Mounting Structures Research Articles

Additively Manufactured Structures for Precise and Robust Mounting of Optical Elements

The design freedom of Additive Manufacturing offers new opportunities for the design of mounting structures of optical systems, which are not feasible for conventional manufacturing approaches, thus opening up new areas of application for optical systems. We use this to develop a fully monolithic mounting structure for precise positioning of the optical elements, while simultaneously increasing their robustness against harsh environmental conditions. We additively manufacture such a mounting structure for an imaging lens and evaluate its optical performance with interferometric measurement of its wavefront, before and after applying a mechanical shock to the entire system. The results indicate a centering accuracy better than 6~µm, both in the initial positioning as well as the subsequent repositioning after a mechanical shock of 15G.

Design and simulation of a photovoltaic plant for maximum use of the solar resource in the Toluviejo municipality of Colombia

Currently, there are various technologies for constructing photovoltaic plants including monofacial and bifacial photovoltaic panels, centralized and string-type inverters, and fixed mounting structures with light followers, to build electrical energy generation systems. This work reviewed the advantages and disadvantages between these technologies, and the implementation of a photovoltaic plant in Toluviejo, Colombia was proposed. To justify and confirm the design, simulations were carried out with the PVsyst software, resulting in the bifacial panels, centralized inverters, and structures with light followers, the most effective solution, and with the highest production for the proposed photovoltaic power generation plant.

Evaluation of the activation of the radiation shielding of the LaDiff neutron triple-axis-spectrometer at FRM-II by simulation/calculation

Neutron radiation is widely used for investigation of matter at research reactors and spallation sources. One undesired side-effect is the production of radioactive nuclides in structure materials of the instruments (e.g. mounting structures and radiation shieldings) due to neutron capture reactions. Hence the structure materials themselves become radiation sources. The knowledge of the activities after a certain time of operation is essential for determination of the accessibility, for modifications of the instrument, for reusing the material and for waste management. It is desirable to have these data in the design phase of the instrument. One possibility to obtain the data is a combination of simulation and calculation. In this paper the simulations/calculations for the LaDiff cold triple-axis neutron spectrometer project at FRM-II (research reactor Munich) are presented. The activities in the shielding house around the experimental area of the instrument made from stainless steel and lead are considered for the cases with and without boron-carbide cover and for different Sb-contents of the lead layer. The influence of the skyshine is also considered.

Industry CPD: Design of solar panel mounting structures made of cold-formed steel

This CPD module, sponsored by GRAITEC UK, explores the structural analysis and design of solar panel mounting structures made of cold-formed steel.

Design and Analysis of Solar Power Cart for Inhouse Application Through ANSYS

The design and analysis of a solar power cart for in-house applications using ANSYS software is presented in this paper. The solar power cart is a portable, self-contained unit equipped with solar panels, batteries, and power electronics, designed to provide a renewable energy source for various in-house applications. The objective of this study is to analyze the structural integrity and thermal performance of the solar power cart using ANSYS simulation tools. The structural analysis focuses on evaluating the cart's mechanical strength and durability under various loading conditions, including static and dynamic loads. Finite element analysis (FEA) is used to simulate the structural behavior of the cart's components, such as the frame, wheels, and mounting structures, to ensure they can withstand the operational loads. The thermal analysis investigates the heat distribution and dissipation within the cart to prevent overheating of the components and optimize the overall thermal performance. ANSYS Fluent is employed to simulate the airflow and heat transfer mechanisms, enabling the design of effective cooling systems and thermal management strategies. The results of the design and analysis are used to optimize the solar power cart's performance, efficiency, and reliability for in-house applications. The proposed design demonstrates the feasibility of using ANSYS software for the design and analysis of renewable energy systems, providing valuable insights for future research and development in this field.. Key Words: Hallow shaft, Catia software Ansys19.0

Using the AIDA Method in the Design of New Elements for the Photovoltaic Mounting Structures

To address diverse challenges and accelerate the adoption of PV technology, innovative and cost-effective PV assemblies are essential. The Analysis of Interconnected Decision Areas—the AIDA method—offers a promising approach to achieving this goal by providing a structured framework for identifying, assessing, and optimizing the design of PV assemblies. The aim is to demonstrate how AIDA can be effectively used to identify and assess potential improvements in PV assembly design, leading to the development of more efficient, cost-effective, and environmentally friendly PV systems. For this, out of 54 combinations, 10 of them were retained, so that in the end only two possible solutions obtained by applying AIDA remained. Both structures were assessed by applying FEM, analysing data regarding equivalent von Mises stresses and displacements but also the existence of stress hotspots. A design insight study was also carried out. Also, the models were first built by additive manufacturing (3D printing). These models were evaluated by a manufacturer so that the evaluation matrix and criteria satisfaction matrix could be successfully completed. Therefore, AIDA can be successfully used in solving problems in product design in the field of mounting structures for PV panels. Depending on the manufacturer’s capabilities, the intended functions can be adapted quickly, because AIDA is quite simple to apply if the data of the problem are known very well. Following the application of the FEM it was concluded that the surfaces as simple as possible are to be followed in the design of components. Also, an assessment of environmental impact was successfully undertaken by means of software assistance. The decision to use one option or another is a subjective one. If the technical data are followed, then one type of structure is the one that the manufacturer should adopt as a solution to the problem. However, if the manufacturer considers that the impact on the environment is important and dedicates resources in this direction, then a different type of structure should be adopted.

Comparative performance evaluation of ground-mounted and floating solar PV systems

The global shift towards sustainable energy sources, driven by the need to reduce carbon emissions and ensure energy sustainability, has shifted from traditional fuel-based energy generation to a surge in interest in Renewable Energy Technologies such as Solar Photovoltaic. Solar Photovoltaic energy has the potential to mitigate carbon emissions and achieve energy security that is in line with Sustainable Development Goals but challenges such as land requirements and system efficiency persist. This study compares the performance of ground-mounted and floating solar Photovoltaic systems at the Bui Generating Station in Ghana. The findings reveal that floating PV systems have several superiorities over ground-mounted systems, including lower temperatures, higher energy generation capabilities, and more efficient area cover use. However, floating PV systems are also prone to aluminium frame corrosion of the Photovoltaic modules and other metallic components within the mounting structures, which could be mitigated through design modifications. The superior performance of floating Photovoltaic systems suggests their viability as a strategic tool in achieving renewable energy targets. As floating Photovoltaic technology advances, it promises to create a greener and more resilient energy landscape.

Economic Feasibility of PV Mounting Structures on Industrial Roofs

This study determines the viability and profitability of photovoltaic (PV) mounting structures on industrial roofs. For this purpose, more than 656,000 different cases have been analyzed, combining different consumption patterns, energy prices, locations, inclinations, azimuths, capacity installed, and excess income. The results show that the industry’s consumption pattern is a key factor, leading to significant reductions in the available assembly budget for inclined structures compared to the coplanar option when the pattern is seasonal and/or irregular. The increase in energy prices experienced in the last 2 years represents a substantial change in the viability of the structures. The budget for inclined structures increases by hundreds of euros compared to the coplanar option. Depending on the azimuth and inclination of the roof, the maximum available budget can vary by more than a thousand euros per kWp, being highly profitable in orientations close to the east and west and on roofs partially inclined to the north. Differences between low-irradiation and high-irradiation locations can mean variations in the average budget of more than 1 k€/kWp, especially with high electricity prices.

Exploring New Frontiers in Coral Nurseries: Leveraging 3D Printing Technology to Benefit Coral Growth and Survival

Coral nurseries and associated techniques are the most common and widespread reef restoration methods worldwide. Due to the rapid decline of coral reefs, coral nurseries need to be eco-friendlier and adapted for effective upscaling to support large restoration projects. We suggest new design and fabrication processes associated with coral gardening and transplantation with 3D printing technology to offer a beneficial solution for growing coral fragments in on-land and underwater nurseries. We describe multiple combinations of building nurseries through the integration of biomimetic substrates and novel solutions for attaching coral fragments. Our methods are supported with supplemental testing of two hybrid substrate designs and coral mounting structures, building upon previous studies in the Gulf of Eilat/Aqaba (GoE/A), Red Sea. We identified and quantified marine invertebrates colonizing the surfaces of our substrates with environmental DNA (eDNA) by targeting the mitochondrial COI gene. We evaluated our coral fragments with and without our mounting structures to obtain an indication of total protein as a proxy for tissue health. We demonstrate the ability to design hybrid nurseries with custom mounting structures using biomimetic substrates, such as large ceramic artificial reefs, or with an interlocking mesh for holding numerous fragments to maximize out-planting efforts. We propose several methods for both land and underwater nurseries catered to various restoration initiatives for cost-effective up-scaling to meet the demands of global reef restoration.

Method for determining the wavefront aberration of deformed optical components under external forces

Wavefront aberration is an essential factor that significantly affects the image quality of an optical system. We proposed a comprehensive method to determine the wavefront aberration of a deformed optical component caused by clamping forces. First, the displacement of the elements on the optical component, induced by external forces, is calculated using ANSYS software. Then, the deformation surface is fitted with an aspherical surface to obtain Zernike coefficients. Finally, the wavefront aberration is obtained from Zemax using the Zernike coefficients and the parameters of the optical component. An experimental study on a spherical mirror is carried out to verify the accuracy of this method. A Zygo interferometer is used to measure the actual wavefront aberration of the deformed mirror. The result indicates a good agreement between the theoretical calculation and the experimental data, with a variation of <10 % for various applied forces. Our finding provides a meaningful and reliable method for designing and selecting reasonable mounting structures to ensure the image quality of an optical system.

Individual finger movement decoding using a novel ultra-high-density electroencephalography-based brain-computer interface system.

Brain-Computer Interface (BCI) technology enables users to operate external devices without physical movement. Electroencephalography (EEG) based BCI systems are being actively studied due to their high temporal resolution, convenient usage, and portability. However, fewer studies have been conducted to investigate the impact of high spatial resolution of EEG on decoding precise body motions, such as finger movements, which are essential in activities of daily living. Low spatial sensor resolution, as found in common EEG systems, can be improved by omitting the conventional standard of EEG electrode distribution (the international 10-20 system) and ordinary mounting structures (e.g., flexible caps). In this study, we used newly proposed flexible electrode grids attached directly to the scalp, which provided ultra-high-density EEG (uHD EEG). We explored the performance of the novel system by decoding individual finger movements using a total of 256 channels distributed over the contralateral sensorimotor cortex. Dense distribution and small-sized electrodes result in an inter-electrode distance of 8.6 mm (uHD EEG), while that of conventional EEG is 60 to 65 mm on average. Five healthy subjects participated in the experiment, performed single finger extensions according to a visual cue, and received avatar feedback. This study exploits mu (8-12 Hz) and beta (13-25 Hz) band power features for classification and topography plots. 3D ERD/S activation plots for each frequency band were generated using the MNI-152 template head. A linear support vector machine (SVM) was used for pairwise finger classification. The topography plots showed regular and focal post-cue activation, especially in subjects with optimal signal quality. The average classification accuracy over subjects was 64.8 (6.3)%, with the middle versus ring finger resulting in the highest average accuracy of 70.6 (9.4)%. Further studies are required using the uHD EEG system with real-time feedback and motor imagery tasks to enhance classification performance and establish the basis for BCI finger movement control of external devices.

Structural Design and Analysis of Electric Car Engine Mount

In this paper, the analysis of engine mounting structures that will be applied to electric vehicles is conducted. The engine mounting structure will be subjected to static loading from the mounted components assembly, including the assembly of the gearbox, electric motor, and corresponding brackets. In the structure arrangement, HSLA material is mostly used and general structural steel such as AISI 4130 is also used. This study aims to evaluate the existing design so that further optimization steps can be carried out. Simulations and analysis with a static approach were performed using SOLIDWORKS. The stress and displacement contours are then created, and the location of the critical points of maximum stress and maximum deflection can be obtained so that the safety factor of the design can be evaluated. Based on the simulation results, the current safety factor value is very high when compared to using materials with lower physical properties. In addition, it is necessary to develop further studies involving dynamic loading so that it can also be considered to reduce production costs and increase production efficiency.

Performance evaluation of different solar modules and mounting structures on an on-grid photovoltaic system in south-central Chile

Solar photovoltaic (PV) plants are popular sources of renewable energy. Factors that affect the performance of energy collection through PV facilities include the material of the solar panels and the incident irradiation that reach their surface. In this context, evaluations reported in the literature normally assess the effects of using different materials and tracking systems to follow the sun position throughout the day; however, these evaluations usually analyze these properties independently and focus mainly on energy yield. From a practical perspective, to assess the effective utility of solar technology as a valid alternative to fossil fuels for energy generation, the evaluations should take a holistic approach, considering different types of technology and the specific operational conditions of the target environment. For example, the relative gains of using an advanced tracking system might be significant in cold climates.This paper presents a performance analysis of an on-grid microgrid installed in the south-central part of Chile, composed by a variety of PV modules, inverters, and fixed and tracking mounting structures, with a combined installed capacity of 41.2 kWp. The evaluation also considers the impact of the different technologies under study in terms of CO2 emission mitigation capacity. The analysis performed over the data collected during two years shows that different configurations and combinations of silicon PV panels and mounting systems have different benefits and drawbacks depending on the target metric and environmental conditions. Regarding tracking performance, the PV Systems with solar tracking develop annual capacity factors of up to 25.89% (with up to 39% during summer), while some of the fixed system can only reach a 18.56% (with up to 24% during summer) during the same period of evaluation. The results allow for the quantification of the impact that different tracking systems have on key performance indicators in regions such as the one considered in this study.

Issues, challenges, and current lacunas in design, and installation of ground mounted solar PV module mounting structure (MMS)

Current energy systems are the outcome of constrained fossil fuels. The energy systems must be transformed and need to be shifted on the maximum penetration of the renewable. Solar photovoltaic (PV) power generation is one of the most promising sources in this regard. This underutilized resource potential needs to be tapped. The Levelized Cost of energy from Solar PV is decreasing nowadays. Still, more efforts are necessary to curtail this cost. The overall efficiency, the life of the power plant, and its reliability in the power supply are mostly dependent on the panel support structure. So, the utmost care should be taken while designing the support structure for these power plants. Depending upon the capacity of these power plants, they are spread over large areas. This paper contributes to the current issues and challenges faced by the support structure designer for the ground-mounted solar PV module mounting structure (MMS). An attempt has been made to found out the exact design lacunas based on Indian code IS:801 and Euro code 1993-1-3 for cold form structures. The current failure patterns of solar module mounting structures (MMS) are analyzed and the design deficiencies related to tilting, stability, foundation, geotechnical issues, tightening clamps, dynamic effects are discussed in detail for the ground-mounted solar PV MMS.

Design and evaluation of eco-friendly mountages for the silkworm, Bombyx mori L.

The silkworm Bombyx mori L. ends its larval stage with construction of silken armour called ‘cocoon’. The management of spinning larvae demands much care to maximize profit to the farmer, which necessitates manual picking of the ripened worms and provide proper anchorage to construct cocoons and the process is called as mounting. More than 40 % of the labour force is dedicated towards mounting (15 out of total 35 mandays/100 DFLs) that draws attention of the researchers striving hard to double farmer’s income by designing self mounting cocooning structures. Though corrugated plastic mountages are available, they are suitable only for Bivoltine (BV) silkworms that have a notable crawling habit. Ourefforts to design and develop new ecofriendly self mounting structures for mounting both crossbreeds (CB) and BV silkwormsevolved four new type of mountages viz., Spiral, Zig-zag, Square mountages made of bamboo and the Ribbon mountage. The lab tests of these mountages in comparison with the regular bamboo mountage and the plastic self mounting structures clearly indicated that the spiral mountages are comparable with the regular bamboo mountage with respect to various cocoon and reeling parameters among both CB (PM X CSR2) and BV double Hybrid (FC1 X FC2). Also these are self mounting cocooning frames that reduce the cost on labour during ripe worm management.

OPTIMUM TILT ANGLE FOR MAXIMIZING LARGE SCALE SOLAR ELECTRICAL ENERGY OUTPUT

Many large-scale solar (LSS) plants that are being installed today have solar photovoltaic (PV) panels mounted on fixed structures, which limits its electrical energy production. Tracking system can be installed so that the PV panels could change its tilt angle automatically in accordance with the sun’s movement. However, it will increase the construction, operation and maintenance cost significantly. Another option is to manually adjust the tilt angle on periodically basis, but the time period and the optimum tilt angle need to be systematically determined. This paper investigates the impact of using monthly and seasonal optimum tilt angle, βopt on electrical energy production of LSS plant. The proposed strategy can be implemented by using tiltable solar panel mounting structures which is far cheaper than the tracking system. For the study, 1 MW LSS system model is used. Twelve cities around the globe with latitude angle ranging from 0º to 55º are strategically selected. The electrical energy output from the 1 MW LSS plant is simulated by using PV mathematical model that is developed in Matlab software. The overall results show that by adjusting the tilt angle of the PV modules into its optimum angle on monthly or seasonal basis, it would increase the generated energy output between 1.91% and 7.24% for monthly adjustments and between 1.59% and 6.06% for seasonal adjustments.

A Novel Heat Shrinkable Ultrasonic Transducer for Rotary Ultrasonic Micro-Nano Precision Manufacturing

Rotary ultrasonic machining (RUM) has been proven to be a suitable technology for micro-nano precision manufacturing for hard and brittle ceramics/composite materials. However, the working frequency of the ultrasonic transducer in current RUM is in range from 20 kHz to 30 kHz. Moreover, the tool is tightened by an elastic chuck, which is in low clamping precision, high radial run-out, and unstable ultrasonic energy transmission. In this paper, we developed a novel heat shrinkable RUM ultrasonic transducer with 60 kHz frequency by equivalent circuit and finite element method (FEM). An analytical electromechanical equivalent circuit model was deduced to obtain the initial structure dimensions of the ultrasonic transducer. Three flange mounting structures were proposed to optimize and improve the energy transmission at the working resonant frequency. The influence of the proposed flanges on the resonant frequency of three transducers was analyzed and presented. The designed transducers were manufactured and tested in experiment. It shows that resonant frequencies of these three transducers with step, circular, and plate flange are 62.2 kHz, 61.46 kHz, and 61.4 kHz, and vibration amplitudes in 90 V driving voltage are $1.33\mu \text{m}$ , $4.74\mu \text{m}$ , $5.33\mu \text{m}$ , respectively. The working resonant frequencies by experimental measurement are consistent with the calculation result of the equivalent circuit and FEM. Moreover, the plate flange transducer shows the optimal amplitude capability with enough ultrasonic energy in micro-nano precision manufacturing.

Comparative Study on Reliability and Advanced Numerical Analysis of BGA Subjected to Product-Level Drop Impact Test for Portable Electronics

In this paper, drop reliability of various PBA (printed board assembly) mounting structures is investigated and compared. Then, we built SAC305 (Sn3.0Ag0.5Cu) interconnects for BGA (ball grid array) package failure model to evaluate the drop impact reliability of handheld devices. In order to simulate actual behavior of the solder joint under the drop impact load of handheld devices, we perform explicit full FEA (finite element analysis) modeling. However, this takes a lot of computing time because of the large aspect ratio of element size between solder joints and other structures such as PCB (printed circuit board) and electronic packages. Therefore, an effective way to represent solder interconnects for FEA is needed which would be relatively simpler yet detailed. Comparable board-level drop tests are conducted after equipping test vehicles with various fixtures considering PBA mounting structures, which make it possible to apply different loading conditions to BGA packages. The results show different drop impact life for solder interconnects depending on the mounting design of the PBA. Particularly, the solder interconnect of the component located at the middle of the PCB exhibits the shortest impact life where the highest tensile stress occurs. Also, the mounting design restraining PBA deflections shows better reliability under the drop impact loading. Sequentially, simulating with a PBA composed of the BGA package and the PCB is considered to assess the feasibility of the solder ball failure modeling when the drop impact load is applied. Especially, for the modeling of the solder balls, detailed solid model and simple beam model are compared regarding computational efficiency and numerical accuracy. We found that the simple beam model significantly shortens computational time from 110 h to less than an hour. Accordingly, the feasibility of the beam model for the solder balls is shown by correlating the stress level and the drop impact life obtained from the experiments.

On the PV Tracker Performance: Tracking the Sun Versus Tracking the Best Orientation

This article models the performance of photovoltaic tracking algorithms worldwide, based on the overall insolation collection, by comparing two tracking algorithms, namely tracking the sun (TS) and tracking the best orientation (TBO). In general, the latter is expected to receive higher irradiance with the drawback of requiring a higher installation and maintenance cost (due to the extra sensors). The aim of this research is then to quantify how big the difference is on irradiance collection from these two trackers worldwide by analyzing the data from 61 ground weather stations. In addition, three different tracking mounting structures are considered in this work: first, horizontal single axis tracker (HSAT); second, tilted single axis tracker (TSAT); and third, dual axis tracker (2T). Furthermore, the irradiance collection from front and rear sides are estimated for installations of monofacial and bifacial modules. The simulations reveal that, although the TBO results are higher than the TS ones, there is not a big difference on their insolation collection for latitude locations below 60° (<1.8%). Nevertheless, for higher latitude locations, TBO tracking systems can achieve a considerably higher performance reaching values of up to 3.3%, 7.1%, and 2.9% for HSAT, TSAT, and 2T systems, respectively. It was also observed that for bifacial and 2T systems in particular, high albedo values would produce a considerable enhancement on the TBO performance with respect to TS.

Considerations of Photovoltaic System Structure Design for Effective Lightning Protection

Photovoltaic (PV) systems are susceptible to lightning strikes. During a lightning strike, an induced overvoltage is generated in the PV system. This overvoltage can damage the inverters connected to the dc cables. In this article, a comprehensive study is presented to address the installation issues that will influence the induced voltage between the +dc and -dc cables in the PV system. By using the partial element equivalent circuit method, the skin effect and ferromagnetic property of the mounting structures are well modeled. The wiring in the PV module is also considered in the simulation. The influences of the mounting systems, lightning protection systems, PV frames, and dc cable arrangements are thoroughly investigated. The simulation results and discussions provide guidance for PV structure design for maximizing lightning protection performance without adding additional protective devices.