Method and arrangement for verifying reflector surfaces of parabolic trough solar collectors
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Solution Overview
Problem
Current methods for verifying the precision of reflector shapes in parabolic trough solar collectors are inefficient and lack precision, leading to potential defects in solar collector performance and increased manufacturing costs due to the production of defective units.
Innovation Solution
A method and arrangement using an image capturing device to capture images of the reflected receiver tube, process the image data to determine reflector parameters such as slope, and compensate for angular errors, allowing for precise quality control of reflector surfaces before installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical sensors or illumination pattern methods are used to verify reflector shape, then the verification process can be performed, but the measurement precision and reliability are insufficient leading to defective solar collector production
Solution Approach 1:
The patent replaces traditional mechanical sensors and illumination pattern methods with an optical measurement system using cameras to capture images of the receiver tube reflected in the reflector surface. This substitution enables non-contact, high-precision measurement of reflector geometry by analyzing the reflected image characteristics, thereby improving both measurement precision and production reliability.
Solution Approach 2:
The patent uses optical imaging to create a visual copy (image) of the receiver tube as reflected in the reflector surface. By capturing and analyzing this optical copy, the system can precisely determine reflector shape parameters without physically contacting the reflector, achieving high measurement precision and enabling reliable quality verification.
2Ease of manufacture
If traditional verification methods are used, then the process can be performed, but manufacturing costs increase due to production of defective units
Solution Approach 1:
The patent implements verification of reflector shape immediately after manufacturing using optical imaging, allowing defects to be detected before the solar collectors are installed or shipped. This preliminary action enables early rejection of defective units, preventing waste of materials and reducing manufacturing losses by identifying problems at the source.
Solution Approach 2:
The system provides immediate feedback on reflector shape quality by capturing images, analyzing the reflected receiver tube pattern, and determining whether the reflector meets specification. This feedback mechanism enables real-time quality control decisions, improving manufacturing efficiency and reducing waste by allowing immediate correction or rejection of defective units.
3Manufacturing precision
If mechanical sensors travel across the reflector surface, then curvature can be determined, but the device complexity and operation difficulty increase
Solution Approach 1:
The patent replaces complex mechanical sensor systems that require physical travel across the reflector surface with a simpler optical imaging system. By using a camera to capture the reflected receiver tube image and analyzing the optical pattern, the system achieves high curvature measurement accuracy without the mechanical complexity and operational difficulties of moving sensors.
Solution Approach 2:
Instead of using complex mechanical measurement systems, the patent creates an optical copy (image) of the receiver tube reflected in the reflector and analyzes this copy to determine curvature. This approach simplifies the measurement device while maintaining high manufacturing precision through optical analysis rather than mechanical sensing.
4Measurement precision
If illumination sources project patterns on the reflector, then curvature can be calculated, but the measurement precision is insufficient for high-quality verification
Solution Approach 1:
Instead of projecting illumination patterns onto the reflector and analyzing the distorted pattern (traditional method), the patent inverts the approach by capturing the reflection of the receiver tube in the reflector surface and analyzing that reflected image. This inversion provides superior measurement precision because it directly utilizes the reflector's optical properties to reveal shape deviations, achieving higher conformity to design specifications.
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 approach enables early identification of defects, reduces service needs, and minimizes the production of defective solar collectors, resulting in cost-efficient and accurate quality control of solar collectors.
Implementation Method 1
capturing an image of the reflected receiver tube in the reflector surface
Data Source
AI summary
A method of determining a reflector parameter of a concentrating solar collector's reflector surface. An image is captured of the reflected receiver tube in the reflector surface, with an image capturing device, e.g. a camera, and processed to put together image data related to the reflected receiver tube. Further, the method comprises determining a location of the image capturing device at a capturing time of the captured image, and determining a position on the reflector surface based on the determined location of the image capturing device and the image data. The method comprises also calculating the reflector parameter at the determined position based on the image data. By numeric calculation of reflector parameters, such as slope, defects, e.g. caused by impacts or material imperfections, may be identified at an early stage before installing the solar collectors, which may reduce service needs.