Method and Apparatus for Sculpting Parabolic Shape

Abstract

This invention is about a method and apparatus for fabricating large scale stationery parabolic solar collector. The method involves use of a robot like apparatus for sculpting shape of underlying base material to define contour of a parabolic collector. The reflective panels installed on the base material form a parabolic shaped mirror which reflects the sun's rays to a well defined focal point. The method of construction is scalable and can be used for fabricating small size parabolic collectors as well as large scale ones.

1 . A method of manufacturing a parabolic solar collector, said method comprising:
 placing a central post into the ground, the central post having length, depth, and orientation in accordance with the desired parabolic solar collector,   attaching a horizontal jib to the central post,   constructing a rim support under a tip of the horizontal jib,   attaching at least one trolley that can move along the horizontal jib,   attaching a vertical working arm to the trolley in a perpendicular position that can move freely up or down on the trolley,   restraining the vertical working arm with an inelastic string connected to a tip of the central post on a first end of the string and to the trolley on a second end of the string while the vertical working arm rests on the inelastic string by way of rollers,   attaching a sculpting apparatus to the tip of the vertical working arm to shape an underlying base material underneath the vertical arm,   turning the horizontal jib incrementally around the central post in angular increments and shaping the underlying base material with the sculpting apparatus,   moving the trolley along the horizontal jib incrementally with distance increments and shaping the underlying base material with the sculpting apparatus,   placing a firming agent on the shaped underlying base material, and   placing at least one sheet with a mirror like surface on the shaped underlying base material to form a parabolic shaped reflecting surface.   
     
     
         2 . The method of  claim 1 , wherein a tip of the central post defines a focal point of the parabolic mirror. 
     
     
         3 . The method of  claim 1 , wherein the horizontal jib turns freely around the central post and the rim support is placed under a tip of the horizontal jib. 
     
     
         4 . The method of  claim 1 , wherein the vertical working arm moves freely up and down under gravity or by hydraulic, pneumatic, electrical means. 
     
     
         5 . The method of  claim 1 , wherein the inelastic string connected to the tip of the central post is only long enough to let the trolley reach the tip of the horizontal jib. 
     
     
         6 . The method of  claim 1 , wherein the sculpting apparatus to shape the base material comprises tool, dispenser, cutter, equipment operated by pneumatic, hydraulic, electrical means. 
     
     
         7 . The method of  claim 1 , further comprising selecting increments for turning and moving in such a way that the sculpted underlying base material forms a parabolic shape. 
     
     
         8 . The method of  claim 1 , wherein the firming agent comprises concrete, metallic, chemical, biological material. 
     
     
         9 . The method of  claim 1 , wherein the said sheet with a mirror like surface comprises one continuous sheet forming a parabolic shaped reflecting surface. 
     
     
         10 . The method of  claim 1 , wherein said sheet with a mirror like surface comprises a plurality of sheets with mirror like surfaces arranged to form a parabolic reflecting surface. 
     
     
         11 . An apparatus for manufacturing a parabolic solar collector, said apparatus comprising:
 a central post,   a horizontal jib,   a set of one or more trolley travelling along the horizontal jib,   an inelastic string connected having a first end connected to a tip of the central post and a second end connected to the trolley,   a vertical working arm placed perpendicularly on the trolley, the vertical working arm moving freely up or down and resting on the inelastic string,   a sculpting apparatus placed at a tip of the vertical working arm,   a motor for incrementally turning the horizontal jib around the central post,   a motor for moving the trolley along the horizontal jib incrementally,   a brake assembly to prevent the vertical working arm from moving freely when activated,   a set of one or more sheets with mirror like surface,   a computer for controlling the movement of the trolley, the horizontal jib, the vertical working arm,the brake assembly, the sculpting apparatus and,   a set of one or more brushes.   
     
     
         12 . The apparatus of  claim 11 , wherein the horizontal jib is attached to the central post and rotated by the motor in such a way that the horizontal jib rotates around the central post under the control of the computer. 
     
     
         13 . The apparatus of  claim 11 , wherein the computer is configured to control movement of the trolley by way of a motor along the horizontal jib. 
     
     
         14 . The apparatus of  claim 11 , wherein the inelastic string is long enough to let the trolley reach no further than an end of the horizontal jib. 
     
     
         15 . The apparatus of  claim 11 , wherein the vertical working arm resting on the inelastic string is forced to move up or down as the trolley travels along the horizontal jib as a result of changing geometry of the inelastic string. 
     
     
         16 . The apparatus of  claim 11 , wherein the sculpting apparatus attached to the vertical arm sculpts the underlying base material underneath the vertical working arm by actions comprising cutting, excavating, evaporating, sweeping, tamping, depositing. 
     
     
         17 . The apparatus of  claim 16 , where the sculpted underlying base material is covered by one or more sheets with mirror like surface forming reflective surface over the underlying base material. 
     
     
         18 . The apparatus of  claim 11  wherein the brake assembly prevents free movement of the vertical working arm under the control of the computer. 
     
     
         19 . The apparatus of  claim 11 , wherein the set of brushes attached to the vertical working arm cleans mirror sheets underneath the vertical working arm by actions comprising rotation, sweeping, polishing, rinsing and squirting.