Heliostat Mirror Facet Alignment Using Theoretical Image Overlay
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Solution Overview
Problem
Current methods for aligning and focusing mirrored facets in heliostats used in solar power towers are inefficient, inaccurate, and time-consuming, especially for large fields with long slant ranges or focal lengths, as they require manual adjustment and are affected by changing sun positions.
Innovation Solution
A system utilizing a target with reference markings and a camera to capture reflected images of the target, with a computing apparatus generating a theoretical image for alignment and focus adjustments, allowing for simultaneous alignment of multiple heliostats and providing instructions for technicians or actuators to achieve optimal alignment and focus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment and focus adjustment of mirrored facets is performed by technicians using visual inspection, then alignment can be achieved, but the process is extremely time-consuming and inefficient for large fields with hundreds or thousands of heliostats
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical measurement system. A camera captures images of the collector and computational algorithms automatically determine facet alignment and focus, eliminating the need for manual visual assessment while dramatically increasing processing speed from hours per heliostat to minutes or seconds per heliostat.
Solution Approach 2:
The patent creates a digital copy (image) of the collector and uses computational analysis to assess alignment and focus. Instead of directly observing the physical flux distribution, the system captures an image and processes it through algorithms to determine alignment parameters, enabling rapid automated measurement.
2Measurement precision
If alignment is performed manually with changing sun positions, then alignment can be achieved, but the changing sun position affects flux distribution making it difficult to accurately judge good flux distribution
Solution Approach 1:
The patent performs alignment measurements at a specific reference sun position and uses computational algorithms to calculate the required adjustments. The system determines the ideal alignment based on the known geometry and sun position, then provides adjustment instructions that account for the specific solar conditions, enabling accurate alignment regardless of when the measurement is taken.
Solution Approach 2:
The patent uses image capture and computational analysis to provide feedback on the current alignment state. The system compares the observed flux distribution or reflected sunlight pattern against the ideal pattern, calculates the deviation, and provides corrective adjustment instructions, creating a closed-loop alignment process that compensates for varying sun positions.
3Productivity
If automated alignment systems are implemented, then alignment speed and consistency improve, but the system complexity and initial cost increase
Solution Approach 1:
The patent employs a camera system that can serve multiple functions: capturing images for alignment measurement, documenting heliostat positions, and potentially monitoring operational performance. The same computational platform processes images for various alignment parameters and can be applied across the entire heliostat field, reducing per-unit complexity through shared infrastructure.
Solution Approach 2:
The alignment system is designed to be self-calibrating and self-correcting through automated image processing and computational algorithms. The system independently determines alignment deviations and generates adjustment instructions without requiring external intervention or complex calibration procedures, simplifying the overall system architecture.
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
This method significantly improves the efficiency and accuracy of aligning and focusing mirrored facets, reducing the time and cost associated with manual adjustments and ensuring optimal solar flux concentration at the collector, leading to increased power generation efficiency.
Implementation Method 1
a camera is positioned relative to a heliostat that comprises a plurality of mirrored facets, such that the camera can capture a reflected image of the target by way of the plurality of mirrored facets
Data Source
AI summary
Various technologies pertaining to aligning and focusing mirrored facets of a heliostat are described herein. Updating alignment and/or focus of mirrored facets is undertaken through generation of a theoretical image, wherein the theoretical image is indicative of a reflection of the target via the mirrored facets when the mirrored facets are properly aligned. This theoretical image includes reference points that are overlaid on an image of the target as reflected by the mirrored facets of the heliostat. A technician adjusts alignment/focus of a mirrored facet by causing reflected reference markings to become aligned with the reference points in the theoretical image.