Segmented Solar Frame Nodes for Easier Assembly and Lower Deflection
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Solution Overview
Problem
Existing solar frame designs face challenges with long, single-piece chords that are difficult to handle, transport, and assemble, requiring large extrusion presses and inducing deflections that affect optical performance. Additionally, conventional CSP solar frames experience torque-related deflections and high installation costs due to manual assembly methods.
Innovation Solution
The use of segmented chords and nodes with strut end pieces allows for more flexible assembly and reduced member sizes, enabling the use of smaller presses and improving deflection results under load. A rolling rib drive mechanism reduces frame weight and enhances optical performance by minimizing torque-induced errors, and innovative assembly methods streamline the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If long single-piece chords are used in solar frame design, then the structural continuity is improved, but the handling, transportation and assembly difficulty increases
Solution Approach 1:
The patent divides the long single-piece chord into multiple shorter chord segments that can be easily handled, transported and assembled. These segments are connected through nodes with sleeve structures, maintaining structural continuity while improving operational ease. The segmentation allows standard handling equipment to be used and reduces transportation constraints.
2Strength
If large extrusion presses are used to produce nodes, then the node strength and load-bearing capacity are improved, but the manufacturing cost and equipment availability worsen
Solution Approach 1:
The node is divided into a body portion and separate sleeve components. The sleeve is inserted into the node body through a guided insertion system, allowing the node body to be produced on smaller, more available extrusion presses. This segmentation reduces the required press size while maintaining node strength through the combined structure.
Solution Approach 2:
The sleeve component is nested within the node body, with the sleeve inserted into a cavity in the node body. This nested structure allows the node to be assembled from smaller components produced on smaller presses, while the combined structure provides the necessary strength and load-bearing capacity.
3Device complexity
If conventional drive mechanisms turning multiple frames are used, then the drive system complexity is reduced, but the torque-induced deflection and optical performance worsen
Solution Approach 1:
The drive system is segmented so that each frame has its own independent rolling rib drive mechanism rather than being driven by a single mechanism turning multiple frames. This segmentation eliminates torque transmission between frames, reducing deflection and improving optical performance, while each individual drive mechanism remains relatively simple.
Solution Approach 2:
The rolling rib acts as an intermediary between the drive mechanism and the frame. The drive mechanism turns the rolling rib, which then rolls along the frame to drive it. This intermediary mechanism reduces direct torque application to the frame, minimizing torque-induced deflection and improving optical accuracy.
Data Source
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.