International Journal of Current Engineering and Technology

ISSN 2277 - 4106

© 2013 INPRESSCO. All Rights Reserved.
Available at http://inpressco.com/category/ijcet

Research Article
Mechatronics Design of Solar Tracking System
Farhan A. Salema,b*
a
Mechatronics program, Department of Mechanical Engineering, Faculty of Engineering, Taif University, 888, Taif, Saudi Arabia.
b
Alpha center for Engineering Studies and Technology Researches, Amman, Jordan.

Accepted 12 April 2013, Available online 1June 2013, Vol.3, No.2 (June 2013)

Abstract

The key element in mechatronics system design is the concurrent synergetic integration, modeling, simulation, analysis
and optimization of multidisciplinary knowledge through the design process from the very start of the design process,
and toward constrains like higher performance, speed, precision, efficiency, lower costs and functionality, resulting in
products with more synergy. This paper proposes the conception and development of smart solar tracking system, based
on mechatronics design approach, such that the solar panel through both day and seasonal changes is accurately
perpendicular to sunlight beam (accurately point towards sun), where illumination is strongest. The whole system and
sub-systems are concurrently selected, designed, integrated modeled, tested and optimized; also, overall system response
is verified for different input types, including actual input altitude angles. The obtained results show the simplicity,
accuracy and applicability of design to meet all design requirements. The proposed design can be used either for
research or educational purposes.

Key words: Mechatronics design, solar tracker, modeling/simulation.

1. Introduction up of many silicon cells connected in series to get a solar

1
Mechatronic system design process can be divided into
systematic, simple and clear design steps including;
Problem statement; Conceptual design and functional
specifications; Parallel (concurrent) design and integration
of system and all subsystems as whole and concurrently
including; selection, design and synergetic integration of
mechanical, electronics, software, control unit, control
algorithm and interface sub-systems; Modeling and
simulation; Prototyping, Testing and Optimization; and
finally Manufacturing, and commercialization (Farhan A.
Salem et al, 2013)( Yu Wang, et al 2012)( Devdas Shetty
et al,2011)( Sarah Brady,2008)( L. Al-Sharif, 2010). This
paper proposes the conception and development of smart
solar tracking system based on mechatronics design
approach.
2. Pre-Study Process-Problem statement.
Among the renewable energy resources, solar energy is the
most essential and prerequisite resource of sustainable
energy because of its ubiquity, abundance, and
sustainability, regardless of the intermittency of sunlight,
solar energy is widely available and completely free of
cost )C.S. Chin,2012) Solar energy is directly converted
into electrical energy by solar photovoltaic modules, made
*Corresponding author: Farhan A. Salem
PV module, the current rating of the modules increases
when the area of the individual cells is increased
(Mohammed S. El-Moghany, 2012). It is known that the
power generated by any solar cell is a function of three
variables: the surface area of the cell exposed to light, the
efficiency of the cell, and an environmental constant
known as irradiance, the best way to increase power
generation would be to increase exposed surface area,
where approximately, each solar cell develops 0.5 V.
Many research studies practically effective methods of
solar energy, one of these methods is solar tracking
system, solar tracker allows the increase of produced
energy amount about 40% in relation to fixed panels.
When solar tracking system is exposed to solar radiation,
it can generate direct current electricity without
environmental impact and contamination and at a lower
maintenance costs.
For optimal operational efficiency of solar energy
receivers, and correspondingly generated electricity, solar
tracking systems are designed such that solar panels are
perpendicular to sunlight, where the illumination is
strongest, to achieve this, an ideal tracker would
compensate for changes in both sun's altitude and
latitudinal angles through both day and seasonal changes
and changes in azimuth angle. In 1986, Akhmedyarov first
increased the output power of a solar photoelectric station
in Kazakhstan from 357W to 500W by integrating the
station with an automatic sun tracking system

417
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)

(Akhmedyarov, K.A et al, 1986),also studies show that, a about 5 kWh of electricity per day, the same installation
solar panel of 3m2 with fixed position to surface produces but equipped with tracker, can provide

Table 1 Requirements analysis

Requirements Value/ Unit Requirements type

Fixed Range or Quantitati Qualitati
Req. soft Req. ve Req. ve Req.
Control unit Compact , cost effective. Fixed Qual.
Control Simple, precise, efficient, and Fixed
algorithm easy to program.
Input Power Stand alone or battery 12 -24 V Soft Qual
supply
One or two actuators for -
Actuators adjusting the solar panel Soft Qual.
rotating altitude and
12 -24 V
latitudinal angles, precise,
simple to interface, control
and inexpensive.
Sensors Light sensors ,simple to - Soft Qual.
interface, available,
inexpensive
Transmission Gears, belt, chain n Soft
Overall To supply Height 100 Cm
System maximum electrical width 45 Cm Soft
dimensions power Length 50 Cm
Depending on solar Height 50 Cm Qual.
Solar panel sells type , number : Soft
dimensions and required Width 38 Cm
electric power Length 40 Cm
User To supply maximum Fixed
requirements electrical power, standalone,
precise, cost-efficient
User Interface Simple and easy to use and Fixed Qual.
understand
Machine Attractive, fits user needs. Soft Quan.
aesthetics
design

Light Light sensor1

sensor2 V.R Power
Power supply supply
Comp arator
angle

Error θ
Solar
Drive

Drive

DC motor Gears User Light Solar

Controller p anel Controller Actuator
interface sensors panel

Position
Position sensor Feedback

Figure 1(a) Figure 1(b)

Figure 1(a)(b) Simplified block diagram representation of proposed solar tracking system

up to 8 kWh per day. Several methods and designs of sun
tracking systems have been proposed, designed and
implemented, main are included in (C.S. Chin, 2012)
(Mohammed S. El-Moghany et al, 2012)( Akhmedyarov
K.A et al, 1986)( Chin CS et ak, 2011)( Ahmad Rhif,
2011)( R. Messenger et al, 2000 )( S.A. Kalgirou, 1996)(
Gustavo Ozuna et al, 2011)( A. Stjepanovic et al, 2010 )(
A. Louchene et al, 2007)( C.S. Chin et al, 2013), a detailed
literature review can be found in (A. Louchene et al, 2007)
Solar tracking systems consist of a photovoltaic generator,

418
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)
actuating unit, control unit, sensing unit, energy storage
devices (such as batteries), and AC and DC elements for
power conditioning. In solar tracking system design, any
light sensitive device, can be used as light detecting sensor
as input sensor unit including phototransistors,
photodiodes, LDR and LLS05-A light sensors. A suitable,
inexpensive, easy to program control unit is
microcontroller; a suitable motion generator is electric
motors and corresponding drive. Target user of proposed
system; Researchers, Educators and wherever such
renewable energy unit is required . User's requirements; it
is required to develop a linear, one/two-dimensional
single-variable solar tracking unit that can be used for
receiving solar energy and to meet the power demands of
supplying maximum electrical power, precise, cost-
efficient, with simple interface. System parameters,
requirements and analysis, are listed in Table 1.
3. Conceptual design
The purpose of design is to propose and develop the
conception and development of solar tracking system
based on mechatronics design approach, such that the solar
User interface Switching system on-off
Reading values
Light sensor Sun position readings
Control system μu-control
Actuator, electric Actuator motion
energy response
Gears ,lever arm Motions transmission
Solar panel position
Position sensor Solar panel angle
measuring
Figure 1(c) Functional Structure block diagram
Table 2 Morphological table, analysis and evaluating the
best solution selection
panel through both day and seasonal changes is accurately
perpendicular to sunlight beam (accurately point towards
sun) and fit user's power needs and requirements. The
conception of light tracking system is quite simple, where
light detectors detect position of the sun, based on sensors
readings, and generated sun tracking error, based on error,
the control unit generates the voltage used to command the
drive circuit to drive a low- speed motor, that outputs the
rotational speed or displacement of electric motor, (to
rotate the solar panel via a speed-reduction system) until it
perpendicularly faces the sun. Based on this and on pre-
study process, a preliminary simplified block diagram
representations of solar tracking system is shown in Figure
1(a)(b). Functional structure block is shown in Figure 1(c).
Morphological Table analysis and evaluating the best
solution are listed in Table 2.
4. Parallel (concurrent) selection, design and
integration of sub-systems and overall system.
Mechatronics system design is Modern interdisciplinary
design procedure; it is a concurrent selection, synergetic
integration and optimization of the system and all its
components as a whole and concurrently, all the design
disciplines work in parallel and collaboratively throughout
the design and development process to produce an overall
optimal design. Mechatronics design approach tends to
develop products with synergy and integration toward
constrains like higher performance, speed, precision,
efficiency, lower costs and functionality.
4.1 Mechanical construction and components selection:
Depending on desired performance, precision, efficiency,
speed, cost, functionality and required maximum energy
receiving of solar panel, different solar tracking system's
types and arrangements exist, there are three main types
particularly; Passive tracker, Chronological tracker and
active tracker, also, there are many system's arrangements,
most applied are shown in Figure 5 . In this paper two
system arrangements are considered; one-axis (one
directional) using two light detectors (Figure 6(a)) and
two-axis (two directional) using four light sensitive
sensors (Figure 6(b) and). A simple and optimal
mechanical design could be as shown in Figure 5, this
arrangements can be used for either or both a one-axis and
two-axis motion control, the vertical axis is perpendicular
to the ground and horizontal axis normal to vertical axis,
by the combinations of two axes any position and location
of solar panel in upward hemisphere could be achieved,
correspondingly, the motions can be manipulated such that
the solar panel is perpendicular to sun light. The proposed
mechanical design shown in Figure 5(c), the Overall
System and solar panel dimensions are listed in Table 1 ,
the system consists of aluminum steel base frame (2), onto
which the solar panel is to be mounted, the steel frame
with solar panel is mounted onto rotating head derived by
first DC motor for horizontal motions (3), and all are
mounted onto a vertical steel beam (4), this steel beam is
also a vertical axis for azimuth control derived by second
DC motor (5). System CAD model is shown in Figure
419
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)
5(b). To make sure the structure is stable and the load is
constant for the rotation of motor, the center of gravity of
tilting structure is aligned at rotating center, this is shown
in Figure 5(c). The system uses external power supply, but
also can be modified to be standalone solar tracking
system.
4.2 Sensor selection: a solar tracker can be built using
sensing unit, or can be built to be senseless (chronological
tracker), where the sun coordinates are calculated for the
any moment of the day, during all year, using this data, the
tracking system moves the solar panel to the optimum
calculated position. For smart precise solar tracker, a
suitable, inexpensive, simple and easy to interface sensor
is analog light dependent resistor (LDR), The LDR sensors
can be used to detect light intensity to which it is exposed,
also to differ from day and night, Different LDR sensors
available in the market, the biggest size is used to
construct the sensor because the more area of the sensor,
the more its sensitivity or less time taken for output to
change when input changes (Mohammed S. El-Moghany
et al, 2012). In both proposed system's configurations,
sensors are integrated with the solar panel, screened from
each other by opaque surfaces; and each is placed in an
enclosure, so that the light will only hit LDR when it is
facing directly at the sun.
The LDR sensor circuitry is designed as a voltage
divider circuit as shown in Figure 4. The desired resistor
value should provide a voltage that covers the sunny and
cloudy conditions, a 100 ohm could be suitable; the output
of the sensor circuit is an analogue voltage that is used as
an input to the control unit ( e.g. microcontroller, PIC) to
calculate error between two LDRs. An extra LDR, located
on panel's front surface, can be used to ensure that solar
panel is perpendicular to the sun.
A variable resistor (potentiometer) can be, also used to
determine the location of the solar panel to prevent the
panel from the impact when it reaches the edges (also, in
case of measured sequence of angle change), When the
potentiometer reaches the value corresponding to edge, the
controller stopped the motor and immune it from rotating
in that direction.
(a) LDR sensor simulation in Proteus
(b) Physical implementation (Chin CS,2011)
(c) connecting to PIC, Figure 4 LDR sensor circuitry
4.3 Control unit selection: Over the years, tests and
researches had proved that development of smart solar
tracker maximizes the energy generation. For
implementing smart precise solar tracker, an embedded
Microcontroller is optimal selection, since it is
inexpensive single chip computer, easy to embed into
larger electronic circuit designs, also, because of their
versatility, Microcontrollers add a lot of power, control,
and options at little cost, capable of storing and running
programs and can be programmed to perform a wide range
of control tasks. Optimal and available microcontroller is
PICmicro Microcontroller (e.g. PIC16F877A), supplied
with 6VDC. Selected PICmicro microcontroller type is
supported with ADC pins, to convert the analog input
sensor readings to digital value, fed to microcontroller.
Microcontroller can be easy programmed, using C
language; C offers unmatched power and flexibility in
programming microcontrollers. MikroC adds even more
power with an array of libraries,
4.4 Control algorithm selection: a review of literature
shows that, different control algorithms can be used to
achieve desired performance of solar tracking system,
where: (M. A. Usta et al, 2011 ) presented a one-axis
tracker using three light resistors (LDRs). The first LDR
detect the desired state of the collector, the second and
third LDRs were designed to establish the presence of
cloud and to make difference between day and night. (S.A.
Kalogirou, 1996) implemented a fuzzy logic control for
sun tracker on a computer controlled the nonlinear
dynamics of the tracking mechanism. (H.A. Yousef, 1999)
modeled and designed a first order fuzzy inference system
for tracking system. (M. Singh et al, 2007) developed a
correction control system made by an artificial technique
vision based on the capture of pictures of the sun
positions. (M. Berenguel et al, 2004) presented a robust
control with MPPT system based on a sliding mode
420
Farhan A. Salem
controller (SMC). In this paper we will propose a simple
and easy to implement control algorithms to achieve
desired output position, particularly PID / PD with
deadbeat response. In the transient mode, PD-controller
speeds up the transient response, and it will decay faster,
resulting in less settling time TS, less time constant T, less
peak time TP , and reduced maximum overshoot MP, while
deadbeat response means the response that proceeds
rapidly to the desired level and holds at that level with
minimal overshoot, combining both characteristics will
desired and satisfactory system response.
The microcontroller can, also, be programmed to apply
the Pulse Width Modulation (PWM) signal to drive the
motor at a controlled speed correspond to a maximum
voltage of 5V. A proposed flowchart of PIC16F877A
programming, is shown in Figure 4(d) , where LDR
readings is converted and compared, and based on
generated error , microcontroller will drive the motor until
the error is zero.
Switching system on-off
Sun position readings Position sensor reading
(LDR1 and LDR2) Vs
Converting and
comparing LDR readings
Error= LDR1 - LDR2
Error, Vs
Yes Error == 0 & Vs ~== edge
No
Set RB? to 0
Error ~= 0 & Vs ~== edge
Yes
Set RB? to 1
Yes
Set RB? to 0
End
Figure 4(d) Flowchart of microcontroller programming
4.5 Actuator selection: Actuator converts an information
signal from the microcontroller control unit, into energy
acting on the basic system, the solar tracking system
requires movement in different directions, the proper
selection of actuator and drive combination can save
energy and improve performance. Mechatronic systems
often use electric motors to drive their work loads, due to
simple principle of working, quick instantaneous and
accurate torque generation, available, inexpensive,
reversible, and ease of designing and implementing
controller to achieve optimal instantaneous, precise motion
control performance, a suitable electric motor is low-
speed DC motor, therefore the control of proposed solar
tracking system is simplified to eclectic motor control. The
driving mechanism includes the motor and the gears with
gear ratio, n
International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)
4.6 Output signal and conditioning: LDRs are used as
current sources and connected in opposite polarity to the
input of an op-amp, any difference in the short-circuit
current of the two cells is sensed and amplified by the op-
amp. Because the current of each cell is proportional to the
illumination on the cell, an error signal will be present at
the output of the amplifier, this error voltage, is fed to
microcontroller to generate signal to cause the motor to
drive the system back into alignment, the op-amp is given
by RF
A voltage regulator (the IC UA723chip) is to be used
to regulate the supply voltage (12 V) lowered to a level
suitable for use in the microcontroller (6V), the charge
controller and the LDR sensors. a heat sink is to be used to
dissipate the heat generated by the long duration used.
Different drives (servo-amplifier) can be used
including, Relay driver and H-bridge. A most suitable and
simple to implement drives for PMDC motor for
bidirectional driving are H-bridge Or H-Bridge in IC’s,
e.g. L293D, L293D is a dual H-Bridge motor driver, it is
a 16 pin chip, so with one IC we can interface two DC
motors which can be controlled in both clockwise and
counter clockwise direction .a common carrier,(see Figure
5-6). The gain of the servo-amplifier –K. A voltage
regulator circuit was used to bring the supply voltage
down to a level suitable for use in the microcontroller and
the LDR sensors.
4.7 Sub-systems placement and integration: The overall
solar tracking system consists of the selected mechanical,
sensing, actuating and electrical subsystems, shown in Fig
2 and Fig 3, all these subsystems are to be integrated with
synergy into the solar tracking system. To make sure the
No
structure is stable and the load is constant for the rotation
motor, the center of gravity of tilting structure is aligned at
Error ~= 0 & Vs == edge No
rotating center , electronics, data outputting and control
Set RB? to 1
circuitry to be located inside the a housing, that will
No
include slots for user interface and input/output ports.
For one-axis sun tracking system, one light tracking circuit
consisting of two similar LDR-sensors, and one electric
motor are to be used, meanwhile for two-axis sun tracking
system, two light tracking circuit consisting of four similar
LDR-sensors which are located at the east, west, south,
and north and two electric motor, each for each axis, are
used, the two drive motors are decoupled, the sensors are
configured in a way that sensor1 and sensor2 are used to
track the sun horizontally meanwhile sensor3and sensor4
allow tracking the sun vertically, in order to achieve
constantly solar panel aligned perpendicularly to sun light,
it is required to find balance between the two light sensors,
both sensors must receive the same light, and
correspondingly produce the same voltage, when one
sensor receives more light than the other, this means the
solar panel is not aligned perpendicularly to sun light and
an error voltage results. When sun's position changes, the
light source intensity received by different sensors is
different, the system then determines which sensor
received more intensive light based on the sensor output
voltage value interpreted by voltage type A/D converter.
421
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)

The system drives the motor towards the orientation of this

sensor. If the output values of the two sensors are equal,
the output difference is zero and the motor’s drive voltage
is zero, which means the system has tracked the current
position of the sun. Based on desired accuracy, a control
system is to be designed (particularly, PID / PD with
deadbeat response), and correspondingly the PICmicro
unit can programmed to continuously track the sun’s
position by continuously scanning the sun location and
continuously drive the system in both directions or a
control system is to be designed to scan the sun's position
every one minute in the horizontal plane and every 1.5
minute in the vertical plane, calculate the error and use it Figure 5(d) One and two DOF system (Ahmad Rhif, 2011)
to drive the system in both directions. It is important to
consider that for each sensor pair the both LDR must be
quasi-identically as possible, because the measurement
method assumes identical currents in the case of
identically irradiance. At the night the LDR-sensors
resistance are maximum, in this case the microcontroller
will rotate the solar panel until the position sensor has the
starting point value. For two axis system, Figure 1 can be
modified to have the arrangement shown in Figure 6(d).

Figure 5(e) One and two DOF system (Ahmad Rhif, 2011)

Sun

Shadow
Light sensor
Enclosure

Figure 5 (a)( Mohanad Alata, 2005) Figure 6 (a) One-axis sun tracking system

North East
sensor1 sensor3

sensor4 sensor2
Figure 5(b) South
West
Figure 6 (b) Two-axis sun tracking system
sensor1
Light

Microcontroller
Comparator

Second tilt
motor
Light
sensor2
Light

sensors
(batteries)
storage
devices

First Control and Figure 6 (c) Light sensor

motor circuitry
Figure 6 light detecting and tracking circuit and
Figure 5(c) Proposed design arrangements.

422
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)

Position sensor
Load
Armature inductance, La is low compared to the armature
resistance, Ra (discussed later). Neglecting motor

angle
DC/AC converter

Drive2
DC motor1 Gears storage devices inductance by assuming, (La =0), manipulating and gives:
(DC-batteries)
North East
Error
Kt
sensor1 sensor3
 (s )
Charge controller
Controller RaJ a

 K t K b 
sensor4

angle
1 
sensor2 Error Solar panel
South & mechanism V in (s )
s s   bm 
West

Drive2
DC motor2 Gears

 J m  R a 
(2)
2 2
Position sensor  N1   N1 
bequiv  bm  bLoad    J equiv  J m  J Load  
N2  N2  (3)
Figure 6(d) Two axis solar tracker system arrangements
m (h 2  a 2 )
J load  , ,
5. Modeling and simulation 12
m total * 2
0.5* m total *  2  0.5* J load *  2  J load 
The key essential characteristics of a mechatronics 2 (4)
engineer are a balance between two skills; G angle (s ) 
Kt / n
modeling/analysis skills and experimentation/hardware s (La J equiv )s 2  (R a J equiv  bequiv La )s  (R abequiv  K t K b ) 
(5)
implementation skills. The mechatronics design approach
challaenge conventional sequancial design approach, by
connecting machine design tools and creating a virtual 5.2 Sensor sub-system modeling: the system is to be built
machine prototype before designing the physical machine, with a unity feedback such that the control system insures
that the output position is met, as noted, a variable resistor
to take all advantages that can result from an integrated
(potentiometer) can be, also used to determine the location
design, this approach offers less constrains and shortened
of the solar panel to prevent the panel from the impact
development, also allows the design engineers to provide
when it reaches the edges. Potentiometer is a sensor used
feedback to each other about how their part of design is
effect by others to measure the actual output position, θL, convert into
Two very important characteristics that determine the size corresponding volt, Vp and then feeding back this value,
the Potentiometer output is proportional to the actual
of electric motor for a particular application are torque and
position, θL, this can be accomplished as follows: The
horsepower. Torque is the turning effort. Horsepower
output voltage of potentiometer is given by: Vp = θL * Kpot.
takes into account how fast the system is turned.
Where: θL :The panel position. Kpot the potentiometer
5.1 Electric motor sub-system modeling constant; It is equal to the ratio of the voltage change to
the corresponding angle change, and given by:
K pot  (Voltage change) / (Degree change)
Solar tracking system motion control is simplified to an , Depending on
electric motor motion control, in terms of output angular maximum desired output angle, the potentiometer can be
displacement; therefore, the conception of solar tracking chosen, for case Vin= 0:12, and angle = 0:180 degrees,
system can be presented as position control of one eclectic substituting, we have Kpot by:
motor, considering the system operation is accomplished K pot  12  0  / 180  0   0.0667 V / degree
by one of two used two motors. The gain of the servo-amplifier –K. The op-amp, for
The DC motor is an example of electromechanical sensors' reading difference, is given by RF
systems with electrical and mechanical components. Based
on (S. Kim et al,2007), the DC motor open loop transfer 5.3 Control system selection, modeling and design
function without any load attached relating the input
voltage, Vin(s), to the output angular displacement, θ(s), is The main function of designed control system is to achieve
given by Eqs(1)(2). The total equivalent inertia, Jequiv and a fast response to a step command with minimal
total equivalent damping, bequiv at the armature of the overshoot; this can be achieved applying different control
motor are given by Eq(3), for simplicity, the solar panel algorithms, including PID/PD with deadbeat response.
can be considered to be of cuboide shape, with the inertia PID controllers are commonly used to regulate the time-
calculated by Eq(4), also the total inertia can be calculated domain behavior of many different types of dynamic
from the energy conservation principle, correspondingly, plants (L. Al-Sharif, 2010). The transfer function of PID
the equivalent mobile robot system transfer function with control is given by:
gear ratio, n, is given by Eq(5)  K K 
K D s 2  P s  I 
 (s ) Kt
K
G PID (s )  K P  I  K D s   K D K D 
G angle (s )  
 
s s
V in (s ) s  La s  R a  J m s  bm   K t K B  (6)
 (s ) Kt Proportional Derivative, PD-controller, The transfer


V in (s )  La J m s 3  (R a J m  bm La )s 2  (R ab m  K t K b )s 
  function of PD-controller is given by:
) 1(

423
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)

G PD (s )  K P  K D s , Rearranging, we have the following Designing and applying Proportional Derivative

form: controller with deadbeat response :Deadbeat response
 K  means the response that proceeds rapidly to the desired
G PD (s )  K P  K D s  K D s  P   K D (s  Z PD ) level and holds at that level with minimal overshoot(Wai
 K D  (7) Phyo Aung et al,2007). The characteristics of deadbeat
The PD-controller is equivalent to the addition of a simple response include; Zero steady state error, Fast response,
zero at Z PD  K P / K D . The addition of zeros to the open- (short rise time and settling time) , percent overshoot
greater or equal to 0.1% and less or equal 2 % and
loop has the effect of pulling the root locus to the left, or
minimal undershoot, less than ±2% error band. PD-
farther from the imaginary axis, resulting in speeding up
controller transfer function is given by Eq.(7). Using
the transient response, where it will decay faster. a suitable
simplified first order form of PMDC
choice is a combination, PD-controller with deadbeat
response
La 1
Kt, Torque constant 4
T, Load torque 7 Jm 2 Angular Acceleration 5 2 Angular position
1

Constant Angular speed 1

3 Curent1 4 Torque1
Product
Product1
speed.
du/dt Derivative
Current
5 1 Torque
Input Voltage1 s 1 1
Product4 Integrator.2 s s
Product11
Product8 Integrator..1 Integrator..4
Sum.1 Product7
Sum.4
Product9
Ra
6
bm
Product10
8

Kb, EMF constant

3

Figure 7(a) actuator sub-system

Angular speed.

Motor1.mat
La La
angular. position.
La Angular speed

Jm Jm

Jm
Motor2.mat
Kb Kb, EMF constant Angular position
Current.
Kb
Kt Kt, Torque constant

Kt Curent1

Input Voltage1 Motor3.mat

Input Volt .
T orque
Ra Ra Torque1

Ra Angular acceleration
Tl T, Load torque
Motor4.mat
T load Angular Acceleration
To File1
bm bm
Motor5.mat
Bm Subsystem
To File2

Figure 7(b) Open loop one DOF solar tracker system, motor function block model

424
 Changing the value of R1, R2, and C1, will chnage the width of the pulse: TIME=0.7*(R1+R2)*C1=1.620370257844658e-005

Farhan A. SalemChanging the value of variable resistor, will chnage the speed International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)

B3
D? 120V B2
1N4007 9V

-204
R1
100
B? R2 A
12V 1k U1
U1

8
8 R5 Q? 4 3
R5 B

VCC
4
VCC
3 R Q
R Q BD139
10k C
33 7
7 DC
DC +88.8 D
5
5
CV D2 D1 CV
1N4001 1N4001
R2
500
D1

GND
GND

100K 2 6
2
TR TH
6 RV1 TR TH R6
220
1

1
NE555 NE555 LED-GREEN
C? C1
C5 0.1uF 5uF
0.1uF

Figure 8(a) Chronological solar tracker, two different circuits

D1
1
1N4370A

C2 +88.8
16 8 U1 5
U? MODFILE=DCMOTOR
22pF 13 33 2 3
OSC1/CLKIN RB0/INT IN1 VSS VS OUT1
X1 14
OSC2/CLKOUT RB1
34 7
IN2 OUT2
6
8Mhz 35 1
C1 RB2 EN1
2 36
RA0/AN0 RB3/PGM
3 37
RA1/AN1 RB4
4 38 9
RA2/AN2/VREF-/CVREF RB5 EN2
22pF 5 39 10 11
RA3/AN3/VREF+ RB6/PGC IN3 OUT3
6 40 15 14
RA4/T0CKI/C1OUT RB7/PGD IN4 GND GND OUT4
7
RA5/AN4/SS/C2OUT
15
RC0/T1OSO/T1CKI
8
RE0/AN5/RD RC1/T1OSI/CCP2
16 L293D LDR1
9 17 TORCH_LDR
RE1/AN6/WR RC2/CCP1
10 18
RE2/AN7/CS RC3/SCK/SCL
23
RC4/SDI/SDA
1 24 R2
MCLR/Vpp/THV RC5/SDO
25
RC6/TX/CK
26
RC7/RX/DT 1.5k
RV1
19 10k
RD0/PSP0
20
RD1/PSP1
21
RD2/PSP2
B2 RD3/PSP3
22
5V RD4/PSP4
27 B1
28 12V
RD5/PSP5
29
RD6/PSP6
30
RD7/PSP7
LDR2
PIC16F877A TORCH_LDR

R4
1.5k
RV1
10k

Figure 8(d) microcontroller based solar tracker using L293D and Relay driver
Angular speed (rad/sec)

-K- -159.6

RPM speed in RPM

solar5.mat -K-
La La
-16.72
Angular speed
. XY Graph2
La
speed in rad/sec
Jm Jm
time1
Error signal Control_signal Angular position Rad2 -0.05004
Jm
Signal From
solar6.mat Kb Kb, EMF constant Angular position solar1.mat Angular position Rad
Workspace4
[output]
theta To File5 Kb Current.
solar.mat
Kt Kt, Torque constant Goto
PID(s)
From To File4
Workspace Kt Curent1 XY Graph
.2 ' time1
31.1288 .1 Input Voltage1 -K-
solar2.mat
s+31.1288 PD(s) Signal From
Transfer Fcn .
Torque Workspace1 XY Graph1
Ra Ra Torque1
, .3 Step
Ra [output]
s+Z0
Kp TL T, Load torque
s+P0 From
Tload Angular Acceleration solar3.mat
''Lead compensator
bm bm
theta X(2Y)
To File1 Graph1
Bm Subsystem Signal From
Workspace2
-K- Angular acceleration
Angle feedback, Ktac solar4.mat

To File2

Figure 9 (a) The simulink model of overall solar tracker system, with main sub-systems

motor transfer function in terms of output angle given by (K p  K D s )K t

Eq.(2): Ra J m
 (s ) K t / Ra J m G forward (s ) 
G angle (s )   b K K 
V in (s )  1  Kt Kb  s 2   m  t b s
s s   bm    J m J m Ra 
 J m  Ra 
The system overall closed loop transfer function transfer
The system forward transfer function is given by:
function is given by:

425
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)

(K p  K D s )K t 5.4 Sub-systems and overall system simulation, testing,

Ra J m analysis and optimization .
T (s ) 
b K K K K  K p Kt
s2  m  t b  D t s  5.4.1 Electric motor sub-system simulation in
 J m J m Ra Ra J m  Ra J m (8) MATLAB/Simulink
Referring to Wai Phyo Aung,2007 The controller gains KP Simulation of one DOF solar tracker open loop system is
and KD depend on the physical parameters of the actuator shown in Figure 7, where in Figure 7(a) is shown, the
drives, to determine gains that yield optimal deadbeat actuator sub-system inner sub-model, that to be used to
response, the overall closed loop transfer function T(s) is built the actuator sub-system model function block shown
compared with standard second order transfer function in Figure 7(b), this model can give designer different
given by (9), and knowing that parameters α and ωn are readings including; speed, angle, current and torque, to
known coefficients of system with deadbeat response evaluate and verify actuator sub-system performance, the
given by (L. Al-Sharif, 2010), α = 1.82 and ωn Tn = 4.82 , Tn same model is used for other direction in case of two DOF
=2 and gives the following: systems
ωn Tn = 4.82 , ωn = 4.82/2=2.41
5.4.2 Electronics and interfaces simulation and testing:
n2
G (s )  3
s  n s 2  n2 (9)
To test and evaluate the selection and integration of
electronic circuit design, microcontroller programming
Equating and comparing the actual and desired and interface components, simulation using ISIS-
Professional Proteus is used. as noted, there are three types
characteristic equations, the gains of controller are found: of trackers; Passive tracker, Chronological tracker and
b K K K K  K p Kt active tracker, shown in Figure 8, different control circuits
s 3  n s 2  n2  s 2   m  t b  D t s 
 J m J m Ra Ra J m  Ra J m can be used to control the motion of solar tracker,
including using timers (Figure 8(a)) to generate pulse to
Systems design with prefilter: Prefilter is defined as a control motor motion. For smart solar tracker, the control
transfer function Gp(s) that filters the input signal R(s) program is written in C language, with the help of MikroC
prior to calculating the error signal. Adding a control program is converted to Hex.File that is downloaded on
system to plant, will result in the addition of poles and/or the simulated solar system including PIC-microcontroller
zeros, that will effect the response, mainly the added zero, and circuit, the simulation of solar tracker is shown in
will significantly inversely effect the response and should Figure 8(d), simplified algorithm can be as follows:
be cancelled by prefilter, therefore the required prefilter
transfer function to cancel the zero is given by (10). In unsigned int LDR1, LDR2,error ;
general. The prefilter is added for systems with lead void main(solarpanel) {
networks or PI compensators. A prefilter for a system with Ansel=0x06;
a lag network, mainly, is not , since we expect the effect of TRISC=0;
the zero to be insignificant. For systems with PD TRISB=0;
compensators, a prefilter is used to eliminate any while(1){
undesired effects of the term s + z introduced in the //dealy(1500)
closed-loop transfer function, the required prefilter transfer LDR1=ADC_Read(1);
function is given by: LDR2=ADC_Read(2);
ZO Z PD error= LDR1- LDR2;
G Pr efilter (s )  , ,G PI _ Pr efilter (s ) 
s  Z O  s  Z PD  (10)
error=abs(error);
if(error == 0){
PORTB.F1=0;
Lead compensator Lead compensator is a soft }
approximation of PD-controller, PD controller transfer if(error > 0){
function is given by GPD(s) = KP + KDs , The PD controller PORTB.F1=1;
is not physically implementable, since it is not proper, and
}
it would differentiate high frequency noise, thereby
}
producing large swings in output. To avoid this, PD-
}
controller is approximated to lead controller of the
following form: 5.4.3 Overall system simulation, testing and analysis.
s Z
G Lead (s )  K C
s P The simulink model of closed loop solar tracker system is
Where : Zo < P o , The larger the value of P, the better the shown in Figure 9 (a), including electric motor, sensor,
lead controller approximates PD control, input altitude angle and two controllers PID, PD with
prefilter sub-systems.

426
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)

5.5 Overall system testing and results 15

Angle VS time
200
Speed/time

With a set of PD controller gains; KP , KD ,the response of 10 100

Rad/s
Rad
the proposed model is shown in Figure 9 (b). Response 5 0
curves show the system reaches desired output position in
0.2 seconds with zero steady state error, but with 0
0 0.2 0.4 0.6 0.8
-100
0 0.2 0.4 0.6 0.8
overshoot. Time (seconds) Time (seconds)
4
Current/time Torque/time
Applying PD controller with deadbeat response, and 2
x 10
400
calculating desired values of gains, we find Kp =
1 200
23.8893525618918 and KD= 0.767435051920526, PD

Amp

Nm
zero Z0 = Kp/ KD =31.1288.Applying PD controller with 0 0
deadbeat response, will result in response curves shown in
Figure 9(c), Response curves show response proceeds -1
0 0.2 0.4 0.6 0.8
-200
0 0.2 0.4 0.6 0.8
rapidly to the desired level and holds at that level with Time (seconds) Time (seconds)

minimal overshoot and steady state error. Figure 9 (b) angle/time, speed/time, current/time,
To further test our design, by using signal builder to torque/timeAngle
response
VS time curves applying PD controller.
Speed/time
15 Angle VS time 150 Speed/time
generate signal that mimic angular input similar to sun 15 150
altitude angle, will result in response curves shown in 10 100
10 100
Figure 9 (d) , the output smoothly follows the output .

Rad/s
Rad

Rad/s
5 50
Rad
Applying PID controller will result in response curves 5 50

shown in Figure 9 (e) 0 0 00

Applying variable angular position to the system, will
-5 -5 -50
-50
result in system responses shown in Figure 10 (f), the 0 0 0.50.5 1 1 00 0.5
0.5 1
Time (seconds)
Time (seconds) Time
Time(seconds)
(seconds)
system stands such variable values. To test the proposed Current/time
Current/time Torque/time
Torque/time
model, for actual input signal values, based on derived 40004000 100
100
equations given supposed by Ashraf Balabel,2013, altitude
2000 50
angle is calculated, for Taif city, western of Saudi Arabia, 2000 50
Amp

Nm
Amp

the altitude angle, which is the angle between the solar

Nm
0 0
radiation and the solar panel surface, is evaluated in the 0 0
day specified, plotting the calculated altitude angle versus -2000 -50
time, is shown in Figure 10(a). The altitude angle is 0
-2000 0.5 1 0
-50 0.5 1
0 0.5
Time (seconds) 1 0 0.5
Time (seconds) 1
changed regularly, based on this, the readings of two Time (seconds) Time (seconds)
LDRs are changed, and the sequenced altitude angle Figure 9 (c) angle/time, speed/time, current/time,
change can be considered as the difference (error) between torque/time response curves applying PD with deadbeat
the readings of two LDR sensors that is used by control response.
Angle VS time Speed/time
system to drive the electric motor. Generally, the sun 3 4
altitude angle change can be simulated assuming, the sun 2
is shining exactly 12 hours, from sunrise at 6 am to 2
Rad/s
Rad

1
sunset at 6 pm, in these 12 hours the sun is to travel from 0
the 0 degree to maximum 180 degrees, correspondingly, 0

the solar panel, in 12 hours will rotate 180 degrees, sun -1

0 2 signal 4 6
-2
0 2 4 6
Control
angle changes per hour can be calculated by dividing 10 Time (seconds) Time (seconds)
Current/time Torque/time
maximum degree over number of hours; or minutes or 10 0.2
5
seconds; 180/(12) = 0.004166=15 degrees per hour or, 5 0.1
18/(12*60*60 ) = 0.004166 degrees per second, with the 0
Amp

Nm

0 0
initial altitude angle is at 30 degrees, and maximum angle -5
-5 -0.1
limit to be 90 degrees, the simulation shown in Figure
-10 -10
9(g) is proposed. 0 0 2 2 4 4 66 -0.2
0 2 4 6
Applying the calculated altitude angle, for Taif city, as Time (seconds)
Time (seconds) Time (seconds)
Error signal Control signal
the input data ( error) for the designed control system, 15 10
will result in corresponding panel angle, plotting both 5
10
input angle and output panel angle in the same graph
window, will result in response curve shown in Figure 5 0

10(b). These response curves show that, the input and 0 -5

output angles curves are allmostly identical, with small
-5 -10
error, by soft tuning of control system, the input can match 0 0.2 0.4 0.6 0.8 0 2 4 6
Time (seconds)
the output without error, comparison show that the solar Time (seconds)
Error signal
panel tracks the sun, resulting in optimal operational Figure 9 (d) Applying PID controller
15 response curves.
efficiency of solar energy photovoltaic module 10

0 427
-5
0 0.2 0.4 0.6 0.8
Time (seconds)
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)

Angle VS time Speed/time Variable input angle

4 10 1.8

1.6 Output angle

Step input
2 0 1.4

Rad/s
Rad

1.2
0 -10
1

Angle
0.8
-2 -20
0 1 2 3 4 0 1 2 3 4 0.6
Time (seconds) Time (seconds)
Current/time Torque/time 0.4
200 5
0.2

0
0 0
Amp

Nm

-0.2
0 0.5 1 1.5 2 2.5 3
-200 -5 Time (Sec)

Figure 10 (d) Responses applying variable input angle

-400 -10
0 1 2 3 4 0 1 2 3 4
Time (seconds) Time (seconds) 6. Prototyping, testing, evaluation and optimization.
Figure 9 (e) Applying PD controllers with deadbeat
response. There is no single model which can ever flawlessly
90
Change of Altitude angle with time for 21st August
reproduce reality, there will always be errors called as
80
max. angle 80.83
unmodeled errors between behavior of a product model
70
and the actual product. In order to take into account the
60
unmodeled errors and enhance precision, performance in
the design process, the mechatronics design approach
50
includes prototyping phase. Prototyping development may
Degree

40
be carried out in the following two forms; Virtual
30
Prototype and Physical Prototype, in this paper, only
20
Sun rise Sunset virtual prototype in MATLAB and Proteus environment is
10
built, shown in Figure 9(d) and Figure 8(d)
0

-10
0 500 1000 1500
7. Conclusion & Future work
Figure 10(a) the calculated altitude angle versus time (the
Time (sec)

input angle change) ( Ashraf Balabel et al, 2013) This paper proposes the conception and development of
90
solar tracking system based on mechatronics design
approach, where realization of design is achieved applying
80 Altitude angle
Panel angle
concurrent design approach and considerations. A
70 complete system and components' selection, design and
60 integration as well as, modeling, simulation, and analysis
50 are presented. Also, a new control method was proposed
40
for achieving smooth fast response without overshoot. The
obtained simulation results are quite encouraging; they
30
show the efficiency and the simplicity of the proposed
20 design. The proposed mechatronics design and models are
Angle10 intended for research purposes, as well as, for application
0
in educational process.
0 500 1000 1500
As a future work, both one and two DOF physical
Time (Min) prototypes of the proposed design to be built tested,
Figure 10(b) calculated altitude angle for Taif city, as compared with current design and optimized.
input and resulted panel angle as system response
time References
12:34 Farhan A. Salem (2013), A proposed approach to Mechatronics
Digital Clock Design and Implementation education-oriented Methodology,
Product Switch1
Product1 Scope submitted to; Mechatronics; The Science of Intelligent
.004167 Machines, ID- MECH-D-13-00070.
-1
15deg/hour 36 Yu Wang, Ying Yu,Chun Xie, Xiaoyang Zhang, Weizhi Jiang
start angle
(2012), Aproposed approach Product2
Constant to mechatronics design
Scope1
education: Integrating design methodology, simulation with
Figure 10 (c) Proposed models for calculating angle projects, Mechatronics, November.
change Switch
90

Constant1

428
Farhan A. Salem International Journal of Current Engineering and Technology, Vol.3, No.2 (June 2013)
Devdas Shetty, Richard A. Kolk (2011), Mechatronics System
Design, Second Edition, SI, Cengage Learning,.
Sarah Brady, Multidisciplinary machine building, the institute of
engineering technology http://eandt.theiet.org/ magazine/2008
/12/machine-building.cfm
L. Al-Sharif, A Saleem, and TA Tutunji (2010), Mechatronic
system design: The ideal capstone course? 7th International
Symposium on Mechatronics and its Applications (ISMA), ,
also L Al-Sharif "Mechatronics System Design 0908531:
Course Notes", Mechatronics Engineering Department,
University of Jordan.
C.S. Chin (2012), Model-Based Simulation of an Intelligent
Microprocessor-Based Standalone Solar Tracking System.
Mohammed S. El-Moghany, Basil M. Hamed (2012), Two axis
tracker using fuzzy controller via PIC16F887a, The 4th
International Engineering Conference –Towards engineering
of 21st century.
Akhmedyarov, K.A.; Bazarov, B.A.; Ishankuliev. B.; Karshenas,
K.E.; Schaimerdangulyev G. (1986), Economic efficiency of
the FV-500 solar photoelectric station with automatic tracking
of the sun. Appl. Solar Energ.22, 44-47.
Chin CS, McBride W. Design (2011), Modeling and Testing of a
Standalone Single Axis Active Solar Tracker using
MATLAB/Simulink, Renewable Energy 36(11), 3075-3090.
Ahmad Rhif (2011), A position control review for photovoltaic
system, Dual axis sun tracker, IETE Technical Review
,Volume 28, Issue 6 ,p. 479-485.
R. Messenger and J. Ventre (2000), Photovoltaic Systems
Engineering, CRC Press.
M. Buresch (1983), Photovoltaic Energy Systems Design and
Installation, McGraw-Hill, New York.
S.A. Kalgirou (1996), Design and construction of a one axis sun-
tracking system, sol. Energy, vol. 57, pp 459-9.
Gustavo Ozuna, Carlos Anaya. Diana Figueroa. Nun Pitalua
(2011), Solar Tracker of Two Degrees of Freedom for
Photovoltaic Solar Cell Using Fuzzy Logic, Proceedings of the
World Congress on Engineering 2011 Vol II WCE 2011, July
6 – 8,London, U.K.
A. Stjepanovic, F. Softic, Z. Bundalo and S. Stjepanovic (2010),
Solar Tracking System and Modelling of PV Module ,
MIPRO,Opatija, Crotia.
A. Louchene, A. Benmakhlouf and A. Chaghi (2007), Solar
Tracking System with Fuzzy Reasoning Applied to Crisp Sets
, Revue des Energies Renouvelables, Vol. 10, No2, pp. 231 –
240.
C.S. Chin, A. Babu, W. McBride(2013), Design, modeling and
testing of a standalone single axis active solar tracker using
MATLAB/Simulink, Renewable Energy, Volume 36, Pages
3075-3090.
M. A. Usta, Ö. Akyazı2 and İ. H. Altaş ( May 2011), Design
and Performance of Solar Tracking System with Fuzzy Logic
Controller, 6th International Advanced Technologies
Symposium (IATS’11), 16-18, Elazığ, Turkey
S. Lakeou , E. Ososanya , Ben O. Latigo , W. Mahmoud G.
Karanga , W. Oshumare (2006), Design of a Low-cost Digital
Controller for a Solar Tracking Photo-Voltaic (PV) Module
and Wind Turbine Combination System, 21st European
Photovoltaic Solar Energy Conference, 4-8, Dresden,
Germany.
Nader Barsoum, Pandian Vasant (2010), simplified solar
tracking prototype , Global journal on technology &
optimaization, volum1,Transaction in Controllers and Energy.
Chia-Yen Lee, Po-Cheng Chou, Che-Ming Chiang , Chiu-Feng
Lin (2009), Sun Tracking Systems: A Review, Sensors,9,
3875-3890; doi:10.3390/s90503875.
S.A. Kalogirou (1996), Design and construction of a one-axis
sun-tracking system, Sol. Energ, Vol. 57, pp. 465-9.
H.A. Yousef (July 1999), Design and implementation of a fuzzy
logic computercontrolled sun tracking system , IEE
International Symposium on Industrial Electronics, Bled,
Slovenia.
M. Singh, S. Srivastava, and J.R.P. Gupta(2007), Identification
and control of nonlinear system using neural networks by
extracting the system dynamics , IETE Journal of Research,
Vol. 53, pp. 43-50.
M. Berenguel, F.R. Rubio, A. Valverde, P.J. Lara, M.R. Arahal,
and E.F. Camacho (2004),An artificial vision-based control
system for automatic heliostat positioning offset correction in
a central receiver solar power plant . Sol. Energ. Vol. 76, pp.
563- 75.
S. Kim (2007), Robust maximum power point tracker using
sliding mode controller for the three-phase grid-connected
photovoltaic system, Sol. Energ. Vol. 81, pp. 405-14.
Wai Phyo Aung (2007), Analysis on Modeling and Simulink of
DC Motor and its Driving System Used for Wheeled Mobile
Robot, World Academy of Science, Engineering and
Technology.
Richard C. Dorf, Robert H. Bishop (2001), Modern Control
Systems 12 Ed, Pearson Education, Inc.
Ahmad A. Mahfouz, Ayman A. Aly, Farhan A. Salem (2013),
Mechatronics Design of a Mobile Robot System , IJISA, vol.5,
no.3, pp.23-36.
Capolino G. A., Cirrincione G., Cirrincione M., Henao H., Grisel
R. (2001), Digital signal processing for electrical machines,
International Conference on Electrical Machines and Power
Electronics, Kusadasi (Turkey), pp.211-219.
Ashraf Balabel, Ahmad A. Mahfouz, Farhan A. Salem (2013),
Design and Performance of Solar Tracking Photo-Voltaic
System , I.J. of control, automation and systems, 2013, Vol, N-
02
Mohanad Alata, M.A. Al-Nimr, Yousef Qaroush (May 2005),
Developing a multipurpose sun tracking system using fuzzy
control, Energy Conversion and Management, Volume 46,
Issues 7–8, Pages 1229–1245
Farhan Atallah Salem AbuMahfouz: B.Sc., M.Sc and Ph.D., in
Mechatronics of production systems, Moscow. Now he is ass.
professor in Taif University, Mechatronics program, Dept. of
Mechanical Engineering and gen-director of alpha center for
engineering studies and technology researches. Research
Interests; Design, modeling and analysis of primary
Mechatronics Machines, Control selection, design and analysis
for Mechatronics systems. Rotor Dynamics and Design for
Mechatronics applications.
429