U.S. patent application number 14/574360 was filed with the patent office on 2015-07-02 for solar receiver.
The applicant listed for this patent is Shmuel Erez, Ben Shelef. Invention is credited to Shmuel Erez, Ben Shelef.
Application Number | 20150184895 14/574360 |
Document ID | / |
Family ID | 53481277 |
Filed Date | 2015-07-02 |
United States Patent
Application |
20150184895 |
Kind Code |
A1 |
Shelef; Ben ; et
al. |
July 2, 2015 |
SOLAR RECEIVER
Abstract
A system and method for maintenance of a reflector with. The
system may be incorporated to be an integral part of the dish
assembly and may be operated autonomously or remotely. The system
may include a controller programmed to activate the system
according to set schedule or according to reflectivity drop of the
light from the dish. The system includes a foldable arm that is
folded when not in use so as not to interfere with the operation of
the dish. When in use, the arm unfolds and includes injectors to
inject fluids, such as air and/or liquids to clean the surface of
the dish. The arm may include water injectors followed by drying
air injectors, such as air knife. The system may include waste
liquid collection system, such as a gutter and reservoir.
Inventors: |
Shelef; Ben; (Saratoga,
CA) ; Erez; Shmuel; (San Jose, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Shelef; Ben
Erez; Shmuel |
Saratoga
San Jose |
CA
CA |
US
US |
|
|
Family ID: |
53481277 |
Appl. No.: |
14/574360 |
Filed: |
December 17, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13086315 |
Apr 13, 2011 |
9006560 |
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14574360 |
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61432584 |
Jan 14, 2011 |
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61407911 |
Oct 29, 2010 |
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61370755 |
Aug 4, 2010 |
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61351946 |
Jun 7, 2010 |
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61334560 |
May 13, 2010 |
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61323857 |
Apr 13, 2010 |
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61917252 |
Dec 17, 2013 |
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Current U.S.
Class: |
134/99.1 ;
134/172; 134/198 |
Current CPC
Class: |
F24S 2023/874 20180501;
Y02E 10/47 20130101; F24S 25/10 20180501; H01L 31/0547 20141201;
F24S 25/00 20180501; F24S 40/20 20180501; F24S 20/20 20180501; F24S
23/71 20180501; Y02E 10/52 20130101 |
International
Class: |
F24J 2/46 20060101
F24J002/46 |
Claims
1. A system for cleaning a reflector dish, the reflector dish
having a base support, the system comprising: an assembly coupled
to the base support; at least one foldable arm configured to assume
a folded position when not in use and an unfolded position for
cleaning; a fluid conduit coupled to the foldable arm and
delivering fluids to be injected by the arm onto the reflector dish
when the arm assumes its unfolded position.
2. The system of claim 1, wherein the assembly is rotatably coupled
to the base support.
3. The system of claim 2, further comprising a motor positioned to
rotate the assembly about the base.
4. The system of claim 3, wherein the motor is energized by fluid
flow.
5. The system of claim 1, wherein the foldable arms comprise a
flexible house and a spring.
6. The system of claim 5, wherein the hose is configured to assume
a flat shape when no fluid flows through the hose.
7. The system of claim 6, wherein the spring comprises a flat
spring inserted inside the hose.
8. The system of claim 7, wherein the spring is configured to have
a spring constant to impart sufficient curling force to fold the
hose when no fluid pressure is in the hose, but to yield to fluid
pressure to unfold the hose.
9. The system of claim 1, further comprising a gutter configured
for collecting fluids sprayed on the reflector dish.
10. The system of claim 9, further comprising a plurality of
reservoirs and a manifold coupled to the gutter, the manifold
having a plurality of outputs, each configured for delivering
fluids from the gutter to one of the plurality of reservoirs.
11. The system of claim 1, further comprising air pressure system
configured for delivering air pressure into the foldable arm.
12. The system of claim 1, wherein the assembly is freely-rotatable
coupled to the base support and wherein the arm comprises fluid
injectors positioned so as to impart rotational motion to the
assembly when injecting fluid.
13. The system of claim 1, wherein the arm comprises air injectors
configured to generate air knife to dry the reflector dish.
14. The system of claim 1, wherein the arm is rotatably coupled to
the assembly.
15. The system of claim 1, wherein the arm comprises liquid
injectors at a leading edge thereof and air injectors at the
trailing edge thereof.
16. The system of claim 1, further comprising: a liquid reservoir,
a pressure conduit coupled to deliver liquid from the liquid
reservoir to the art, and a pressure pump configured to pump liquid
from the reservoir into the pressure conduit.
17. The system of claim 1, further comprising a plurality of
injectors provided on the arm and configured such that collective
injection front of the plurality of injectors follows curvature of
the dish surface.
18. The system of claim 1, further comprising a plurality injectors
provided on the arm and configured such that separation distance
between surface of the dish to outlet of each injector is the same
for all of the plurality of injectors.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional
Patent Application No. 61/917,252, filed on Dec. 17, 2013. This
application is also a continuation-in-part of U.S. patent
application Ser. No. 13/086,315, filed on Apr. 13, 2011, which
claims priority from U.S. Provisional Patent Application No.
61/323,857 filed on Apr. 13, 2010; 61/334,560 filed on May 13,
2010; 61/351,946 filed on Jun. 7, 2010; 61/370,755 filed on Aug. 4,
2010; 61/407,911 filed on Oct. 29, 2010; 61/432,584 filed on Jan.
14, 2011; the entireties of all of which are incorporated herein by
reference.
FIELD
[0002] The present application belongs to the field of solar energy
systems.
BACKGROUND
Context
[0003] Concentrated solar power (CSP) systems are ones that
concentrate incoming solar light before converting it into useful
power. The conversion itself can be photovoltaic or thermal, but
the common theme is that it is cheaper to collect the light over a
large area and into a small power conversion unit (PCU) than it is
to build a large power converter.
[0004] There are several methods to concentrate solar power,
including lenses, sun-tracking parabolic dish reflectors that
position the PCU at the focus of a paraboloid, and central tower
systems in which a large number of principally flat tracking
mirrors direct the sun onto the top of a tower where the PCU is
housed.
[0005] In the case of dish reflectors, the PCU is part of the
moving structure since it has to be kept at the focal point of the
dish as it tracks the sun. Additionally, since dish reflectors are
typically large, they themselves are comprised of smaller
reflectors held rigidly together to form the complete optical
surface. Typically, these smaller reflectors need to be aligned
relative to the dish structure during assembly in the field. Dish
reflectors can use photovoltaic (PV) PCUs, Stirling engines,
turbines, or heat collectors and steam generators.
State of the Art
[0006] FIG. 1 shows a conventional solar thermal dish design
(manufactured by Stirling Energy Systems of Arizona) containing a
thermal PCU [10] connected to a dish through a boom [11] (or
balance beam), which connects to pivot actuation machinery [12]
that is mounted on a pole (also called a pedestal) [13]. The dish
and PCU [10] are roughly balanced via the boom [11] with respect to
the pedestal [13], reducing the gravity loads on the actuation
machinery [12]. The dish is comprised of a carrier truss [14] and
reflector tiles [15]. Because of the balance-beam design, such
dishes must have a slice [16] cut into them to prevent the pedestal
[13] from hitting the dish when it points upwards. The shape of the
reflector surface of the dish (made up of the sum of the reflector
surfaces of the tiles [15]) is approximately a paraboloid (a
parabolic arc revolved around its optical axis) and the aperture of
the PCU [10] is located at the focal point of the paraboloid. The
pivot actuation machinery [12] is controlled by a sun-tracker that
keeps the optical axis of the dish pointed at the sun.
[0007] The reflector tiles [15] themselves are made from thin glass
which is warped elastically over a metallic shell and bonded to it.
In other systems, thick glass is hot-formed and plastically
deformed into the desired shape. In other systems, the thin glass
is replaced with a thin Aluminum or Steel sheet with a reflective
coating.
[0008] FIG. 2 shows a schematic of a Stirling engine PCU, which is
a type of a thermal engine. (In FIG. 1, the PCU was denoted as item
10). Like all thermal engines, this PCU has a hot side [20] and a
cold side [21]. The hot side [20] is illuminated by the light
reflected from the dish and is traditionally mounted facing it and
closest to it. The cold side [21] is therefore traditionally
mounted further away from the dish, towards the sun. The cold side
[21] is connected to a heat exchanger [22] which rejects heat into
the environment and keeps its temperature from rising. An electric
generator [23] is powered by the engine and mechanically coupled to
it. In most thermal designs, both the heat exchanger [22] and the
generator [23] are part of the PCU package [10]. It is the high
weight of thermal PCUs that traditionally dictates the balance-beam
design for the dish.
[0009] FIG. 3 shows a conventional dish-based photovoltaic system
(manufactured by Solar Systems of Australia). Since photovoltaic
PCUs are lighter than thermal PCUs, the system does not use a
balance beam, and instead the PCU [30] is connected to the dish via
a focal support structure [31]. The dish, in turn, is directly
connected to the actuation machinery [hidden] and pedestal [32].
The dish is comprised of a carrier truss [33] and reflective tiles
[34], same as in the solar thermal dish and the shape of the
optical surface of the primary dish is similarly a piece-wise
segmented paraboloid. In a PV system, there is no generator, but
there is still a need for a heat exchanger, since the PV cells need
to be kept cold. In many PV dishes, the heat exchanger is located
on the ground and coolant is piped between it and the PCU [30].
[0010] The optical area of both dishes shown above is about 100
m.sup.2. In the PV dish, the concentration factor is about 1000,
the area of the aperture of the receiver is 0.1 m.sup.2, and it is
built from approximately 1000 PV cells, each only 1 cm on a side,
arranged in a "dense array" roughly 30 cm across (shown
schematically in FIGS. 4b, 44). Since PV cells produce low voltage
(.about.3V), and since the output voltage of the dish must be high
(100 --600 V) to keep the current manageable, many of the cells
need to be wired in series, a process known as "stringing". Cells
on the same string must produce the same amount of current or else
the efficiency of the string drops due cell current mismatch, known
as a "stringing losses".
[0011] FIG. 4a shows a single photovoltaic cell. The cell has an
active area [41] covered with thin conductive lines known as the
collection grid [42] that leads to two side contacts [43] commonly
known as bus bars. The two bus bars [43] correspond to the "plus"
side of the photovoltaic junction, and the back surface of the cell
corresponds to the "minus" side. The grid lines [42] are created by
metallic deposition and are made tall and thin to minimize shading,
but still produce significant shading for light that is arriving at
a shallow angle relative to the front surface of the cell. Cells
designed for high concentration are typically made by depositing
multiple layers of semiconductor materials on a Germanium
substrate, but other technologies are equally relevant to this
invention. Such "multi-junction" cells are made by companies such
as Spectrolab, Emcore, and Solar Junction.
[0012] In traditional dish systems, the carrier truss is
non-adjustable and is assembled in the field to the best practical
precision. The truss is then placed on top of the pedestal, and the
reflector tiles are assembled onto it using adjustable mating
mechanisms--typically three adjustment screws at the back of each
tile that connect to three points on the truss. At this stage,
using an optical reference (e.g. pointing at the moon, or a laser
system that bounces off of the reflector tiles) the orientation of
each reflector tile is adjusted by turning the screws until it is
properly aligned relative to the focal point.
Deficiencies in Existing Art
[0013] The "truss and glass" dish architecture described above is
performance limited due to several factors.
[0014] Typical truss-based primary mirror designs weigh around 50
kg/m.sup.2, and their assembly and alignment in the field is very
time consuming, taking more than a day for the 100 m.sup.2
reflector described above.
[0015] The truss is made from a very large number of members, which
have to be bolted, riveted, or welded together, in the field. The
large part count introduces tolerance stack-up errors, and the
large number of joints are all sources of stress concentration,
fatigue, and structural creep.
[0016] The tile alignment process requires bringing each tile into
the correct orientation by tweaking three screws on its back side.
The required tolerance is 1 mRad or tighter, and for 100 tiles
there are 300 such screws. The person doing the tweaking cannot see
the reflection from the tile, and so needs to receive the
information from someone else. If the structure creeps over time,
alignment has to be re-done. If tiles need to be replaced, they
need to be re-aligned--all requiring highly-trained manpower.
[0017] The heavy weight of the dish and in particular its large
moment of inertia makes precise tracking difficult, and either
increases the cost of the actuation machinery or reduced tracking
accuracy, which results in reduced output. In boom-based designs,
the mass is distributed in a dumbbell-like way, which is the worst
case in terms of rotational moment of inertia, which makes tracking
more difficult. Boom flexing adds another oscillation mode and
further complicates alignment and tracking Stiffening the boom adds
mass to the system. The slice that has to be cut in the dish
reduces the optical area, reduces its rigidity, and degrades
optical accuracy.
[0018] The optical surface precision of the reflector tiles is also
lacking in practice, due to the shell/glass structure having
insufficient precision. This problem can be solved with "brute
force" precision optical processes such as glass grinding, but in
solar power design, cost and fabrication speed are major design
considerations, and those processes are prohibitive.
[0019] Finally, optical performance is hindered by accumulated dust
and dirt on the optical surfaces. Cleaning frequency is limited
since it requires extensive manpower, and since it wastes large
quantities of water.
[0020] Dense array photovoltaic receivers also suffer from several
performance issues:
[0021] Thermal: The temperature of the PV cells has to be kept
low-typically less than 100 C to prevent failure, but preferably
near 30 C to prevent performance losses and lifetime issues. The
receiver therefore has to reject the generated heat, and at
1000.times. illumination and with tightly packed PV cells this is a
difficult problem, since there is very little area the cells can
reject heat into.
[0022] Optical: Any lit area covered with the wires or traces used
to collect the electricity from the front surface of the cells plus
any gaps between the cells, do not produce electricity and thus
lead to a corresponding loss in efficiency. Since the cells are
small and the current densities large, these effects are much more
significant than in non-concentrating PV cells.
[0023] Electrical: The above constraints motivate the use of very
thin conductors, which create Ohmic losses and wasted power in the
conductor network.
[0024] Uniformity: In the dense array receiver, the cells near the
edge of the array receive more cooling and less illumination than
those near its center. The non-uniform illumination stems from
several reasons, all ultimately stemming from the imaging nature of
the paraboloid optics. (In an imaging optical system, if for
example one side of the sun is blocked by a cloud, then half the
receiver correspondingly goes dark, whereas in a perfect
non-imaging optical system, the entire receiver becomes uniformly
half-lit.)
[0025] First, the sun is not a uniform source but rather a Gaussian
one. Second, the image on the receiver is the sum of many images
from the various reflector panels, and since they each have
independent deviations, the statistical sum is brightest at their
nominal aiming point. Finally, tracking errors move the sun away
from the center of the image, so the point of peak illumination
moves around and does not coincide with the center of the receiver,
thus requiring the field of view of the receiver to extend around
the nominal position of the sun and resulting in an image that is
even darker in its periphery.
[0026] These effects create a large variance in the electricity
production level of the cells, and so result in stringing losses.
It is not uncommon for a receiver that uses 40% efficient PV cells
to provide only 25% efficiency at the system level.
Other Art
[0027] Many solar system designs have been proposed and implemented
over the years. The challenge in them is not simply to make
electricity from solar light, but to do so in a way that has
acceptable cost, construction time, efficiency, longevity, and
environmental impact.
[0028] Other PV dish systems were developed by companies such as
Solar Systems of Australia and Zenith Solar of Israel.
[0029] Other Thermal dish-based systems were developed commercially
by companies such as Stirling Energy Systems of AZ, Infinia
Corporation of WA, and Southwest Solar of AZ, and HeliFocus of
Isreal.
[0030] There have been many designs proposed for improving on the
truss based design, ranging from flexible structures (e.g. U.S.
Pat. No. 4,056,309) to inflatable structures (e.g. U.S. Pat. No.
4,432,342) and even vacuum-pulled membranes (e.g. U.S. Pat. No.
4,352,112). Commercial companies that design dishes include
Schlaich Bergermann Solar of Germany.
SUMMARY
[0031] The following summary of the invention is included in order
to provide a basic understanding of some aspects and features of
the invention. This summary is not an extensive overview of the
invention and as such it is not intended to particularly identify
key or critical elements of the invention or to delineate the scope
of the invention. Its sole purpose is to present some concepts of
the invention in a simplified form as a prelude to the more
detailed description that is presented below.
[0032] The invention described herein is a dish-based solar power
generation system that has several novel features whose utility is
to reduce or eliminate the problems outlined above. While each of
these features provides independent benefits and can be utilized
alone or in combination with other features to enhance prior art
systems, they can be made to work in concert with each other to
provide a complete system, and so they are described jointly in
this specification.
[0033] The primary reflector structure is based on a unique
spoke-wheel-like tensile carrier structure that is very
lightweight, has a low moment of inertia, high strength and
stiffness, and allows for rapid field alignment during assembly.
Reflector tiles are mounted to it to create the complete primary
reflector.
[0034] In various embodiments of this invention, opposite to the
way customary dishes are built, it is the carrier structure that is
the entity aligned to form, and the reflector tiles are fixed to it
in a non-adjustable way. A very important feature of this structure
is that the alignment procedure is based on its geometry and does
not rely on its optics, which allows the creation of any revolved
optical shape, not just a paraboloid. The structure is named the
Alignable Carrier Structure, or ACS.
[0035] Additionally, in embodiments of this invention the primary
structure has a central rigid hub which is concentric to the axis
of revolution and supports the functioning of several other system
components. Like a bicycle wheel, the structure has adjustable
tensioners between the spokes and the rim, but in this invention
the tensioners are implemented in a kinematic way to enhance
precision. The rim is comprised of many individual straight
segments, and each tensioner has four lines of force (two spokes
and two rim segments) that cross each other at a single point.
[0036] According to embodiments of the invention, the reflectors
that complete the dish structure, which in this application are
called reflector tiles or panels, are constructed using a unique
method based on a special vacuum-formed core that yields very rigid
and lightweight bodies, which can have any arbitrary continuous
optical shape. The reflector tiles can use any thin reflector
material as their front surface.
[0037] According to embodiments of the invention, the reflector
structure and reflector panels work in concert to achieve several
other advantages. The tiles attach to the primary structure from
the back side, which allows them to be replaced without
interference with the rest of the dish, without placing people
inside the optical path, and without requiring subsequent
re-alignment.
[0038] Additionally, according to embodiments of the invention, the
primary structure determines the position of the front surface of
the tiles which enhances the precision of the formed surface. The
composite front surface created is continuous, and so allows for
collection of the water used while washing the mirror. The central
hub is used to support a built-in rotating washing arm so that the
washing process is autonomous.
[0039] Being rigid and coaxial to the optical axis, the front side
of the hub may also be used as the anchor point for a kinematic
hexapod used to position the secondary optic or PCU. At the front
end of the hexapod a precision mechanical mount (called "the
fiduciary") may be attached and may be used to co-locate the PCU, a
laser guide used to guide and test the alignment of the primary
reflector, and an optical tracker used for solar tracking By having
all three of these components attach to essentially the same
mechanical interface, precision is further enhanced.
[0040] In a photovoltaic embodiment of the invention, the shape of
the primary optical reflector surface is not a regular paraboloid
as is customarily used, but rather a revolved shape around an axis
of revolution (also sometimes called axis of rotation) with a
generatrix in the shape of a parabola whose optical axis is
parallel but radially offset from the axis of revolution. In this
application, this shape is called an offset paraboloid (OP). An OP
is naturally constructed with a hole in its center with a radius at
least as large as the offset between the optical axis and the axis
of revolution.
[0041] The offset paraboloid structure creates a novel narrow ring
shaped optical form that has several advantages for a PV
receiver.
[0042] In a traditional "dense array" PV dish receiver the PV cells
are packed into a 2-dimensional array that is placed at the focal
point. This creates differentiation between the cells near the
center of the array and those near its edges, with the central
cells getting more illumination and less cooling. This
non-uniformity is further enhanced due to tracking inaccuracies, as
the image of the dish shifts relative to the receiver. Since the
cells need to subsequently be stringed into a larger electrical
circuit, this non-uniformity creates a large drop in overall
receiver efficiency.
[0043] Embodiments of the invention provide a ringed receiver. In
the ringed receiver, all the cells are geometrically equivalent,
and so receive the same amount of illumination and cooling.
Additionally, since the ring is essentially a 1-dimensional array
of cells, the radial dimension is free to be uses for cooling and
electrical connection routing, two tasks which are very difficult
in a two-dimensional array.
[0044] Since each point in the ringed receiver sees its
corresponding portion of the offset paraboloid dish with a narrow
field of view, a ringed secondary optical element (SOE) can be used
to further increase the level of concentration and uniformity of
the received light. Several such SOEs are described.
[0045] Several cooling methods are described, including using a
conductive heat sink and forced air flow, using a pumped
vapor-chamber and a separate condenser, and using liquid
coolant.
[0046] The effect of a tracking error on the ringed receiver is
always a predictable non-uniformity illumination pattern, with
minimum and maximum illumination occurring on diametrically opposed
points, along the direction of the tracking error (which is itself
not known), and illumination varying smoothly between the minimum
to maximum points. Taking advantage of this predictability, in
order to reduce stringing losses, the cells are divided into
several interleaved groups referred to as circuits, with each
circuit having cells distributed essentially uniformly around the
ring. Each circuit is wired internally in parallel so in and of
itself can accommodate non-uniform illumination. However, since the
interleaved circuits are affected in a similar way by this
non-uniform illumination effect, the circuits can then be wired in
series and only incur minimal stringing losses. The output from the
individual cells of any of the circuits is also used as the sensor
for providing feedback to the closed-loop tracking system.
[0047] The features just described work in concert to eliminate the
problems outlined in the background portion of this specification.
For example, the electrical interleaving and cooling method are
benefitted by the ring geometry of the receiver, which is itself
benefitted by a practical non-paraboloid dish, which is itself
benefitted by a non-optical alignment method.
[0048] Some of the design features outlined above have utility
outside the scope of a ring-optics photovoltaic dish system. For
example, the ACS in combination with the reflector tiles can create
any optics of revolution, including a traditional parabolic dish,
and thus can be used with other PCU technologies such as thermal
PCUs. The reflector tile technology by itself can create reflective
optical bodies for other geometries such as for parabolic troughs
or rigid heliostats. The ACS can be used for any lightweight
approximately round reflector such as a stretched membrane
heliostat reflector, or even for non-reflective surface such as
thin film solar panels.
[0049] In addition, the ACS is useful when constructing a
non-optical receiver or transmitter such as a direction RF antenna,
where the reflective surfaces reflect longer wavelength EM
radiation, often not for the purpose of producing power but for
signal communication.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The accompanying drawings, which are incorporated in and
constitute a part of this specification, exemplify the embodiments
of the present invention and, together with the description, serve
to explain and illustrate principles of the invention. The drawings
are intended to illustrate major features of the exemplary
embodiments in a diagrammatic manner. The drawings are not intended
to depict every feature of actual embodiments nor relative
dimensions of the depicted elements, and are not drawn to
scale.
[0051] FIG. 1: Prior art--Traditional solar thermal dish with
payload boom
[0052] FIG. 2: Prior art--Schematic of a Stirling engine
[0053] FIG. 3: Prior art--Traditional photovoltaic dish
receiver
[0054] FIGS. 4A-4B: Prior art--Dense array photovoltaic receiver
and cell
[0055] FIG. 5: Prior art--tensile torque bearing spoked bicycle
wheel
[0056] FIG. 6: System overview--Dish system with solar thermal
receiver according to an embodiment of the invention
[0057] FIG. 7: System overview--Dish system with solar thermal
receiver optical path according to an embodiment of the
invention
[0058] FIG. 8: System overview--Offset paraboloid with ring
photovoltaic receiver according to an embodiment of the
invention
[0059] FIG. 9: System overview--Offset paraboloid with ring PV
receiver optical path according to an embodiment of the
invention
[0060] FIG. 10: Carrier--Tensile spoked wheel carrier structure
according to an embodiment of the invention
[0061] FIGS. 11A-11C: Carrier--Rim and kinematic tensioner node
design according to an embodiment of the invention
[0062] FIG. 12: Carrier--Rib, alignment guide ruler, and tile
interface according to an embodiment of the invention
[0063] FIG. 13: Carrier--Assembly unit according to an embodiment
of the invention
[0064] FIG. 14: Carrier--Hub design with hexapod and fiduciary
plate, actuated according to an embodiment of the invention
[0065] FIG. 15: Carrier--Laser alignment guide according to an
embodiment of the invention
[0066] FIG. 16: Carrier--Fiduciary reference plate with three
spheres according to an embodiment of the invention
[0067] FIGS. 17A-17C: Reflector tile--Core and fabrication
according to an embodiment of the invention
[0068] FIGS. 18A-18E: Reflector tile--Structure and fastening
according to an embodiment of the invention
[0069] FIGS. 19A-19C: Reflector tile--Core rib patterns according
to an embodiment of the invention
[0070] FIG. 20: Reflector tile--Plastic print pattern according to
an embodiment of the invention
[0071] FIGS. 21A-21C: Reflector tile--Sheet metal core according to
an embodiment of the invention
[0072] FIG. 22: Dish--Hub mounted cleaning arm according to an
embodiment of the the invention
[0073] FIG. 23: Dish--Hub mounted condenser/heat exchanger
according to an embodiment of the invention
[0074] FIG. 24: Thermal receiver--Hexapod mount according to an
embodiment of the invention
[0075] FIG. 25: Ring receiver--Cell placement according to an
embodiment of the invention
[0076] FIG. 26: Ring receiver--Interleaved cell circuit according
to an embodiment of the invention
[0077] FIG. 27: Ring receiver--Ring receiver with pumped vapor
chamber according to an embodiment of the invention
[0078] FIG. 28: Ring receiver--Ring receiver in context of ACS
according to an embodiment of the invention
[0079] FIG. 29: Ring receiver--Ring receiver with convective
cooling according to an embodiment of the invention
[0080] FIG. 30: Ring receiver--Ring receiver with air-cooled heat
sink according to an embodiment of the invention
[0081] FIGS. 31A-31B: Carrier--Flat reflector for heliostats
according to an embodiment of the invention
[0082] FIG. 32: Carrier--ACS with stretched membrane design
according to an embodiment of the invention
[0083] FIG. 33: Carrier--The ACS with vertical band spokes
according to an embodiment of the invention
[0084] FIG. 34: Carrier--The ACS with horizontal band spokes
according to an embodiment of the invention
[0085] FIG. 35: Carrier--Rim-based tensioner node according to an
embodiment of the invention
[0086] FIG. 36: Carrier--Hub-based tensioner according to an
embodiment of the invention
[0087] FIG. 37: Prior Art--A honeycomb core composite panel
[0088] FIG. 38: Prior Art--A compound Parabolic Concentrator
(CPC)
[0089] FIG. 39: Carrier--ACS with conical hub according to an
embodiment of the invention
[0090] FIGS. 40A-40C: Deployment mechanism, wrapped states
according to an embodiment of the invention
[0091] FIGS. 41A-41B: Deployment mechanism, unwrapped state
according to an embodiment of the invention
[0092] FIG. 42: Deployment mechanism, deployed state according to
an embodiment of the invention
[0093] FIG. 43: Deployment mechanism, ACS with ribs according to an
embodiment of the invention
[0094] FIG. 44: Hub tensioners, with radial attachment bands
according to an embodiment of the invention
[0095] FIG. 45: Hub tensioners, with no radial attachment bands
according to an embodiment of the invention
[0096] FIG. 46: Hub tensioners, showing both crowns according to an
embodiment of the invention
[0097] FIG. 47: Rim-side non-adjustable connection node according
to an embodiment of the invention
[0098] FIG. 48: Band spoke according to an embodiment of the
invention
[0099] FIG. 49: Band spoke with rim-side non-adjustable connection
node according to an embodiment of the invention
[0100] FIG. 50: Slotted CPC secondary optical element with PV ring
according to an embodiment of the invention
[0101] FIG. 51: Slotted CPC secondary optical element transparent
view according to an embodiment of the invention
[0102] FIG. 52: Circular walker single arm according to an
embodiment of the invention
[0103] FIG. 53: Circular walker multiple arms flexure according to
an embodiment of the invention
[0104] FIG. 54: Circular walker multiple arms hub according to an
embodiment of the invention
[0105] FIG. 55: Circular walker one arm according to an embodiment
of the invention
[0106] FIG. 56: Flower receiver circular according to an embodiment
of the invention
[0107] FIG. 57: Flower receiver single tile according to an
embodiment of the invention
[0108] FIG. 58: Automatic washing apparatus--deployed according to
an embodiment of the invention
[0109] FIG. 59: Automatic washing apparatus--operating according to
an embodiment of the invention
[0110] FIG. 60: Automatic washing apparatus--tube cross section
according to an embodiment of the invention
[0111] FIG. 61: Automatic washing apparatus--linked arm according
to an embodiment of the invention
[0112] FIG. 62: Automatic washing apparatus--linked arm and water
processing according to an embodiment of the invention
[0113] FIG. 63: Focal Plane Flux Sensor--front according to an
embodiment of the invention
[0114] FIG. 64: Focal Plane Flux Sensor--back according to an
embodiment of the invention
[0115] FIGS. 65 and 66 show an embodiment of the cleaning system of
the invention.
[0116] FIG. 67: Hexapod hub according to an embodiment of the
invention
DETAILED DESCRIPTION
[System Level and Optical Path]
[0117] FIG. 6 shows an embodiment of this invention using a solar
thermal PCU. The system is comprised of a pedestal [60], pivot
actuation machinery [66] at the top of the pedestal, a dish
reflector [61], a hexapod mount [62], a thermal PCU [63] having a
hot end [64], and a heat exchanger [65]. In this embodiment the hot
end is shown surrounded by heat absorbing coils in which the
thermodynamic fluid flows, but in other embodiments the heat can be
transferred directly through the wall of the hot end.
[0118] Note that in this embodiment the thermal engine is oriented
so that its hot end is away from the dish (opposite to the
conventional mounting scheme), and the light illuminates its entire
perimeter, transferring heat inwards. The structure of the dish is
discussed further below under the sections "Alignable Carrier
Structure" (ACS) and "Reflective Tiles", and the placement and
structure of the Thermal PCU is discussed under the section
"Thermal PCU"
[0119] The role of the pedestal [60] and actuation machinery [66]
is to ensure that the dish reflector [61] is correctly pointing
into the sun and tracking it. The role of the dish reflector [61]
is to concentrate the solar light towards its focal point. The role
of the hexapod [62] is to position the hot end [64] of the PCU [63]
at the focal point. The role of the PCU [63] is to convert the
light into electricity. The role of the heat exchanger [65] is to
cool the cold end of the PCU [63] by exchanging heat with the
environment. These roles are largely the same as in a traditional
dish-based system.
[0120] FIG. 7 shows the optical path of this embodiment in a
meridian cross-section. (one that passes through the center axis of
revolution [79]). At each such cross-section, incoming solar light
[70] is reflected off of the primary reflector parabolic arc [71]
and focused into a focal point [72] which lies on the optical axis
of the arc. Since in a paraboloid the optical axis of the
generatrix parabolic arc and the center axis of revolution are one
and the same, the focal points of all the arcs in the revolved
shape coincide and become the single focal point of the paraboloid.
The focal point lies inside the hot end [73] of the thermal engine
[74]. Roughly speaking, the acceptance full-angle [76] of the
system is equal to the length of the hot end [73] of the engine
[74] divided by the mean distance from it to the parabolic arc
[71]. The heat engine was labeled as [63] in FIG. 6
[0121] FIG. 8 shows an embodiment of this invention using a
photovoltaic PCU. The system is comprised of a pedestal [80], pivot
actuation machinery [86] at the top of the pedestal, a reflector
dish [81], a hexapod mount [82], a photovoltaic PCU [83], and a
heat exchanger [84]. The structure of the dish is discussed further
below under the sections "Alignable Carrier Structure" (ACS) and
"Reflective Tiles". The placement and structure of the PV PCU is
discussed under the section "PV PCU".
[0122] The role of the pedestal [80] and actuation machinery [86]
is to ensure that the dish reflector [81] is correctly pointing
into the sun and tracking it, the role of the dish reflector [81]
is to concentrate the solar light towards the PCU [83]. The role of
the hexapod [82] is to position the PCU [83] correctly in relation
to the dish reflector [81], and the role of the PCU [83] is to
convert the light into electricity. These roles are the same as in
a traditional dish-based system.
[0123] In this embodiment of the invention, the shape of the
primary optical reflector [81] surface is not a regular paraboloid
as is customarily used, but rather a revolved shape with a
generatrix in the shape of a parabola whose optical axis is
parallel but offset in the radial direction from the axis of
revolution of the dish. In this application, this shape is called
an offset paraboloid and abbreviated as OP.
[0124] FIG. 9 shows the optical path of this embodiment, in a
meridian cross-section, showing the axis of revolution [99] of the
dish [81]. At each such cross-section, incoming solar light [90] is
reflected off of the primary reflector parabolic arc [91] and
focused into a focal point [92] which lies on the optical axis [98]
of the arc. Thus, light reflected from the complete revolved dish
[81] is focused into a ring [97], rather than into a single focal
point. A secondary optical element [93] (SOE) has a cross section
that is also revolved around the axis of revolution [99] of the
dish [81] and has an aperture [94] that encompasses the focal ring
[97], further concentrating the light and homogenizing it before
directing it to the PV cells [95] that are appropriately arranged
in their own ring shape. Thus, light reflected from dish [81] is
concentrated onto the ring of PV cells [95]. The surfaces of the
SOE [93] as well as the active PV surface of the cells [95] are
also surfaces of revolution or close approximation thereof. Roughly
speaking, the acceptance full-angle [96] of the system is equal to
the width of the aperture [94] of the SOE [93] divided by the mean
distance from it to the parabolic arc.
[0125] It is important to note that unlike in a paraboloid dish
where the individual focal points of each parabolic arc in a
meridian plane coincide into a unique focal point of the entire
paraboloid, in an OP the individual focal points do not coincide
but rather form a ring. In this embodiment, the ringed shape of the
PV PCU [83] matches the ringed focal shape of the focal region of
the OP dish [81].
[0126] In the conventional paraboloid optical path shown in FIG. 7
all of the focal points coincide, and the optical path is called
"imaging", which means that for a non-point light source such as
the sun, the light forms an image of the sun around the focal
point. So for example if the sun has a sun spot or is partially
obscured by a passing airplane or cloud, there will be a drop in
intensity in the corresponding spot in the image. This property is
detrimental for photovoltaic receivers since it only affects some
of their cells, resulting in stringing losses as described above.
The concentration level achieved by the conventional paraboloid
dish is equal to the square of the concentration achieved by the
parabolic arc of the concentrator. Thus if in a meridian cross
section the parabolic arc achieves a concentration factor of 30,
then the paraboloid dish will achieve a concentration factor of
30.sup.2=900.
[0127] In contrast, the offset paraboloid (OP) optical path
described in FIG. 9, the focal points of the parabolic arcs do not
coincide but rather form a ring. This means that if the sun is
similarly partially obscured, the corresponding localized drop in
intensity is repeated an infinite number of times around the ring,
and so is naturally "smeared" across the entire receiver. This is
highly advantageous for a photovoltaic receiver. In addition the
concentration achieved by the OP dish is comprised of three
factors: The concentration achieved by the parabolic arc in the
meridian plane, the added concentration achieved by the secondary
optical element, also in the meridian plane, and finally the
"radial squeezing" concentration that results from the fact that
the circumference of the receiver ring is significantly smaller
than the mean circumference of the OP dish. For example, if the if
the parabolic arc achieves a concentration factor of 30, and the
SOE achieves a concentration factor of 3, and the radial squeeze
concentration factor is 9, the total concentration of the OP dish
is 30.times.3.times.9=810. It is possible to trade off these
concentration levels. For example, if the SOE is eliminated
completely, but the diameter of the receiver ring is reduced by a
factor of 3 thus increasing the radial squeeze concentration factor
from 9 to 27, then the total concentration of the SOE-less OP dish
remains the same as 30.times.1.times.27=810. The SOE has other
advantages such as further homogenization of the light but in
general the optical design can be tweaked by using less aggressive
or even completely eliminating the SOE.
[0128] In both types of dishes described above, the focal length of
the parabolic arc in the generatrix plays an important role, since
it determines the length of the physical structure that positions
the PCU there. The focal distance is often stated as a multiple of
the dish diameter, known as the focal ratio (f/d). Commonly used
focal ratios in parabolic dishes are between 0.5 and 1.5 of the
diameter of the dish. Longer focal lengths make it difficult to
maintain the position of the PCU accurately. In addition, longer
focal lengths mean that the image of the sun has more distance to
diverge, and so the level of possible concentration drops. Shorter
focal lengths mean that the PCU sees the dish with a wider apparent
angle, and so is illuminated over a large arc of itself.
Additionally, short focal length dishes have more steeply inclined
surfaces, and are so less efficient in their use of reflector
material. Thus an f/D ratio of 0.5 to 1.5 is a good design choice
for dish systems. For non-round or polygonal rims, the mean
diameter, or the perimeter/pi, is used as an approximation for a
true diameter.
[0129] In heliostats applications (discussed later) the PCU resides
on a separate immobile structure and is shared by many reflectors.
In such applications, larger f/D ratio, typically over 5, are used,
and the reflectors are very close to being flat. Since the
direction of illumination in Heliostat systems varies throughout
the day, and since the desired concave shape is so close to flat,
the precise shape of the reflector is less important and the
concavity is often stated as the ratio of the depth of the mirror
surface to its diameter, typically no more than a few cm per m.
[0130] As described further below, these components work in concert
to eliminate or reduce all of the problems that plague
state-of-the-art photovoltaic dish reflectors systems, as
enumerated in the background section of this specification. Some of
these components have further utility for other types of dish
systems, and for other types of solar systems.
[Nomenclature]
[0131] When describing geometries of revolution, there is always a
unique axis of revolution, and any plane that contains the axis of
revolution is referred to as a "meridian plane", and the two
principal directions of the plane are the axial and radial
directions. The local circumferential direction is perpendicular to
a meridian plane. The shape in a meridian plane that creates the
geometry of revolution is called a generatrix. A surface is
considered to be a surface of revolution even if it is only partial
to a complete surface or revolution spanning a complete revolution
of the generatrix about the axis of revolution.
[0132] A paraboloid is a surface of revolution created by a
generatrix whose shape is a parabolic arc whose axis coincides with
the axis of revolution.
[0133] In this specification, an offset paraboloid (OP) is the
surface of revolution created from a generatrix whose shape is a
parabolic arc [91] whose optical axis [98] is parallel to and
offset radially from the axis of revolution [99]. For example, in
the embodiment shown in FIG. 8 and whose meridian plane description
is shown in FIG. 9, the optical surface of the dish reflector [81]
is an OP, and the aperture [92] of the PCU is a conical ring whose
radius is approximately equal to the offset of the axis of the
generatrix of the OP. The optical axis of the entire revolved dish
is the axis of revolution.
[0134] The angle of acceptance in solar systems is the angle by
which light rays can deviate from the nominal direction (parallel
to the optical axis of the dish) and still be directed into the
aperture of the PCU. In this application the "full angle" is used,
which is the angle between the two most extreme light rays that
still get directed into the aperture. (as opposed to the "half
angle", which is the angle between the nominal ray and an extreme
ray. Depending on the symmetricity of the optical path, the full
angle value is typically twice that of the half angle value.
[0135] In this specification, when describing portions of the
system, the direction towards the sunlight is labeled "front", with
associated descriptors such as "in front". Similarly, the opposite
direction is labeled "back". Note that inside the solar receiver,
which is typically mounted facing towards the primary reflector,
the "front" end is the one closer to the primary reflector.
[0136] In this application, the term Photovoltaic (abbreviated PV)
device refers to any device that converts light into electricity
directly without relying on first converting the light into heat.
The prevalent photovoltaic technologies today belong to the group
of semiconductor band-gap materials, but other direct conversion
methods such as optical rectennas or advanced quantum phenomena
such as quantum dots are also considered as photovoltaic in this
application. These technologies stand in contrast to thermodynamic
technologies that use solar light to heat up a working medium, and
then generate power from this heat without reliance on the source
of the heat. Some proposed photovoltaic technologies operate at
elevated temperatures, but they do not make use of that temperature
to produce power, since simply heating them up without exposing
them to light will not create any power.
[0137] In this application the term power conversion unit (PCU)
refers to the device that converts solar light into electricity. A
PCU can be photovoltaic, thermal, or employ a yet-unclassified
technology.
[0138] In this application, the term UTS is used in its common
capacity to denote Ultimate Tensile Strength for a material,
measured in units of stress, equivalent to units of pressure.
[Alignable Carrier Substructure]
[0139] The alignable carrier structure (ACS) replaces the carrier
truss in conventional dishes. It differs from a conventional truss
in several ways. First and foremost, unlike a conventional truss
which is of a fixed shape, the ACS is an adjustable structure,
designed to be assembled first, and then tweaked into shape.
Second, rather than being built entirely from rigid members like a
conventional truss, the ACS mimics the structure of a tensile
spoked bicycle wheel, where the radial load carrying members (the
spokes) are slender and flexible (bendable) and only loaded in
tension. This is achieved by preloading them in tension to a
sufficient degree--to a tension higher than the maximum compressive
load they would have otherwise experienced. This way, when an
external load is applied, the pretension decreases and compressive
forces never occur.
[0140] Bicycle wheels can be either free-spinning, in which case
the centerlines of the spokes intersect the centerline of the
wheel, or torque-carrying, in which case the centerlines of the
spokes are tangent to a small circle around the centerline of the
wheel and so do not intersect it. Non-torque-bearing spoke geometry
are sometimes referred to as radial spokes, and do not have spokes
crossing each other. Since the torque loads in the plane of the
dish are negligible, in some of the embodiments described herein
the spokes may be radial. A spoked bicycle wheel is depicted in
FIG. 5, showing the hub [50], rim [51], and spokes [52]. At the
connection between the spokes and rim are adjustable tensioners
[53]. This image is of a torque carrying (non-radial) wheel.
[0141] FIG. 10 shows an embodiment of the ACS. A central hub has a
barrel section [100] and two crowns [101]. The crowns [101] are
used to anchor thirty-six pairs of spokes [102] which connect to a
rim at thirty-six coupling nodes [106]. In this embodiment the rim
is not made of a single ring but is rather composed of thirty-six
straight rim segments [103], thereby making it easier to transport
and assemble. The tensioner nodes [106] are located at each
intersection of two spokes [102] and two rim segments [103], and
can adjust the effective length of each of their spokes [102]. Ribs
[107] are provided on the back spokes [102] and include reflector
guides, as will be described more fully below. In this embodiment
the coupling node serves as a tensioning device as explained below,
but in other embodiments the tensioning can also occur from the
hub, as also detailed below. Also shown are reflector tiles [109]
though they are not part of the ACS and will be described
later.
[0142] The embodiment of the ACS shown in FIG. 10 differs from a
bicycle wheel in several ways. First the rim is not a continuous
circle but made out individual straight segments. This is an
improvement from a structural point of view since the rim is loaded
in compression and straight segments are more resilient against
buckling than curved segments. It is an improvement from a
logistical point of view since the straight segments are easier to
transport than a single monolithic rim hoop. Second, the tensioner
nodes contain two spokes and two tensioners each, as opposed to a
standard bicycle wheel where each tensioner node has only one spoke
and one tensioner. This arrangement eliminates out-of-plane forces
on the rim as are present in a traditional bicycle wheel.
[0143] The amount of tension preload (pretension) applied to the
spokes is calculated so that when the external load is at its
maximum value, all of the spokes remain in tension. This can be
seen by considering a single spoke pair. It the tensioning node is
pushed backwards in the axial direction, the tensile load on the
front spoke increases, while the tensile load on the back spoke
decreases. If it is not pretensioned enough, the tensile load on it
will decrease past zero and become a compression load, at which
point the spoke will buckle since it is too slender to resists
compressive loads. Since the most significant source of external
loads is wind, and the direction of the wind is not predictable,
this can affect both front or back spokes, and so each of them has
to be pretensioned to the value load induced on the spoke by the
maximum predicted wind in its most unfavorable direction to that
spoke. However, when the wind is blowing in the opposite direction,
the tensile load on the spoke will equal the sum of the pretension
and the wind-induced load, thus equaling to twice the pretension.
Thus the UTS of the spoke must be at least equal to twice the
pretension load. It is not necessary, however, to preload the
spokes all the way to 50% of the UTS, since the designing engineer
will typically leave a design margin below the UTS, and also
because other considerations (such as stiffness) can drive towards
a spoke that has a much higher UTS than the design requires. Even a
10% UTS preload is sufficient to create a tensile structure that
can resist significant load, and a 33% UTS preload will leave 33%
margin on UTS in the worst-case external load situation, which is a
reasonable margin to prevent low-cycle fatigue failure of the
spokes. Thus a pretension value of 25% -40% UTS is a good design
range, depending on the specific properties of the spoke
material.
[0144] In order to decrease the risk of fatigue related failures,
in this embodiment the spokes are made of twisted multi-strand wire
ropes or cables. Similarly, a weaved roped can be used, or a
fiber-composite thin rod. In this specification, the term "braid"
is used to include various multi-stranded tensile member
structures.
[0145] FIGS. 11a-c shows the detailed composition of a tensioner
node according to an embodiment of the invention. A central
coupling element [110] in the shape of a short thick-walled tube
has two spherical depressions [111] on its ends. The coupling
element [110] is held in compression between two rim segments in
the form of tubes [112], each of which has spherical protrusions
[113] at its ends, thus forming two ball-and-socket compression
joints. Two tensioner links [114] are free to rotate around the
coupling element [110], and each of them pushes against it with an
adjustment screw [115]. The two links [114] are also each connected
to a spoke [116]. Turning the adjustment screw [115] causes the
tensioner link [114] to move in the direction of the spoke [116],
pulling it inwards or outwards. The lines of force therefore
intersect (to a very close degree) at the center of the coupling
element [110], creating a kinematic joint. This is true even during
assembly when the angles between the components are not at their
nominal value, since both the rim tubes and the tensioner links can
rotate to self-align to the direction of the force. In general, an
assembly is kinematic if the numbers of degrees of motion equal the
number of constraints. In this case since the forces meet at a
single point and therefore do not exert torques, there are only
three degrees of motion per tensioner node, and in the complete
dish there are three times as many constraints (rim segments and
spokes) as there are tensioner nodes. It is also possible to
replace the direction of each of the ball-and-socket joints, so
that the in the joint the ball is on the coupling element and the
socket (spherical depression) is on the rim segment.
[0146] In this embodiment therefore the tensioners are used to
adjust the ACS until the rim becomes circular and flat. At each
tensioner node, turning the adjustment screws in opposite
directions shortens one spoke and elongates the other, thus moving
the tensioner node in the axial direction. Turning the adjustment
screws in the same direction either elongates or shortens both
spokes, moving the tensioner node in the radial direction. The
alignment of the ACS is therefore a systematic procedure which can
be carried out repeatedly to almost arbitrary precision--as is done
in bicycle shops on a regular basis.
[0147] The resultant structure is kinematic, highly rigid, and
unlike a traditional dish truss does not have lattice arms that
cantilever from the center outwards--the ACS is actually most stiff
and precise right at the rim. Just like a bicycle wheel, all the
spokes merely pull the rim inwards, and the rim is compressed in
the circumferential direction. It is the imbalance in spoke
tensions that results from the application of load that provides
the rigidity of the rim in respect to the hub, both for in-plane
and out-of-plane forces.
[0148] As is the case with a regular bicycle wheel, the spokes
[102,116] are pre-tensioned so as to never go slack, and therefore
the rim segments [112] are always loaded in compression. The hub
barrel [100] is compressed by the combined action of the spokes
[102,116], and the hub crowns [101] work principally in tension.
When the hub is used to impart torque on the dish in the tip or
tilt directions, the magnitude of the forces in the individual
spokes vary, but the design is such that the polarity of the load
never changes (between tension and compression). These consistent
loads reduce fatigue issues and allow for very efficient use of
material. (For example, the spokes are slender enough that if they
ever experience compression, they will buckle)
[0149] As is common in large diameter sheet metal cylindrical
structures, to optimize transportation costs, the barrel can be
shipped to the field in three 120.degree. slices which can be
nested for packaging and shipping and assembled together to form
the a complete cylinder.
[0150] In this embodiment, the back set of spokes has stiffener
ribs [104, 117] attached to them. The ribs are not cantilevered
from the hub, but are merely attached to the spokes, encompass
them, and serve to stiffen the spokes from bending in a radial
plane. The back spokes are only visible as they emerge from the
ribs at their ends, near the back crown and the tensioners.
[0151] Each back spoke is encapsulated by a rib [117] which
stiffens it and contain curved guide rulers [118] welded to them
that are later used to position the reflector tiles, which will be
brought from the back side and pushed against it. Thus if the
coupling elements [110] are brought into their correct locations in
space, the guide rulers [118] establish precise radial guides for
the optical surface. These continuous radial guides are much more
precise than individual support points on a conventional truss.
[0152] It is important to note the dual role of the ribs. In a
tensile bicycle wheel, the spokes create a very strong and rigid
spatial relationship between the hub and the rim (both in and
out-of-plane) but the spokes themselves can be bent by pushing on
them sideways in their mid-spans. Since the load on the solar dish
will be distributed, the ribs function to stiffen the spokes
against such deflections. Additionally, the ribs mediate
mechanically between the straight spokes and the curved guide
rulers which establish the final optical shape of the dish. The
guide rulers are attached to the ribs in-factory during
fabrication, and so this process can be done to a very high degree
of accuracy--much higher than the accuracy of field assembly.
[0153] It is also important to note that the ACS is constructed,
stabilized, and aligned before the tiles are attached. Thus the
hub, rim, and spokes together provide the alignable carrier
structure. The ribs provide a geometrical fit between the spokes
and the desired optical shape and further stiffen the structure for
supporting a distributed load, and the tiles merely attach to the
ribs and do not contribute in any significant manner to the
strength or stiffness of the ACS in bending or translation. If the
ACS has radial spokes, the tiles do contribute to stiffness against
torsional motion around the optical axis, but such torsional loads
are insignificant.
[0154] When the rim is aligned to shape, the guide rulers are
necessarily in place and provide thirty-six arcs that are precisely
located in space. In the case of a simple paraboloid dish, these
arcs are parabolas whose optical axis coincides with the central
axis (define as being central and perpendicular to the rim circle).
In the case of an OP, the guide rulers are also parabolic arcs, but
during fabrication they are attached to the ribs so that their
optical axes are properly offset. Thus by controlling the shape of
the guide rulers during fabrication, different dish shapes can be
produced when the rim is brought into alignment.
[0155] The alignment of the dish is indifferent to which optical
shape is being created by the guide rulers, and this is very
important if the desired optical shape is not a simple paraboloid.
Additionally, the alignment of the dish can take place before any
reflector tiles are installed on the ACS. This is also important
since reflector tiles can later be replaced without affecting
alignment.
[0156] FIG. 12 shows how the reflector tile [120] interfaces with
the rib guide ruler [121] in this embodiment. The tile is brought
from the back of the dish and pushed forward [122] against the
guide ruler. In this tile embodiment, this is done using spring
clips shown as [188] in FIG. 18d. Since the guide rulers position
the front surface of the tile, the alignment is insensitive to
variations in the thickness of the tile--it is the optical surface
of the tile that is brought to place.
[0157] The ACS is assembled around its hub on its pedestal. The hub
is first oriented vertically so it can spin around the vertical
axis without wobbling. At that point, the subassembly shown in FIG.
13, comprised of two spokes [130], a rib [131], and a tensioner
node [132] is attached to the hub, followed by a rim segment [not
shown, close to perpendicular to the plane of the page], and the
hub is then rotated by 10 degrees. This step is repeated thirty-six
times, until the ACS is complete. During assembly, the adjustment
screws on the tensioners are set for maximum spoke length, and
after assembly is complete they are tightened to create the
pre-tension in the spokes.
[0158] In this embodiment, the ACS is 8 m in diameter, and the 36
spokes are 1/4'' multi-stranded 7.times.19 steel cable, preloaded
in tension at about 500 kgf of force. A typical hub has a diameter
of about 10% of the dish diameter, and a height of about 25% of the
dish diameter. Other embodiments can have different proportions,
diameters, numbers of spokes, cable thicknesses, and material
selections. Specifically, the number of rim segments can be reduced
very significantly from the value of thirty-six. As this is done,
the length of the rim segments increases, and they become more
susceptible to buckling. However, even having as few as six
segments is still an approximation to a round rim.
[0159] The hub of the ACS is its backbone and most rigid and dense
component. The tracking actuation mechanism attaches to the
back-side crown of the hub, and the front-side crown attaches to
the PCU mount. The rest of the ACS structure is distributed and
will not support a concentrated load at any single point. This is a
positive trait that indicates that material is used
efficiently.
[0160] In addition to aligning the primary reflector to shape, the
ACS has to precisely locate the PCU relative to the primary. The
connection between the ACS and the PCU must therefore be rigid and
precise.
[0161] In the embodiment shown in FIG. 14, this is achieved using a
kinematic truss structure known as a hexapod. A hexapod consists of
six rods, and attaches to three points on each of two bodies,
kinematically constraining the six degrees of freedom that can
exist between them. As shown in FIG. 14, the six rods are connected
as three pairs to three anchor points 144a-144c on the back of the
hexapod which is co-located with the front crown [101] of the hub
[100], but each rod from these three pairs form a pairing with a
rod from another pair to be pair-connected to anchor points on the
front of the hexapod which is co-located with the PCU interface
[141], also referred to herein as the fiduciary.
[0162] The six struts [140] connect the front hub crown to a
precision mechanical interface [141] called the fiduciary which
serves as the defining optical reference for the dish. In other
embodiments the hexapod can be replaced by a thin walled-tube, or a
thin walled tube with a perforated wall surface for weight
reduction. As described later, the hexapod can be actively tilted
to perform a tracking function using liner actuators [143].
[0163] The fiduciary is a kinematic coupling. Kinematic couplings
are used to connect two objects in a way that a) relieves any
stresses due to thermal expansion or misalignments and b) allows
them to be disassembled from each other and then reassembled in a
highly repeatable way, so each reassembly results in the same
spatial relationship between the objects. The kinematic coupling is
later used to attach the PCU and other optical elements to the
fiduciary interface [141].
[0164] This embodiment uses the kinematic coupling described in
U.S. patent application Ser. No. 13/032,607, but other standard
kinematic couplings such as a three-groove mount, a six-point
mount, or a flat surface with locating pins can also be used.
[0165] In this embodiment, the portion of the kinematic coupling
that resides on the fiduciary consists of a triplet of conical
depressions [142]. Each cone serves as a seat for a fixed-size
sphere that is tangent to it, and so defines a unique point at the
center of this sphere. The reference plane is defined as passing
through the centers of these spheres, and the reference axis is
defined as being perpendicular to this plane and passing through
the center of the circle defined by the centers. As per U.S. patent
application Ser. No. 13/032,607, the PCU has three beads on it that
match the cones.
[0166] In an embodiment that uses the standard three groove mount,
the fiduciary has three spheres attached to it, and the PCU has
three radial grooves that match the spheres.
[0167] In order to establish a fiduciary-based reference against
which to perform the rim alignment, a rotary laser guide (RLG) is
fastened to the fiduciary interface. By using the fiduciary
interface for both the primary mirror (ACS) alignment guide and as
the positioning mechanism for the PCU, there is no need to later
align the position of the PCU to the focal point or axis of the
ACS. To allow the concurrent mounting of both a PCU and an RLG, the
fiduciary interface in the embodiment below contains two triplets
of co-located conical depressions--an inner one [157] for the RLG,
and an outer one for the PCU.
[0168] FIG. 15 shows an embodiment of the RLG which uses two
intersecting laser beams that rotate around the main dish axis.
This rotation describes two coaxial cones of light that intersect
at a circle, which becomes the reference for the rim. A baseplate
[150] is mounted to the inner fiduciary interface [157], leaving
the outer one free for mounting the PCU. An inner guide tube [151]
is attached to the baseplate and is perpendicular to it. A coaxial
outer tube [152] encapsulates the inner tube [151] and rotates
around it. A suitable bearing (not shown) may be provided between
the inner and outer tubes. A rigid carrier plate [153] carried two
lasers [154a,154b], mounted through an adjustment mechanism [156]
so that their beams [155a, 155b] are made to intersect at a
predetermined point relative to the fiduciary. In this embodiment,
many holes are drilled in the carrier plate [153] so as to reduce
its weight. As the outer tube [152] rotates, the point of
intersection describes a circle to which the rim is subsequently
aligned. It is beneficial to have the two laser beams be of
different colors.
[0169] In this embodiment the fiduciary has two kinematic couplings
and thus two triplets of cones--an inner one and an outer one--with
the alignment guide attached to the inner triplet, leaving the
outer one for the PCU, so the alignment guide can be mounted even
when the PCU (described later) is in place.
[0170] An integral or temporary laser target [159] is placed on
each tensioner node as it is being adjusted. The target rests on
the center-body of the ACS and on the front spoke, so its position
and attitude relative to the rim is fully constrained. An aiming
zone [158] is marked on the target. During adjustment, the operator
turns the adjustment screws of the tensioner so as to bring both
laser beams into the aiming zone.
[0171] FIG. 16 shows another embodiment, in which three tooling
balls [160] are placed on a reference plate [161] that attaches to
fiduciary interface [162]. The distance between the balls is
pre-known and they define a reference axis in the same way that the
fiduciary interface does. The alignment of the dish relative to the
balls is ascertained either using a laser radar (such as Nikon
model MV224) or photogrammetry techniques, using the edges of the
rim tubes [163] as the defining features of the inspected geometry.
The tooling balls can be made a permanent feature of the fiduciary
plate itself, situated permanently in the inner set of conical
depressions.
[0172] In another embodiment, alignment is done by placing the dish
horizontally and rotating it while comparing the position of the
tensioners to a fixed ground base--as is done in bicycle shops when
truing a bicycle wheel. Each of the thirty-six data points will
have an axial component and a radial component. If the elevation
drive does not perfectly align the rim axis with the axis of
rotation, there will be a sine-wave embedded in the axial component
of the measurement, but it can be removed using statistical
fitting. This method does not relate the alignment to the
fiduciary, but can serve as a fast "low tech" way of quickly
inspecting a dish with no special equipment.
[0173] Another method to confirm that the dish is perfectly aligned
is by monitoring the tension of the spokes which should be uniform
for all the front spokes, and for all of the back spokes. Since the
front spokes are not encapsulated by ribs, their tension can be
measured acoustically by plucking them. This can done spoke by
spoke with the equivalent of a guitar string tuner, or by imparting
a mechanical impulse to the hub and using a microphone and spectrum
analyzer to pick up vibration frequencies that indicate an
off-tension spoke.
[0174] In another embodiment, as shown in FIG. 14, the three mount
points [144a-c] between the hexapod [140] and the hub are actuated
along the direction of the optical axis of the dish by short-travel
linear actuators [143], resulting in a 3-DOF tip-tilt-piston motion
of the fiduciary plate from its nominal position. Only a small
actuation travel range is required to tilt the hexapod a few
degrees, and so it is used to correct tracking errors in real time.
This either enhances the effective tracking accuracy, or
alternatively compensates for a much reduced performance tracker.
The actuation can be achieved using means such as pistons, bellows,
lead screws, voice coils, piezo drives, cams, or eccentric
shafts.
[0175] Among the novel features of the ACS as described above are:
unlike conventional trusses, the structure itself is adjustable,
and its alignment procedure is independent of the optics of the
dish. Unlike conventional trusses (including cable-assisted ones)
there are no radial members cantilevered or loaded in
compression--it is the rim that enables the "magic" by which all
radial members are always in tension. The ACS can therefore be
fabricated in relatively small parts that can be easily transported
to and assembled on location, without losing precision due to
tolerance stack ups.
[0176] Among the utilities of the ACS as described so far are:
ability to align-to-form in the field even for complex optical
shapes, ability to replace reflector tiles without re-alignment,
low weight, low moment of inertia, low part count, high strength
and rigidity, high geometrical precision, single fiduciary
mechanical interface that defines the optical axis for all optical
components of the dish.
[0177] The ACS can additionally be used for any lightweight
approximately round reflector such as a stretched membrane
heliostat reflector, or even for non-reflective surface such as
thin film solar panels or Fresnel-lens sheets. In heliostat
systems, there is no PCU on the ACS, since it is located on the
central tower. In a Fresnel lens embodiment, the tiles held by the
ACS are transparent, refracting the light to a focal point behind
the plane of the ACS.
[0178] In another embodiment shown in FIG. 39, a ACS is shown with
a conical hub [390]. Conical hubs are beneficial in that they nest
for transport, and as explained above, they minimize shading if the
reflector is not pointed directly at the sun, as in the case of
heliostats.
[0179] Another embodiment, also suitable for a heliostat, is shown
in FIGS. 31a-b. The reflector tiles [310] are principally flat and
located near the front of the hub [311] in order to minimize
shading (since heliostat mirrors do not point directly into the
sun) and the spokes [312] and ribs [313] are largely behind the
tiles.
[0180] In another such embodiment, shown in FIG. 32, the ACS is
used to hold a stretched membrane [320] reflector usable with
either heliostats in central-tower solar thermal systems or with
dish systems. In this embodiment the flatness of the rim [321]
controls the periphery of the stretched membrane. The curvature of
the membrane is induced from its back side [not shown] either by a
mechanical structure or a second membrane and vacuum in between
them. (Stretched membrane reflectors are existing art and not in
the scope of this specification). Again, to reduce shading in
heliostats, the hub [322] is conical in shape.
[0181] In another embodiment of the ACS shown in FIG. 33, the
spokes [330] are bands oriented roughly in parallel with the
optical axis of the dish, to minimize shading. The reflective
surface [331] of the dish in this embodiment is a Fresnel
paraboloid, comprised of two paraboloid rings with different focal
lengths but sharing the same focal point. Openings [332] in the gap
between the rings help reduce pressure differentials across the
dish caused by aerodynamic effects. A Fresnel paraboloid can have
two or more rings.
[0182] In another embodiment shown in FIG. 34, the spokes [340] are
band oriented roughly in parallel with the plane of the dish, and
simply wrap around the rim [341]. The rim tensioner mechanisms are
not implemented in this embodiment, and preloading of all the
spokes after assembly is achieved by moving the two crowns [342a,
342b] away from each other on the hub using threaded rods [343].
Since this embodiment is less precise, it useful as a large
tracking structure for flat panel PV receivers.
[0183] Another embodiment of the tensioner node is shown in FIG.
35. A central coupling element [350] in the form of a thick-walled
tube is held in compression between two rim segments in the form of
tubes [352]. The coupling element [350] has two surfaces at its
ends that are appropriately angled with respect to its axis to
accommodate the two rib segments [352]. The coupling element [350]
also has a fixed bracket [357] attached to it. Two spokes [353] are
connected at their ends to a movable bracket [358]. Two adjustment
screws [351] adjust the position of the movable bracket [358] with
respect to the fixed bracket [357]. Stiffening ribs [354] are
attached to the back spokes just like in the embodiment shown in
FIG. 11.
[0184] Another embodiment of a tensioner is shown in FIG. 36. In
this embodiment, the spoke tensioners reside on the hub rather than
on the rim. The drawing depicts the back crown [360] of the hub,
with the hub walls removed for clarity. A central column [361] is
part of the support structure connecting the back crown [360] to
the front crown (not shown). Each spoke [362] is terminated with a
swage [363] and goes through a tensioning screw [364] that has a
hole drilled through it and is threaded into the crown. By turning
the screw [364] clockwise (inwards), the spoke [362] is pulled
inwards with it, and is thus tightened. Also shown is the stiffener
rib [365]. For clarity, only one spoke is shown. This embodiment is
useful if tensioning is automated and motorized, since the
tensioning motors all reside next to each other and wiring is thus
minimized.
[Reflector Tiles]
[0185] As explained above, in various embodiments of the invention,
the ACS provides each reflector tile with two precisely formed and
located radial curved guide rulers as mounting points. While other
manners of affixing the reflector tiles to the ACS can be used, it
is believed that the embodiments described herein provide enhanced
precision.
[0186] Traditional composite panels are comprised of a front
membrane, a back membrane, and a core. The term membrane signifies
that a sheet-like member can only support in-plane stresses. It is
stiff in-plane, but flexible out-of-plane. A letter-size sheet of
paper and a 1 m.sup.2 sheet of 0.5 mm thick Aluminum are two
examples of membranes. The core's role is to connect the two
membranes and transfer sheer between them, so that the entire
panels can resist out-of-plane bending. Typically, the core itself
is rather flimsy and cannot support bending by itself either.
Typical cores include honeycombs, general ribbed structures (even
including cardboard ribs), and expanding foams. The membranes can
be made out of Aluminum, steel, plastic, or glass. A traditional
residential door, for example, is made from two very thin plywood
membranes, and cardboard ribs in between acting as a core.
Surfboards are often made with fiberglass membranes and foam cores.
A person's weight will bend the membrane and break the foam, but
the composite surfboard can support the person's weight even when
the board is supported only at its tips.
[0187] FIG. 37 depicts a standard flat honeycomb core composite
panel. The panel is comprised of the honeycomb core, which consists
of a large number of ribs [370] oriented in three principal
directions, and two membranes [371]. It is evident that the bonding
area between the ribs and the membrane is very limited, consisting
only of the edges of the ribs.
[0188] Precisely curved composite panels are more difficult to form
quickly, since most ribbed structures are naturally flat.
Honeycombs in particular, which are the most efficient ribbed
structures, are almost exclusively flat, are awkward to handle in
small, irregular shapes, and can be difficult to bond to because of
the small surface area of the membrane-core joint. Injectable
expanding foams get around these limitations and function well in
flat or curved panels, but their mass/stiffness ratio is lower,
their cost is high, and the curing process is both time consuming
and environmentally problematic since it releases large amounts of
solvents.
[0189] In some of the embodiment shown here, the core of the
reflector tiles is formed using the process of thin-gauge vacuum
forming, which is typically used to create objects such as yogurt
cups. In this process, a thin plastic sheet is heated to a
temperature in which it is easily deformed plastically. It is then
placed over a mold containing an array of depressions, and lowered
down to seal against it. Vacuum is then applied between the sheet
and the mold, and the soft sheet it sucked into the depressions,
creating an entire tray of yogurt cups at once. This process is
fast, scalable, and cheap.
[0190] In these embodiment, we adapt this process to create a
honeycomb-like ribbed core structure which is pre-curved to match
the intended curvature of the tile, pre-formed to match the
non-regular shape of a slice of a dish, and is able to conform to a
high precision optical surface without inducing stresses in itself.
(The ideal panel core structure has high stiffness in shear, but
low stiffness in bending.)
[0191] FIG. 17a shows the vacuum forming mold that forms the core,
which has a front surface [170] that conforms to the intended
optical shape of the tile. The back surfaces of the depressions in
the mold [171] jointly form a piece-wise surface that defines the
back side of the core. As in all vacuum forming molds, small
conduits or holes allow the vacuum forming machine to apply vacuum
into the depressions, sucking the heated and softened thin plastic
sheet being formed into them.
[0192] FIGS. 17b-c depict the formed core, as derived from the
mold. It has a front surface [173] that approximates the intended
optical shape, but also has a large bonding area (when compared to
a conventional honeycomb core). The back of the core [174],
comprised of the backs of the formed cups, also features a large
bonding area that will attach to the back membrane. In this
embodiment, the back surface is curved so as to make the tile
thicker in the middle, to optimize it for bending loads when
supported by the two guide rulers provided by the ACS. This is
evident in the five cups [175] closest to the viewer in the bottom
most view of FIG. 17c. The sidewalls [176] of the cups are the
members that carry the sheer forces in the completed tile. In this
embodiment they are slightly slanted since the depressions in the
vacuum mold must be tapered.
[0193] FIGS. 18a-e show the structure and assembly order of the
complete tile. As shown in FIG. 18a, The front membrane [180] is
first placed (face down) on a precision bending mold [181] that
gives it its proper optical shape. The bending mold pulls the
membrane down to it using vacuum, ensuring a good surface fit
throughout its area. For the curvatures needed for solar
applications, the membrane typically only undergoes elastic
in-plane deformation during this step. Electrostatic forces or
pressure can be used instead of vacuum to constrain the front
membrane to the bending mold. It is important to differentiate
between the vacuum mold used during the vacuum forming process to
form the core and the bending mold which might use vacuum to
constrain the front membrane to it.
[0194] As shown in FIG. 18b, the core [182] (which was previously
formed to shape) is then placed on the back side of the membrane
and bonded to it. Note that since the cups are connected only via
the front surface of the core, the core is free to bend in both
directions as it is being attached to the front membrane. This is
important since the accuracy of the bending mold is higher than the
results of the vacuum forming process.
[0195] Next, sidewalls [183] are placed around the tile's
perimeter. The sidewalls contain fastening features [184] used to
later attach the tile to the ACS. At this point in the process, the
backs of the core cups are still exposed and free, and if the tile
is removed from the mold, the front surface would still be able to
deform and lose its desired shape, by causing the individual cups
to "wiggle" as it does so.
[0196] To complete the tile, as shown in FIG. 18c, the back
membrane [186] is bonded to the backs [185] of the cups of the
core, preventing them from moving relative to each other, and thus
making the structure stiff and capturing the geometry of the front
membrane that is still held conformant to the mold. The function of
the cups is evident in a cross-section of the complete tile (FIG.
18e), as their sidewalls create a web of cross-ribs [187] all
throughout the tile.
[0197] In another embodiment, the back membrane is pre-formed
around its edges to includes the sidewalls, thus creating a single
backshell which encloses the tile, reducing the part count of the
complete tile.
[0198] Spring clips [188] are then attached to the sidewalls (FIG.
18d). The clips will be used during dish assembly to mount the tile
to the ACS ribs and preload the tile in the forward direction
against the ACS rib guide rulers [121, in FIG. 12].
[0199] FIGS. 19a-c shows several embodiments of the core with diff