SMALL-SCALE SOLAR

TRACKING SYSTEM
ZACHARY MATHEWS, DANE MAXWELL & JALEN SMITH
ADVISED BY DR. PABLO GOMEZ & SPONSORED BY CONSUMERS ENERGY
PROJECT
BACKGROUND

• A desire for efficient

means of solar power
production

• Teaching future
generations about solar
power technology
through demonstration

• Progress the design of

the previous senior
design team
 ❖ To simulate and display concepts of solar power
PROJECT NEED generation without making changes to larger more
expensive solar panel arrays.
❖ Addition of a solar tracking system will help to
better model systems that Consumers Energy is
currently using.
 Design must closely match preexisting project (small-scale Solar
Generation Station), maintaining probability and similar
aesthetic design

Durable, yet lightweight structure with secure connections to

PROJECT minimize any Possible Damage during travel
SPECIFICATIONS
PHYSICAL Enclose/insulate all electrical connections to dramatically
reduce the chance of electrocution

Must include “banana ports”

 System must remain efficient enough as to not negate the
benefit of adding the solar tracking system

Ability to energize system through both battery power and

PROJECT solar energy
SPECIFICATIONS
FUNCTIONALITY Ability to fully make rotations without any external assistance

Seasonal variation to ensure system closely follows the sun

regardless of the time of year, given that the solar panels are
facing east upon startup.
BLOCK DIAGRAM
 Battery
Pack

Arduino
Mega

Solar Panels USB

Port

Bread
H-Bridge
Board
SYSTEM DESIGN COMPONENTS (MECHANICAL)

PVC Pipe Battery Solar Motor

USB ports
Gear Pack Panel Base Gears
 SYSTEM DESIGN COMPONENTS (ELECTRICAL)

RC High
Arduino
Solar Panel Breadboard H-Bridge Torque
Mega 2560
Motor
CIRCUIT DESIGN
H-Bridge Motors
Solar Panel
Location

Click to add text

Dip Switch
ARDUINO
CODE
Gear System

Leg/Base

Solar
Panel
Bases
3D MODELING
DESIGNS
These two-3D printed parts
make up the LEG of the
tracking system.
3D MODELING
DESIGNS
These two-3D printed parts
make up the BASE for the solar
panels.
3D MODELING
DESIGNS
These two-3D printed parts are
the mechanical system that
rotates the solar panels.

Top Gear: Connected to the pipe

Bottom Gear: Connected to the
motor
PLAN FOR SEASONAL VARIATION

• Using a timer system, the need for seasonal variation

was essential to maintain year-round efficiency

• WMU PhD student, Faraj Hussain Alyami, created

expansive spreadsheets of solar positioning
information for Eaton County, MI.

• Taking average of monthly Azimuth angles, a system

semi-hourly angles was created to significantly
increase efficiency
 TESTING
• Test the motors to see how long it takes them to rotate the solar panels 180 degrees.
• Adjust the delays in the code to properly match the best position of the sun at each interval
• Set the tracking system to follow the sun for a seasonal period and then record this data in
one of two ways
• Use a DMM and periodically record the voltage being generated by the solar panel array.
• Connect into the generation station and use the graphical interface system to monitor
the voltage being produced.

• This
data would then be compared to the voltage produced from the fixed solar panel
array.
SPECIFICATIONS MET: ESTIMATED 80%
PHYSICAL CHARACTERISTICS FUNCTIONALITY

• Design closely matches Small-Scale • System is efficient enough to benefit

Solar Generation Station from the tracking system

• Durable yet lightweight makes for • Ability to energize by both solar

easy transport and battery back-up

• Enclosed/insulated all electrical • Can easily interact with the

connections Small-Scale Solar Generation
Station via banana plugs
DELIVERABLES

• One row of solar panels designed to rotate on

a single axis tracking system

• System efficient enough to run purely off solar

energy with energy to spare

• "Demo-Mode" to display full range of movement

• System easily connects with Small-Scale Solar
Generation Station to take advantage of
graphical interface system.
 Small-Scale Solar Tracking System Total Budget
Item Quantity Price Per Total Price
H-Bridge Motor Drive 3 $6.99 $20.97
Arduino Mega 2560 1 $13.99 $13.99
3Vdc High Torque Motor 2 $4.61 $9.22
Toggle Switch 1 $3.96 $3.96

PROJECT BUDGET PVC Pipe (2 ft)

Monocrystalline Silicon Solar Panel
1
8
$7.61
$16.99
$7.61
$135.92
18650 Battery Packs 1 $8.99 $8.99

DISCUSSION 18650 Batteries (6pcs)

Banana to Banana Plug Test Lead Set
1
1
$15.99
$12.99
$15.99
$12.99
4 Pack of Sandpaper 1 $12.99 $12.99
Velcro Tape 1 $6.09 $6.09
1 kg 1.75 mm Black PLA 4 $22.99 $91.96
Lock Pins (2pcs) 1 $8.99 $8.99
Hardware 1 $6.86 $6.86
Wood 1 $5.99 $5.99

Total amount spent was $489.56. Dupont Wire (120pcs)

Arduino Mega 2560 Case Enclosure
1
2
$8.99
$9.99
$8.99
$19.98
Mini Breadboard 1 $5.69 $5.69
Cutting waste/unused materials, 16 Pin Dip Switch (8pcs) 1 $6.99 $6.99
Uxcell 3Vdc Mini Gear Box Motor 2 $9.57 $19.14
recreation could be taken down to an USB Charger Socket 1 $15.59 $15.59
AA Battery Pack w/ USB Connector 1 $7.95 $7.95
estimated total of $281.27. Miscellaneous (spray paint, hardware, wire, etc.) 1 $15.00 $15.00

Total Amount Spent: $461.85

Tax: $27.71

Final Cost: $489.56

Budget Remaining: $1,010.44
RECOMMENDATIONS FOR CURRENT WORK

• Data collected from Alyami needs to be worked into the Arduino code
• Complications with either motor, or power supply to the motor
• In current state, cannot make unassisted rotations
• Wire containment and weather-proofing
• A way to tightly secure the PVC pipe gear and still allow for easy removal.
• We were not able to obtain data to compare fixed solar panels to our solar
tracking system.
RECOMMENDATIONS FOR FUTURE WORK

A rack and pinion

system for the
rotation of the solar
tracker A hollow circular
casing to house the
circuity and
mechanical system.
The solar tracker will
be mounded near
the top
 • For just under $500, the Small-Scale Solar Tracking
System was developed to better model photovoltaic
generation stations used by Consumers Energy

• System is fully compatible with Small-Scale

Solar Generation Station

SUMMARY • While not fully functioning due to time constraints

posed by COVID-19, roughly 80% of specifications
were met.

• On top of fine tuning the seasonal variation settings,

change from a single-axis to a duel-axis system
would improve efficiency.
CONCLUSIONS
• This project was a joy to work on and showed our team what it’s like to have
a budget, design a physical project and construct it.
• The design works and all our issues leading up to the final weeks could have been
resolved
• The development of solar power technology is important, and every future generation
shall improve upon what's left behind.
SPECIAL THANKS TO...

• Associate Professor & Director of WMU Power Lab, Dr. Pablo Gomez
• WMU PhD Student, Faraj Hussain Alyami
• Jesse Jackson, Director of Engineering at Consumers Energy, Grand Rapids
• Consumers Energy