Overview
Utility-scale solar installations demand continuous, reliable performance under harsh environmental conditions. For Nextracker, one of the global leaders in solar tracking systems, validating structural loads, motion behavior, and environmental response in the field is critical.
W5 Engineering partnered with Nextracker to design and deploy a fully ruggedized, solar-powered data acquisition system capable of operating autonomously in remote environments while delivering high-fidelity measurement data.
The Challenge
Nextracker required a field-deployable system to monitor tracker performance under real-world conditions, with several constraints:
- Remote deployment with no fixed power infrastructure
- Continuous operation in harsh outdoor environments (heat, dust, moisture)
- Multi-sensor integration, including:
- Load cells (FUTEK systems)
- Structural and mechanical signals
- Reliable data logging and retrieval
- Compact, rugged enclosure for long-term field use
Additionally, the system needed to:
- Be self-powered via solar
- Maintain uptime across variable sunlight conditions
- Be rapidly deployable across multiple test locations
W5 Engineering Solution
W5 Engineering delivered a turnkey rugged instrumentation platform, integrating power, sensing, and data acquisition into a single deployable system.
1. Rugged Data Acquisition Core
- DEWESoft KRYPTON platform
- IP67-rated for harsh environments
- Distributed architecture for flexible sensor placement
- High-resolution measurement for:
- Load monitoring
- Structural response
- System performance validation
2. Precision Load Measurement Integration
- Integrated FUTEK load cells with calibration traceability
- Ensured:
- Accurate force measurement across dynamic conditions
- Long-term stability in outdoor environments
3. Solar-Powered Energy System
W5 engineered a self-sustaining power architecture, including:
- Solar panel array sized for continuous operation
- MPPT charge controller for efficiency optimization
- Battery storage system for:
- Night operation
- Low-light conditions
- Power distribution and protection (Lynx distributor, battery protection modules)
This enabled:
- Fully autonomous operation
- No reliance on grid power or generators
4. Ruggedized Enclosure & System Integration
- Designed and built a weather-resistant enclosure system
- Integrated:
- Cable management and sealed feedthroughs
- Multi-cord grips for environmental protection
- Internal mounting for DAQ, power electronics, and computing hardware
- Included fanless industrial PC (POC-series) for:
- Data logging
- Edge processing
- Remote access capability
5. System Architecture & Wiring
- Developed full BOM and system layout
- Delivered:
- Clean wiring architecture for maintainability
- Shielded signal routing to reduce noise
- Modular design for scalability
Deployment & Execution
W5 Engineering supported the project end-to-end:
- System Design & Engineering
- Power modeling for solar/battery sizing
- Sensor and DAQ selection
- Environmental protection strategy
- Build & Assembly
- Full system integration and wiring
- Pre-deployment validation and testing
- Documentation
- Schematics and interconnect diagrams
- Installation manuals and system layouts
- Field Deployment Support
- Commissioning assistance
- Validation of data streams and system performance
Results & Impact
The deployed system enabled Nextracker to:
- Capture high-quality structural and load data in real-world conditions
- Operate fully off-grid with solar power
- Maintain continuous uptime in harsh environments
- Rapidly deploy across multiple test sites
- Reduce reliance on temporary infrastructure or manual data collection
This solution significantly improved:
- Validation of tracker performance
- Understanding of field loading conditions
- Speed of engineering decision-making
Why W5 Engineering
W5 Engineering specializes in real-world instrumentation deployment, where lab systems must perform reliably in uncontrolled environments.
We don’t just design systems—we deliver field-ready solutions:
- Rugged system design for harsh environments
- Solar and off-grid power integration
- Remote data acquisition and monitoring
- Deep expertise in sensor integration and validation
Whether it’s solar infrastructure, aerospace testing, or industrial R&D, W5 enables customers to capture accurate data—anywhere, under any conditions.
Let’s Talk
Need a rugged, deployable measurement system for your next project?
Visit www.W5Engineering.com or contact us to discuss your application
