Adapting Solar Trackers For Complex Terrains

The ideal landscape for solar trackers has traditionally been flat land. However, with readily available flat land becoming more scarce or expensive, solar projects are increasingly encountering the challenge of complex terrain. Traditional tracker designs may not be suitable for uneven ground, requiring solutions like extensive land grading – a costly and environmentally-disruptive process – to create a level surface. Alternatively, increasing pier length to maintain a uniform slope can be implemented, but this approach comes with the drawback of increased material needs and project costs. The best solution, and one that has become increasingly popular, is adapting trackers to the terrain, as it offers a solution that minimizes the need for extensive grading or earthwork. This topic has sparked significant interest in the tracker segment, leading several companies to develop smart solutions (see Digital Solutions For Smart Solar Tracking)

Nextracker was the first to introduce a solution for terrain-following trackers under the brand name XTR. This product has already seen widespread global deployment, with total shipments exceeding 12 GW, according to Nextracker. The uniqueness of this system lies in Nextracker’s balanced mass system that allows articulation at each foundation. Nextracker has further enhanced the XTR with the XTR 1.5, which doubles its terrain-following capabilities. The XTR’s ability to follow the natural slope of the ground minimizes environmental impact, lowers project risks, and accelerates project timelines by eliminating the need for extensive grading. The XTR system accommodates a slope of up to 15%, with XTR 1.5 allowing for a 1.5° angular deviation at each foundation, contributing to overall cost savings (see Nextracker’s TrueCapture Solar Tracker Technology With Intelligent Control Systems).

Similarly, TrinaTracker is developing a flexible solar tracker designed to adapt to varying terrains, expected to launch next year. This initiative requires close coordination between EPCs, project developers and manufacturers to implement terrain-adapted solar trackers effectively.

Jenya Meydbray from Nevados highlights terrain following as a critical trend in the tracker industry. Nevados has focused on developing technologies that reduce the need for grading, central to the company’s approach for nearly a decade, he said. Meydbray identifies terrain mapping as a major bottleneck for traditional terrain-following systems, where obtaining precise measurements is not only costly but also time-consuming. In the field, achieving accurate measurements is inherently challenging due to variables like dirt, steel and ongoing construction activities. However, Nevados' system is designed to accommodate terrain variations, thus reducing dependency on extremely precise mapping. This system operates in 3 dimensions, utilizing custom software and processes developed over the years. Meydbray notes that while the engineering process is complex, it has led to more efficient installations and operations. Nevados' tracker distinguishes itself from competitors by handling up to 15° of angle change per pile, offering significant flexibility with a joint mechanism, he emphasized. “Unlike our key competitor, which flexes the torque tube, we actually have a joint,” said Meydbray.

JSolar has also developed a terrain following tracker. Electrical synchronization, combined with spherical bushing integrated into the tracker, enables its product to attain a slope adaptability of up to 25%. Regarding the use of software to analyze topography and customize tracker configurations, Gonzalo Baselga Navarro, the chief business development officer at Gonvarri Solar Steel (GSS) mentioned an upcoming project involving trackers with carbon joints designed to enhance slope adaptation and reduce assembly costs. Gonvarri's system can adjust to up to a 15% slope with the tracker alone, and further adjustments can be made by modifying the pile length to absorb variations, potentially avoiding a significant portion of civil works, according to the company.

Frank Wang, senior technology engineer at Antai emphasized that his company’s adaptive terrain technology is particularly suitable for small projects under 20 MW in challenging areas, allowing trackers to adapt to about 20% terrain variation. Axial noted a trend towards adaptability, with projects exploring a hybrid approach that combines trackers with fixed tilt structures to address the constraints related to wind conditions and slopes. Scorpius’ business development and sales manager Shivranjan Jadhav said that the company's trackers support up to a 5° slope in a single row and he recommends segmenting rows for steeper terrains to manage topographical challenges effectively.

The text is an excerpt from the latest TaiyangNews Solar Trackers Market Survey 2024, which can be downloaded for free here.