Segmented Solar Reflector Frame Nodes for Low-Deflection Assembly
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Solution Overview
Problem
Existing solar reflector frame designs face challenges with long, single-piece chords that are difficult to handle and assemble, require large extrusion presses, and induce deflections under load, leading to reduced optical performance and increased costs.
Innovation Solution
The use of segmented chords and nodes with strut end pieces allows for more flexible design and assembly, reducing the need for large presses and minimizing deflections, while the rolling rib drive mechanism reduces frame weight and improves optical accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If long single-piece chords are used, then structural continuity is improved, but handling and assembly difficulty increases
Solution Approach 1:
The chord is divided into multiple segments that can be separately manufactured, transported, and assembled. Each segment connects to adjacent segments through nodes, providing connection points for struts while maintaining the overall structural continuity of the chord assembly.
2Ease of manufacture
If large extrusion presses are used, then manufacturing capability is improved, but equipment availability decreases
Solution Approach 1:
The chord is segmented into multiple smaller sections that can be manufactured using standard-sized extrusion presses. These segments are then assembled through nodes to form the complete chord structure, eliminating the need for rare large-capacity presses.
Solution Approach 2:
Multiple chord segments are combined through nodes to create the functional equivalent of a long single-piece chord. This merging of segments achieves the required manufacturing capability using widely available equipment.
3Adaptability or versatility
If nodes are used to connect chords, then assembly flexibility is improved, but deflection under load increases
Solution Approach 1:
The nodes are designed with pre-configured connection geometries and reinforcement features that minimize deflection under load. The structural design of the nodes accounts for load paths in advance, allowing flexible assembly while maintaining strength.
4Reliability
If frames closer to drives are designed for higher torque, then drive reliability is improved, but frame weight increases
Solution Approach 1:
The frame structure implements local quality variations where members closer to the drive mechanism are designed with higher torque capacity, while members farther away use optimized lighter sections. This allows the frame to withstand drive torques reliably without unnecessarily increasing overall weight.
Data Source
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AI summary
A node for connecting together at least a first support element, a second support element and a third support element of a support frame such as a solar frame which supports solar reflectors. A method for connecting together at least a first support element, a second support element and a third support element of a solar frame which supports solar reflectors. A system for supporting solar reflectors includes a first support frame upon which the solar reflectors are disposed. A method for forming a support frame for solar reflectors. A system for constructing a support frame from parts, including chords, for solar reflectors. A method for constructing a support frame for solar reflectors. A support frame for solar reflectors.