s
battery and the charge controller.
Ensure there is a solid electrical
connection and ensure the solar panel
is properly connected to the charge
controller.
Care/Maintenance
Gears
It is recommended to inspect the gear system every 6 months to ensure it is
properly lubricated. If lubrication is needed, use an all-purpose lubricating oil or
automotive grease.
Lazy-Susan Bearing
It is recommended to lubricate the lazy-susan bearing periodically, as needed.
Recommended lubrication: WD-40.
Metal Frame
Use a damp wash cloth and mild soap to remove dirt from the AceTrack
structure.
Statement of Conformance
Acceptance Test Procedure
Approved By:
1 INTRODUCTION ....................................................................................................................... 1
2 ACCEPTANCE TEST APPROACH ............................................................................................... 1
3 ACCEPTANCE TEST PROCESS ................................................................................................... 1
3.1 Establish Acceptance Test Framework 1
3.2 Plan Acceptance Test Activities 1
3.3 Develop Acceptance Test Cases 2
3.3.1 Sources for Test Cases Error! Bookmark not defined.
3.3.2 Structure for Acceptance Test Error! Bookmark not defined.
3.3.3 Test Procedures Development 5
3.4 Set Up the Acceptance Testing Environment Error! Bookmark not defined.
List of Exhibits
Planned
Actual
Deliverable/
Activity Completion Completion
Checkpoint
Date
Date
Planned
Actual
Deliverable/
Activity Completion Completion
Checkpoint
Date
Date
- Exhibit 2:
o Purpose: Test the efficiency of a single axis vs a dual axis system.
o Equipment: Solar panel, base/column/T-Bracket/Large Multimeter, Elevation
Angle Printout.
o Procedure:
1. Meet on the 7th floor of the ARC Parking Structure on a sunny & clear
day
2. Set up the Base/Column/T-Bracket and place the solar panel on the T-
Bracket so that the solar panel is elevated off the ground.
3. Position the Solar Panel at a 90 degree horizontal angle position and tape
on the Elevation Angle Printout to one side of the solar panel. (Ensure
that the 0 degrees line is running parallel with the side of the solar panel.)
4. Position the entire apparatus towards the sun so that the Solar Panel is
getting as much sunlight as it can. (Point in the general direction)
5. Position the solar panel at 0 degrees and record the current and voltage.
6. Elevate the solar panel by increments of 5 degrees and wait until the
string/weight stops moving to ensure that this is the correct angle. Once
it has stop, record the current and voltage.
7. Repeat step 7 until you get to 55 degrees.
8. After recording all of the current and voltage, calculate the power for
each angle and look at the power generation between each angle.
o Results:
1. Pass Criteria: The Azimuth Angle provided a substantial amount of power
improvement.
2. Fail Criteria: Negligible power improvement from the elevation angle.
Test Procedures Development
Test procedures provide the testers with precise steps that should be followed to execute
a test.
*Please refer to Exhibit 1 & 2 for the procedures*
Test Tools
- Elevation Angle Printout (Strings & Key/Nut/Weight)
o Similar to a protractor, this is used in order to help ensure that the solar panel
elevation angle is at the desired angle.
- Large Multimeter
o Used to measure the current and voltage of the solar panels.
.
Environment Preparation
In preparation for acceptance testing, the team identifies and addresses missing or
incorrectly configured hardware. Preparatory activities involve constructing the actual
acceptance test environment and ensuring that all of the required material to perform the test is
there. Prior to the test, the team reviews a list of affected components and the planned
activities. Deviations from the planned activities are recorded and reported to the project
manager. The team then begins the acceptance testing.