Light concentrator system for precision thermal processes
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Solution Overview
Problem
Existing solar concentration systems lack consistency in delivering high temperatures and precise thermal control, leading to inefficiencies in applications such as additive manufacturing and materials processing, and are often costly and require extensive infrastructure.
Innovation Solution
A light concentrator system utilizing a primary collector with two-axis tracking, a redirecting mirror, and a compound parabolic concentrator, coupled with feedback and control mechanisms, to achieve precise temperature control and scalable energy delivery from 65°C to 2,200°C with minimal equipment and operating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If stationary solar concentration facilities with heliostat mirrors and louvre shutter systems are used, then extremely high light concentration ratios and temperatures (3,500°C) can be achieved, but the systems lack consistent temperature delivery and require extensive infrastructure
Solution Approach 1:
The patent implements dynamic tracking systems that actively follow the sun's movement across the sky, allowing the concentrator to maintain optimal alignment throughout the day. This dynamic adjustment capability enables consistent temperature delivery without requiring fixed, infrastructure-heavy heliostat fields, as the system adapts its position rather than relying on stationary mirrors and complex shutter mechanisms
Solution Approach 2:
The invention extracts and eliminates the need for extensive infrastructure components such as heliostat mirrors and louvre shutter systems by using a more streamlined optical concentration approach. The system achieves high temperatures through direct solar concentration with tracking optics, removing the complex intermediate components while maintaining temperature consistency through active control
2Temperature
If two-axis solar tracking and high light concentration ratios are implemented, then high temperature thermal processes can be driven, but consistent temperatures and thermal spot sizes are not delivered to the receiver
Solution Approach 1:
The patent incorporates feedback control systems that continuously monitor the position and focus of the concentrated solar beam, adjusting the tracking mechanisms and optical elements in real-time to maintain consistent thermal spot size and temperature at the receiver. This closed-loop control ensures manufacturing precision in thermal delivery by compensating for variations in solar position and atmospheric conditions
Solution Approach 2:
The system dynamically adjusts optical parameters such as focal length, aperture size, and tracking angles to maintain consistent thermal spot characteristics. By changing these parameters in response to varying solar conditions, the system delivers uniform temperatures and spot sizes to the receiver throughout the day, overcoming the inconsistency problems of fixed-ratio concentration systems
3Ease of manufacture
If conventional solar concentration systems are used, then solar energy can be concentrated, but the systems are costly and require extensive infrastructure
Solution Approach 1:
The patent employs simpler, more cost-effective optical components and tracking mechanisms compared to expensive heliostat fields and shutter systems. The system uses affordable solar concentrators with basic tracking capabilities that can be manufactured and deployed without extensive infrastructure, reducing both capital costs and installation complexity while maintaining effective solar concentration
Solution Approach 2:
The invention creates a versatile solar concentration system that can be deployed in various locations without requiring specialized infrastructure. The modular design and adaptable tracking mechanism allow the system to function effectively in different environments, from remote areas to urban settings, eliminating the need for location-specific infrastructure investments
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 system consistently delivers high temperatures with precise control over thermal spot size and energy flux density, reducing costs and enabling applications like additive manufacturing and 3D printing, even in remote or resource-constrained environments, with the potential for use in space and on other planetary bodies.
Implementation Method 1
A light concentrator system utilizes a primary collector with two-axis tracking
Implementation Method 2
primary collector with two-axis tracking, a redirecting mirror, and a compound parabolic concentrator
Implementation Method 3
compound parabolic concentrator, coupled with feedback and control mechanisms, to achieve precise temperature control
Implementation Method 4
consistently delivers high temperatures with precise control over thermal spot size and energy flux density
Data Source
AI summary
An example light concentrator system for precision thermal processes includes a stabilizing base and a structure attached to the stabilizing base. The structure includes support arms. An azimuth control rotates the structure. A primary solar collector on the support arms is rotatable about two axes based on various positions of the sun throughout the day. Elevation actuators adjust an angle of the primary solar collector relative to position of the sun. Collector distancing actuators adjust distance of the primary solar collector toward and away from the sun. A variety of Thermal Processing Units (TPUs) are configured for a specific process or set of processes implementing concentrated solar energy from the primary solar collector at the receiver plane. Position of the spot can be moved on a fixed receiver plane through translation of the lens relative to the support arms or through rotation of a redirecting mirror.