Technology / System Architecture
System Architecture
TrackLab is a three-tier solar tracker control architecture: field controllers (TCUs) manage individual rows, site controllers (NCUs) coordinate the field, and a cloud platform provides remote monitoring and management.
This architecture is designed for utility-scale solar farms where independent row operation, multi-protocol communication, and remote management are critical for uptime and operational efficiency.
Architecture Overview
Architecture Layers
Field Layer — Tracker Controller Units (TCUs)
Each tracker row is managed by its own TCU. The TCU handles solar position tracking, motor control, sensor inputs, and autonomous stow-for-safety. Independent row operation means a single failure never cascades across the site.
- One TCU per tracker row — no shared controllers
- Autonomous solar tracking algorithm runs locally
- Configurable stow thresholds for wind, hail, and snow
- RS485, CAN-2.0, LoRa, or Fibre (TCP/IP) communication to the NCU
Site Layer — Network Control Units (NCUs)
The NCU coordinates all TCUs on a site or site section. It handles parameter broadcasting, data aggregation, weather integration, and upstream connectivity. If the cloud link drops, the NCU continues autonomous site operation.
- Manages up to hundreds of TCUs per site section
- Broadcasts tracking parameters and firmware updates
- Aggregates field data for cloud transmission
- Local decision-making continues without cloud connectivity
Cloud Layer — Monitoring Platform
The TrackLab monitoring platform receives data from every NCU through the deployment’s chosen upstream networking model. It provides real-time monitoring, historical analytics, remote configuration, and over-the-air firmware updates through a browser-based portal.
- Real-time device status and performance dashboards
- Remote configuration and parameter changes
- Over-the-air firmware updates to every TCU
- Role-based access for operators, managers, and partners
Data Flow
Design Principles
Fault Isolation
Every tracker row operates independently. If one TCU fails, every other row continues tracking. No single point of failure at the row level.
Protocol Flexibility
Choose LoRa for long-range wireless, RS485 or CAN-2.0 for wired reliability, or fibre for high-bandwidth TCP/IP connections. Mix protocols across a single farm.
Autonomous Operation
The system is designed for degraded-connectivity environments. NCUs and TCUs continue operating autonomously when upstream links are temporarily unavailable.
Layered Visibility
Each layer handles its own responsibilities. Field devices control trackers. Site controllers coordinate. The cloud provides visibility. Clean separation simplifies troubleshooting.
Related Documentation
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TrackLab Solar. (2026). System Architecture. Retrieved from https://tracklabsolar.com/technology/system-architecture
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