Amid the global energy transition and the trend of grid parity for photovoltaics (PV), enhancing power generation efficiency is a core objective in the renewable energy sector. Solar tracking systems (Trackers) can significantly increase energy yield by 15%-25% by continuously aligning PV panels with the sun. These outdoor systems place extremely rigorous demands on the drive system: 1) Extreme Reliability: Must operate 24/7 in unattended field environments for over 20 years, enduring wind, sand, rain, snow, and extreme temperatures (-40°C to +85°C). 2) High Torque & Stiffness: Requires sufficient torque to drive massive PV arrays (often 100 meters long) and must reliably self-lock or be locked at any angle to withstand high wind loads (especially in the “stow” or flat position). 3) Low Power Consumption: The tracker’s own energy consumption must be minimal, implying high transmission efficiency. 4) Low Cost: As a key component of the Balance of System (BOS) cost, the drive solution must be highly cost-effective.
AKT Product Solution
AKT provides long-life, high-reliability drive solutions for solar tracking systems, with a focus on high-protection-rated BLDC motors and high-torque stepper motors.
- High-Reliability & High-Efficiency Solution:
This is the advantage of BLDC motors. Our high-protection-rated (IP65+) BLDC motors are designed for harsh outdoor environments. Their brushless design ensures a maintenance-free life of tens of thousands of hours, fully meeting the 20-25 year operational requirement of a power plant. Critically, the high efficiency of BLDC motors (>85%) is far superior to PMDC motors, meaning less power is consumed during daily tracking movements, reducing the plant’s “parasitic losses.” - High-Efficiency Transmission & Locking Solution:
While traditional worm gears are self-locking, their efficiency is extremely low (50-70%). We recommend integrating our high-efficiency (>90%) planetary gearboxes with BLDC motors. This combination can reduce the required motor power and energy consumption by nearly half for the same load. To solve the non-locking nature of planetary gearboxes, our solution is to integrate a power-off, normally-closed electromagnetic brake (Brake) onto the motor. When the motor is not moving, the brake automatically engages, providing powerful wind-load holding capability, thus balancing high efficiency with high safety. - Cost-Effective Positioning Solution:
For some cost-sensitive or distributed-drive trackers, our high-torque hybrid stepper motors (e.g., NEMA 23, 34) are a highly reliable choice. The stepper’s powerful holding torque at standstill provides natural resistance to wind loads, and its open-loop control system is simple and low-cost. We can also provide IP65 protection and wide-temperature customization for these motors.
Engineering & Customization Capabilities
We provide deep customization for the PV industry: including IP67-level sealing designs for motors and planetary gearboxes, use of high/low-temperature resistant bearings and grease, custom motor windings to match 12V/24VDC field power, and integrated modules with pre-installed electromagnetic brakes and waterproof connectors.
Typical Application Equipment Examples
- Single-Axis Tracker (SAT):
This is the mainstream in utility-scale PV plants. Typically, one motor drives an entire 100-meter row via a slew drive or linear actuator. Our high-torque BLDC motor + planetary gearbox + electromagnetic brake assembly is the ideal power source for the slew drive. It provides high-efficiency tracking power and reliable brake-locking, ensuring the array’s structural safety in extreme weather (e.g., wind-stow). - Dual-Axis Tracker:
Used for CPV (Concentrated Photovoltaics) or in high-latitude regions, these trackers must follow the sun on both azimuth and elevation axes. This requires two independent drive units. Our small BLDC servo systems or stepper motor + planetary gearbox modules can provide high-precision independent control for both axes, ensuring perfect solar tracking all day to maximize efficiency. - Energy Management Valve Actuators:
In solar thermal plants or traditional energy management, remote control of large fluid valves is required. Our high-torque stepper motor paired with a planetary gearbox is an ideal actuator for these valves. It provides powerful opening/closing torque, and the stepper’s open-loop nature allows it to hold any position with high reliability.
Summary
AKT is committed to enhancing PV system efficiency and long-term ROI through stable, reliable drive technology. We have deeply studied the application conditions of solar trackers and provide drive solutions centered on high-protection BLDC motors, high-torque stepper motors, and high-efficiency planetary gearboxes. Our products are fully validated through comprehensive environmental and lifetime testing, and we are ready to build long-term partnerships with clients in the new energy sector to advance clean energy technology.