Solar tracking systems can boost energy yield by 25–40% over fixed-tilt panels. The linear actuator is the heart of that  movement — and choosing the wrong one will cost you far more than you save in energy. This guide covers everything  solar engineers and system integrators need to know.

Why Solar Trackers Need Linear Actuators

A solar tracking system continuously adjusts the angle of photovoltaic (PV) panels to follow the sun's path across the sky. This maximizes the amount of direct sunlight hitting the panel surface throughout the day.

Single-axis trackers (the most common type) rotate panels along one axis — typically east to west. Dual-axis trackers adjust both horizontal and vertical angles for maximum precision.

The role of the linear actuator:

• Converts electrical energy into precise linear (push/pull) motion
• Drives the mechanical linkage that tilts the panel frame
• Holds the panel angle steadily against wind loads
• Moves slowly and incrementally throughout the day

Electric linear actuators have largely replaced hydraulic cylinders in modern solar installations due to lower maintenance requirements, no hydraulic fluid leakage risk, simpler electrical control integration, and lower total cost of ownership.

Key Requirements for Solar Tracker Actuators

Solar trackers operate in uniquely demanding conditions. Here are the critical specifications every system must address:

1.Force (Load Capacity)

The actuator must generate enough force to:

• Overcome the weight of the panel array and frame
• Resist wind loads (typically designed for wind speeds up to 120–160 km/h in survival mode)
• Account for dynamic forces during acceleration and deceleration

How to estimate required force:

For a single-axis tracker with N panels of mass M (kg), mounted on an arm of length L (m):

Where r_actuator is the effective moment arm of the actuator mounting point. Always add a safety factor of 1.5–2x  to the calculated value.

For most residential and small commercial arrays, actuators in the 1,000–5,000N range are sufficient. Large commercial arrays may require 10,000N or higher.

JDR recommends using our Engineering Force Calculator for precise force calculation based on your panel configuration.

2.Stroke Length

Stroke length determines how far the actuator can extend, which directly controls the angular range of panel tilt.

Typical parameters:

• Single-axis trackers: ±45° to ±60° tracking range
• Required stroke typically ranges from 150mm to 600mm depending on the frame geometry
• Measure your linkage geometry carefully — a longer arm requires a shorter stroke, and vice versa

3.IP Rating (Weatherproofing)

Solar actuators are permanently mounted outdoors, exposed to:

• Rain, humidity, and condensation
• Dust, sand, and pollen
• Temperature extremes (from -30°C to +60°C in some climates)

Minimum requirement: IP65 (dust-tight, protected against water jets)

Recommended: IP66 or IP67 for locations with heavy rainfall, coastal salt spray, or sandstorm exposure

An actuator with insufficient IP rating will corrode internally within 1–2 seasons, causing catastrophic failure.

4.Operating Temperature Range

Standard commercial linear actuators are typically rated for -20°C to +50°C operation. For installations in extreme climates (desert or arctic), verify the actuator's extended temperature range.

JDR Industrial Series actuators maintain full performance ratings from -30°C to +70°C ambient temperature.

5.Speed

Solar trackers don't need to move fast — the sun moves approximately 15° per hour. Most tracker actuators operate at 2– 8 mm/s, which is comfortably within the range of standard electric linear actuators.

However, the actuator must move quickly enough to:

• Complete the full east-to-west tracking sweep during daylight hours
• Perform the overnight return stroke (east reset) efficiently

For most tracker geometries, a speed of 3–5 mm/s is optimal.

6.Feedback Control (Position Sensing)

For precise tracking, the actuator must communicate its current position to the tracker controller. Two main feedback options:

Hall Effect Sensor (Pulse Feedback)

Generates pulses proportional to motor rotation

High resolution, accurate positioning

Digital signal, compatible with most tracker controllers

JDR models: FY011G, FY015D, FY021D series (with feedback option)

Potentiometer (Analog Feedback)

Outputs a variable voltage corresponding to position

Simpler wiring, direct analog input to controller

Suitable for less precision-demanding systems

For solar trackers, Hall effect sensor feedback is strongly recommended for its higher precision and resistance to noise.

7.Voltage

Most solar tracker systems use 12V DC (small residential systems) or 24V DC (most commercial systems). Ensure actuator voltage matches your control system supply.

JDR solar-suitable actuators support 12V, 24V, and 48V DC operation, allowing direct integration with battery storage systems.

Single-Axis vs. Dual-Axis Trackers: Actuator Configuration

Single-Axis Tracker

• Actuator count: 1 per tracker table (or 1 per row in long tables)
• Motion: Linear push/pull drives a rotating torque tube
• Synchronization: Multiple actuators on long rows must be synchronized via closed-loop position control

Dual-Axis Tracker

Actuator count: 2 per tracker (one for elevation, one for azimuth)

Control complexity: Higher; requires 2-axis controller

Applications: Concentrating solar power (CSP), high-precision research arrays

For dual-axis trackers, matched pairs of actuators with identical speed and stroke are essential. Even slight speed mismatches cause frame distortion.

Calculating the Number of Actuators per Tracker

For single-axis trackers, determine whether one or two actuators per table are needed:

• Single actuator: Suitable for lighter arrays (< 800kg total panel weight) with a rigid, centrally mounted torque tube
• Twin actuators: Required for heavier arrays or long tracker rows where single-point drive creates excessive torque

A common rule of thumb: one actuator per 8–12 standard 72-cell panels in a single row.

Environmental Considerations by Climate Zone

JDR Actuator Recommendations for Solar Trackers

Based on the requirements above, here are the JDR models best suited for solar tracking applications:

All JDR industrial actuators for solar applications include:

• IP66-rated sealing (standard) or IP67 (on request)
• Hall effect position feedback option
• Extended temperature rating (-30°C to +70°C)
• Corrosion-resistant aluminum alloy housing
• CE certification

Installation and Wiring Best Practices

Mounting Points

• Use clevis mounts (front and rear) for clean pivot action
• Ensure the actuator can rotate freely at both mounting ends to prevent side-loading
• Avoid mounting configurations where the actuator must absorb bending forces

Wiring

• Use UV-resistant, double-insulated cable for all external wiring
• Run cables in conduit where possible to prevent wind damage
• Use waterproof cable glands at all entry points
• For multi-actuator rows, consider pre-wired harness kits for faster installation

Controller Integration

• Ensure your tracker controller supports the actuator's feedback type (Hall pulse or analog)
• Program software end-stop limits that are 5–10mm before the physical hard stops to prevent mechanical damage
• Set current-limit protection in the controller to detect jammed or stalled actuators

Maintenance

Electric linear actuators for solar tracking require minimal maintenance:

Annual inspection: Check mounting bolts, cable condition, and connector sealing

Biennial lubrication: Internal lead screw grease (some sealed units are lifetime-lubricated)

After severe weather: Inspect for physical damage and verify full range of motion

Frequently Asked Questions

Q: Can I use a standard (non-industrial) linear actuator for a solar tracker?

A: Only for small residential installations in mild climates. Standard actuators typically lack IP66 sealing and are not rated for the temperature extremes or continuous outdoor exposure of commercial solar applications. For any commercial project, always specify industrial-grade actuators.

Q: What force rating should I use for a 20-panel tracker in a high-wind area?

A: This requires a full structural calculation considering panel weight, frame mass, wind load (based on local wind speed codes), and mounting geometry. As a starting point, budget 5,000–8,000N for a typical 20-panel row in a 120 km/h wind zone, then verify with your structural engineer. Use JDR's Force Calculator for initial sizing.

Q: How long should a solar tracker actuator last?

A: A properly specified and installed actuator should last 10–15 years — essentially the maintenance interval of the solar installation. Key factors: correct duty cycle, proper IP rating for the environment, and protected wiring. JDR industrial actuators are tested for 50,000+ cycles under rated load.

Q: Do I need synchronized actuators for long tracker rows?

A: Yes. For rows longer than approximately 30 meters (depending on torque tube stiffness), a single actuator creates unacceptable torque variation along the row. Use a synchronized pair of actuators with closed-loop position control to maintain <2mm position difference between them.

Summary

Choosing the right linear actuator for your solar tracker comes down to five key factors:

1. Force — properly calculated with a 2x safety factor for wind loads

2. IP rating — IP66 minimum for all outdoor commercial installations

3. Feedback type — Hall effect sensors for precision tracking

4. Voltage — match your system's DC supply (12V, 24V, or 48V)

5. Temperature rating — verified for your climate zone's extremes

JDR's Industrial Actuator Series is engineered specifically for demanding outdoor applications like solar tracking — combining high force output, IP66 sealing, precision feedback, and multi-voltage compatibility in a robust aluminum housing.

Ready to specify actuators for your solar project? Contact our engineering team for application-specific recommendations, or browse our full Industrial Actuator Series. For custom specifications (special stroke lengths, voltage, or feedback options), JDR offers OEM manufacturing with full certification support.