NZ602345B - Improvements to reflector supports and methods of manufacture - Google Patents
Improvements to reflector supports and methods of manufacture Download PDFInfo
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- NZ602345B NZ602345B NZ602345A NZ60234512A NZ602345B NZ 602345 B NZ602345 B NZ 602345B NZ 602345 A NZ602345 A NZ 602345A NZ 60234512 A NZ60234512 A NZ 60234512A NZ 602345 B NZ602345 B NZ 602345B
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- reflector
- reflector support
- support
- ridges
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Abstract
602345 A reflector support deck (2) for a Linear Fresnal Reflector solar power station is disclosed. The support deck includes at least one corrugated sheet of material (3) with two or more ridges (5) of differing heights, the ridges (5) are positioned relative to each other so that the crests (9) of the ridges collectively define a curved bearing surface (10) that curves along a single axis. The curved bearing surface (10) supports a mirror reflector and the deck (2) may be supported by a plurality of support modules (1A). of the ridges collectively define a curved bearing surface (10) that curves along a single axis. The curved bearing surface (10) supports a mirror reflector and the deck (2) may be supported by a plurality of support modules (1A).
Description
James & Wells ref: 134134/60 HCS
IMPROVEMENTS TO REFLECTOR SUPPORTS AND METHODS OF MANUFACTURE
TECHNICAL FIELD
The present invention relates to improvements to reflector supports and methods of
manufacture.
BACKGROUND ART
Solar power generation is a rapidly developing industry due to the increasing costs of fossil
fuels and greenhouse effect. Therefore considerable effort is being spent on renewable energy
sources.
One efficient and cost effective form of solar power station is known as a Linear Fresnel
Reflector (“LFR”). Of LFR power stations, the Compact Linear Fresnel Reflector power stations
(“CLFR”) are particularly important as they produce more power than a LFR power station
having a comparable area.
LFR and CLFR power stations both use arrays of mirrors to focus and concentrate sunlight onto
absorbers containing a liquid having a high heat capacity. The sunlight transfers heat into the
liquid, increasing its temperature causing it to change phase. The resulting gas is then passed
through a heat inverter, and the extracted heat is used to power a steam generator.
The difference between LFRs and CLFRs is the arrangement of the mirrors, with CLFRs having
more reflectors, which are focused onto multiple absorbers. In addition, the reflectors in CLFR
power stations are arranged into vertically staggered rows. This reduces adjacent rows of
reflector casting shadows on each other as the sun progresses through the sky throughout the
day.
The orientation of the reflectors is adjusted to maximise the sunlight reflected onto the absorber.
This helps to account for daily and seasonal variations in the sun’s path through the sky.
Reflector supports are currently made from a support deck having a curved bearing surface to
which the reflectors are secured. The curved bearing surface assists in ensuring that the
reflectors focus the sunlight onto the absorber. That curved surface also helps to ensure the
deck provides adequate support to the reflector along its length and across its width.
James & Wells ref: 134134/60 HCS
The reflectors used in LFR and CLFR power stations utilise the Fresnel lens effect. These
mirrors have a large aperture and a short focal length, which allows the mirror to efficiently and
accurately concentrate sunlight into the absorber.
The arrangement of reflectors creates a number of problems for manufacture of CLFR power
stations. It is necessary for the rows to be long enough to minimise non-reflective components
and maximise use of land area. Furthermore, the rows must be supported only at each end
with no support for the rows at points along their length. This is because the reflector support
must be able to rotate through 360 degrees about an axis extending along its length. This
rotation facilitates cleaning, maintenance and replacement of reflectors.
Furthermore the supports must be rigid enough to withstand the static loads experienced in use.
Those static loads are the combined result of the materials forming the support, the weight of
reflectors, and the lengths which the supports must span without support. Deflection of the
supports from an equilibrium (non-loaded position) can result in cracking of the reflectors.
The traditional approach to designing and manufacturing reflector supports for CLFR power
stations has been to increase the amount of materials used e.g. use thicker sheets of material.
However, this increases the static loads on the reflector supports. As a result reflector support
design often falls into a vicious cycle of increasing the weight of components to obtain additional
strength, which in turn increases static loads and requires additional support.
The logistics of manufacturing, transporting, and installing reflector supports can also be
problematic.
It has also been proposed that the reflector supports could be constructed in shorter length
modules, transported to site, and connected together to form a reflector support having the
desired length. However, the existing designs of reflector supports do not facilitate that type of
construction partially because the components forming the structure have round cross-sections.
That means that the components do not have a surface area conducive to the use of
mechanical fasteners to secure two adjacent modules together.
Furthermore, it is necessary that the reflector supports are made from galvanised steel to
ensure that they can withstand the environmental conditions that they may experience in use,
and last for a reasonable time period. This is particularly relevant as CLFR power stations are
generally constructed in inhospitable locations.
James & Wells ref: 134134/60 HCS
It is not however possible to weld galvanised materials. As a result, the existing reflector
supports are generally constructed using welding techniques to the total length required, and
then galvanised before transport.
Therefore, the fully assembled and galvanized reflector supports are subsequently transported
to the site at which the CLFR power station is being constructed. However, transport can be a
problem because the reflector supports are in excess of 20 metres in length. These
components therefore often exceed the standard dimension for shipping which complicates
transportation, and significantly increases costs.
It is an object of the present invention to address the foregoing problems or at least to provide
the public with a useful choice.
All references, including any patents or patent applications cited in this specification are hereby
incorporated by reference. No admission is made that any reference constitutes prior art. The
discussion of the references states what their authors assert, and the applicants reserve the
right to challenge the accuracy and pertinency of the cited documents. It will be clearly
understood that, although a number of prior art publications are referred to herein, this
reference does not constitute an admission that any of these documents form part of the
common general knowledge in the art, in New Zealand or in any other country.
Throughout this specification, the word "comprise", or variations thereof such as "comprises" or
"comprising", will be understood to imply the inclusion of a stated element, integer or step, or
group of elements integers or steps, but not the exclusion of any other element, integer or step,
or group of elements, integers or steps.
Further aspects and advantages of the present invention will become apparent from the ensuing
description which is given by way of example only.
DISCLOSURE OF THE INVENTION
According to one aspect of the present invention there is provided a reflector support module,
including
a reflector support deck,
a first support arm formed from a sheet of material,
a second support arm formed from a sheet of material,
James & Wells ref: 134134/60 HCS
wherein the support arms are secured to each other and to the reflector support deck to form a
substantially rigid structure,
and wherein the support arms include complementary surfaces that bear against each other
According to another aspect of the present invention there is provided a method of
manufacturing a reflector support,
wherein the reflector support includes a reflector support deck, a first support arm formed from a
sheet of material, and a second support arm formed from a second sheet of material, the
method including the following steps in any order:
(a) positioning the first and second support arms with respect to each other;;
(b) securing a reflector support deck to the first and second support arms;
(c) securing the first and second support arms to each other so that complementary
surfaces of the first and second support arms bear against each other.
According to another aspect of the present invention there is provided a reflector support
including one or more reflector support modules.
Throughout the present specification, reference to the term “reflector support module” should be
understood as meaning a component as described above that contributes to the overall length
of the reflector support.
According to another aspect of the present invention there is provided a reflector support deck,
including
at least one corrugated sheet of material having two or more ridges of differing heights,
characterised in that
the ridges are positioned relative to each other so that the crests the ridges collectively define a
curved bearing surface that curve about a single axis.
According to another aspect of the present invention there is provided a method of
manufacturing a reflector support deck,
James & Wells ref: 134134/60 HCS
wherein the reflector support deck includes a corrugated sheet of material having two or more
ridges of differing heights,
the method including the steps of:
(a) feeding a length of a sheet material into a forming device;
(b) engaging the forming device to deform the length of sheet material to create ridges,
such that the ridges are positioned relative to each other so that the crests of the ridges
collectively define a curved bearing surface that curves about a single axis.
The present specification describes in particular reflector supports for use in Linear Fresnel
Reflector and/or compact Linear Fresnel Reflector power stations (referred to herein collectively
as “LFRs”).
Curved bearing surfaces for mirrors are known in the prior art. See for example United States
Patent Publication No. 2006/0012895 which discusses light weight mirror blank supports. These
supports are particularly intended for use with high end telescopes such as those used in
ground or space based astronomy.
However, the mirror supports of United States Patent Publication No. 2006/0012895 all have
bearing surfaces which have a spherical curve e.g. curve in two or more axis. This is because
telescopes require mirrors to reflect and concentrate an image/light to substantially a point.
In contrast LFRs require reflectors to reflect an image/light to a long narrow focus point.
maximising the length of the focus point will assist in maximising the efficiency of the LFR.
It would be impossible to take the mirror supports of United States Patent Publication No.
2006/0012895 and adapt them for use in LFRs due to the shape of the bearing surfaces. Simply
put, using United States Patent Publication No. 2006/0012895in an LFR application would
require a series of individual reflector supports along the length of the LFR, and use of individual
spherical mirrors. That would be an inefficient arrangement.
In addition, the forming techniques discussed in United States Patent Publication
No. 2006/0012895 are costly. That is acceptable for the high value mirrors and telescopes
subject of the invention described in United States Patent Publication No. 2006/0012895.
However, the cost of those techniques would prohibit use of the invention described in United
States Patent Publication No. 2006/0012895 in applications such as LFRs which require
considerable lengths of reflector supports.
James & Wells ref: 134134/60 HCS
Throughout the present specification, reference to the term “reflector support” should be
understood as meaning an assembly to which a reflector may be secured, and that in-use holds
a reflector(s) in position.
In particularly preferred embodiments, the reflector supports are configured to be mounted on
axles. The axles are preferably aligned with the longitudinal axis of the reflector support and
rotated to rotate the reflector supports.
It should be noted that the reflector supports are supported only at two points, being at or near
the ends of the reflector support’s length. That is, the reflector support is supported only at the
points where the axles are secured to the reflector supports. This is as should be understood
by one skilled in the art.
Throughout the present specification, reference to the term “reflector support deck” should be
understood as meaning the part of a reflector support to which a reflector(s) is secured.
Further aspects of the reflector support deck should become clearer from the following
description.
Throughout the present specification, reference to the term “reflector” should be understood as
meaning a device to reflect and concentrate light.
In a particularly preferred embodiment, the reflector(s) with which the present invention is
intended for use are mirrors having a large aperture and narrow focal point. These mirrors are
as should be understood by one skilled in the art and is commonly used in LFRs.
The reflectors have a reflective surface and a back surface. The back surface has a curve
corresponding to the curve of the reflective surface. This is because the reflectors are made
from glass having a reflective substance coated thereon, and it is not currently possible to
manufacture tapered glass. Accordingly, the cross sectional area of the reflectors along their
length is constant.
In addition, these types of reflectors are fragile. This is because the types of glass from which
they are made is brittle, and they are often thin, having thicknesses in the range of 3 – 5mm.
The result of the forgoing is that a curved bearing surface must be provided to sufficiently
support the reflector.
James & Wells ref: 134134/60 HCS
Throughout the present specification, reference to the term “support arm” should be understood
as meaning a structural component to support the reflector support deck.
In a preferred embodiment the reflector support modules according to the present invention may
include support arms that extend along the entire length of the reflector support so the support
arms can therefore support the reflector support deck at positions along its length.
In a particularly preferred embodiment, the arrangement of the support arms and support deck
in the reflector support modules forms a triangular shape when a reflector support module is
viewed end on.
The inventors have identified that the reflector support having a triangular shape may be
particularly beneficial in LFRs. This is because the shape ensures that the reflector support has
sufficient integral strength to be able to withstand the static loads experienced as it is rotated
about its longitudinal axis.
In contrast, the inventors have found that other shapes of the reflector support do not have
sufficient strength to withstand those static loads without significantly increasing the weight of
material used.
For instance a reflector support module having a square shape could collapse. In these
embodiments increasing the thickness of sheet materials used in manufacturing the reflector
support modules would not provide the required strength. Rather, the additional weight of
material would increase the static load experienced by the reflector support module in use and
increase the chances of failure. As a result, the triangular shape of the reflector support module
may be particularly beneficial.
In particularly preferred embodiments, the sheet of material may be sheets of galvanised steel.
In these embodiments, the sheets may be provided in coils. The coils can be continually fed
into a forming device, or cut to length before being fed into a forming device.
In a particularly preferred embodiment, the sheets have a width of 1800 mm. This width is the
widest of galvanised steel sheets currently being manufactured.
The inventors have found that sheet steel having this preferred width is particularly
advantageous in manufacturing a reflector support. This width enables support arms capable of
supporting the reflector deck to be formed from a single sheet of material.
James & Wells ref: 134134/60 HCS
In addition it is not necessary to join two or more sheets of material together. Such joins would
require overlapping of sheets and increase the weight of the reflector support.
Further joining two sheets of material would increase the number of joints which are potential
weak spots, and therefore reduce the strength of the reflector support module.
However, the forgoing should not be seen as limiting on the scope of the present invention as
alternatives for the sheet(s) of material are envisaged.
In a preferred embodiment the sheet of material may have a thickness in the range of 0.5 –
2mm.
In a particularly preferred embodiment, the components forming the reflector support module
may each be made from a sheet of material having a different thickness to the other sheet(s).
For instance, in one embodiment, the reflector support may be made from a sheet of material
having a thickness of substantially 0.6mm, while support arm(s) may be made from a sheet
having a thickness of substantially 1.6mm.
The inventors have identified that these ranges for sheet thickness and the preferred
embodiments are particularly beneficial. For instance, the sheets are thin enough that they do
not increase the weight of the constructed reflector support module. In addition, these ranges of
thicknesses provide the sheets of material with sufficient strength for the components once
formed.
Furthermore, the thickness of the sheets enables them to be manipulated to form the
components of the reflector support module without tearing or ripping. The selection of the
sheet thickness is particularly important to forming the components of the present invention due
to the unique arrangement of these. Therefore, sheet thickness is an important consideration
and manufacturing reflector support modules according to the present.
In a preferred embodiment, the sheets of material may be stainless steel having a grade of 200
– 600MPA.
In a preferred embodiment, the grade of the sheet material forming a component is selected
according to the specific components. For instance, preferably the support arm(s) are formed
from stainless steel having a grade of 300MPA, while the corrugated sheets of the reflector
support deck are stainless steel of a grade of 450MPA.
James & Wells ref: 134134/60 HCS
However, the forgoing should not be seen as limiting on the scope of the present invention. It is
also envisaged that the stainless steel sheets can be formed from other grades of stainless
steel, or non-stainless steel material.
In a preferred embodiment, the sheet of material may be pretreated with a coating material.
Throughout the present specification, reference to the term “pretreated with a coating material”
should be understood as meaning a protective layer(s) applied to an outer surface(s) of the
sheet material.
In preferred embodiments, the sheets of material may be galvanised, zinc coated, or coated
with paint.
The protective coating protects the sheet material, and the components of the reflector support
module(s) formed using the material. Therefore, the manufactured reflector support modules
may be better able to withstand environmental conditions. In addition, the protective coating
may reduce or otherwise prevent corrosion of the components of the reflector support module.
The result of the foregoing is that the reflector support modules may be more durable.
Throughout the present specification reference to the term “complementary surfaces” should be
understood as meaning at least two surfaces having corresponding shapes.
In a preferred embodiment the corresponding shapes may be flat surfaces that bear against
each other when the support arms are adjacent to each other.
However, the foregoing should not be seen as limiting as alternatives are envisaged as being
within the scope of the present invention. For example the complementary surfaces may be
curved surfaces or triangular surfaces.
In a preferred embodiment the complementary surfaces are mated with each other so as to
engage with each other and provide resistance to the surfaces moving.
In a particularly preferred embodiment the engagement of the complementary surfaces may be
created by deforming the surfaces.
However, the foregoing should not be seen as limiting on the scope of the present invention as
alternatives are envisaged, including those where the complementary surfaces are not mated.
James & Wells ref: 134134/60 HCS
Throughout the present specification reference to the term “bear against” should be understood
as meaning that the complementary surfaces are engaged with each other. Therefore the
surfaces provide a frictional resistance to movement of the support arms relative to each other.
The inventors have identified that having complementary surfaces which bear against each
other may help to increase the rigidity of the reflector supports. In addition, the complementary
surfaces facilitate securing the support arms together.
In contrast, the prior art reflector supports do not have complementary surfaces. Therefore the
flat end surfaces of the arms bear against the curved surfaces of other arms. Those
arrangements do not provide an adequate contact to secure the components together using
non-welding techniques.
In a particularly preferred embodiment, the support arm(s) may include one or more apertures.
In a particularly preferred embodiment, the apertures in the support arm(s) have a triangular
shape.
The inventors have identified that forming apertures in the support arms may improve the ability
of the reflector support modules to withstand the necessary static loads experienced in use.
This is surprising because traditional engineering wisdom is that to increase the strength of a
component more material should be used e.g. use thicker sheets of steel to increase strength.
This arrangement is not possible in manufacturing reflector supports because these must be
unsupported except at each end. That arrangement leads to the weight of the reflector being a
primary design issue.
In a preferred embodiment, each support arm(s) may be formed from a single sheet of material.
In these embodiments, the single sheet of material is deformed by a forming device to the
necessary shape.
The inventors have identified that it is possible to manipulate a sheet of material so as to
provide a support arm having the necessary rigidity.
In a particularly preferred embodiment, the length of a support arm(s) may extend substantially
parallel to the length of the reflector support deck.
In these embodiments, each support arm(s) may be a single component which can support the
reflector support deck along its length. Therefore, it is not necessary weld or otherwise connect
James & Wells ref: 134134/60 HCS
a large number of individual arms together to support a reflector support deck. This is a
significant saving in labour and therefore facilitates decreasing manufacturing costs.
Furthermore, it is possible to accurately create the desired shapes for the components of the
reflector support. Accordingly, the reflector supports of the present invention may provide an
improved solution to the problems with manufacturing reflector supports in LFRs. However, the
foregoing should not be seen as limiting on the scope of the present invention. It is also
envisaged that the support arm(s) may be formed from two or more sheets of material.
In a particularly preferred embodiment the support arms may be secured together by crimping
the complementary surfaces of the support arms. In this embodiment, pressure is applied to the
complementary surfaces to deform these into mated components. The resulting shape and
configuration of the components provides resistance to the support arms moving with respect to
each other, thereby securing the components together.
However, alternatives are also envisaged including those using mechanical fasteners such as
nuts and bolts, screw type fasteners, and clamps. In these embodiments the mechanical
fasteners extend through the complementary surfaces to secure the support arms together.
Therefore, the forgoing should not be seen as limiting.
The inventors have identified that the preferred methods of securing the support arms can
significantly reduce the costs of manufacturing reflector supports. This is because the skill and
time required to accurately weld components together to manufacture a reflector support for
LFRs is significant. Crimping on the other hand is less labour intensive than welding.
Furthermore, the present inventions remove the need for labor intensive and difficult quality
control steps like checking the orientation of the components before and after welding
In addition, the inventors have found that crimping provides sufficient strength for the reflector
support to perform its intended use. This may be due to the interaction of the components
forming the reflector supports of the present invention, and that in preferred embodiments each
support arm is formed from a sheet of material.
It should be appreciated that the use of crimping is not simply a design choice. There is a
binding interaction between the deformed surfaces e.g. the support arms, and/or the reflector
support deck. That interaction helps to increase the rigidity of the reflector support.
James & Wells ref: 134134/60 HCS
Throughout the present specification, reference to the term “substantially rigid structure” should
be understood as meaning that the reflector support does not deflect more than a specified
standard.
In operation, the reflector support preferably does not deflect more than 10 – 20mm from its
equilibrium support e.g. the position when the substantially rigid structure is lying flat on a
substantially horizontal plane with no load thereon.
Ideally, the reflector support does not deflect more than substantially 15mm from its equilibrium
position.
However, the foregoing should not be seen as limiting on the scope of the present invention.
In preferred embodiments, the reflector support may be constructed from one or more reflector
support modules.
In preferred embodiments, there is a reflector support which includes one or more reflector
support module(s) having a length of:
11 – 12.5 metres, and more preferably in the order of 12 metres; and
4 – 6 metres, and more preferably in the order of 5 metres.
Constructing the reflector support from a plurality of modules provides a number of advantages.
For instance, each module can have a length within the standard shipping dimensions.
Therefore, the costs of transporting components to a construction site may be reduced.
In contrast, the reflector supports of the prior art are generally preassembled to the length
needed for the purpose, and then shipped to site. Given that these reflector supports often have
a length of 22 metres the transport costs are significant. Accordingly being able to manufacture
reflector supports from shorter length modules is a significant potential cost saving.
In addition, the preferred construction of the reflector support modules means they can be
nested together to maximise the use of space within shipping containers. Again, this may
significantly reduce transportation costs. In contrast, the known reflector supports have
insufficient strength and rigidity to be nested together. Rather, they would collapse which would
prohibit them being nested for transportation purposes.
James & Wells ref: 134134/60 HCS
In a particularly preferred embodiment, reflector supports according to the present invention
may be constructed from three or more reflector support modules.
The inventors have identified that using at least three support modules may help to ensure that
there are no joins between modules near the centre of the reflector support. This is particularly
beneficial as joints at the centre experience considerable forces when used and are therefore
prone to failure. As a result, ensuring that there are no joints near the centre addresses a
significant problem with manufacturing reflector supports from modules.
In particularly preferred embodiments the reflector support modules may include end on
connectors.
Throughout the present specification reference to the term “end on connectors” should be
understood as meaning components to secure two reflector support modules together in an end
on manner.
In a preferred embodiment the end on connectors may be complementary flanges on the end of
each module. To assemble the reflector support the modules are abutted together in an end on
manner. In doing so, the flanges align. Mechanical fasteners such as bolts and nuts can be
used to secure the flanges, and thereby the reflector support modules, together.
These aspects of the present invention should become clearer from the following description.
Throughout the present specification, reference to the term “forming device” should be
understood as meaning one or more devices that can manipulate the shape of a sheet of
material.
The forming device may be a roll former, a press and/or cutting station. These embodiments for
the forming devices are as should be understood by one skilled in the art.
In particularly preferred embodiments, the forming device may be a production line including
one or more roll formers, one or more presses, one or more cutting stations, and/or one or more
decoilers.
In these embodiments, the devices forming the production line individually or collectively
manipulate galvanised sheet steel to shape the components forming a reflector support module
and/or reflector support deck.
James & Wells ref: 134134/60 HCS
However, the foregoing should not be seen as limiting on the scope of the present invention as
it is also envisaged that the forming device(s) may take other embodiments.
Throughout the present specification, reference to the term “corrugated sheet” should be
understood as meaning a sheet of material having corrugations. The corrugations are defined
by ridges and troughs in the sheet of material.
This is as should be understood by one skilled in the art.
Throughout the present specification reference to the term “ridge” should be understood as
meaning a long raised section of the sheet of material.
Throughout the present specification, reference to the term “crest” should be understood as
meaning the top surface of a ridge. In use, the crest is the surface of a ridge to which a reflector
is secured. Therefore the crests provide a bearing surface.
Throughout the present specification reference to the term “trough” should be understood as
meaning the lowest point of a corrugation between two ridges.
Throughout the present specification reference to the term “base plane” should be understood
as meaning an imaginary surface from which the ridges extend.
In a preferred embodiment, the ridges extend substantially along the entire length of the sheet
of material.
However, it is also envisaged that a ridge(s) may be discontinuous along the length of the
corrugated sheet. Accordingly the foregoing should not be seen as limiting.
In a preferred embodiment, the ridges may have a substantially trapezoidal cross section.
However, the forgoing should not be seen as limiting as the ridges can have other cross
sections such as triangular or curves.
In a preferred embodiment, one or more of the crests are curved.
In these embodiments, the curved crests collectively define a curved bearing surface.
Throughout the present specification, reference to the term “curved bearing surface” should be
understood as meaning a surface to which a reflector(s) can be secured and which has a curve.
James & Wells ref: 134134/60 HCS
In addition, the space between the adjacent ridges enables airflow along the reflector support
decks. That airflow can be beneficial to cooling of the reflectors.
The curved bearing surface is a section of a cylinder. This should be understood as referring to
an outer surface of an imaginary cylinder having a radius and a length.
The length of the curved bearing surface is substantially the length of the reflector support
module(s) according to the present invention.
The radius of the curved bearing surface can be selected according to the curve of the
reflector(s) to be used with the reflector support modules. Therefore, the curved bearing
surface may have a radius in the range of 20 – 50 metres, and more preferably in the order of
30 metres.
It should be understood that the radius of the curved bearing surface can be selected to
correspond to the curve of the reflector to be secured to the reflector support module. That
radius is therefore selected according to the parameters known to one skilled in the art.
However, a key feature of the present invention is that the curved bearing surface is defined by
creating curved ridges and the orientation of two or more ridges relative to each other.
However, the foregoing should not be seen as limiting on the scope of the present invention.
Alternatives are also envisaged.
Throughout the present specification reference to the term "single axis" should be understood
as meaning that the curved bearing surface curves about only one axis.
In a preferred embodiment, the single axis extends along the length of the reflector support
module.
In contrast, reflector supports with curved bearing surfaces according to the present invention to
the inventors' knowledge all curve about two or more axis. For instance, US Patent Publication
No. 2006/0012895 discloses mirror support blanks with spherical bearing surfaces eg the
bearing surfaces curves about two axes.
The use of a bearing surface that curves about a single axis is particularly beneficial for reflector
supports used with LRFS. For instance, having a bearing surface that curves about a single axis
enables the bearing surface to support a reflector along a greater length than the mirror support
blanks of US Patent Publication No. 2006/0012895.
That is useful where a reflector/mirror is required that can focus light to a long focus point.
James & Wells ref: 134134/60 HCS
In a preferred embodiment, the reflector support deck may be made from two or more sheets of
material secured together.
In a particularly preferred embodiment, the two or more sheets of material forming the reflector
support deck are both corrugated.
The two or more sheets of material are preferably orientated so that their ridges are
substantially perpendicular to each other. This may increase the strength and rigidity of the
reflector support deck. Therefore, for a relative weight of sheet material a desired strength for
the reflector support deck can be achieved. The inventors have surprisingly found that the
interaction of the two or more sheets of material, and the orientation of the ridges, may
significantly and unexpectedly increase the strength of the reflector support deck.
However, the foregoing should not be seen as limiting as alternatives are envisaged. Those
include reflector support decks made from single sheets of material, or three or more sheets of
material, or two sheets of material having substantially parallel corrugations.
In a preferred embodiment, the two or more sheets of material forming the reflector support
deck may be secured together at substantially all points of contact between the two sheets.
In the particularly preferred embodiments where the reflector support deck is formed from two
sheets of material having ridges, the points of contact are those where troughs of ridges on one
sheet contact crests of ridges on another sheet.
The inventors have identified that securing the two sheets of material at substantially all points
of contact effectively forms a single sheet of material. This may be particularly beneficial in
providing a comparatively stronger reflector support deck for a lower weight of material.
In particularly preferred embodiments, securing of the two sheets of material forming the
reflector support deck occurs by crimping the sheets where one sheet bears on another.
However, this should not be seen as limiting as other forms of securing the two sheets of
material together are envisaged as being within the scope of the present invention.
It should be appreciated that the present inventions provide a number of advantages over
reflector support decks according to the prior art. These may include:
Involving considerably less skill and labour to manufacture than the prior art supports
and methods, thereby significantly reducing the costs of manufacture.
James & Wells ref: 134134/60 HCS
Reducing the volume of material necessary to manufacture a reflector support,
thereby reducing the costs of manufacture.
Being capable of being manufactured and transported to site in short length
modules. Thereby decreasing transportation costs and the overall costs of
manufacturing LFRs.
Providing a cost effective method to manufacture a reflector support deck having a
curve to the necessary degree of accuracy.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects of the present invention will become apparent from the ensuing description
which is given by way of example only and with reference to the accompanying drawings in
which:
Figure 1 is a side view of an assembled reflector support according to the present
invention;
Figure 2 is a view through Section A-A of Figure 1;
Figure 3 is an end on exploded parts view of a reflector support module;
Figure 4 is an end on view of a curved bearing surface provided by a first corrugated
sheet;
Figure 5 is an isometric exploded view of a section of a reflector support according to the
present invention;
Figure 6 is a close up view of a Section of Figure 1;
Figure 7 is an isometric view of an aperture in a truss arm; Figure 8 is an isometric view
of a reflector support according to the present invention;
Figure 9 is a cross sectional view of an arm defined by a pair of apertures in a truss arm;
Figure 10 is a sectional view through section B-B in Figure 1, showing securing of reflector
support modules secured together lengthwise through Section B-B in Figure 1;
James & Wells ref: 134134/60 HCS
Figure 11 is a schematic showing a method of manufacturing a reflector support according
to the present invention;
Figure 12 is a plan view of an assembled reflector support with reflectors secured thereto;
Figure 13 is a view through line A-A in Figure 12; and
Figure 14 is a view through section B-B in Figure 12.
BEST MODES FOR CARRYING OUT THE INVENTION
Figure 1 shows a side view of a reflector support indicated generally as (1). The reflector
support (1) is constructed from a plurality of reflector support modules (1A, 1B, and 1C).
The reflector support modules (1A – 1C) are and differing mainly in their respective lengths.
Therefore, only reflector support module (1A) will be discussed herein.
Referring now to Figure 2.
The reflector support module (1A) includes a reflector support deck indicated generally as (2).
The reflector support deck (2) is formed from a first corrugated sheet (3) and a second
corrugated sheet (4).
The first corrugated sheet (3) has a plurality of ridges (5) that are separated by troughs (6). The
corrugations extend along the length of the first corrugated sheet (3).
The troughs (6) are flat surfaces and all substantially lie on a flat plane (7). The ridges (5)
extend away from the plane (7) and have a substantially trapezoidal cross section.
Each ridge (5) has a crest (9), being the top surface of the ridge (5)
The crests (9) are not parallel to the plane (7). Rather the crests (9) are all curved and lie on an
imaginary curved plane indicated by (10).
Each crest (9) has a height (8). However, the heights (8) are not uniform across each ridge
because the crests are curved.
In addition, each ridge (5) has a different height to each other.
The cross section of each ridge is constant along its length.
James & Wells ref: 134134/60 HCS
The ridges are positioned relative to each other so that collectively the crests (9) define a
curved bearing surface which lies on imaginary plane (10).
The curved bearing surface curves about a single axis that extends along the curved bearing
surface (not shown). The axis extends along the length of reflector support modules 1A, 1B, 1C.
The curved bearing surface has a radius of 180 metres the radius is the distance between axis
and the curved bearing surface.
The curved bearing surface in effect lies on an outer surface of an imaginary plane which can
be considered to be a section of a cylinder. The cylinder has a radius of 180 metres and a
length substantially equal to the length of the reflector support module.
The axis lies at the centre of the cylinder.
The second corrugated sheet (4) has a plurality of ridges (11) separated by troughs (12).
Each ridge (11) has a crest (13). The crests (13) all lie on the same flat plane (not indicated in
the Figures).
Troughs (12) all lie on a flat plane (not indicated in the Figures).
The troughs (12) and ridges (11) are substantially flat, so that the respective planes on which
they lie are substantially parallel.
A first support arm (14) is formed from a sheet of galvanised stainless steel.
The first support arm (14) has a length indicated by line (15) and a width dimension (16). The
width dimension (16) is the distance between inner edge (17) and outer edge (18).
The first support arm (14) has a first complementary surface (19) that extends along the length
(15). The first complementary surface (19) extends from the inner edge (17) to edge (20). A
step (21) extends away from first edge (20) to an upper edge (23).
A main body section (22) extends away from upper edge (23) of step (21) and to outer edge
(25) of main body section. In addition the main body extends substantially along the entire
length (15).
A second complementary surface (24) extends away from outer edge (25) of main body (22).
James & Wells ref: 134134/60 HCS
A flange (26) extends upwards from second complementary surface (24) and is folded back
over top of second complementary surface (24).
The above features are also shown in Figure 3 being an exploded view of Figure 2, and Figure
4 being an end on view of a first sheet of corrugated material (3). This forms part of the
reflector support deck (2), and Figure 5 is an exploded isometric view of a reflector support (1).
Referring now to Figure 6 which shows a close up view of a section of Figure 1.
The collars (28) are substantially perpendicular to inner face (29) of first truss arm (14).
A series of apertures (27) are formed in main body section (22).
Referring now to Figure 7 which shows a close up isometric view of an aperture and collar (28).
The apertures (27) have collars (28) which extend substantially around the entire perimeter of
the aperture (27). However, the collars (28) have a cut out section (28B) at each corner of the
aperture (27). The cut out sections (28B) are parts of the collars (28) that are lower than the
rest of the collar (28).
The collars (28) are formed by folding the sheet material forming the first arm (14) as will be
discussed in more detail below.
Outer face of support arm (14) is substantially flat along the length (15).
Figure eight shows a cross sectional view through reinforcing arm (32). Ridges (33) are formed
into the reinforcing arm (32). The ridges (33) provide additional strength to the arm (32) and
may increase the strength of the first truss arm (14).
The reflector support (1) includes a second support arm (31) that is identical to first support arm
(14). Therefore second support arm will not be discussed in detail. However, like numerals
refer to like components.
The first and second arms (14, 31) are secured together by crimping the first complementary
surfaces (24).
The reflector support deck (2) bears on second complementary surfaces (24). The second
corrugated sheet (4) is secured to the first and second support arms (14, 31) by crimping as will
be discussed in more detail below. All troughs (12) and crests are crimped together.
James & Wells ref: 134134/60 HCS
Reflectors (not shown in Figures 1 - 4) can be secured to the curved bearing surface (10) as will
be discussed in more detail below.
The first and second support arms (14, 31) and reflector support deck (2) form a monocoque
structure. The structure has sufficient rigidity such that it can support its own weight under
transport. In addition, the monocoque structure ensures that the reflector support (1) can
support the weight of reflector (not shown in Figures 1 - 11) when assembled.
Figure 9 shows an end cap (33) that can be used to reinforce a module (1A – 1C). The end
caps (33) have a triangular shape generally corresponding to the cross-section the reflector
support modules (1A – 1C).
An aperture (34) is provided in end cap (33). This decreases the weight of the end cap (33).
The end cap can be secured to an end face of a reflector support module (1A – 1C) using
mechanical fasteners such as screws or nuts and bolts.
Figure 10 shows a view through line B-B in Figure one and the end on attachment of two
modules (1A, 1B, and/or 1C).
Edges of first and second support arms (14, 31) are folded towards inner faces to form length
wise connection flanges (35). The flanges (35) are substantially perpendicular to the length of
support arms (14, 31).
The flanges (35) are orientated so that when two reflector support modules (1A – 1C) are
aligned in an end on manner the flanges (35) lie substantially adjacent to each other.
Therefore, bolts (36) can be inserted through the flanges (35) to secure the reflector support
modules (1A – 1C) together.
The orientation of the first and second support arms (14, 31) helps to distribute the load through
the flanges (35) and into the first and second support arms (14, 31). Accordingly, the
orientation of the flanges assists in securing reflector support modules (1A – 1C) together in an
end on manner and ensuring that the reflector support does not deflect from an equilibrium
position more than a necessary standard.
Method of manufacture
Referring now to Figure 10.
James & Wells ref: 134134/60 HCS
A decoiler, generally indicated as (38) holds coils of 1.8 meter wide, 450MPA, 0.6mm thick
galvanised steel (not shown).
The decoiler (38) continuously feeds the steel sheets into roller former (39).
The cut lengths are transferred to stacking station (41). The cut sheets are stored in stacking
station (41) until required for manufacturing a reflector support module (1).
The roll former (39) includes dies (not visible in the drawings). A sheet steel passes through the
roll former (39) the dies (not shown) apply pressure to deform the sheets and create
corrugations in the form of ridges (6).
The dies are uniquely orientated and configured to create ridges having a substantially
trapezoidal shape but with a curved crest. The trough (6) between each ridge (5) is flat, and all
substantially lie on the same flat plane (7).
The deformed sheets exit roll former (39) and enter cutting station (40). Cutting station (40)
cuts the deformed sheets into lengths (3).
The cut sheets (3) are transferred to stacking station (41) where they are stored until required.
A second decoiler (42) holds coils of 1500mm wide, 0.6mm thick, 450MPA galvanised steel
sheets (not shown).
The stainless steel sheets (not shown) are continuously fed into second roll former (43). The
roll former (43) includes dies (not visible in the drawings). As the sheet steel passes through
the roll former (43) the dies exert pressure to deform the sheets and create corrugations in the
form of ridges (11).
As the sheet material exits second roll former (43) it is fed into cutting station (44). The cutting
station (44) cuts the deformed sheet material into lengths. The cut lengths are transferred to
stacking station (41). The cut lengths are stored in stacking station (41) until required to form a
reflector support module.
A third decoiler (45) holds coils of 1800mm wide, 1.6mm thick, 300MPA galvanised steel sheets
(not shown).
The sheets are continuously fed into roll former (46).
James & Wells ref: 134134/60 HCS
The roll former (46) manipulates the sheets of material to create the first complementary surface
(19) and second complementary surface (24).
As the sheets of material exit third roll former (46) they are fed into press (47).
The press (47) forms apertures (27) in the sheet material collars (28) and curves (28B) and
flanges (35). As the sheets exit press (47) they enter second cutting station (48). The cutting
station (48) cuts the sheets to length. The cut sheets are transferred to stacking station (52)
where they are stored until required.
A first support arm (14) and a second support arm (31) are fed into a crimp press (49) and
orientated so that the first complementary surfaces (19) of support arms (14, 31) overlap and
contact each other.
The crimp press (49) is engaged so as to deform the complementary surfaces (19) and thereby
secure the first support arm (14) and second support arm (31) together.
The secured support arms (14, 31) are moved into a second crimp press (51).
The crimp press (51) includes pairs of crimping elements (not visible). The pairs of crimping
elements are engaged to move towards each other from opposite sides of the sheets. The
crimp press (51) forces the pairs of crimping elements together and applies sufficient force to
deform the first and second sheets (3, 4) at those points where they meet.
The crimp press (51) is disengaged and crimping elements move away from each other. The
sheets of material and/or crimping elements are repositioned with respect to each other. The
crimp press (51) is again engaged to cause crimping elements to move towards each other and
thereby deform the sheets of material (3, 4) at points where they contact each other that may
not have already been deformed.
The above process may be repeated so as to ensure that the sheets of material (3, 4) are
secured together at all of the points where they contact.
The reflector support deck (2) is positioned so as to bear against second complementary
surfaces (24).
The third crimping press is engaged to deform the second sheet of material ( ) and second
mating surfaces (25). This secures the reflector support deck (8) to the first and second support
arms (14, 31).
James & Wells ref: 134134/60 HCS
It should be noted that the fourth crimping press deforms the second sheet of material and
second complementary surfaces (24) at substantially every point of contact therebetween.
Constructing a Reflector Support
Referring now to Figures 12, 13, and 14 showing an assembled reflector support constructed
using reflector support modules (1A – 1C) to form a LFR power station (not shown).
Reflector support modules (1A – 1C) are packed into standard shipping containers. In doing so,
the reflector support modules (1A – 1C) are nested together so as to create substantially
triangular shapes. The triangular shape of the reflector support modules (1A – 1C) enables
efficient packing in the shipping containers.
The shipping containers can be easily transported to the site where a LFR is to be constructed.
The reflector support modules (1A – 1C) are removed from shipping containers.
A reflector support module (1A) having a length of substantially 12 metres is placed in a clear
site.
A reflector support module (1B) having a length of substantially 5 metres is positioned relative to
the reflector support module (1A).
The end (47) of reflector support module (1B) is positioned so as to abut end (48) of reflector
support module (1A). In doing so, the lengths of the reflector support modules (1A, 1B) are
substantially aligned.
In addition, flanges (35) are aligned with each other.
Fasteners (not shown) are inserted through the flanges (35) to secure the reflector support
modules together.
A reflector support module (1C) can be positioned so that its end (49) is adjacent to end (50) of
reflector support module (1A). In doing so, the lengths of reflector support modules (1A, 1C)
are substantially aligned. In addition, flanges (35) are aligned.
Fasteners (not shown) are inserted through flanges (35) to thereby secure the reflector support
modules (1A, 1B) together.
End caps (33) are secured to ends (51, 52) of reflector modules (1B, 1C).
James & Wells ref: 134134/60 HCS
This is achieved by using fasteners (not shown) which extend through flanges (not visible) on
reflector modules (1B, 1C) and end caps (33).
An axle (not shown) is secured to reflector support (1). The axles extend beyond ends of
reflector support modules (1B, 1C). The axles are configured to be engaged by actuators in a
LFR reflector arrays (not shown).
Reflectors (53) are secured to crests (9) using adhesives or fasteners as should be known to
one skilled in the art.
The crests (9) provide a curved bearing surface to support reflectors (53) along the length.
The axles and reflectors are as should be understood by one skilled in the art.
Aspects of the present invention have been described by way of example only and it should be
appreciated that modifications and additions may be made thereto without departing from the
scope thereof as defined in the appended claims.
James & Wells ref: 134134/60 HCS
Claims (10)
1. A reflector support deck for a Linear Fresnal Reflector power station, including at least one corrugated sheet of material having two or more ridges of differing heights, characterised in that the ridges are positioned relative to each other so that the crests of the ridges collectively define a curved bearing surface that curves along a single axis.
2. The reflector support deck as claimed in claim 1, wherein one or more of the ridges have a substantially trapezoidal cross section.
3. The reflector support deck as claimed in either one of claims 1 or 2, wherein one or more of the crests are curved.
4. The reflector support deck as claimed in any one of claims 1 to 3, wherein one or more of the ridges has a constant cross section along its length.
5. The reflector support deck as claimed in any one of claims 1 to 4, wherein the curved crests have a radius in the range of 20 – 50 metres.
6. The reflector support deck as claimed in claim 5, wherein the radius is in the order of 30 metres.
7. The reflector support deck as claimed in any one of claims 1 to 6, including a second sheet of material secured to the corrugated sheet of material.
8. The reflector support deck as claimed in claim 7, wherein the second sheet of material is a corrugated sheet of material having two or more ridges.
9. The reflector support deck as claimed in claim 8, wherein the two or more ridges on the second sheet of material have a substantially trapezoidal cross section.
10. The reflector support deck as claimed in either one of claims 8 or 9, wherein the crests and troughs of the ridges on the second sheet are positioned substantially parallel to each other. James & Wells ref:
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ622275A NZ622275B2 (en) | 2012-10-29 | Improvements to reflector supports and methods of manufacture | |
NZ602345A NZ602345B (en) | 2012-10-29 | Improvements to reflector supports and methods of manufacture | |
US14/434,713 US20150286029A1 (en) | 2012-09-10 | 2013-09-09 | Reflector supports and methods of manufacture |
PCT/NZ2013/000165 WO2014038967A1 (en) | 2012-09-10 | 2013-09-09 | Improvements to reflector supports and methods of manufacture |
AU2013313725A AU2013313725A1 (en) | 2012-09-10 | 2013-09-09 | Improvements to reflector supports and methods of manufacture |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ602345A NZ602345B (en) | 2012-10-29 | Improvements to reflector supports and methods of manufacture |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ602345A NZ602345A (en) | 2014-04-30 |
NZ602345B true NZ602345B (en) | 2014-08-01 |
Family
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