1. Field of the Invention
This invention relates to mechanical pointing mechanisms. Particularly, this invention relates mechanical pointing mechanisms for controlling solar energy systems, such as used by ground-based solar stations.
2. Description of the Related Art
Solar energy has the potential to provide a significant fraction of all electrical power needs with a clean and virtually endless energy source. Development and commercialization of solar energy systems has been underway for half a century and the ability of solar energy solutions to provide power at costs competitive with fuel-burning solutions has steadily improved. However, contemporary solar energy systems are still too expensive to enjoy widespread commercial use.
Photovoltaic (PV) cells are the preferred building block in solar energy systems for generating electricity from the sun since they convert sunlight directly to electricity. (Alternately, solar thermal systems are known to employ a much more complex heat engine where a working fluid heated by the sun, coupled to a generator that produces electricity.) However, some of the most efficient photovoltaic cells are also the most expensive. These devices can produce electricity at efficiencies of approximately 28% under direct solar illumination today and up to approximately 39% under concentrated sunlight. It has been recognized by many in the solar power industry that concentrator systems, in which optical elements focus energy on much smaller cells, can provide overall system solutions that are lower in installed cost per watt than competing conventional flat direct solar illumination panels. Because these systems can reduce the required area of expensive semiconductor solar cells by a factor of a hundred or more, these high concentration photovoltaic (HCPV) solar power systems are the one of the better prospects for becoming economically competitive with electricity generated from other sources. In addition, the economics for concentrator systems permit the use of the highest efficiency cells. In turn, this allows concentrated solar power systems to produce significantly more power per unit of surface area, potentially satisfying a larger fraction of the electrical load of a site within a limited land or rooftop space.
In order to maximize efficiency, a solar power system must also provide a way to track the sun. All conventional tracking approaches are based on tracking of arrays of concentrator cells. In general, there are three conventional mechanical systems to provide tracking, “pan and tilt”, “azimuth and elevation”, and “lazy susan”. These terms refer to the basic mechanism for pointing a full array of solar cells. In a three-axis coordinate system (x, y, z) in which the z axis is the vertical axis, the “pan and tilt” approach rotates the entire array around the x and y axes. The “azimuth and elevation” method rotates the array around the z axis and one of the other axes (x or y). The “lazy susan” approach may be viewed as a variant of the “azimuth and elevation” type in which the elevation rotation is performed on rows of elements linked mechanically to an elevation drive motor mechanism.
One primary disadvantage of the conventional solutions is that they require large-scale movements of all of the elements of the array. With the “pan and tilt” and “azimuth and elevation” approaches, the entire panel is steered to point at the sun and both suffer particularly from the fact that they present large surfaces to the wind and require significant increases in structural cost and motor cost to withstand these loads, or else (as is more typically the case) the systems have limited ability to remain operable in strong winds and must instead be positioned in “safe mode” wherein a low profile is exposed to the wind. The “lazy susan” approach is pursued by some implementers primarily to reduce these unfavorable wind loads, but still requires the entire array to be rotated.
Finally, another significant disadvantage of the conventional tracking approaches is that they are undesirable for use in many important commercial applications of solar energy such as residential rooftops and portable systems, because of the structure and appearance necessary for pointing large two-axis tracking arrays.
In view of the foregoing, there is a need in the art for apparatuses and methods for implementing concentrated solar power systems. Particularly, there is a need for improved systems and methods for pointing arrays of solar cells in solar power systems. Further, there is a need for such pointing systems and methods to operate without requiring large scale movements of an array of solar cells. In addition, there is a need for such pointing systems and methods to operate with unobstrusive structures for portable and/or terrestrial applications, such as on residential rooftops. These and other needs are met by the present invention as detailed hereafter.
Mechanical systems and methods are disclosed for pointing a plurality of elements in an array in any direction within a near-hemispherical field of view without pointing the entire array as a single unit. A fixed frame and an adjuster frame disposed substantially parallel to and offset from each other are each coupled by universal joints to carriers for a plurality of optical elements. One or more drive mechanisms are used to move the adjuster frame relative to the fixed frame to produce coordinated pointing of the pointing axes of the plurality of optical elements. The systems and methods can be used in a variety of applications including pointing of solar concentrator receivers or antennas.
A typical embodiment of the invention comprises an apparatus for coordinated pointing of elements including a plurality of elements each having a pointing axis and each being attached to a carrier, a fixed frame including a first universal joint coupled to the carrier for each of the plurality of elements, an adjuster frame disposed substantially parallel to the fixed frame and including a second universal joint coupled to the carrier offset from the first universal joint for each of the plurality of elements, and at least one drive mechanism to move the adjuster frame relative to the fixed frame to produce coordinated pointing of the plurality of elements.
In some embodiments, the plurality of elements comprise photovoltaic cells in a solar power system. For example, the solar cells may be high concentration photovoltaic cells. In other embodiments, the plurality of elements may be antenna elements in an antenna array.
Typically, the fixed frame is disposed between the adjuster frame and the plurality of elements. The carrier may comprise a rod coupled to both the first universal joint and the second universal joint and substantially parallel to the pointing axis. The one or more drive mechanisms may comprise an azimuth drive and an elevation drive. In addition, the azimuth drive and the elevation drive may each include a jack screw. Furthermore, the first and second universal joints may each include a rotary joint and a clevis joint coupled in series to the fixed and adjuster frames, respectively.
In a similar manner, a typical method embodiment of the invention comprises the steps of coupling a carrier for each of a plurality of elements each having a pointing axis to a first universal joint of a fixed frame for each of the plurality of elements, coupling the carrier for each of the plurality of elements to a second universal joint of an adjuster frame for each of the plurality of elements offset from the first universal joint, the adjuster frame disposed substantially parallel to the fixed frame, and moving the adjuster frame relative to the fixed frame with at least one drive mechanism to produce coordinated pointing of the plurality of elements. The method may be further modified in a manner consistent with the apparatus embodiments described herein.
In another embodiment of the invention, a pointing apparatus comprises a plurality of element means for pointing, each having a pointing axis and each being attached to a carrier, a fixed frame including a first universal joint coupled to the carrier for each of the plurality of element means, an adjuster frame disposed substantially parallel to the fixed frame and including a second universal joint coupled to the carrier offset from the first universal joint for each of the plurality of element means, and at least one drive mechanism means for moving the adjuster frame relative to the fixed frame to produce coordinated pointing of the plurality of element means. The plurality of element means may comprise high concentration photovoltaic cells. This apparatus may be similarly modified consistent with the other systems or methods described herein.
Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
1. Overview
The implementation of high concentration photovoltaic power systems necessitates a pointing and tracking system to point the optical elements toward the sun. The accuracy of pointing required depends on several factors related to the optical and mechanical design of the system. Under an ideal case, the optical acceptance angle is theoretically limited to θ=sin−1(1/√{square root over (C)}) for a three-dimensional or point-focus concentrator, where C is the concentration ratio (assumed isotropic). Thus, a concentration ratio of 500 has a maximum theoretical optical acceptance angle of approximately 2.56°, for example. However, practical design considerations require additional tolerances throughout the system that typically drive pointing requirements to much tighter tolerances (e.g., typically ±0.1°).
As detailed hereafter, embodiments of the invention can address the problems outlined above by implementing two-axis pointing of the individual photovoltaic cells/optical modules. Embodiments of the invention can reduce costs in all applications and permit more widespread use of high concentration photovoltaic solar power systems to small-scale, rooftop and portable applications.
Embodiments of the invention afford numerous advantages over conventional systems. For example, embodiments of the invention can eliminate steel structure associated with pole mounting and/or rotation of large structures of conventional solar power systems. Embodiments of the invention can also eliminate costly structure that is required with conventional systems to support higher wind loads and stiffness requirements resulting from larger, bulky structures. Embodiments of the invention can also be readily mass produced and take advantage of the economies of scale of a much higher manufacturing volume. Further, embodiments of the invention can eliminate any motion of the main structure, permitting fixed mounting installation in contrast to conventional systems. Thus, embodiments of the invention may be applied to lower cost to be more competitive with other sources of energy, and provide more widespread application to other potential solar energy market segments.
It should be noted that embodiments of the invention are not only useful for pointing optical elements such as photovoltaic cells, but may be applied in any situation where multiple individual elements must be pointed in a coordinated manner. For example, antenna systems may also employ a plurality of antenna elements that require coordinated pointing as will be appreciated by those skilled in the art. Accordingly, all embodiments described herein as implemented with an optical element, may be similarly implemented with any other form of pointed element, such as a radio frequency element as will be understood by those skilled in the art.
Pointing of the system 200 is performed just as described for the single optical element 102 in
2. Exemplary Coordinated Pointing System for a Plurality of Elements
The elimination of inter-module tolerances permits very substantial relaxation of overall mechanical pointing accuracy. For a well-designed optical system with C=500, approximately an order of magnitude reduction in pointing accuracy is obtainable over conventional systems; a pointing accuracy requirement of ±1° to ±1.5° is permissible, compared with the ±0.1° accuracy required in conventional systems.
In the example system 300 the range of adjustment can be slightly less than 180° about each axis. However, the elevation range need only be approximately ±23° if the system 300 is mounted in a position aligned with the Earth rotation axis. Thus, the minimum height of the optical element 302 above the fixed frame is approximately D/2×sin 23° or approximately 0.2×D, where D is the diameter of the optical element 302. The system configuration allows space under the optical element 302 for cooling, e.g. via air circulation. The single optical element 302 may be employed in an array of optical elements as shown in the system 400 of
As previously mentioned, embodiments of the invention are particularly useful for photovoltaic power systems employing photovoltaic cells as the optical elements. Precision coordinated pointing afforded by embodiments of the invention is particularly beneficial to high concentration photovoltaic cells which capture sunlight from a wider area and focus it onto a smaller photovoltaic cell area. In other embodiments the optical elements may comprise individual antenna elements of an antenna array. For clarity some details inherent to any practical design as will be understood by those skilled in the art have not been shown. For example, wiring to the optical elements may be routed across one or more of the joints to the power control system. Such wiring may be conveniently routed across the joints 410A-410D to the fixed frame 414 to minimize the number of moving interfaces to be traversed.
Embodiments of the invention can be operated to economically point a small opto-mechanical system to the modest accuracy and angular rate required for sun tracking. In contrast to conventional photovoltaic pointing systems, embodiments of the present invention can eliminate mass movement of the entire array as a single unit. In addition, embodiments of the invention can permit a fixed installation.
3. Method of Coordinating Pointing of a Plurality of Elements
This concludes the description including the preferred embodiments of the present invention. The foregoing description including the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible within the scope of the foregoing teachings. Additional variations of the present invention may be devised without departing from the inventive concept as set forth in the following claims.