Solar Collector Optical Element Assembly With Precision Frame Alignment

Solution Overview

Problem

The assembly of optical elements in concentrating photovoltaic solar collectors is time-consuming, costly, and prone to inaccuracies due to the individual adjustment of solar reflectors, which can be unreliable and labor-intensive.

Innovation Solution

A method involving the precise alignment and adhesion of a structural frame to optical elements using high precision surfaces and adhesive joints, allowing for efficient assembly and alignment of solar collectors, reducing labor and costs while improving accuracy and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If individual adjustment of solar reflectors is performed, then alignment accuracy is improved, but assembly time and cost increase

Engineering Contradiction:

Improvealignment accuracyVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-aligning optical elements during the manufacturing process before final assembly. The elements are pre-positioned and pre-aligned with high precision, then transported as pre-assembled units to the final installation site. This eliminates the need for time-consuming individual adjustment during on-site assembly, resolving the contradiction between alignment accuracy and assembly time.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If individual adjustment of solar reflectors is performed, then alignment accuracy is improved, but assembly cost increases

Engineering Contradiction:

Improvealignment accuracyVSAvoidassembly cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-aligning optical elements during the manufacturing process before final assembly. The elements are pre-positioned and pre-aligned with high precision, then transported as pre-assembled units to the final installation site. This eliminates the need for time-consuming individual adjustment during on-site assembly, resolving the contradiction between alignment accuracy and assembly time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies copying by using master alignment templates or jigs that define the precise positions and orientations of optical elements. These templates serve as reusable copies of the ideal alignment configuration, allowing multiple elements to be aligned quickly and accurately without requiring skilled manual adjustment for each element, thereby reducing assembly cost while maintaining high alignment precision.

Inventive Principle:

Principle #26Copying

3Adaptability or versatility

If traditional assembly methods are used, then flexibility is maintained, but reliability decreases

Engineering Contradiction:

ImproveflexibilityVSAvoidassembly reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-aligning optical elements during the manufacturing process before final assembly. The elements are pre-positioned and pre-aligned with high precision, then transported as pre-assembled units to the final installation site. This eliminates the need for time-consuming individual adjustment during on-site assembly, resolving the contradiction between alignment accuracy and assembly time.

Inventive Principle:

Principle #10Preliminary action

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 method enhances the assembly process by reducing labor time and costs, improving alignment precision, and increasing the reliability of optical element assemblies, leading to more efficient and accurate solar collector arrays.

Implementation Method 1

adhesive is applied to adhere the structural frame to the optical elements

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS8641861B2Solar collector devices and methods of assembly

Publication Date: 2014.02.04 THE BOEING CO

AI summary

In one embodiment, a method of assembling optical elements is provided. At least a portion of each optical element is disposed against at least a portion of a high precision surface. A structural frame is disposed adjacent the optical elements. At least two portions of the structural frame are aligned relative to each other and to the high precision surface with high precision. Adhesive is applied to adhere the structural frame to the optical elements. The adhesive is cured. In other embodiments, optical element assemblies are provided.