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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

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.

14 SOLAR ENERGY↗
DOE OSTI2023

Collimated phase measuring deflectometry

Phase measuring deflectometry has been applied for free-form specular surface metrology, but its measured slope results are sensitive to the depth of sample positioning, which is also called the height-slope ambiguity. The objective of this work is to tackle this height-slope ambiguity problem. The main idea is to introduce collimated camera rays using a telecentric imaging lens and collimated structured-light illumination with a Fourier lens. This setup makes the fringe phases become only sensitive to the surface slopes and insensitive to the depth of the sample positioning. In this way, the slope calculation is theoretically independent of the sample depth. We call this new deflectometry technique Collimated Phase Measuring Deflectometry (CPMD). With our developed CPMD experimental setup, the measurement is insensitive to the depth of sample positioning, e.g., the measured height dispersion is less than 30 nm RMS within a 10 mm depth range when measuring a 50-mm-diameter spherical mirror with a 200 mm radius of curvature. In conclusion, the merits and limitations of the proposed CPMD technique are discussed, revealing its prospects in practical metrology applications and potential future investigations.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Collimated phase measuring deflectometry II: Re-design of the optical layout for high-curvature surfaces

Collimated phase measuring deflectometry (CPMD) is an optical metrology technique developed to improve upon traditional phase measuring deflectometry (PMD). CPMD utilizes telecentric imaging and collimated structured light illumination to eliminate the height-slope ambiguity present in traditional PMD measurements. After the publication of the first CPMD paper, efforts began to optimize the optical layout of the CPMD system. The first proposed change, and the one detailed in this work, was to move the Fourier transform (FT) lens closer to the surface under test (SUT). Moving the FT lens closer to the SUT meant that for a given FT lens diameter, a larger range of surface slopes on the SUT could be measured. This change to the optical layout was not trivial and introduced at least two concerns that had to be addressed: telecentricity in the imaging path and possible ghost reflections from the re-located FT lens. Here, in this work, we examine how these concerns were addressed and present results showing that the revised optical layout is capable of measurement results at least as good as the original CPMD optical layout. We also demonstrate the increased slope measuring range of the revised optical layout.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Self-driven ion deflectometry measurements using MeV fusion-driven protons and accelerated deuterons in the deuterated hybrid x-pinch on the MAIZE LTD generator

Abstract We report on the results of point-projection ion deflectometry measurements from a mid-size university z-pinch experiment. A 1 MA 8 kJ LTD generator at the University of Michigan (called MAIZE) drove a hybrid x-pinch (HXP) with a deuterated polyethylene fiber load to produce a point-like source of MeV ions for backlighting. In these experiments, 2.7 MeV protons were generated by DD beam-target fusion reactions. Due to the kinematics of beam-target fusion, the proton energies were down-shifted from the more standard 3.02 MeV proton energy that is released from the center-of-mass rest frame of a DD reaction. In addition to the 2.7 MeV protons, strongly anisotropic beams of 3 MeV accelerated deuterons were detected by ion diagnostics placed at a radial distance of 90 mm from the x-pinch. Numerical reconstruction of experimental data generated by deflected hydrogen ion trajectories evaluated the total current in the vacuum load region. Numerical ion-tracking simulations show that accelerated deuteron beams exited the ion source region at large angles with respect to the pinch current direction.

Physics↗
DOE OSTI2024

Proton deflectometry analysis in magnetized plasmas: Magnetic field reconstruction in one dimension

Proton deflectometry is used in magnetized high-energy-density plasmas to observe electromagnetic fields. Here we describe a reconstruction algorithm to recover the electromagnetic fields from proton fluence data in 1-D. The algorithm is verified against analytic solutions and applied to example data. Next, we study the role of source fluence uncertainty for 1-D reconstructions. We show that reconstruction boundary conditions can be used to constrain the source fluence profile and use this to develop a reconstruction using a specified pair of boundary conditions on the magnetic field. From these considerations, we experimentally demonstrate a hybrid mesh-fluence reconstruction technique where fields are reconstructed from fluence data in an interior region with boundary conditions supplied by direct mesh measurements at the boundary.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

OpenCSP Deflectometry Technical Description, Document Version 1.0

This document provides a technical description of algorithms used in the OpenCSP code repository that are common to deflectometry. This document is meant to be a technical reference that describes the internal algorithms of OpenCSP. An example program that uses these algorithms is SOFAST 2.0.

14 SOLAR ENERGY↗
DOE OSTI2025

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.

14 SOLAR ENERGY↗
DOE OSTI2023

Improvements in Reflected Target Non-intrusive Assessment (ReTNA)

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. In 2022, NREL presented a new indoor optical measurement system to measure fully assembled heliostats during development and on the assembly line for quality assurance purposes, which has undergone significant development in the last year, including the installation of a new, larger laboratory setup. This system, called ReTNA (Reflected Target Non-intrusive Assessment), uses a printed pattern as a deflectometry target. Using printed pattern features as deflectometry targets instead of fringes allows the software to measure the surface slope in two dimensions, eliminating the need to for changing, projected targets. In the last year, NREL's ReTNA tool has been adapted to use a tall, thin target, that only spans one dimension of the mirror, and a camera moving on an automatic track system. We will present these new developments, including the new setup, target patterns, software methodology for fast, automatic optical analysis, and important lessons learned throughout the process. ReTNA results will be compared to established tools, to establish the uncertainty of this new method. ReTNA leverages recent improvements in computer vision and photogrammetry to remove as much careful calibration from the setup process as possible, making the tool low cost, simple, and portable. While it will not achieve the resolution of a fringe deflectometry system, its advantages make it well suited for CSP evaluation, and allow it to fill a different industry need.

concentrating solar power↗
DOE OSTI2024

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.

CSP↗
DOE OSTI2024

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.

14 SOLAR ENERGY↗
DOE OSTI2026

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).

14 SOLAR ENERGY↗
DOE OSTI2026

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.

14 SOLAR ENERGY↗
DOE OSTI2026

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.

14 SOLAR ENERGY↗
DOE OSTI2024

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.

computer vision↗
DOE OSTI2024

Laser-driven quasi-static B-fields for magnetized high-energy-density experiments

We present measurements of magnetic fields generated in laser-driven coil targets irradiated by laser pulses of nanosecond duration, 1.053 μm wavelength, 500 J energy, and ∼1015 W/cm2 intensity, at the LULI2000 facility. Using two perpendicular probing axes, proton deflectometry is used to characterize the coil current and static charge at different times. Results reveal various deflection features that can be unambiguously linked to a looping quasi-steady current of well-understood polarity or to a static charging of the coil surface. Measured currents are broadly consistent with predictions from a laser-driven diode-current source and lumped circuit model, supporting the quasi-steady assessment of the discharges. Peak magnetic fields of ∼50 T at the center of 500-μm-diameter coils, obtained at the moderate laser intensity, open up the use of such laser-driven coil targets at facilities worldwide to study numerous phenomena in magnetized high-energy-density plasmas, and its potential applications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗