SunArx builds Solar Trackers, a solar panel system that “tracks” the sun all day long.

With renewable energy at the top of the nation’s mind, SunArx is strategically placed, considering that numerous local and state municipalities are offering attractive rebates and tax credits to anyone willing to buy. SunArx builds Solar Trackers, a solar panel system that “tracks” the sun all day long.

Based in Colorado, this relatively new company just started shipping their product after nearly two years of R&D. When talking with company president Eric Wahl, one quickly gets a sense that he is a prudent businessman, a self-proclaimed perfectionist. In the world of product development, these are important attributes.

SunArx Trackers are constructed of a steel main frame with large aluminum extrusions, and a clock-based control board that tilts the panels to seize the maximum amount of sunlight. SunArx’s niche is residential and smaller commercial customers, as opposed to the customized megawatt solar products their competitors cater to.

When building the prototype, SunArx knew they would have to keep their costs low to maintain a position in their market, which meant developing a standard model with little-to-no customization, and minimal pieces and parts. The research and development has been a long time coming for this small company, but has been necessary in order to create an off-the-shelf panel system with functionality that would be relevant for years to come.

The SunArx Tracker initial designs were 2D CAD, but Wahl and his team knew 3D was imperative to illustrate and manipulate the complex loading and drawings. SunArx hired EAC Product Development Solutions (EAC) as their product development partner to recreate the model in 3D and run specific analysis and simulation tests. 

EAC was given the SunArx design parameters, which in turn helped drive the geometry. Using Pro/ENGINEER Behavioral Modeling Extension, EAC could take components like the actuator arm and input the variables to identify the mount point, as well as length and width. With a realistic design in place, the next step was analyzing and improving the tracker structure. 

SunArx knew their tracker needed to withstand wind loads of 100 miles per hour. EAC computed the wind loads against the tracker frame in Mathcad to determine force balance equations to be applied later in stress tests. Before the stress tests, however, SunArx needed a simulated look at the tracker in action. Through Pro/ENGINEER’s Mechanism Design function, EAC could verify the actuator arm covered the desired range of motion.

EAC’s final piece of the analysis and simulation happened within Pro/ENGINEER Mechanica—one of the heavy-hitters in PTC’s suite. Mechanica took the wind force equations and applied them to the entire tracker structure to simulate the stress and displacement points within 3D. The results helped EAC and SunArx identify weak spots and understand what needed tweaking to be able to withstand the elements.    

In talking about the development of the tracker design, Wahl said, “[Simulation] was very valuable. It really works, as far as creating a cheaper design if you can interpret it properly. You have to have a feasible concept that can work at a certain price…and we see competitors that are 75 percent of the way there; but without that refinement they don’t have a successful product. You’ve got to take that last step to really optimize it, or it just ends up too heavy or doesn’t look good.”

Fortunately for SunArx, their trackers seem to have managed that beautiful balance of an optimized design within the right pricing structure. Wahl and his associates recently returned from the Solar Power International Conference in Anaheim, California. With 24,000 attendees, Wahl was encouraged by their exposure and the opportunity to network with other solar technologies suppliers and businesses.

When asked about his business prospects in 2010, Wahl expresses his optimism based on the fact that the solar industry is growing fast and his niche clients are responding. Wahl understands that in any industry, only the strong survive—but Wahl’s conservative approach and passionate belief in product refinement certainly improves their odds.