Frame support and method for connecting a sleeve to a chord and a strut end piece for a frame support
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Solution Overview
Problem
Concentrated Solar Power (CSP) systems, particularly parabolic trough facilities, face challenges in reducing costs and improving performance due to the weight and complexity of traditional steel or aluminum frame support structures, which hinder efficient energy conversion and maintenance.
Innovation Solution
A frame support structure and method for connecting a sleeve to a chord and a strut end piece using a single pin connection, featuring a single fin sleeve design with guided insertion and swage connections, which reduces material usage and simplifies assembly while maintaining high load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional steel or aluminum frame support structures are used, then structural strength and stability are ensured, but weight and complexity increase, reducing assembly efficiency and increasing material costs
Solution Approach 1:
The frame support structure is divided into modular components including sleeves with fins, strut end pieces with legs, and connection pins. Each component is independently fabricated and then assembled together, allowing for simplified manufacturing and reduced overall complexity while maintaining structural integrity through the distributed modular design
Solution Approach 2:
Multiple structural functions are merged into single components. The sleeve both supports the chord and provides fin structures for strut attachment. The strut end piece combines engagement portions for the strut with legs that wrap around fins. This merging reduces the total number of separate parts and simplifies the overall frame assembly
2Ease of manufacture
If traditional aluminum extrusions are used, then ease of manufacture is improved, but weight remains high, increasing material costs and reducing assembly efficiency
Solution Approach 1:
The sleeve and strut end pieces feature localized thickening at specific regions where structural strength is needed, such as at the fin bases and leg connections. The rest of the components can be thinner, reducing overall weight while maintaining strength at critical load-bearing locations. This selective material distribution optimizes the weight-strength ratio
3Strength
If complex connection methods are used, then structural integrity is ensured, but assembly time and labor costs increase
Solution Approach 1:
The fins are pre-formed as integral parts of the sleeve, and the strut end pieces are pre-fabricated with their legs and engagement portions. This preliminary formation of connection features eliminates the need for field welding or complex fastening operations, allowing for quick mechanical assembly while ensuring consistent connection strength
Solution Approach 2:
The curved legs of the strut end piece are designed to self-align and wrap around the fins during assembly. The geometry of the components guides the assembly process, with the legs naturally positioning themselves for pin insertion without requiring precise external alignment or additional alignment fixtures
4Productivity
If lighter frame materials are used, then assembly efficiency is improved, but load-bearing capacity under high loads decreases
Solution Approach 1:
The strut end piece features asymmetric leg geometry with different curvatures and thicknesses optimized for specific loading conditions. The engagement portion has an asymmetric design that maximizes contact area with the strut while the legs provide different levels of reinforcement based on the directional loads expected in the frame structure
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A strut end piece for a strut for connecting with a fin of a sleeve for a solar mirror frame support. A strut for receiving a strut end piece for a solar mirror frame support. A sleeve for connecting with a chord and a strut end piece for a solar mirror frame support having a main portion having an opening for receiving the chord. A method for connecting a sleeve to a chord and a strut end piece for a solar mirror frame support.