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1
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DualActua*ngSolarTrough
Solvesdecienciesweseeinothersystems:
Justbecauseeveryoneelseisdoingitdoesntmeanthatyoushould
2
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SolarEnergyPoten*al
NM,CA,AZ,NVcurrentlygenerate423MW
CARPSmandates20%by2017
4132GWpoten*alcovering32,000sqmi.undevelopedland
3
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SolarEnergyCapture
4
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PowerGenera*onwithCSP
5
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Concentra*ngSolarFields
6
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KeyDecienciesofCurrentSystems
Complexspaceframes Fluidjoints Fragileexpensivemirrors
Levelingground Environmentaldamage Cost
900mx1800m7
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ComplexSpaceFrames
8
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FragileGlassMirrors
9
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FluidJoints&HydraulicActuators
10
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KeyCompe*tors
SopogySkyFuel
WithContracts:BrightSourceMojaveSunPowerSolel
11
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TakingANewApproach
Complexspaceframes Fluidjoints Fragileexpensivemirrors
Levelingground
Environmentaldamage Cost
Fiberglassstructure Sta*onarypipe Reectechaluminalm
Morefrequentactua*on
ElectroPneuma*c Op*mizeforcost
12
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Func*onalRequirementsofourSystem
1pieceparabolicreec*ngsurface Sta*onaryheatpipe
260degreesoftravel Lowtrackingerror Modular Survivewindloads
13
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Oursolu*on
Trackingsystemthatusestwolinearactuatorstopointaparabolicmirroratthesun
14
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Keyconcepts
Pivotsaboutfocus Twolinearactuators Oneactuatorfordailymo*on
Stowagemode
15
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KeyAeributes:ReducedComplexity
SimplerassemblyFewerpartsMonolithicberglassaeachessimplytostructure
Modular Massproduceable
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Keyaeributes:EasierMaintenance
FocuspivotNoneedtoshutdownen*reline
Nomovinguidseals,noexibletubing
Modular,breakawaycomponents
Stowagemode
17
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Keyaeributes:CheaperMaterials
SingleberglasspieceStrongerperweightlighter
Cheaperthanglass SteelsupportframeStrongerper$
18
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Summaryofoursystem
Usestwolinearactuatorstopointparabolicmirroratthesun
Advantages: Reducedcomplexity
Simplerassembly Cheapermaterials Improvedcapabili*es
Massproduceable Stowagemode Modular
Patentclaim19
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Demo
20
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WindLoadingStandards(ASCE798)
Methodsofcalcula*ngwindloadingandgustfactors
Provideslocalaveragewindspeedsbyclass
ImagesfromWindTunnelTestsofParabolicTroughCollectorsNREL/SR55032282,May2008
21
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WindLoadingCalcula*ons
Experimentalcoecientsofdragdeterminedfromwindtunnelmeasurements
Calculateloadsfordierentgeometriesandwindspeeds
Sizeactuatorsaccordingtospecs
22
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MeasuringEciency
Specularreec*on Findincidentangleforvariousincidentrays
Determinewhetherornotthereectedrayhitstheenvelopeoftheheatpipe
23
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Deec*onsError
Theparabolaissubjectedtosignicantwindloads
Resul*ngdeforma*onfrombendingcons*tuteintrinsicerror
Mustconsidertheimpactofaddi*onalerror
Bendingdeec9onsalongthevertexlineoftheparabola
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PipePlacementError
Eciencyasafunc9onofwindvelocity,forvariouspipeplacementerrors
25
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AngularError
Eciencyasafunc9onofwindvelocity,forvarioussupplementalangularerrors
26
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ManufacturedPartsError
Encoderresolu*on Primaryactuatorbacklash
Errorinmanufacturedcomponents: Crankarm Actuatormounts
KeyedshaqsAlsoaectrequiredactuatorforceandtravel
27
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Mul*variableSystem:Variables
28
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CrankArmLengthError
Cri*calComponent:crankarm
y0
29
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ActuatorPosi*oningErrors
Exactactuatorplacementislessimportant
30
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ErrorAnalysis:ExperimentalValida*ononPrototype
Combinederrorofabout0.40degreesfrombacklash,manufacturingtolerancesandcontrolsystem
Valida*onofmodelforangularerrorimpactoneciency
31
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ComparisontoCompe**on
32
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ShiqingCostStructure
$0 $5,000 $10,000 $15,000 $20,000 $25,000
Exisi(ng
Proposed
Costperunit
Receivers Mirrors CollectorStructure Erec*onDrive
Interconnec*onPiping Electronics&Control
HeaderpipingFounda*ons/OtherCivil Other Con*ngency
33
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Concentra*ngSolarPowerGrossMargins
34
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ExpendituresCostofR&Deort Misc.Expenditures ROI
Developmentof10thScalePrototype SG&A R&D $551,800
Materials $800 OceSpace $100,000 CAPEX $475,000
ActuatorsandPowerSystems $800 Admin.Expenses $40,000
RecurringYearlyExpenses $140,000
ControlSystem $3,200 Total $140,000 UnitCost $18,000
Researchteam $22,000 CapitalExpenditures UnitPrice $24,000
Total $26,800 Molds/DiesandTooling $475,000 Prot/Unit $6,000
PendingR&DExpenses Total $475,000 UnitSales/year 375
10thScalePrototypeValida*on $75,000 TotalMisc.Exp. $615,000
FullSizeSystemDetailedDesign $150,000
FullSizeSystemBuilding $150,000
FullSizeSystemValida*on $150,000
Total $525,000
TotalR&Dcosts $551,80035
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36
TimeToMarketMonths: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Cash
Validate Prototype $75,000
Design Full Size System $150,000
Build Full size Prototype $150,000
Validate Prototype $150,000
Production Tooling $475,000
Production TBD
$1,000,000+
$500kDOE/FederalGrants$500k+OutsideCapital
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ScheduleandBudget
Item Initial Updated ActualMotor/Encoder/Gearing 600 2400
800Control System / Power Supply 300 1000 3200
Bearings 200 800 100Machined Parts 400 2000 700
Total:1500 6200 4800
2/112/182/25 3/4 3/113/183/254/14/84/154/224/29 5/6
5/135/205/27
Determine Critical FRs
Background Research = Initial
Brainstorm = Actual
Detailed CAD
Scale Design
Spec Components
Build Prototype
Test Prototype
37
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WhyTheScheduleSlipped?
Func*onalRequirementsChangedasDesignEvolved
OverlyOp*mis*c
38
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39
RiskManagement
CostCompe**veDesign SargentandLundy/NRELReportBenchmark
LargelyDrivenByCommodityPrices
MinimizeMaterialUsage
ScaledPrototypetoValidate FeasibilityofActua*onMechanism
ErrorMeasurement Loading
Windtunnel Performance
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LingeringRisks
CostisParamountTroughS*ness/WeightMylarLongevityPerformanceIsMassProduc*onSustainable?
40
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Conclusions
ManagingadiverseprojectOp*cs,Dynamics,Mechanics,Controls,Pneuma*cs
Experienceinnewelds
Understandingrequirementsfromcustomer,manager
BudgetmindedmechanicaldesignCrea*ngacostcompe**vedevice,notjustinnova*veprototype
41
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Acknowledgements
42
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Ques*ons?
43
