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Swept-Lookback Deflectometry for High Performance Concentrating Solar Power Optical Metrology
This report describes an initial investigation into a proposed solution to the important problem of performing a detailed evaluation of heliostat optical performance, in situ in a heliostat field. Our approach is to place digital cameras in a position near the receiver where they look back toward the heliostat mirrors. The pixels of each camera sensor identify a set of small cells on the mirror surface, each corresponding to a “mixel.” By either passing reflected sunbeam over the camera or passing the camera through the reflected sunbeam, the cameras intercept sunlight reflected from each mixel. We then analyze the recorded video data to determine times when each mixel transitions from dark to light, and then back to dark. We then use these transitions to construct vectors from the camera to the mixel, and then from the mixel to the edge of the Sun at that moment. We then compute the surface normal at the mixel, which bisects the angle between these vectors. Performing this analysis for all mixels in the mirror yields a high-resolution map of slope across the mirror surface. We have implemented most of this process, successfully collecting data for an example heliostat facet and computing a preliminary estimated slope map. However, more work remains to complete this calculation, since certain factors and transformations are not yet included. Our observations so far support our hypothesis that such a system is possible, but we have not yet completed our quantitative evaluation of the concept.
Diffraction effects and special advantages in electronic heterodyne moire deflectometry
Effects of diffraction on the performance of electronic heterodyne readout of moire fringes are investigated. The sensitivity, accuracy, and resolution of the system are calculated, and it is shown that these features are significantly improved compared with the conventional intensity moire readout technique. The sensitivity of the system can be tripled without changing the distance between gratings. The system was evaluated experimentally by measuring the refractive-index derivatives of a weak phase object consisting of a large KD(asterisk)P crystal. Effects of nonlinear fringe modulation were studied both theoretically and experimentally. It is shown that in this case the electronic phase is not linearly related to the fringe shift, and calibration of the system is necessary.
Vapor concentration measurement with photothermal deflectometry
Theoretical and experimental results for using the photothermal deflection technique to measure vapor species concentration, while minimizing the disturbance of the transport (material) parameters due to vapor heating, are developed and described. In contrast to common practice, the above constraints require using a pump-beam duty cycle of less than 50 percent. The theoretical description of the shortened heating time is based on a step-function formulation of the pumping cycle. The results are obtained as closed-form solutions of the energy equation for many chopping cycles until steady state is reached, by use of a Green's-function method. The Euler formulation of the Fermat principle is used to calculate the deflection angle. The equations are expanded to include the effects of vapor velocity on both the temperature and temperature gradient profiles. The effects of finite (unfocused) pump and probe beams and thermal (Soret) diffusion are also accounted for. Excellent agreement between theory and experiment is obtained.
Deferred electronic heterodyne moire deflectometry: A method for transient density fields measurement
Effects of spherical aberrations of the mirror used in the moire system on the angular resolution of the system are investigated. It is shown that the spherical aberrations may reduce significantly the performance of the conventional moire deflectometer. However, due to the heterodyne procedure, this is not the case with the heterodyne moire system. A moire system with a constant speed moving grating is demonstrated. It is shown that the system readout is linear and the system does not need calibration. In addition, the repeatability of the measurements is improved in this system as compared to the sinusoidally moving grating setup. The problem of the photographic plates alignment is solved by using a mechanical system in which the plate is held firmly throughout the experiment and accurately replaced after removing for photographic processing. The effect of a circular detector's aperture size on readout was tested. It is shown that the spatial phase variations, observed when scanning along a straight moire fringe, may considerably be reduced. At present we may say that both the on-line and the deferred heterodyne moire techniques may reliably be used. The errors of phase readings are 1 deg and 5 deg for the on-line and deferred methods. The total error due to subtraction of two readings at each position is, therefore, 1.4 deg and 7 deg, respectively. Further research for improving the deferred system is suggested.
Quantitative rainbow schlieren deflectometry
In the rainbow schlieren apparatus, a continuously graded rainbow filter is placed in the back focal plane of the decollimating lens. Refractive-index gradients in the test section thus appear as gradations in hue rather than irradiance. A simple system is described wherein a conventional color CCD array and video digitizer are used to quantify accurately the color attributes of the resulting image, and hence the associated ray deflections. The present system provides a sensitivity comparable with that of conventional interferometry, while being simpler to implement and less sensitive to mechanical misalignment.
Tracing dynamics of laser-induced fields on ultrathin foils using complementary imaging with streak deflectometry
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Advanced optical measuring systems for measuring the properties of fluids and structures
Four advanced optical models are reviewed for the measurement of visualization of flow and structural properties. Double-exposure, diffuse-illumination, holographic interferometry can be used for three-dimensional flow visualization. When this method is combined with optical heterodyning, precise measurements of structural displacements or fluid density are possible. Time-average holography is well known as a method for displaying vibrational mode shapes, but it also can be used for flow visualization and flow measurements. Deflectometry is used to measure or visualize the deflection of light rays from collimation. Said deflection occurs because of refraction in a fluid or because of reflection from a tilted surface. The moire technique for deflectometry, when combined with optical heterodyning, permits very precise measurements of these quantities. The rainbow schlieren method of deflectometry allows varying deflection angles to be encoded with colors for visualization.
Demonstration and Automation of Reflected Target Optical Measurement for Heliostats
Accurate optical surfaces are a primary driver of concentrated solar power plant performance. Errors in pointing and tracking mirrors, the canting of individual mirror facets, and the surface slope of the mirror itself can be caused by errors during assembly, transportation, wind loading, gravity, and many other sources. The tools that exist to measure these error sources today largely rely on fringe deflectometry (SOFAST, QDec, others), or photogrammetry with targets attached to the mirror surface. Since 2022, NREL has been developing a measurement method called the Reflected Target Non-intrusive Assessment (ReTNA) system. This system differs from most established methods in that we perform deflectometry with a pattern of coded targets, identified in space with photogrammetry. Reflected target systems have several advantages over traditional fringe deflectometry systems. Firstly, they can be operated in bright or ambient lighting, a challenge for fringe systems that use a projector and screen. Reflected target systems also can use a much lighter and less expensive target than projector-based systems. Lastly, 2D slope measurement can be solved from a single image, which leads to several advantages for accommodating faster measurements and smaller sized targets. These advantages make ReTNA particularly well-suited for applications where there are space or lighting constraints, like performing heliostat quality assurance on an assembly line. It's also useful when a lightweight, flexible system is needed, like for heliostat developers to quickly measure a new heliostat design at different orientations, to observe gravitational effects on the mirror surface shape. In the last year, significant improvements were made to this tool to make it more useful for these applications. These improvements were focused around validation of the ReTNA measurement system, and automation of the setup and measurement process. First, we present an improved ReTNA layout, for use on the heliostat assembly line. Next, we detail the various changes to the ReTNA software and computer vision methods to automate data collection in this new setup, and lessons learned from this process. The goal with this new setup is to perform a full heliostat surface characterization without removing the mirror from the assembly line. Lastly, we share results from several ReTNA validation studies undertaken over the last year. These include repeated ReTNA measurement on demonstration mirror facets, comparisons with other optical measurement tools, and some studies aimed at quantifying the uncertainty of ReTNA measurement under various constraints (mirror-target spacing, camera resolution, etc.). These results are compared with 2024 HelioCon performance targets, and our planned next steps for the ReTNA measurement system are presented.
Static metrology of the meter-scale deformable heliostat
This paper describes a heliostat metrology system which is developed based on deflectometry, utilizing a static perforated panel instead of conventional dynamic monitor displays to provide incident rays. The developed method is named static screen deflectometry (SSD). This robust and scalable method is especially valuable for outdoor tests of large reflectors used in concentrating solar-thermal power (CSP) systems. The developed method has been successfully demonstrated on a 2.4 𝑚 × 3.3 𝑚 float glass deformable reflector bent to focus sunlight at 113 𝑚 distance throughout a day. From images obtained from a camera at 50𝑚 distance, the reflector surface was measured to an accuracy of less than 1 𝑚𝑟𝑎𝑑 rms slope error in the full test scope.
SOFAST 2.0 User Guide and Technical Description, Document Version 1.0
This report accompanies Sandia’s deflectometry tool, SOFAST 2.0, providing both a user guide and a basic technical description. SOFAST is a deflectometry tool used to measure surface slope maps of concentrating solar power (CSP) mirrors and collectors. The original SOFAST performed high-resolution measurement of a variety of CSP mirror types. SOFAST 2.0 is a completely new version, re-implemented in Python and including many extensions and improvements.
Projector Selection for SOFAST Testing
In Concentrating Solar Power (CSP) there is a need for mirrors that are optically accurate, as they are used to focus light onto a receiver at high concentration. To test the accuracy of the mirrors’ optical slopes, we employ a technique called deflectometry. Deflectometry measures mirror slope directly. A projector displays an image onto a screen or wall, and a mirror is positioned to reflect the image to a camera. The camera sees the mirror’s reflection of the screen and sends imaging information to software which analyzes the reflected images from the mirror to determine the local slopes and curvature of the mirror. For this, projectors that can provide a crisp and clear image are imperative. Choosing the right projector(s) can be a long and tedious process; this paper will cover the process we used to select projectors for the SOFAST systems in the Sandia Concentrating Solar Optics Laboratory (CSOL).
Advancements in reflected target nonintrusive assessment (ReTNA) for large optical surface measurement
Reflected computer vision targets are a powerful tool for measurement of mirror surface shape, with several important advantages over traditional fringe deflectometry methods. This method was first presented in 2021 and has undergone significant improvement and demonstration since. We describe a new baseline system using reflected computer vision targets, and present results from a large-scale measurement campaign conducted on both commercial heliostats and test mirrors in the laboratory. Calibration of the measurement system with photogrammetry allows for accurate measurement without careful control of target shape or camera position. Overall, the results show that a baseline setup using this method achieves measurement uncertainties in the slope error root-mean-square less than ±0.11 milliradian due to a series of repeatability conditions, varying sample position, rotation, lighting, camera settings, and system rebuild and recalibration. We present a detailed description of the setup, the results generated by this measurement tool, repeated measurement results, and the strengths and limitations of this metrology system.
Improvements in Mirror Surface Measurement with Reflected Computer Vision Targets
Over the last several years, NREL has been developing a system to measure large optical surfaces of heliostat mirrors by reflecting computer vision targets. An advantage of this system, called Reflected Target Nonintrusive Assessment (ReTNA), is that it lends itself well to stitching together many images, each reflecting only part of a larger heliostat. In the last few months, this was taken to a new extreme, with a small target (<5m2) being used to measure a >25m2 long focal length heliostat. These measurements were compared with traditional fringe deflectometry methods, which require a >50m2 target, and photogrammetry. The strengths, weaknesses and limitations of ReTNA are discussed. An estimated uncertainty in this new measurement is presented, along with software improvements and a new wireless data collection system. A bill of materials for this measurement system is presented, which has been designed to use all low-cost, off-the-shelf components. Finally, the next steps for future ReTNA development are presented. Overall, ReTNA can be a valuable optics measurement system, complimentary to existing measurement techniques available for large reflective surfaces.
Improvements in Optical Surface Measurement Using Reflected Computer Vision Targets
Since 2021, NREL has been developing a system to measure heliostats by measuring the deflection of printed computer vision targets, called the Reflected Target Non-intrusive Assessment (ReTNA) [6], [7]. While this system will have lower resolution than a fringe deflectometry system, it has several important advantages that make it a complimentary technology: 2D surface slope measurement can be generated from a single image, it can operate in ambient lighting, target points can be directly located in 3D space with photogrammetry allowing for a non-flat target, and it's well suited to using a smaller target, and multiple images to measure larger optical surfaces. ReTNA has undergone several significant changes and improvements, described below. This talk will summarize new system layouts designed for commercial use, new computer vision algorithms used to automate the analysis process and validation campaigns for the ReTNA software.
Dual-Image Color Normalization to Enable High-Performance Concentrating Solar Optical Metrology
Concentrating Solar Power (CSP) requires precision mirrors, and these in turn require metrology systems to measure their optical slope. In this project we studied a color-based approach to the correspondence problem, which is the association of points on an optical target with their corresponding points seen in a reflection. This is a core problem in deflectometry-based metrology, and a color solution would enable important new capabilities. We modeled color as a vector in the [R,G,B] space measured by a digital camera, and explored a dual-image approach to compensate for inevitable changes in illumination color. Through a series of experiments including color target design and dual-image setups both indoors and outdoors, we collected reference/measurement image pairs for a variety of configurations and light conditions. We then analyzed the resulting image pairs by selecting example [R,G,B] pixels in the reference image, and seeking matching [R,G,B] pixels in the measurement image. Modulating a tolerance threshold enabled us to assess both match reliability and match ambiguity, and for some configurations, orthorectification enabled us to assess match accuracy. Using direct-direct imaging, we demonstrated color correspondence achieving average match accuracy values of 0.004 h, where h is the height of the color pattern. We found that wide-area two-dimensional and linear one-dimensional color targets outperformed hybrid linear/lateral gradient targets in the cases studied. Introducing a mirror degraded performance under our current techniques, and we did not have time to evaluate whether matches could be reliably achieved despite varying light conditions. Nonetheless, our results thus far are promising.
NLR CSP Optical Facilities: Illuminating the Path Forward Through Innovation and Impact: Agreement 38490
This initiative is a multi-faceted project at the National Laboratory of the Rockies (NLR) aimed at strengthening its Concentrating Solar Power (CSP) Optical Facilities to advance the development of low-cost, high-performance materials for solar and other applications. The project's strategy is built on three pillars: strategic stakeholder engagement, diligent facility maintenance and utilization, and the development of new research capabilities. The overarching goal is to ensure the facilities remain state-of-the-art resources for industry and academia, thereby accelerating the conversion of concentrated sunlight into energy. A key driver of the project is an international Advisory Board, which provides critical guidance on research priorities and industry needs, leading to new collaborations and secured funding. This external engagement, combined with proactive outreach to industry partners, ensures the lab's work remains aligned with real-world challenges, including materials durability and performance certification. Significant efforts in facility maintenance have addressed challenges with aging infrastructure. Notable achievements include the complete refurbishment of the hail-damaged Ultra-Accelerated Weathering System (UAWS) and the successful replacement of a failing 15-year-old Lambda 1050 spectrophotometer with a new-generation model, substantially upgrading material characterization capabilities. These maintenance activities were complemented by achieving a prestigious ISO 9001:2015 certification for the Advanced Optical Materials Labs, formally recognizing the quality and reliability of NLR's measurement capabilities. Despite these successes, challenges remain, including high demand for the High Flux Solar Furnace (HFSF) and intermittent failures of other key instruments. The project has delivered major advancements in research techniques and capabilities. At the Flatirons campus, a new indoor laboratory, was established to house advanced deflectometry and photogrammetry systems for heliostat characterization. For on-sun testing, a novel, actively cooled turning mirror was developed for the HFSF, enabling more realistic testing of particle receivers and components. A collaboration with Virginia Tech successfully demonstrated the high-temperature durability of a new solar absorber coating through extensive cyclic testing. Concurrently, new modeling took place to better predict material degradation on rough, fractal surfaces. In summary, this project has systematically enhanced NLR's CSP Optical Facilities through strategic upgrades, rigorous maintenance, and stakeholder-guided research. By overcoming equipment failures, budgetary constraints, and logistical hurdles, the project has reinforced NLR's role as a central hub for CSP innovation and materials testing. Future work will focus on securing diverse funding, expanding collaborations, and continuing to provide the critical infrastructure needed to accelerate the development and deployment of next-generation technologies.