Robotic Heliostat Calibration Using Onboard Sensors

Solution Overview

Problem

Current solar tracking and calibration systems for photovoltaic and concentrated solar thermal systems are inefficient, particularly for smaller heliostats, as they require labor-intensive sun sensor alignment and lack flexibility in installation, making them cost-ineffective and inflexible.

Innovation Solution

A robotic controller with onboard sensors and a drive system that autonomously positions itself to gather data, using GPS, distance sensing, cameras, and other sensors to calibrate and inspect solar surfaces, optimizing alignment and health assessment without the need for extensive manual labor or precise sensor installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional sun sensor calibration methods are used, then calibration accuracy can be achieved, but labor costs increase and installation flexibility decreases

Engineering Contradiction:

Improvecalibration accuracyVSAvoidinstallation flexibility

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The robotic controller autonomously performs calibration by independently determining its own position and orientation using onboard sensors (GPS, accelerometers, magnetometers, sun sensors) without requiring manual positioning or external sensor installation. The system self-calibrates by comparing encoder readings with sensor measurements across multiple positions, eliminating the need for labor-intensive traditional calibration methods while maintaining accuracy.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical calibration operations with an automated robotic system that uses electronic sensors and computational algorithms. Instead of workers physically positioning sun sensors and taking measurements, the robotic controller uses GPS coordinates, accelerometer data, magnetometer readings, and sun sensor measurements combined with mathematical calculations to achieve calibration, substituting mechanical labor with electronic and computational processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If manual sun sensor alignment is used, then calibration can be performed, but productivity decreases due to labor-intensive processes

Engineering Contradiction:

Improvecalibration accuracyVSAvoidcalibration efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The robotic controller autonomously performs calibration by independently determining its own position and orientation using onboard sensors (GPS, accelerometers, magnetometers, sun sensors) without requiring manual positioning or external sensor installation. The system self-calibrates by comparing encoder readings with sensor measurements across multiple positions, eliminating the need for labor-intensive traditional calibration methods while maintaining accuracy.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The robotic controller continuously collects data from multiple positions and orientations during its inspection path, accumulating calibration information throughout its operation rather than requiring separate calibration steps. This continuous data collection process integrates calibration into the normal inspection workflow, improving productivity by eliminating redundant operations while maintaining comprehensive calibration accuracy.

Inventive Principle:

Principle #20Continuity of useful action

3Measurement precision

If precise sensor installation is required, then calibration accuracy improves, but device complexity and installation cost increase

Engineering Contradiction:

Improvecalibration accuracyVSAvoidinstallation requirements

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The robotic controller autonomously performs calibration by independently determining its own position and orientation using onboard sensors (GPS, accelerometers, magnetometers, sun sensors) without requiring manual positioning or external sensor installation. The system self-calibrates by comparing encoder readings with sensor measurements across multiple positions, eliminating the need for labor-intensive traditional calibration methods while maintaining accuracy.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The robotic controller integrates multiple functions into a single system: it performs both inspection and calibration tasks, uses multiple sensor types (GPS, accelerometers, magnetometers, sun sensors) for various measurements, and determines position and orientation without requiring external calibration infrastructure. This multi-functional approach eliminates the need for separate precision installation of external sensors while achieving comprehensive calibration accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9506783B2Robotic heliostat calibration system and method

Publication Date: 2016.11.29 TESLA INC

AI summary

A robotic controller for autonomous calibration and inspection of two or more solar surfaces wherein the robotic controller includes a drive system to position itself near a solar surface such that onboard sensors may be utilized to gather information about the solar surface. An onboard communication unit relays information to a central processing network, this processor combines new information with stored historical data to calibrate a solar surface and/or to determine its instantaneous health.