Solar Reflector Mirror Assembly With Adjustable Support Links
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Solution Overview
Problem
Existing methods for manufacturing reflectors with mobile mirror support structures face challenges in achieving high manufacturing tolerances without compromising the mirror's shape or optical properties, often requiring bulky adhesive blocks that can lead to deformation and increased manufacturing complexity.
Innovation Solution
The use of rigid metallic links that can be adjusted and securely attached to both the mirror and support structure, allowing for high manufacturing tolerances without the need for specific flat surfaces or bulky adhesives, and enabling the mirror to maintain its shape and optical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If blocks of adhesive of substantial volume are used to compensate for high manufacturing tolerances, then the manufacturing precision of the support structure can be relaxed, but the mirror's shape is deformed and optical properties deteriorate
Solution Approach 1:
Rigid adjustment links are introduced as intermediary elements between the mirror and support structure. These links serve as mediators that can be precisely adjusted to compensate for manufacturing tolerances in the support structure, while maintaining the mirror's required shape and optical properties. The links transfer positional adjustments without deforming the mirror.
Solution Approach 2:
The connection system is segmented into multiple adjustable links rather than using a single bulky adhesive block. This segmentation allows independent adjustment of each link's position and length, enabling precise compensation for manufacturing tolerances while distributing the adjustment function across multiple small components that do not deform the mirror.
2Ease of manufacture
If blocks of adhesive are heated to soften them for assembly, then the adhesive can be deformed to accommodate tolerance variations, but additional manufacturing constraints and residual shape defects are introduced
Solution Approach 1:
The thermal softening mechanism is replaced with a mechanical adjustment system. Instead of heating adhesive to make it pliable for assembly, rigid adjustment links with mechanical adjustment mechanisms (such as threaded rods or sliding joints) are used to accommodate tolerance variations. This substitution eliminates thermal effects and residual shape defects while maintaining assembly flexibility.
3Manufacturing precision
If very small manufacturing tolerances are required for the support structure, then the mirror can be pressed directly against the support structure, but manufacturing cost increases significantly
Solution Approach 1:
Adjustment links are pre-installed on the support structure with preliminary positioning features. During assembly, these pre-installed links can be quickly adjusted to the correct position without requiring high-precision pre-alignment of the entire support structure. This preliminary preparation enables the use of larger manufacturing tolerances in the support structure while achieving the required final precision.
Data Source
AI summary
The invention relates to a method of manufacturing a reflector (6) including a mirror (16) supported by a support structure (18), where the said method includes a step of positioning the mirror relative to the said support structure by moving a mold (30) supporting the mirror relative to the said structure, According to the invention, the method also includes a step of adjustment of multiple links (20) between the mirror and the structure, implemented during the step of positioning of the mirror, and/or after this step, and causing at least a proportion of the links to be moved relative to the structure (18).