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glass primary mirror and redesign the tracking mechanism in such a way as to establish a path forward toward a lower-cost tracking unit. unit was over-engineered to meet the extremely high tracking accuracies originally thought to be necessary. Design evaluations and field experience in FYs 2003 and 2004 provided a better understanding of the tolerances and requirements of the solar collector and, consequently, these modifications were incorporated into a 3rd-generation system. To ensure that the fabrication cost for the 3rd- generation system was significantly reduced versus previous units, a mechanical design house (Protomet Corp.) was used that specialized in design-for-manufacturer evaluations of prototype instruments. The results of their analysis and redesign are discussed in the following section. 3. Results and Accomplishments To date, a fabrication technique has been identified for manufacturing an acrylic mirror that meets the tolerances and requirements of an HSL solar collector. A 48”-diameter parabolic acrylic mirror is being fabricated by Bennett Mirrors of New Zealand. Early efforts appear promising, with the surface quality of the mirror rivaling that of its glass counterpart. The estimated cost of the new mirror is less than $300 (compared to $3,500 for the glass mirror) and weighs only 9 pounds (compared to 50 pounds for the glass mirror). Completion of a prototype mirror is expected in early FY 2005. The development of a reduced-cost tracker mechanism for the HSL solar collector was begun in FY 2004. An initial “manufacturability” analysis was completed by Protomet Corp. and design modifications were suggested. The use of a high-precision linear actuator in combination with a gear-train drive unit was recommended for reducing cost while still providing high tracking accuracy. From this analysis, the tracker cost has been reduced from $25,000 to less than $4,000. Detailed modeling and final drawings have been completed and fabrication and testing of the new solar tracking unit is expected in mid FY 2005. A broad-based public-private alliance continues to work together for the purpose of commercializing HSL. In addition to ORNL, the Hybrid Lighting partnership includes members such as the Tennessee Valley Authority (TVA), Wal-Mart, Fig. 1. The hybrid solar lighting concept 2. Technical Approach Back-surfaced acrylic mirrors have proven to be a viable option for mirrors that must be deployed outside and exposed to harsh weather condition for a number of years. For the past 50 years, acrylic has been used routinely in applications such as traffic mirrors, aircraft windshields, and vehicle lighting and much data exists on its environmental durability to UV exposure and harsh weather conditions. As such, the development of a back-surfaced acrylic mirror to replace the 46”-diameter glass parabolic mirror currently used with the HSL solar collector was of great interest. Several manufacturers of acrylic mirrors were contacted regarding the requirements for the new mirror, and various fabrication and coating techniques were considered. Finally, a New Zealand company, Bennett Mirrors, was selected to pursue the fabrication of a 48”- diameter acrylic mirror with a second-surface silver coating. In tandem with this effort, redesign of the HSL solar collector was performed to support and incorporate the new plastic mirror while also significantly reducing the complexity of the tracker assembly. The previous tracker, called the 2nd-generation unit, was designed around the size, weight, and structural properties of the glass primary mirror. In addition, this 2nd-generationPDF Image | FY 2004 ANNUAL REPORT DOE Solar
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