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The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

Posted December 18, 2007 8:53 AM by Steve Melito

Editor's Note: CR4 would like to thank Brian White (gaiatechnician) for contributing this story, which originally appeared in "Brian's sustainable development group".

The mechanical mathematician is a new device to help people make large parabolic reflectors for solar cookers. It evolved out of the solar cooker work that I did last summer. I was making funnel cookers in various forms but the problem is size. They concentrate light to a line that goes through the centre of the funnel, which means that the ideal food container is a long skinny one. The light line from a collector for 1 sq meter of sunlight might be nearly a half meter long! I had an idea that you could reflect sunlight all the way down a horn shape tube.

It didn't work!

When you do the math, you realize that it is impossible to do this!

I wanted something to shine on a bowl and heat it up. This drew me to parabolic reflectors (perfect for focusing sunlight to a spot)

But the math is SO intimidating! And I want to make a parabolic bowl, not a parabolic throff. More bloody calculations! GAWD

Not too happy was i.

Eventually, I found a website where a German guy working in Africa designed his parabolic curves just using a T square with string pinned to it and a pencil. AWESOME!

You can lengthen the string to get a different parabola or tie it at a different height to get a different parabola.

The rest of his procedure was pretty involved though (Wood model, metal rings and welding), and I wanted to keep things simple and really low tech

And most of all - APPROPRIATE. If you are building a solar cooker in a dirt poor village in Africa, all the welders will have left to get gainful employment, and all you are left with are poor people and dirt!

What skills might the people have? How about building with dirt or mud? Probably really skilled at, too!

I am a stone mason and for years, I knew it is easy as pie to draw an elliptical curve for rock planters and so on. Just use 2 sticks hammered into the ground, some string line, and another stick to mark the curve. Perhaps I could use this method to approximate a parabolic dish?

I looked long and hard at the German relief worker's diagrams and saw that if I could stop the T square from cutting through the parabolic curve, I could make a parabolic shape in 3 dimensions! Not just a line in 2 dimensions. This is a HUGE improvement (if it can be done).

It means that your device can be used directly on-site to mark a parabolic dish. One STEP - can it be done?

A little idea was gelling in my mind, so I set to work making a cob parabolic dish. Cob is clay sand and straw mixed together and it drys hard. (I have a self-built cob shed in my backyard). I am not at all technically good, so I used part of an old office chair, string line and some curtain rods to make my first mechanical mathematician! It worked really well! It really surprised me how quickly it all went. You start on the outside and work in. Excess cob is just trowelled down as you work. You find the surface of the dish with the mathematician and trowel to it.

This is not perfect because my form was too narrow at one side (I used scrap wood) and because one of the legs of the chair was wobbly, but it sure looked dishy when the curve was done! I let it dry a bit, stuck kitchen foil to the cob and tipped it onto its side to face the sun, and I had my 40-inch square parabolic dish!

Not too bad. It has taken me nearly 4 months (!) to get this diagram done up. I tried to explain with the cob parabola image, but it just looks like a space alien or a junkyard robot. I think the diagram is good enough to explain the mathematician.

The next stage is informing people in relief agencies and so forth. I have got no feedback from relief people except some positive stuff from one man who is going to work in a hospital in Haiti.

Seriously, this thing means that you could easily make a 3 or 4 meter fixed parabolic dish in-situ for very little cost. (Just point the central post of the mathematician at the midday sun, decide on your focus, and extend the string to make the parabola with minimal material use) and away you go!

I have scavenged the solar cooker to add to my cob shed. While it was in use, I never thought to use it as a MOULD for cardboard solar cookers. DARN!

What you do is make radial cuts in your cardboard and put it in the cooker to fit its shape, cut out as directed and tape it together, and then add and stick on the aluminum foil. Then take it out and tape the back, too!

It should work but I have never done this.

If you have an old satellite dish at home, try it please and send me the results!

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#1

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/18/2007 8:55 AM

Do you have a DIY story to share with CR4? If so, please message Moose or frankd20. We'd like to hear from you!

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#2

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/18/2007 11:11 AM

Looks like an interesting project, Ive used aluminum foil for many things, although Ive never had much luck using it as a solar reflector. I did once put foil on a 18" parabolic dish but the foil wasn't a good enough reflector to do much with a small dish. I am curious as to how long it takes to get a pot of water boiling with your setup?

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#15
In reply to #2

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

05/03/2008 1:49 PM

Water to boil depends on how smooth you make your foil and how big you make your parabola. There have been devellopments, I have made a tracking solar accumulator! The idea is to keep the focus in one spot and mount the parabola to follow the sun all day. All that means is equatorial mount and the focus on the axis of the mount too. What you generally have to do for this is have an off centre dish. I used a "mechanical mathematician" to make a cob mould, put a piece of a plastic sign in the mould, made some cuts, fitted it to the mould snugly, cut out the "underlaps, taped it together and stuck kitchen foil to it and IT WORKED!!!! Even with my crappy first time effort. I really really think people into solar should check it out http://www.youtube.com/watch?v=npmx28KYth4 The big thing is to make an off the centre parabolic dish. And this is easy to do with the mathematian! I really hope the solar dish manefacturers in china are watching. They could use a machine shop version of the mathematician to make the dies for their dishes. I want to see thousands of these things across the world this year. Brian

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#16
In reply to #15

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

05/03/2008 5:07 PM

You ought to learn how to make your links active.

Its very simple, just mark the whole link and you will see a globe with a chain become active in the toolbar, just click on submit, I have done it for you here:-

http://www.youtube.com/watch?v=npmx28KYth4

You can also give it a different name if you wish like here by changing the text line only...:-

My Link

by the way, there are cheap matt black Alu cooking pots about that must do a better job of absorbing the heat than a shiny reflective one that you are using......something like probably 100% more effective I would imagine.....

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#3

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/19/2007 12:41 AM

Hi,

with this ratio of collector to target (near 5:1 linear) you do not need a parabolic shape.

Anything near circular works well because the deviation of reflected rays from ideal direction is not big enough to miss your target.

We made one for lighting purpose (buildings) from highly polished aluminum by clamping the square sheet at the edges and clamping a second rigid sheet and pressing water from the tap (6bar pressure) inbetween the sheet to simply blow the deformable aluminum.

This is not giving a parabolic surface - the deviation is big at the corners but still better focusing than needed for conduction of light inside a 4 storey building.

RHABE

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#14
In reply to #3

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

01/03/2008 3:53 AM

There have been some new devellopments. Please check http://groups.google.com/group/Sustainable-devellopment/web/tracking-solar-accumulating-barbecue for the details. It seems the mechanical mathematician could be used to make a much more user friendly solar cooker.

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#4

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/19/2007 2:13 AM

this solar heater is widely using in china.

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#5

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/19/2007 6:00 AM

Papier-maché parabolae from a positive (convex) mould.

We cut a half-parabola, calculated on millimetric-squared paper, out of 3/8" plywood. The lower edge was carefully rounded, so as not to lose the precise form The ply had mounted about its axis of rotation a stout steel rod. Driving a vertical water-pipe into the ground, we arranged it such that the ply could swing around in a circle.We filled the space under the swinging parabola, first with rocks, stones, gravel, to economise on the cement, which is coming next. Piling excess cement onto the heap, we then skimmed it all around with the jig. The pivot must be well-adjusted - we thought of using a bicycle-hub...

When dry, sanded, gloss-painted, the parabolic mould is fairly tight to the ideal form.


(Parenthesis)

You could, of course, operate on a big board, perhaps with fancy expansive foams - mirrors with an interesting focal length, i.e, those where you can be at a safe distance from the action, are surprisingly flat, but also thus lack some of the auto-rigidity of deeper dishes... Any pool-player should know the rules of equiangular reflection, so you can work out focal length using only geometry, no maths needed. Er, good job...

/(Parenthesis)

We burnished aluminium kitchen foil onto the furniture-spray-polish-lubricated mould with the back of a spoon. The pieces will overlap more or less at hazard, but this matters not. The foil has a shiner side, so obviously...


We then applied moultes layers of papier-maché, using PVA glue, with a touch of Teepol. Strips of newspaper, or, better, Kraft paper, espouse the form easily, so it goes quite fast.

Even 39" dishes needed some support to be durable. We applied old rope, the tattier the better, and then continued with the paper, tucking it in well with a stiff paint-brush. .

At first, naïvely, we applied the rope in a radial pattern. Error. By far the most effective
re-inforcement was achieved with patterns resembling Fuller's geodesic domes, or the structures of Pier Luigi Nervi, an unsung genius of whom I have more to say, and about whom much more to find out.

Chunky fish-net drapes nicely over the form... Many-smaller-lines seems to be advantageous.

The finished dish de-moulds with ease. The edges can be trimmed with scissors - mark the cut-line whilst the dish is on the mould. Use the pivoting template, jacked-up a bit.

We never tried this, but in fact for holed mirrors it might be best not to fabricate the centre at all - a step in the former would give a cylindrical plug on top of the mould, easy to work around. Economy, even if you're only saving an 8" hole, and ensures concentricity...


We slit some 3-core flex and applied the PVC sheathing around the edge. This greatly strengthens, and gives an all-together more serious air to the device. Rigid 'Acorn' water-pipe would be even better.

Oh, yes, and paint the back generously with one of those old end-of-tins somewhere in the garage.

This technique could be scaled up - if our calculations are correct, under African skies you would need a 16' mirror to power a 10 cubic foot, well-insulated cold-store down to -15°C.

The mirrors would be made in-situ. All that is needed is the half-parabolic template, and, most important, the know-how.

And once made with skill the same mould can serve for dozens, hundreds of identical paraboli.

I think it logical, although I've never seen it done, to mount an hyperbolic mirror at the primary focus, and direct the beam through a hole in the main mirror, to a steam (or other) generator mounted behind this same - the generator would cast no shadow, the weight would be lower down, the connecting hoses much shorter...

This is the principle of some optical reflecting telescopes - the Cassegrain:

http://en.wikipedia.org/wiki/Cassegrain_reflector

The Gregorian (ellipsoid secondary):

http://en.wikipedia.org/wiki/Gregorian_telescope

And probably others. With a deformable secondary mirror one could, in theory, bring the focal spot anywhere. Adaptable optics - hmm, must look into this... But I digress...

My pet idea for this would be to mount the boiler of an ammonia (absorption) refrigeration system at this focal. Only by bringing the hot-spot behind the main mirror would this be possible, for gravity plays a large rôle in the absorption system.

This, if it could be made to work, would provide an extremely low-tech (almost no moving parts) way of making cold from hot - handy really, for it's in the hottest countries that you most need cold storage; for foodstuffs, vaccines...

We made (stop me if you've heard it before) smaller (39") dishes from papier-maché, and the focal spot was surprisingly small (20mm.), and thus surprisingly hot. Tissue paper would ignite instantly if dropped through the hot-spot - "Whoof!" Light, waterproof (they also served as umbrellas*), they were "neat, dangerous and impressive". What more could boy-scouts and girl-guides desire!

Such a mirror, on an equatorial mount, could easily track the sun. I imagined an heliostat that might do this without an external power source, a great advantage in the bush. Here's my humble representation:

http://simeonlapinbleu.googlepages.com/heliostatics

*And Frisbees, and shields, and parasols, water-carriers, panning for gold...

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#10
In reply to #5

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/22/2007 5:02 AM

ISAAC=intermitant solar amonia adsorption chiller see more on this unit at the sustainable village website

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#12
In reply to #10

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/28/2007 4:53 AM

ISAAC=intermitant solar amonia adsorption chiller.

Thanks for the link, duke! Spent half the night on this fascinating site...

Bags off things for Do-It-Yourselfers to do, and all of them more or less green.

Their ISAACs are excellent, and some (63') fairly hefty. I had not expected the low-concentration heat in a parabolic trough to make the ammonia solution boil enough, but they've obviously cracked it.

I like their quote from Einstein, to the effect that we cannot solve the considerable problems we have created using the same science that made them...

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#6

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/19/2007 6:08 AM

Hey...great blog...

I have looked into this and found one site where a guy made a parabola from about 3 ring sections of ply wood, each with a small section removed and the ends then pulled in to join...(hope you get the idea)..I haven't got the link .

BUT... this ties in a bit with my string lampshade.
String soaked in PVA adhesive and draped randomly in your cob mold (covered in cling-film first...this could give a nice light relatively rigid backing for the foil (although pva is a bit expensive ). Would be more weather proof than card or papier mache.

Presumably a damp sand mold could be made...can we lookforward to solar cookers on the beach this summer?

I love your practical approach...Brill'

Del

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#7
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Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/19/2007 8:26 AM

Thanks, Del.

One advantage of the 'male' mould is that the finished reflective surface is formed directly in contact with the mould 'hump'. This gives a parabola nearer to the ideal form.

A dish made in a 'female' mould, such as appears to be suggested by Moose (whose stick-and-string parabola generator is a stroke of genius), has a surface which is 'free', and any imperfection runs the risk of being amplified...

But I like your idea with the PVA- coated string, which would work in either system!

And PVA's not that expensive - buy no-name, by the gallon - it's the same stuff, no matter what they tell you on TV...

=+=+=+=+=+=+= Same subject, different approach.

The concave mould made by spinning a dish of setting plaster is interesting - I'd heard of this proposed with Mercury * , great for a mirror that looks straight up...

- We set a 10" Tupperware bowl of dental plaster on an old turntable and made four parabolae - focals 16, 33, 45 and 78 rpm, I suppose... We then burnished Aluminium foil (with the back of a spoon) onto a thin film of Gold Size.

To the eye the mirrors seem perfect, without humps or hollows, but this is natural for there's not more regular than centrifugal force, and gravity is also fairly constant...

The flattest, 16 rpm, gives a focal length of nearly 6' , and is light enough to be portable. The 78 focuses around 18" but is chunky and heavy, and hot!... Gold leaf would be swanky, and not too expensive...

* The Mercury mirrors I read about were 8' in diameter, but the experimenters found a slight rippling of the surface, due to the air currents generated by the rotation of the tank. This was eventually solved by stretching a big cling-film across - sometimes the simplest solutions are the best. But we don't need telescope-quality - such an accurate mirror would probably melt holes in the cookware, not good...

²(;o'#

Siméon, with béret, beard and roll-up. We even make our own emoticons here...

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#13
In reply to #7

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/31/2007 8:23 AM

Thank you for the kind words, Lapinbleu, but I am only the editor for this story. Credit for the "stroke of genius" belongs to Brian White (gaiatechnician), the builder of the reflector (and the author of this story).

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#8

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/19/2007 3:02 PM

Really I am just thinking out loud, your design of the mold is fantastic and should be taken up by some of us asap.....many thanks for your Pioneering ideas.

If asked, I would have made a huge bucket paper paste (its easy with flour or buy wallpaperpaste and used papermache to make the reflector (with some plastic to stop it sticking).

Papermache is quite stable especially if 1/2" thick and then painted once dry on the outside and of course foil glued in on the inside....even 1/4" thick can be stable if some hoops of wood are used to help it hold together.....

Probably, if instead of painting, it was coated with fiber glass and some matting, it could be really really strong.....or forget the cardboard and papermache and make it from fiber glass in the first place!!!

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#9

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/20/2007 2:33 AM

Howdy,

I live near Calgary Alberta and am currently using three old 12 ft satellite dishes covered with silvered mylar film for auxiliary heat in my house and to heat my hot water.. They work awesome and one dish will bring 40 gallons of water to a boil in about 20 minutes on a sunny day.The best thing about using the old sat dishes is that they are free because there aren't many people using them anymore. Try to get the solid ones as the mesh units tend to bend easily and are difficult to keep the mylar on. You can get silvered mylar at a hydroponic grow shop. I find that flooring adhesive works well for putting the mylar on because it gives you time to work before it dries. Start by cutting the mylar into about 12 wedges that radiate from the center. Use a squeegee and work from the center out cutting the wedge into smaller wedges using a razor blade as you work it into place.

I also made one using a small bell dish that I use to make coffee when I go camping.

Be careful though because even the small unit will start wood on fire in less than a minute.

Cheers, Mo.

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#11
In reply to #9

Re: The Mechanical Mathematician: Large Parabolic Reflectors for Solar Cookers

12/27/2007 8:05 PM

Mo, can you take some pictures? I would love to see it. And lots of others would too. Thanks for a great post. Brian

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