Torque Tube Coupler Assembly for 360° Solar Reflector Rotation
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Solution Overview
Problem
The high initial cost and installation expenses of solar energy collection systems, particularly due to expensive manufacturing and radiant heating effects that reduce efficiency, hinder widespread adoption, and existing reflectors are heavy and lack the ability to rotate during inclement weather, leading to torque loss.
Innovation Solution
A torque coupler and support point system that allows 360° rotational freedom for reflectors, using a torque tube coupler assembly with a rigid shaft and bearing stake for continuous variable control, enabling mirrors to be flipped over for protection and minimizing torque loss, while being lightweight and cost-effective.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shaft couplers are used to connect mirrors in a reflector assembly, then the mirrors can be supported, but torque is lost in transmission from one mirror to the next and the mirrors cannot be turned over during inclement weather
Solution Approach 1:
The patent employs a torque tube assembly that allows dynamic rotation of mirrors through 360 degrees while maintaining torque transmission. The torque tube connects mirrors in a series arrangement, enabling each mirror to rotate independently to face the sun or be turned over during inclement weather, while still transmitting torque efficiently from one mirror to the next through the rigid tube structure.
Solution Approach 2:
The torque tube assembly serves multiple functions: it supports the mirror, transmits torque for positioning, enables 360-degree rotation for sun tracking, and allows mirrors to be turned over for weather protection. This multi-functional design replaces the need for separate mechanisms for each function, improving both torque transmission and adaptability.
2Strength
If heavy traditional reflectors are used, then structural strength is sufficient, but the system cost increases and installation becomes more expensive
Solution Approach 1:
The patent utilizes thin-film flexible mirror assemblies that can be formed into curved reflective surfaces. These thin-film mirrors provide sufficient structural strength for their application while being significantly lighter and less expensive than traditional solid reflector materials, reducing both manufacturing and installation costs.
Solution Approach 2:
The reflector assembly employs composite construction combining lightweight materials with sufficient structural properties. The torque tube assembly itself uses composite design elements that provide the necessary strength and rigidity while minimizing weight, contributing to reduced overall system cost and easier installation.
3Productivity
If solar energy collection systems are made with high efficiency components, then energy collection performance improves, but the initial manufacturing and installation cost increases substantially
Solution Approach 1:
The patent employs cost-effective torque tube assemblies and mirror components that can be manufactured at lower cost using simplified designs and materials. While individual components may have limited lifetimes, the overall system achieves high energy collection efficiency at reduced initial cost, allowing for economical replacement and amortization over time.
Solution Approach 2:
The solar reflector system is divided into modular mirror assemblies, each with its own torque tube and mounting mechanism. This segmentation allows for standardized mass production of individual modules at lower cost, while maintaining high overall system efficiency through proper optical alignment of the segmented reflectors.
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
Enables efficient and cost-effective solar energy collection by allowing mirrors to rotate freely, reducing damage from inclement weather and maintaining torque consistency, thus lowering system costs and enhancing efficiency.
Implementation Method 1
A bearing is mounted on the bearing stake. The bearing is configured to facilitate rotational freedom of three hundred sixty degrees for the first reflector and the second reflector
Data Source
AI summary
A torque tube coupler that rigidly connects reflectors and provides for substantially 360° rotational freedom for the reflectors as well as the ability to transmit rotation from one reflector to another so that the reflectors may essentially be placed at the same angle. The torque coupler includes first and second torque tube coupler assemblies each configured to be connected to a reflector in a solar energy collection system. The torque coupler also includes a support point that supports said first torque coupler assembly and said second torque tube coupler assembly. This support point includes a shaft that facilitates the rigid connection of the first torque tube coupler assembly to the second torque tube coupler assembly and a bearing that facilitates 360° rotation of the first reflector and the second reflector.