Systems and methods of calibrating a heliostat
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Solution Overview
Problem
The internal mirror angle of heliostats used in rotational molding processes can become inaccurate over time, reducing the amount of reflected light impinging on targets, necessitating a calibration system to correct this error and enhance light reflection efficiency.
Innovation Solution
A heliostat calibration system comprising a system controller and a heliostat controller that calculates tracking errors using a modified reflection equation, identifies calibration offset angles, and transmits adjustment instructions to correct the internal mirror angle, thereby improving light reflection on targets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the internal mirror angle of the heliostat is not calibrated, then the device complexity remains low, but the manufacturing precision deteriorates due to inaccurate light reflection angles
Solution Approach 1:
The calibration system uses feedback by measuring the actual reflected light position and comparing it with the expected position based on the mirror angle. The system calculates a calibration offset angle based on this feedback and applies it to correct the mirror angle, thereby improving manufacturing precision without requiring complex hardware modifications
Solution Approach 2:
The patent replaces complex mechanical calibration mechanisms with a computational approach. Instead of using complex mechanical adjustment systems, the invention uses software-based calculations involving reflection equations and coordinate transformations to determine and apply the necessary calibration offset, reducing device complexity while maintaining high precision
2Productivity
If the heliostat operates without calibration correction, then the ease of operation is maintained, but the productivity deteriorates due to reduced light reflection efficiency
Solution Approach 1:
The calibration is performed as a preliminary action before the heliostat enters normal operation. The system calculates and applies the calibration offset angle in advance, storing it for use during subsequent operations. This preliminary calibration improves productivity by ensuring optimal light reflection efficiency without requiring continuous calibration operations that would complicate ease of operation
Solution Approach 2:
The calibration system is designed to be self-servicing by automatically calculating the calibration offset angle using measured data and reflection equations. The system performs self-diagnosis and self-correction without requiring complex manual intervention, thereby improving productivity while maintaining ease of operation through automated processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The calibration system effectively identifies and corrects the internal mirror angle error, increasing the amount of reflected light on targets, thereby enhancing the efficiency of the rotational molding process.
Implementation Method 1
a heliostat 120 configured to reflect radiant solar energy 102 onto a target 116
Data Source
AI summary
A heliostat calibration system having a system controller, and a heliostat having a heliostat controller, wherein: the system controller is configured to receive a calibration data point and initial calibration offset angle guess, calculate a tracking error, identify a calibration offset angle, and the heliostat controller configured to transmit a calibration data point, receive adjustment instructions, and execute the adjustment instructions.