Design of efficient stamped mirror facets using topography optimisation

Nicholas Rumsey-Hill*, Johannes Pottas, Joe Coventry

*Corresponding author for this work

    Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

    2 Citations (Scopus)

    Abstract

    Significant cost reduction is required to improve the competitiveness of concentrating solar power. Heliostats make up a significant proportion of the capital cost of solar tower plants, with low-cost, high-performance designs required to meet levelised cost of energy targets. Lightweight stamped mirror facets are seen in leading commercial solar tower plants, with low manufacturing costs and high optical performance. Here, topography optimisation is investigated as a tool for designing lighter and structurally efficient stiffening bead patterns for stamped mirror facets. A case study is presented demonstrating topography optimisation as a promising tool for facet design, with tailored optimisation approaches incorporating wind and gravity load cases, manufacturing constraints, and combined optical-structural objectives. A range of concepts were generated, and their performance assessed to develop a design framework for high-performance supports. Wind loads in the stow position were found to influence and limit weight reduction more than gravity loads during operation. For the various concepts generated by optimisation, a common geometric feature was clearly-defined radial beads from the mounting points to a peripheral bead, driven by the need to overcome high bending stresses. Prototyping stamped structures is typically expensive. A low-cost and accessible rapid-prototyping method for stamped facets was developed using incremental sheet forming. A framework is presented for fabricating facets incorporating optimised supports, with photogrammetry and deflection tests enabling rapid assessment and structural modelling validation.

    Original languageEnglish
    Title of host publicationSolarPACES 2018
    Subtitle of host publicationInternational Conference on Concentrating Solar Power and Chemical Energy Systems
    EditorsChristoph Richter
    PublisherAmerican Institute of Physics Inc.
    ISBN (Electronic)9780735418660
    DOIs
    Publication statusPublished - 25 Jul 2019
    Event24th SolarPACES International Conference on Concentrating Solar Power and Chemical Energy Systems, SolarPACES 2018 - Casablanca, Morocco
    Duration: 2 Oct 20185 Oct 2018

    Publication series

    NameAIP Conference Proceedings
    Volume2126
    ISSN (Print)0094-243X
    ISSN (Electronic)1551-7616

    Conference

    Conference24th SolarPACES International Conference on Concentrating Solar Power and Chemical Energy Systems, SolarPACES 2018
    Country/TerritoryMorocco
    CityCasablanca
    Period2/10/185/10/18

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