Investigations of the Fresnel Lens Based Solar Concentrator System through a Unique Statistical-Algorithmic Approach

This work investigates the Fresnel-lens-based solar concentrator-receiver system in a multi-perspective manner to design, test and fabricate this concentrator with high-efficiency photon and heat outputs and a minimized effect of chromatic aberrations. First, a MATLAB®-incorporated algorithm optimizes both the flat-spot and the curved lens designs via a statistical ray-tracing methodology of the incident light, considering all of its incidence parameters. The target is to maximize the solar ray intensity on the receiver's aperture, and therefore, achieve the highest possible focal flux. The algorithm outputs prismatic and dimensional geometries of the Fresnel-lens concentrator, which are simulated by COMSOL® Multiphysics to validate the design. For the second part, a novel genetically-themed hierarchical algorithm (GTHA) has been investigated to design Fresnel-lens solar concentrators that match with the distinct energy input and spatial geometry of various thermal applications. Basic heat transfer analysis of each application decides its solar energy requirement. The GTHA incorporated in MATLAB® optimizes the concentrator characteristics to secure this energy demand, balancing a minimized geometry and a maximized efficiency. Two experimental applications were selected from literature to validate the optimization process, a solar welding system for H13 steel plates and a solar Stirling engine with an aluminum-cavity receiver attached to the heater section. In each case, a flat Fresnel-lens with a spot focus was algorithmically designed to supply the desired solar heat, and then a computer simulation of the optimized lens was conducted showing great comparability to the original experimental results. Thirdly, the prismatic geometry of the Fresnel lens was further optimized through a statistical approach that incorporates laws of light refraction and trigonometry. The proposed design produces high focal irradiance that is more suitable for thermal applications. The motivation was to enhance the tolerability of a flat Fresnel-lens concentrator to tracking errors, without the use of secondary optics or sophisticated, and normally costly, meticulous tracking equipment. A comparative simulation analysis was conducted for two case studies from literature, each with a different design method. Fresnel lenses optimized by this work enhanced the concentration acceptance product (CAP) significantly, compared to that in literature. Then, this work introduced an innovative code-based, detailed, and deterministic geometrical approach, which couples the optimization of the Fresnel lens primary optical element (POE) and the dome-shaped secondary optical element (SOE). The objective was to maximize the concentration acceptance product, while using the minimum SOE and receiver geometries at a given f-number and incidence angle (also referred to as the tracking error angle). The laws of polychromatic light refraction along with trigonometry and spherical geometry were utilized to optimize the POE grooves, SOE radius, receiver size, and SOE–receiver spacing. Two literature case studies were analyzed to verify this work's optimization, and the equivalent POEs designed by this work, with optimized SOEs, showed a significant enhancement in the CAP values compared to that of literature. Lastly, four methods for prototyping the Fresnel lens were discussed and experimentally tested; 3D printing, acrylic resin casting, direct CNC machining in acrylic and hot embossing. Once tested, the methods of CNC machining and hot embossing of acrylic proved to be the most promising in terms of cost, fabrication time, and concentration effectiveness. Future work will focus on enhancing the algorithmic design and improving the quality of lens fabrication.