Single axis in-line gearbox modular tracker system

Abstract

Modular tracker systems that include at least first and second tables or are continuous without the use of tables, a single motor driving the first and second tables, first and second intra-table drive shafts and an inter-table drive shaft. Each table includes a support structure including first and second mounting posts, a frame supported by the support structure, at least one solar panel supported by the frame, and first and second gearboxes being concentrically aligned for each table. The first and second gearboxes are each configured to produce first and second outputs. The first output has a first rotational speed, and the second output has a second rotational speed less than the first rotational speed, and is operatively coupled to the frame. The inter-table drive shaft couples the second gearbox of the first table with the first gearbox of the second table, whereby the first and second tables are rotated synchronously.

What is claimed is: 
     
         1 . A modular tracker system comprising:
 at least first and second tables rotatably arranged in a row, each of the first and second tables including:
 a support structure including first and second mounting posts that are configured to be mounted in the ground; 
 a frame supported by the support structure; 
 at least one solar panel supported by the frame; 
 a first gearbox operatively coupled to the first mounting post and defining an axis of rotation, the first gearbox being configured to produce first and second outputs, wherein the first output has a first rotational speed and the second output has a second rotational speed that is less than the first rotational speed, and wherein the second output is operatively coupled to the frame; and 
 a second gearbox operatively coupled to the second mounting post and concentrically aligned with the first gearbox of the same table, the second gearbox being configured to produce first and second outputs, wherein the first output has the first rotational speed and the second output has the second rotational speed, 
   a single motor driving both the first and second tables;   a first intra-table drive shaft connecting the first and second gearboxes of the first table;   a second intra-table drive shaft connecting the first and second gearboxes of the second table, and   an inter-table drive shaft coupling the second gearbox of the first table with the first gearbox of the second table to connect the first and second tables, whereby the first and second tables are rotated synchronously.   
     
     
         2 . The modular tracker system of  claim 1 ,
 wherein an input of the first gearbox of the first table is coupled to the single motor,   wherein the first output of the first gearbox of the first table is coupled to a first end of the first intra-table drive shaft, and   wherein the first output of the second gearbox of the first table is coupled to a second end of the first intra-table drive shaft that is disposed opposite the first end of the first intra-table drive shaft.   
     
     
         3 . The modular tracker system of  claim 2 ,
 wherein an input of the second gearbox of the first table is coupled to a first end of the first inter-table drive shaft, and   wherein an input of the first gearbox of the second table is coupled to a second end of the inter-table drive shaft that is disposed opposite the first end.   
     
     
         4 . The modular tracker system of  claim 1 ,
 wherein the single motor is coupled to the first output of the first gearbox of the first table,   wherein the input of the first gearbox of the first table is coupled to a first end of the first intra-table drive shaft, and   wherein the input of the second gearbox of the first table is coupled to a second end of the first intra-table drive shaft that is disposed opposite the first end.   
     
     
         5 . The modular tracker system of  claim 1 , further comprising:
 a universal joint connecting the inter-table drive shaft to at least one of the second gearbox of the first table and the first gearbox of the second table allowing rotation to be transmitted from the first table to the second table without imposing alignment requirements.   
     
     
         6 . The modular tracker system of  claim 5 ,
 wherein the inter-table drive shaft includes a hollow shaft having first and second through holes,   wherein the first gearbox of the second table includes a gearbox shaft including an elongate slot disposed therethrough, and   wherein the universal joint further comprises:
 a yoke having arcuately shaped end surfaces disposed opposite one another, and a through hole extending between the arcuately shaped end surfaces, and 
 a fastener extending through the first through hole of first inter-table drive shaft, the through hole of the yoke, the elongate slot of the gearbox shaft, and the second through hole of the inter-table drive shaft. 
   
     
     
         7 . The modular tracker system of  claim 6 , wherein the universal joint further comprises:
 a bracket having a first end and a second end disposed opposite the first end, wherein the first end includes first and second through holes,   wherein the fastener extends through the first through hole of the first end of the bracket, through the first through hole of the inter-table drive shaft, through the hole of the yoke, the elongate slot of the gearbox shaft, the second through hole of the first inter-table drive shaft, and through the second through hole of the first end of the bracket.   
     
     
         8 . The modular tracker of  claim 1 , wherein the inter-table drive shaft is a flexible shaft that has an angle of bending of less than 6 degrees, and is configured to be rigid enough to carry the torque load, yet flexible enough to accommodate misalignment by bending. 
     
     
         9 . The modular tracker system of  claim 1 , further comprising:
 at least one rigid joint couples the first and second gearboxes of the first table to the first intra-table drive shaft.   
     
     
         10 . The modular tracker system of  claim 9 ,
 wherein the first intra-table drive shaft includes a hollow shaft including first and second through holes disposed adjacent a first end of the first intra-table drive shaft,   wherein the first gearbox of the first table includes a gearbox shaft including an elongate slot, and   wherein the rigid joint that couples the first gearbox of the first table to the first intra-table drive shaft further comprises:
 a spacer including a first through hole extending in a first direction and a second through hole extending in a direction perpendicular to the first direction and configured to accept the gearbox shaft, and 
 a fastener extending through the first through hole of the first intra-table drive shaft, the first through hole of the spacer, the elongate slot of the gearbox shaft, and the second through hole of the first intra-table drive shaft. 
   
     
     
         11 . The modular tracker system of  claim 10 , wherein the rigid joint that couples the first gearbox of the first table to the first intra-table drive shaft further comprises:
 a bracket having a first end and a second end disposed opposite the first end, wherein the second end includes first and second through holes,   wherein the fastener extends through the first through hole of the second end of the bracket, the first through hole of the first intra-table drive shaft, the first through hole of the spacer, the elongate slot of the gearbox shaft, the second through hole of the first intra-table drive shaft, and through the second through hole of the second end of the bracket.   
     
     
         12 . The modular tracker of  claim 1 ,
 wherein the first gearbox of the first table is coupled to the first mounting post using a mounting bracket and a lever arm.   
     
     
         13 . The modular tracker system of  claim 1 , further comprising:
 a first spherical bearing supporting the first output of each of the first gearboxes of the first and second tables;   a second spherical bearing supporting the first output of each of the second gearboxes of the first and second tables.   
     
     
         14 . The modular tracker system of  claim 1 ,
 wherein the first and second gearboxes of the first table are aligned along a first axis of rotation, and   wherein the first and second gearboxes of the second table are aligned along a second axis of rotation.   
     
     
         15 . The modular tracker of  claim 1 , wherein an input of the first gearbox is formed on a common shaft as the first output of the gearbox, whereby the input has the same speed ratio as the first output of the first gearbox. 
     
     
         16 . The modular tracker of  claim 1 , wherein the first output of the first gearbox of the first table has a speed ratio of about 1:1 compared to an input of the first gearbox of the first table and the second output of the first gearbox of the first table has a speed ratio of about 1:60 or less compared to the input. 
     
     
         17 . A modular tracker system comprising:
 at least first and second tables rotatably arranged in a row, each of the first and second tables including:
 a support structure configured to be mounted in the ground; 
 a frame supported by the support structure; 
 at least one solar panel supported by the frame; 
 at least one gearbox supported by the support structure, the gearbox being configured to produce first and second outputs, wherein the first output has a first rotational speed and the second output has a second rotational speed that is less than the first rotational speed, and wherein the second output is operatively coupled to the frame; 
   a single motor driving both the first and second tables; and   an inter-table drive shaft connecting the first and second tables, the inter-table drive shaft coupling the first output of the gearbox of the first table with an input of the gearbox of the second table, whereby the first and second tables are rotated synchronously.   
     
     
         18 . The modular tracker system of  claim 17 , wherein the first and second tables are rotated synchronously by connecting the first output of the gearbox of the first table to the input of the gearbox of the second table using the inter-table drive shaft and at least one universal joint. 
     
     
         19 . The modular tracker system of  claim 17 ,
 wherein the support structure of each of the first and second tables includes first and second mounting posts that are configured to be mounted in the ground, and   wherein the gearbox of the each of first and second tables is operatively coupled to one of the first or second mounting posts of each of the first and second tables.   
     
     
         20 . A modular tracker system comprising:
 a support structure configured to be mounted in the ground;   a frame supported by the support structure;   a plurality of solar panels supported by the frame;   a first gearbox supported by the support structure, the first gearbox being configured to produce first and second outputs, wherein the first output has a first rotational speed and the second output has a second rotational speed that is less than the first rotational speed, and wherein the second output is operatively coupled to the frame;   a second gearbox supported by the support structure and concentrically aligned with the first gearbox, the second gearbox being configured to produce first and second outputs, wherein the first output has the first rotational speed and the second output has the second rotational speed and is operatively coupled to the frame;   a single motor driving the modular tracker system; and   a drive shaft connecting the first and second gearboxes, the drive shaft coupling the first output of the first gearbox with the input of the second gearbox, whereby the plurality of solar panels are rotated synchronously.   
     
     
         21 . The modular tracker system of  claim 20 ,
 wherein the drive shaft includes a hollow shaft having first and second through holes,   wherein the first gearbox includes a gearbox shaft including an elongate slot, and   wherein the frame is rotated synchronously by connecting the first output of the first gearbox to the input of the second gearbox using the drive shaft and at least one universal joint to allow rotation to be transmitted without imposing alignment requirements, wherein the universal joint further comprises:
 a yoke having arcuately shaped end surfaces disposed opposite one another, and a through hole extending between the arcuately shaped end surfaces, and 
 a fastener that extends through the first through hole of the drive shaft, through the hole of the yoke, the elongate slot of the gearbox shaft, and the second through hole of the drive shaft. 
   
     
     
         22 . The modular tracker system of  claim 20 ,
 a third gearbox supported by the support structure and concentrically aligned with the first gearbox, the third gearbox being configured to produce first and second outputs, wherein the first output has the first rotational speed and the second output has the second rotational speed that is less than the first rotational speed, and wherein the second output is operatively coupled to the frame;   a fourth gearbox supported by the support structure and axially aligned with the third gearbox concentrically aligned with the third gearbox, the fourth gearbox being configured to produce first and second outputs, wherein the first output has the first rotational speed and the second output has the second rotational speed and is operatively coupled to the frame;   second drive shaft connecting the second and third gearboxes, the second drive shaft coupling the first output of the second gearbox with the input of the third gearbox; and   a third drive shaft connecting the third and fourth gearboxes, the third drive shaft coupling the first output of the third gearbox with the input of the fourth gearbox, whereby the plurality of solar panels are rotated synchronously.