Scalable heliostat surface predictions from focal spots: Sim-to-Real transfer of inverse Deep Learning Raytracing

Concentrating Solar Power (CSP) plants are a key technology in the transition toward sustainable energy. A critical factor for their safe and efficient operation is the distribution of concentrated solar flux on the receiver. However, flux distributions from individual heliostats are sensitive to surface imperfections. Measuring these surfaces across many heliostats remains impractical in real-world deployments. As a result, control systems often assume idealized heliostat surfaces, leading to suboptimal performance and potential safety risks. To address this, inverse Deep Learning Raytracing (iDLR) has been introduced as a novel method for inferring heliostat surface profiles from target images recorded during standard calibration procedures. In this work, we present the first successful Sim-to-Real transfer of iDLR, enabling accurate surface predictions directly from real-world target images. We evaluate our method on 63 heliostats under real operational conditions. iDLR surface predictions achieve a median mean absolute error (MAE) of 0.17 mm and show good agreement with deflectometry ground truth in 84% of cases. When used in raytracing simulations, it enables flux density predictions with a mean accuracy of 90% compared to deflectometry over our dataset, and outperforms the commonly used ideal heliostat surface assumption by 26%. We tested this approach in a challenging double-extrapolation scenario-involving unseen sun positions and receiver projection-and found that iDLR maintains high predictive accuracy, highlighting its generalization capabilities. Our results demonstrate that iDLR is a scalable, automated, and cost-effective solution for integrating realistic heliostat surface models into digital twins. This opens the door to improved flux control, more precise performance modeling, and ultimately, enhanced efficiency and safety in future CSP plants.