Array Technologies employee Ben Theune explains the manufacturing process for the company’s patented universal module mounting clamps.
In 1985, Ron Corio began a move from automotive R&D into solar manufacturing. He was working on a new type of ignition system for automobile engines in Albuquerque when a solar startup, the Wattsun Corporation, asked for help designing a concentrator PV module. As a consultant, Corio worked in-depth on the module design including the cell metallization, receiver sheet, optics and manufacturing processes. He was offered a job with Wattsun in 1989.
Part of Corio’s work with Wattsun included the development of a dual-axis solar tracker for the module. Once a tracker and module system was ready for production, Wattsun lobbied for matching funding from the Department of Energy for a pilot production facility. Indications initially were positive, but two weeks before the award was to be made, government funding was cut.
“We were left to try to figure out where to go as a company,” Corio said. “We tried to sell the module to some Japanese companies. That didn’t work, so we decided to start selling the tracker to the remote-home market in order to keep the company alive.”
The remote-home market was small, Corio said, but it was the only market available at the time, along with water pumping for livestock and a few telecommunications projects.
A break came in 1992 when Home Power magazine published a review of the Wattsun two-axis PV tracker. In the days before the Internet, the magazine was the go-to source of information for the off-grid market. The Home Power test tracker was the third tracker the company sold.
“The Wattsun is the most effective PV tracker I have ever seen,” wrote reviewer Richard Perez. “Its performance is reliable and precise. I have never been excited enough by a PV tracker to install one in our system.”
In 1992, Corio raised $55,000 from people he knew who were “solar friendly,” and bought-out the Wattsun Corporation. The company was in debt $39,000, so that left Corio with $16,000 to operate the business.
“There were a lot of times I thought, ‘What am I doing?’” Corio said. “But I will say I was always a true believer in solar energy. I believed that it was ludicrous to just burn fossil fuels—a finite thing. That’s what kept me going, my belief in solar and being around like-minded people.”
Every year, Array Technologies Inc. (ATI) grew a little. It started out with three employees, and by 2003, there were about 10. The company sold a lot of residential trackers—over 20,000 of them across the world, to locations including Fiji and Canada. Corio even sold trackers to Steve Fossett for an attempt to circumnavigate the globe in a helium balloon outfitted with solar panels to power on-board electronics. He also sold 36 trackers designed to look like sunflowers to Robin Williams for his ranch in Napa Valley.
Yet Corio had his eye on utility-scale solar, which was still in its infancy in the U.S. In 2001, ATI won its first utility-scale project, a 250-kW contract with BP Solar for a horizontal axis tracker. Soon after, the company sold 5.7 MW in South Korea followed by a 6-MW project in Spain.
Then in 2007, Corio was offered what he considers a landmark project, the Alamosa Solar Project in Colorado with SunEdison. It was to be the largest system in the U.S. at the time. The newly designed tracker for the project would use linear actuators to move each row. But soon into the engineering, Corio knew there were problems, such as how many modules could be loaded onto a single actuator.
Corio was working late on the tracker design for Alamosa when he was struck with another idea—an epiphany—a linked tracker block using a worm gear at each row. He would link the rows together with a rotating driveline and universal joints to follow the terrain. The next day he filed a provisional patent. A week later, the design started to gel, and he called SunEdison. He set up a meeting with the Alamosa project engineer, the commander of construction and others to discuss the new system, not long before construction was set to begin.
“They were freaking out,” Corio said. “They were saying, ‘We’ve already got this permitted.’”
Corio convinced them, however, with diagrams, details and clear proof of his new design’s superiority.
“I knew it was our opportunity, so I put everything I had into it, and that’s how the DuraTrack was born,” Corio said. “If that project would have failed, Array Technologies would have failed.”
Corio was on-site during the commissioning. He said he remembers turning on the first motor, thinking about all of his calculations—whether the motors would lift the weight. Up until that point, his math hadn’t been tested and he was estimating the friction in the bearings and the efficiency of the gearing. It was not practical to test a large block of trackers in the shop, and the strict timeline didn’t allow for anything more than the most essential testing. But the array worked, and continues to work today.
Looking toward the future, Array Technologies is unveiling a new version of its single-axis solar tracker, the DuraTrack HZ v3. Corio said they have taken 25 years and 2.5 GW of manufacturing trackers and rolled that experience into the development of another differentiated tracker design.
“We call it engineered simplicity—it is truly a case of less is more,” Corio said. “The v3 tracker considers what’s most important to the owners, financiers, engineers and builders of the power plant and delivers it.” SPW
Solar Power World