1

DualActua*ngSolarTrough
Solvesdeciencieswe
seeinothersystems:
Justbecauseeveryoneelse
isdoingitdoesntmean
thatyoushould

SolarEnergyPoten*al
NM,CA,AZ,NV
currentlygenerate
423MW
CARPSmandates20%
by2017
4132GWpoten*al
covering32,000sqmi.
undevelopedland

SolarEnergyCapture

PowerGenera*onwithCSP

Concentra*ngSolarFields

KeyDecienciesofCurrentSystems
Complexspaceframes
Fluidjoints
Fragileexpensive
mirrors
Levelingground
Environmentaldamage
Cost

900mx1800m
7

ComplexSpaceFrames

FragileGlassMirrors

FluidJoints&HydraulicActuators

10

KeyCompe*tors
WithContracts:
BrightSource
MojaveSunPower
Solel

Sopogy
SkyFuel

11

TakingANewApproach
Complexspaceframes
Fluidjoints
Fragileexpensive
mirrors
Levelingground
Environmentaldamage
Cost

Fiberglassstructure
Sta*onarypipe
Reectechalumina
lm
Morefrequent
actua*on
ElectroPneuma*c
Op*mizeforcost

12

Func*onalRequirementsofourSystem

1pieceparabolicreec*ngsurface
Sta*onaryheatpipe
260degreesoftravel
Lowtrackingerror
Modular
Survivewindloads

13

Oursolu*on
Trackingsystemthatusestwolinearactuators
topointaparabolicmirroratthesun

14

Keyconcepts
Pivotsaboutfocus
Twolinearactuators
Oneactuatorfordaily
mo*on

Stowagemode

15

KeyAeributes:ReducedComplexity
Simplerassembly
Fewerparts
Monolithicberglass
aeachessimplyto
structure

Modular
Massproduceable

16

Keyaeributes:EasierMaintenance
Focuspivot
Noneedtoshut
downen*reline
Nomovinguid
seals,noexible
tubing

Modular,breakaway
components
Stowagemode
17

Keyaeributes:CheaperMaterials
Singleberglasspiece
Strongerperweight
lighter
Cheaperthanglass

Steelsupportframe
Strongerper$

18

Summaryofoursystem
Usestwolinearactuatorstopointparabolicmirrorat
thesun
Advantages:
Reducedcomplexity
Simplerassembly

Cheapermaterials
Improvedcapabili*es
Massproduceable
Stowagemode
Modular

Patentclaim
19

Demo

20

WindLoadingStandards(ASCE798)
Methodsofcalcula*ng
windloadingandgust
factors
Provideslocalaverage
windspeedsbyclass

21
ImagesfromWindTunnelTestsofParabolicTroughCollectorsNREL/SR55032282,May2008

WindLoadingCalcula*ons
Experimental
coecientsofdrag
determinedfromwind
tunnelmeasurements
Calculateloadsfor
dierentgeometries
andwindspeeds
Sizeactuatorsaccording
tospecs
22

MeasuringEciency
Specularreec*on
Findincidentanglefor
variousincidentrays
Determinewhetheror
notthereectedrayhits
theenvelopeoftheheat
pipe

23

Deec*onsError

Bendingdeec9onsalongthevertexlineoftheparabola

Theparabolais
subjectedtosignicant
windloads
Resul*ngdeforma*on
frombendingcons*tute
intrinsicerror
Mustconsiderthe
impactofaddi*onal
error

PipePlacementError

Eciencyasafunc9onofwindvelocity,forvariouspipeplacementerrors

25

AngularError

Eciencyasafunc9onofwindvelocity,forvarioussupplementalangularerrors

26

ManufacturedPartsError
Encoderresolu*on
Primaryactuator
backlash
Errorinmanufactured
components:
Crankarm
Actuatormounts
Keyedshaqs
Alsoaectrequired
actuatorforceandtravel
27

Mul*variableSystem:Variables

28

CrankArmLengthError
Cri*calComponent:crankarm

y0

29

ActuatorPosi*oningErrors
Exactactuatorplacementislessimportant

30

ErrorAnalysis:ExperimentalValida*on
onPrototype

Valida*onofmodelfor
angularerrorimpacton
eciency

Combinederrorof
about0.40degrees
frombacklash,
manufacturing
tolerancesandcontrol
system

31

ComparisontoCompe**on

32

ShiqingCostStructure
Proposed

Exisi(ng

Costperunit $0

$5,000

Receivers
Drive
Founda*ons/OtherCivil

$10,000

Mirrors
Interconnec*onPiping
Other

$15,000

CollectorStructure
Electronics&Control
Con*ngency

$20,000

$25,000

Erec*on
Headerpiping

33

Concentra*ngSolarPowerGrossMargins

34

Expenditures
CostofR&Deort

Misc.Expenditures

Developmentof10thScalePrototype

SG&A

ROI
R&D

$551,800
$475,000

Materials

$800

OceSpace

$100,000

CAPEX

ActuatorsandPowerSystems

$800

Admin.Expenses

$40,000

RecurringYearlyExpenses $140,000

ControlSystem

$3,200

Total

$140,000

UnitCost

$18,000

Researchteam

$22,000

UnitPrice

$24,000

Total

$26,800

Prot/Unit

$6,000

PendingR&DExpenses
10thScalePrototypeValida*on

$75,000

FullSizeSystemDetailedDesign

$150,000

FullSizeSystemBuilding

$150,000

FullSizeSystemValida*on

$150,000

Total

$525,000
TotalR&Dcosts

$551,800

CapitalExpenditures
Molds/DiesandTooling

$475,000

Total

$475,000

TotalMisc.Exp.

UnitSales/year

375

$615,000

35

TimeToMarket
Months:

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
36

ScheduleandBudget
2/11 2/18 2/25 3/4 3/11 3/18 3/25 4/1 4/8 4/15 4/22 4/29 5/6 5/13 5/20 5/27
Determine Critical FRs
Background Research

= Initial

Brainstorm

= Actual

Detailed CAD
Scale Design
Spec Components
Build Prototype
Test Prototype

Item

Initial

Motor/Encoder/Gearing
Control System / Power Supply
Bearings
Machined Parts

600
300

200
400
Total: 1500

Updated

Actual

2400
1000

800
3200

800
2000
6200

100
700
4800

37

WhyTheScheduleSlipped?
Func*onalRequirementsChangedas
DesignEvolved

OverlyOp*mis*c

38

RiskManagement
CostCompe**veDesign
SargentandLundy/NRELReportBenchmark
LargelyDrivenByCommodityPrices
MinimizeMaterialUsage

ScaledPrototypetoValidate
FeasibilityofActua*onMechanism
ErrorMeasurement
Loading
Windtunnel

Performance

39

LingeringRisks
CostisParamount
TroughS*ness/Weight
MylarLongevity
Performance
IsMassProduc*onSustainable?

40

Conclusions
Managingadiverseproject
Op*cs,Dynamics,Mechanics,Controls,
Pneuma*cs
Experienceinnewelds

Understandingrequirementsfromcustomer,
manager
Budgetmindedmechanicaldesign
Crea*ngacostcompe**vedevice,notjust
innova*veprototype
41

Acknowledgements

42

Ques*ons?

43