Solar bay construction system and related methods

Abstract

A method for automatic solar bay assembling is provided that includes feeding a torque tube from a torque tube dispensing system onto a conveyor system to initiate an assembly for a solar bay, wherein the conveyor system is arranged to stabilize the torque tube, positioning the torque tube via the conveyor system at one or more locations in a solar bay construction system, fastening a plurality of solar rails to the torque tube and a plurality of solar panels to the plurality of solar rails, thereby producing a complete solar bay, exiting the solar bay from the solar bay construction system via the conveyor system in preparation for installation.

Description

SOLAR BAY CONSTRUCTION SYSTEM AND RELATED METHODS TECHNICAL FIELD[1] The present invention relates to a system for constructing utility solar structures and related methods.BACKGROUND[2] Solar energy in the form of industrial solar panels or farms that provide solar energy have the potential to reduce costs of energy production and to reduce carbon emissions. However, labor costs for installing industrial or utility solar panels remain high, and labor shortages may also present problems for the efficient installation of solar panels in industrial settings. Installation environments may be harsh with high temperatures and physically demanding labor, and solar farms may be located in remote areas. Labor shortages may constrain the speed at which solar power is deployed.[3] A utility solar farm generally comprises solar structures comprising ground piles that support torque tubes, on which mounting brackets or rails are affixed to the tube and solar panels are affixed to the rails. Current manual methods of utility solar farm construction are labor intensive, expensive, and potentially hazardous. Recently, automation methods for a limited scope of industrial or utility solar construction have been developed; however, more efficient automated industrial or utility solar construction is needed.SUMMARY[4] According to some embodiments, a solar bay construction system includes a torque tube dispensing system configured to dispense one or more torque tubes onto a conveyor; a solar rail construction system configured to connect one or more solar rails on to the torque tube; a solar panel construction system configured to connect a solar panel on the plurality of solar rails to provide a solar bay; and a solar bay installation system configured to pick, hold, and position one or more solar bays to install in a solar array.BRIEF DESCRIPTION OF THE DRAWINGS[5] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain principles of the invention.[6] FIG. 1A is a perspective view of a solar panel installed on a solar torque tube to provide a solar bay according to some embodiments.[7] FIG. 1B is a flowchart illustrating operations according to some embodiments.[8] FIG. 1C is a schematic diagram of a controller and a solar bay construction system according to some embodiments.[9] FIG. 1D is a schematic diagram of the controller and the solar bay construction system according to some embodiments.

[10] FIG. lE is a perspective view of the solar bay construction system of FIG. 1D.

[11] FIG. 2 is a perspective view of a solar torque tube dispensing system with torque tubes loaded on the torque tube dispensing system according to some embodiments.

[12] FIG. 3 is a perspective view of the torque tube dispensing system of FIG. 2 with the torque tubes removed.

[13] FIG. 4 is a side exploded view of the lower end of the torque tube dispensing system of FIG. 2.

[14] FIGS. 5-6 are exploded side views of the lower end of the torque tube dispensing system of FIG. 2 with the torque tube loaded onto a torque tube transporter.

[15] FIGS. 7-8 are side views of the torque tube dispensing system of FIG. 2 illustrating a dispensed torque tube moving along the vertical axis of the torque tube dispensing system according to some embodiments.

[16] FIGS. 9-10 are perspective views of the torque tube dispensing system of FIG. 2 and a torque tube carrier and conveyor according to some embodiments.

[17] FIG. 11 is a perspective view of the torque tube carrier and conveyor according to some embodiments.

[18] FIGS. 12-13 are side views of the torque tube carrier and conveyor of FIG. 11 illustrating the torque tube in a carried position (FIG. 12) and a position that is placed on the conveyor (FIG. 13) according to some embodiments.

[19] FIGS. 14-17 illustrate an alternative torque tube dispensing system according to some embodiments.

[20] FIGS. 18-19 are side views of a conveyor system according to some embodiments.

[21] FIGS. 20A-20B are perspective views of a support for a conveyor system according to some embodiments.

[22] FIGS. 21-23 are perspective views of a solar rail construction system illustrating operations and related methods thereof according to some embodiments.

[23] FIGS. 24-25 are perspective views of an end effector of a robot arm for positioning a solar rail according to some embodiments.

[24] FIGS. 26-33 are perspective views a solar rail construction system illustrating operations and related methods thereof according to some embodiments.

[25] FIGS. 34A-34D are perspective views of a strap for connecting a solar rail to a torque tube according to some embodiments.

[26] FIGS. 35, 36A and 36B are perspective views of an end effector for connecting a strap of a solar rail according to some embodiments.

[27] FIG. 36C-36D are perspective views of a drilling robot configured to drill a solar rail to a torque tube.

[28] FIG. 37 is a schematic diagram of a parts presentation system configured to present connecting parts according to some embodiments.

[29] FIGS. 38-40 are perspective views of a parts presentation stand and a robot arm for connecting a solar rail to a solar panel according to some embodiments.

[30] FIGS. 41A-41B are perspective views of a parts presentation stand according to some embodiments.

[31] FIGS. 42A-42B are perspective views of a robot arm configured to connect a solar rail to a solar panel according to some embodiments.

[32] FIGS. 43-48 are perspective views of a solar panel construction system configured to connect a solar panel to a solar rail on a torque tube according to some embdodiments.

[33] FIGS. 49A-49C are perspective views illustrating a rivet and washer connection of a solar rail to a solar panel according to some embodiments.

[34] FIGS. 49D-49E are cross sectional views of the rivet and washer connection of FIGS. 49A-49C.

[35] FIG. 50A illustrates a solar bay output buffer system according to some embodiments.

[36] FIG. 50B is a perspective view of a solar bay installation system according to some embodiments.

[37] FIG. 51-52 are front views of a solar bay installation system according to some embodiments.

[38] FIG. 53A is a perspective view of the solar bay installation system of FIGS. 50B and 51-52.

[39] FIG. 53B is a top view of the solar bay installation system of FIGS. 50B, 51-52 and 53A.

[40] FIG. 54A is a bottom perspective view of a temporary rail module during solar bay installation according to some embodiments.

[41] FIG. 54B is a side view of the temporary rail module of FIG. 54A.

[42] FIGS. 54C-54D are perspective views of the temporary rail module of FIGS. 54A-54B illustrating a detachment operation according to some embodiments.

[43] FIGS. 55-57 are schematic illustrations of a multi conveyor system according to some embodiments.DETAILED DESCRIPTION

[44] As described herein, systems and methods for dispensing a torque tube used to install industrial solar arrays or solar farms may be provided. A torque tube for a solar array used in industrial solar farms is a horizontal structural element that typically connects multiple solar bays. These tubes are generally made of high-strength materials The torque tube is used to provide rigidity and structural integrity to the array and to assist in placing the panels in desired positions and / or orientations. As used herein, the terms "solar panel" and "solar module" are generally used interchangeably to refer to a solar energy generating device configured to absorb energy from the sun and generate electricity or heating. A "solar bay" refers to a structure whereby a solar panel(s) is(are) mounted on a torque tube, for example, via a mounting rail. Accordingly, a solar bay may comprise a solar tube, solar rails, and solar modules.

[45] A "controller" as used herein refers to a computerized device that may optionally include a user interface to receive user input to manipulate devices in the system, or a controller may include fully automated controls that manipulate devices in the system through programs, software, and / or algorithms, which may incorporate sensor input.

[46] A "robot" as used herein may include a programmable mechanical positioning device that is used to execute tasks, including specific tasks such as positioning, manipulating, and / or sensing objects.

[47] A "robot arm" may include a robot or a portion of a robot that includes interconnected segments joined by actuated joint structures, which allows for controlled motion and manipulation of objects and / or sensing of data.

[48] As illustrated in FIG. 1A, a solar array 10 includes solar panels 12, vertical supports 14, a horizontal torque tube 16, and solar panel support brackets or rails 18. Further, a solar array used herein, generally means solar bays mounted on vertical supports 14. During installation, the solar rails 18 are mounted on the torque tube 16 and the solar panels 12 are mounted on the solar rails 18. The assembled panels 12 together with the torque tube 16 and rails 18, which are referred to as a "solar bay," are then positioned on the vertical supports 14 in the field, forming or augmenting the solar array.

[49] Therefore, in order to further automate the construction of the solar array 10, the torque tubes 16 may be positioned on a conveyor prior to construction, and the solar rails 18 and solar panels 12 may be affixed to the torque tubes 16 successively, while the tube is held by and moved appropriately on the conveyor. Manual placement of large torque tubes on the conveyor or other surface used for construction of the solar array 10 may be cumbersome and present challenges.

[50] Automated systems for dispensing torque tubes in a controlled or partially automated construction system for a solar array will now be described.

[51] As shown in FIG. 1B, during an installation process, the torque tube 16 is dispensed from a torque tube holder onto a conveyor (Block 1000). The solar rails 18 are installed on the torque tube 16 after the torque tube 16 is positioned on a conveyor (Block 1010). The solar panels 12 are lifted or picked up and placed or mounted on respective ones of the solar rails 18 (Block 1020). After all of the solar panels 12 are mounted on the rails 18, the resulting solar bay is picked by a gantry system 4200 and positioned on a support system 4100, both of which are attached to a mobile base 4116 that is attached to and transported by a vehicle (Block 1030) to a location where the solar bay is installed in a solar array, for example, in a solar farm (Block 1040).

[52] As illustrated in FIG. 1C, a torque tube dispensing system 10 including a controller / analyzer 500, solar bay construction devices(s) 520, and sensors 400 are shown. The controller 500 includes a processor 510, data 512, and a planning module 514. The planning module 514 is configured to analyze the data 512, which may include instructions and other data for building solar panels and / or feedback data from sensors 400. The planning module 514 analyzes the data 512, which can include data from sensors 400, and provides instructions to the solar bay construction device(s) 520. The solar bay construction device(s) 520 are described in detail herein and can include a torque tube dispensing system 100 and a carrier system 200 (FIGS. 2-13). The controller 500 may be in wired or wireless communication with the solar bay construction device(s) 520 and / or sensors 400 as would be understood by those of skill in the art to control operations of components of the system as described herein. Further, the controller 500 is location agnostic. That is, the controller 500 may be positioned at any suitable location, and in some embodiments, multiple controllers may be used. It should be understood that the controller 500 be fully or partially automatic and control components based on sensor data and / or programmed operations; however, in some embodiments, the controller 500 may include a user input configured to receive input from a use, for example, through a graphical user interface. Therefore, the operations described herein may be fully automatic, partially automatic and partially controlled by a user through a user interface, or fully controlled by a user.

[53] As shown in FIGS. 1D-1E, a solar panel construction system may include a partially or fully automated conveyor system 300 that receives torque tubes thereon from a torque tube dispensing system 100 (seeFIG. 1E). A torque tube 16 is moved from the end of the torque tube dispensing system 100 along the conveyor system 300 to an opposite end of the conveyor system to a solar rail construction system 2000. At the solar rail construction system 2000, solar rails 18 are attached to the torque tube 16. The torque tube 16 with solar rails 18 attached then moves to the solar panel construction system 3000 via the conveyor system 300. The modules or solar panels 12 are affixed to the rails 18 by robots R in the solar panel construction system 3000, for example, using solar panels from a panel station and fasteners from a fastener feeder system. The solar panels may utilize a panel feeding conveyor system 2001 to house a plurality of panels and present them near the robots for replenishment. The solar rails may utilize a solar rail feeding conveyor system 2002 to house a plurality of rails and present them near the robots for replenishment. The torque tube dispensing system 100, the solar rail construction system 2000, and the solar panel construction system 3000 are described in additional details below. As shown in FIG. 1E, a solar bay output buffer 7000 may be provided to load the assembled solar bays onto a transportable installation system structure to install the solar bay in the field, such as in an industrial solar array or solar farm.

[54] In some aspects, the solar bay construction systems described herein may also include an element protection structure for protecting the construction system from elements such as, but not limited to, water elements.Torque Tube Dispensing System

[55] A torque tube dispensing system 100 for dispensing torque tubes 16, for example, to be positioned on a conveyor or other surface for further construction is illustrated in FIGS. 2-13. As shown in FIGS. 2-3, a torque tube dispensing system 100 includes a frame 102 that has a base 104 and a one or more vertical support structures 106 extending away from the base 104. A one or more holders 110 are mounted on respective ones of the vertical support structures 106 and are configured to support the torque tubes 16. Each of the holders 110 includes a first end 112, an opposing second end 114, and a sloped intermediate portion 116 therebetween. As illustrated, the first end 112 is lower than the second end 114, and the torque tubes 16 extend across the holders 110 such that the torque tubes 16 are generally biased towards the lower first end 112 of the holders 110. For example, gravity may cause the torque tube 16 to roll towards the lower first end 112 of the holders 110. Retaining structures, such as pin-like structure 120, 122 in this illustration, are positioned at the first end of each of the holders 110.

[56] As illustrated, the retaining structures, depicted by retaining structures 120, 122, are movable between a raised position and a retracted position. When the retaining structures 120, 122 are in a raised position, the retaining structures 120, 122 generally retain the torque tubes 16 in the intermediate portion 116 of the holders, and when the retaining structures 120, 122 are in the retracted position, the retaining structures 120, 122 are substantially coplanar with or at or below a surface of a respective holders to thereby allow one of the torque tubes 16 to move to the first end 112 of the holders 110. As illustrated, the first retaining structure 120 is closer to the first end 112 of the holders 110 and lower than the second retaining structure 122.

[57] In some embodiments, the torque tube dispensing system 100 further includes a torque tube transporter or roller 130. The roller 130 is positioned and configured to receive one of the torque tubes 16 thereon and to move the torque tube 16 away from the torque tube dispensing system 100, for example, to a conveyor or other area for further construction. Although as illustrated, the torque tubes 16 are shown with the same length, it should be understood that in some embodiments, the torque tubes 16 may have different lengths. In particular, torque tubes of different lengths may be positioned on different levels of the holders 110 such that the roller 130 may be moved to a predetermined height to transport a torque tube 16 with a predetermined length. Stated otherwise, each length of a torque tube may be assigned a different height for storage on the different levels of holders 110, and when a desired length is transported, the controller 500 (FIG. 1C) moves the roller 130 to the corresponding height of the holders 110 to transport the desired length torque tube 16.

[58] FIGS. 4-5 illustrate four successive positions of the retaining structures 120, 122 that may be utilized to dispense a single one of the torque tubes 16. In a first step A, the second retaining structure 122 of the holder 110 is in the raised position and the torque tubes 16 are retained in the intermediate portion 116. As illustrated, the first retaining structure 120 is also in the raised position. In the second step B, the second retaining structure 122 of the holder 110 is lowered to the retracted position while the first retaining structure 120 is in the raised position so that the torque tubes 16 move toward the first end 112 of the holder 110. In the third step C, the second retaining structure 122 moves to the raised position to thereby retain one of the torque tubes 16 between the retaining structures 120, 122. In the fourth step, the first retaining structure 120 of the holder 110 moves to the retracted position to thereby allow the torque tube 16 to move to the first end 112 of the holder 110. As illustrated, the second retaining structure 122 is in the raised position to retain the torque tubes 16 that are not being dispensed on the holder 110 on the sloped intermediate portion 116 while one of the torque tubes 16 is being dispensed onto the roller 130. Accordingly, a single one of the torque tubes 16 may be dispensed from the holders 110.

[59] As shown in FIGS. 4-5 in the fourth step D, one torque tube 16 is thereby dispensed on the roller 130. As illustrated in FIG. 6, the roller 130 may move upward along the vertical support pillars 106 to lift and support the torque tube 16 on the holder 110. In this configuration, the roller 130 may carry the torque tube 16 away from the holder 110 by rotating so that the roller 130 moves the torque tube 16 along its longitudinal axis generally perpendicular to the holders 110.

[60] Although some embodiments are illustrated as including two retaining structures 120, 122, it should be understood that a single retaining structure or lifting or lowering mechanism may be used to dispense a single torque tube onto a transporter or conveyor system.

[61] Some embodiments are further illustrated with stationary holders 110; however, in some embodiments the holders 110 may include a pivot mechanism to change the slope of the holders 110. The pivot mechanism may be used to load and unload the tubes 110.

[62] As illustrated in FIGS. 7-8, the roller 130 may move in a vertical direction up or down to carry a dispensed torque tube 16 from any of the holders 110. The rollers 130 may be controlled by a controller so that all of the rollers 130 are positioned to receive the same torque tube 16 from one row of the holders 110.

[63] As illustrated, the torque tube dispensing system 100 includes rows of holders 110 that each hold torque tubes 16 so that the torque tubes 16 are biased toward the lower ends 112 of the holders 110. The holders 110 are sized and spaced so that the torque tubes 16 may be held in position on the torque tube dispensing system 100 without bending or damaging the torque tubes 16. However, any suitable configuration may be used, such as a single holder that is sufficiently wide to hold the tubes (e.g., a ramp shape) and any suitable number of holders 110 may be used. Although a column of rows of holders 110 or an array of holders is illustrated, it should be understood that the holders 110 may be configured in any number of columns, including as a single row of holders 110 holding one row of torque tubes 16. In some embodiments, the holders 110 can be configured as a first set or row of holders 110 and a second set or row of holders 110 arranged in columns with the roller 130 being configured to move between sets of the holders 110.

[64] In this configuration, the torque tubes 16 may be dispensed individually and carried to another surface or area for further construction. For example, as shown in FIGS. 9-10, a torque tube carrier 200 is configured to carry the torque tubes 16 to a conveyor system 300. The torque tube carrier 200 includes a carrier frame 210 and carrier arms 220 having an end 222, which are configured to be positioned to receive the torque tube 16 from the roller 130. As shown in FIG. 10, the roller 130 moves the torque tube 16 along its longitudinal axis to the end 222 of the carrier arms 220. The carrier frame 210 is movable along a surface on carrier holders 230 as shown in FIG. 11. The conveyor system 300 includes one or more conveyors 310 with holders 320 for receiving the torque tubes 16. As shown in FIGS. 12-13, the carrier arm 220 is movable in a horizontal direction to move the torque tube 16 away from the frame 210 to rest on one of the holders 320, where the torque tube 16 is released from the end 222 of the carrier arm 220.

[65] Although the torque tube 16 is shown as being carried to a conveyor system 300 by a torque tube carrier 200, it should be understood that the torque tube 16 may be transported by any suitable technique to a desired surface for further construction or by any suitable carrier. In some embodiments, different carriers and / or conveyors may be used, such as an arm that pulls the torque tube 16 towards the conveyor system 300, for example, using either a mechanical connection to grasp the tube 16 or magnetic connection. In some embodiments, the carrier 200 may be omitted, and the torque tube 16 may be transported directly by the roller 130 on the conveyor system 300 or other surface for further construction.

[66] Once the torque tube 16 is in position on the conveyor system 300, then additional steps may be performed to attach the rails 18 and the solar panels 12 onto the torque tube 16 as shown in the assembled configuration of FIG. 1. The assembled solar panel 12, rails 18 and torque tube 16 may then be positioned on the vertical supports 14 in the field to form the solar array 10 as illustrated in FIG. 1.

[67] In some embodiments, sensors may be used to determine a placement or length of a torque tube 16. For example, as illustrated in FIGS. 9-10, a sensor 400 may be positioned on the torque tube carrier 200 to detect when a torque tube 16 is on the carrier 200. With reference to FIG. 1C, the controller 500 may control the speed that the torque tube 16 moves on the carrier 200, and based on the time during which a portion of the torque tube 16 is sensed by the sensor 400, the controller 500 may determine the length of the torque tube 16, for example, to confirm that the torque tube 16 is the correct length. If the torque tube is of incorrect length, the controller may stop the construction system to allow for manual intervention. Further, if the torque tube is of incorrect length, the controller may reverse the operation to move the tube back to the appropriate holder and then unload the tube off of the dispensing system structure.

[68] The torque tube dispensing system 100 and the frame 102 and holders 110 may be formed of any suitable material, such as steel, or shape, such as torque tubes or holders.

[69] The retaining structures 120, 122 may be any suitable shape for retaining the torque tubes 16 in the raised position and movable to a lowered position. The retaining structures 120, 122 may include an actuator or motor and a microprocessor or controller for controlling the retaining structure movement to dispense the torque tubes 16 and may be controlled by the controller 500 (FIG. 1C). Although two retaining structures 120, 122 are illustrated, it should be understood that any suitable number of retaining structures may be used. In some embodiments, a single retractable retaining structure may be used to dispense a torque tube 16 from the holders 110.

[70] The roller 130 may be a sloped roller with an actuator or motor configured to rotate the roller as described herein and controlled with a microprocessor or controller. However, any suitable shaped torque tube transporter may be used.

[71] Accordingly, the torque tube dispensing system 100 may include two movable elements, such as retaining structures 120, 122, for dispensing a single torque tube 16 onto a torque tube transporter or onto a conveyor. Although retaining structures 120, 122 are illustrated, additional configurations may be used as the two moveable elements, as described below.

[72] An alternative torque tube dispensing system 100' is illustrated in FIGS. 14-19. As illustrated in FIGS. 14-18, the torque tube dispensing system 100' includes a top carrier holder 110' and a bottom carrier holder 400'. Stopper structures 112', 114' are between the top carrier holder 110' and the bottom carrier holder 400' and are facing opposite one another to facilitate retention and dispensing of a single tube 16. The bottom carrier holder 400' is attached to a movable arm 410' that is an actuator 420', such as a hydraulic, pneumatic, or electric actuator or motorized positioning mechanism. The Stopper structure 114' and the bottom carrier holder 400' are movable between a raised and a lowered position by an actuator 120'. As shown in FIG. 15, the Stopper structure 114' holds the torque tube 16 in position on the top carrier holder 110' when the Stopper structure 114' is in a raised position. When the Stopper structure 114' and the bottom carrier holder 400' move to a lowered position, then the torque tube 16 moves downward and is stopped by the stopper structure 112'. The actuator 120' is then moved vertically to create a tube singulation mechanism with the Stopper structure 114'. As further shown in FIGS. 16-17, when the stopper structure 114' is lowered and / or the Stopper structure 112' is raised, the tube 16 is permitted to roll downwards along the bottom carrier holder 400a toward the conveyor system 300. Notably, the torque tube carrier is omitted and the torque tube 16 is placed directly into the convey system 300.

[73] As shown in FIGS. 18-20B, conveyor system 300 includes conveyors 310, and holders 320 and supports 305, which are movable along the conveyor 310 in both directions. In this configuration and as illustrated, the holder 320 includes an anti-snag cable shroud configured to secure the tube 16, a switchable permanent magnet gripper 323, a drive motor 325, a belt drive pulley 327, belt idlers 329, and a column drive belt 331 that are configured to move the holders 320, and to thereby move the torque tube 16, along the conveyor(s) 310. Additional supports 305 may further move and support the tube 16 during solar bay construction. In some aspects, the solar infrastructure is positioned on the conveyor system 300 and stabilized by clamping methods on the torque tube 16.

[74] In some aspects, the conveyor system 300 may include a pin retention mechanism for stabilizing solar infrastructure on the conveyor system 300. The pins of the pin retention mechanism may be pneumatically actuated locating pins that first enforce location and then constrain motion of the torque tube 16 in three dimensions, and further constrain the rotation of the torque tube 16 in the horizontal direction.

[75] It should be understood that the torque tube dispensing system 100 may be controlled by a controller 500, either automatically based on sensor inputs and programming or based on user inputs or with a combination thereof.Solar Rail Construction System

[76] The solar rail construction system 2000 is illustrated in FIGS. 21-23 and FIGS. 26-33. FIGS. 24-25 illustrate an end effector of a robot arm. It should be understood that the elements of the solar rail construction system 2000 may be controlled by the controller / analyzer 500 or one or more additional controllers and analyzers that communicate with the elements of the solar rail construction system 2000, for example, wirelessly or by a wired communication connection.

[77] As shown in FIGS. 21-23, the solar rail construction system 2000 may be used to position an end solar rail 2300, also referred to as a bearing housing assembly or "BHA" rail, on the ends of the torque tube 16. The end solar rails 2300 are typically preassembled and may be pushed, threaded, or installed onto the end of the torque tube 16. The solar rail construction system 2000 includes a solar rail container 2200. Further it should be understood that the solar rails may be positioned and replenished for picking by the robot arms via a solar rail feeding conveyor system 2002.

[78] As shown in FIG. 21, a robot arm 2100 includes an end effector 2110. The end effector 2110 includes a base 2112, an array of magnets 2114, and sensor(s), such as an image sensor or camera 2116, as shown in FIGS. 24-25. The magnets 2114 may be switchable permanent magnets. The end solar rail 2300 includes or is formed of a metal material that is magnetic, such as steel. In some aspects, the end effector 2110 can further comprise nut runners that may be used to tighten and torque fasteners, such as nuts, on the Solar Infrastructure

[79] In this configuration, when the robot arm 2100 moves the end effector 2110 adjacent to the solar rail container 2200, the magnets 2114 become attached to the end solar rail 2300, and the robot arm 2100 is configured to lift the end solar rail 2300 as illustrated in FIG. 21. The robot arm 2100 moves the end solar rail 2300 such that the circular strap of the end solar rail 2300 is aligned with the end of the torque tube 16 as illustrated in FIG. 22, for example, with the aid of the camera 2116. The end solar rail 2300 is positioned on the end of the torque tube 16 as shown in FIG. 23.

[80] After the end solar rail 2300 is positioned on the torque tube 16, a middle solar rail 2400 is installed on the torque tube 16. The solar rail 2400 includes a connector 2402.

[81] As illustrated in FIGS. 34A-34D, the connector 2402 includes a strap 2410, a screw 2420, and a first connector end 2430 and a second connector end 2440. The screw 2420 is mounted on the second connector end 2440 and may be released from the first connector end 2430 as shown in FIG. 34B. When the screw 2420 is inserted into the first connector end 2430 as shown in FIG. 34C, the screw 2420 may be rotated to thereby thread the screw 2420 through an opening in the first connector end 2430. As the screw 2420 is threaded through the first connector end 2430, the distance between the first connector end 2430 and the second connector end 2440 is reduced to thereby tighten the strap 2410 and reduce the circumference of the strap 2410, for example, around the circumference of the torque tube 16.

[82] As illustrated in FIG. 26, the robot arm 2100 lifts a solar rail 2400 using the magnetic end effector 2110. It is noted that a conveyor or support for the torque tube 16 is omitted in FIGS. 26-33 for clarity and ease of representation. In this configuration and as illustrated in FIGS. 26-27, the solar rail construction system 200 includes two side robot arms: a robot arm 2500 with an end effector 2510, and a robot arm 2600 with an end effector 2610. As will be described in greater detail, the robot arm 2500 and the robot arm 2600 are configured to manipulate the connector 2402 of the solar rail 2400 to position and affix the solar rail 2400 to the torque tube 16.

[83] The solar rail construction system 2000 further includes an imaging chamber 2700 with sensor(s), such as an image sensor or camera 2710. In some embodiments, the strap 2410 of the connector 2402 may move relative to the top portion of the connector 2402. As shown in FIG. 27, the solar rail 2400 may be positioned in the imaging chamber 2700 and an image may be captured by the camera 2710. As illustrated, the imaging chamber 2700 reduces the impact of the outside environment on an image of the solar rail 2400, for example, by reducing shadows or movement due to wind or precipitation or other elements. Accordingly, the imaging chamber 2700 may obtain an image from the camera 2710 that is sufficiently clear and accurate so as to identify the coordinates of the strap 2410 with respect to the other components of the solar rail 2400 for additional accuracy and ease of installation on the torque tube 16. For example, the imaging chamber 2700 may communicate an image of the solar rail 2400 and a controller may use the image to adjust the motion of the robot arms 2100, 2400 and 2500 accordingly to install the solar rail 2400 on the torque tube 16.

[84] The robot arm 2100 moves the solar rail 2400 into position above the torque tube 16 using sensor data from the camera 2116 as illustrated in FIGS. 28-30. The robot arms 2500 and 2600 and end effectors 2510 and 2610 grasp the ends 2430 and 2440 of the connector 2402 of the solar rail 2400 as illustrated in FIG. 29. The end effector 2510 unscrews the screw 2420 and disengages the screw 2420 from the first connector end 2430 to form an opening for the torque tube 16 as illustrated in FIG. 30. The solar rail 2400 is positioned, such as lowered and maneuvered side-to-side in this configuration, as needed and as guided by a controller with aid of sensor 2116 data such that the torque tube 16 is positioned in the strap 2410 as shown in FIGS. 31-32. The screw 2420 is positioned in the first connector end 2430 and rotated by the end effector 2510 to thereby tighten the strap 2410 around the torque tube 16 as shown in FIG. 33. Because the solar rail 2400 is affixed and mounted on the torque tube 16, the end effector 2110 may be lifted away and disengage from the solar rail 2400 as further shown in FIG. 33.

[85] As illustrated in FIGS, 35, the end effector 2510 is configured to grasp the first connector end 2430 of the solar rail 2400, to loosen and tighten the screw 2420, and to position the solar rail 2400. In particular, the end effector 2510 includes a torque or force sensor 2512, a part sensor 2514, a magnet 2516, a gripper 2520, a camera 2530, an auto torquing screwdriver 2540 with a screw driver end 2544 and a motor 2542, and an actuator or pneumatic slide 2550 for advancing and retracting the screwdriver 2540. In this configuration and as illustrated in FIGS. 36A-36B, the gripper 2520 includes two opposing arms that move away from one another to accept the first connector end 2430, and then move towards one another to grip the first connector end 2430. The magnet 2516 is used for part registration, and the part sensor 2514 inductively senses when a metallic part is in position on the end effector 2510. The part sensor 5214 may be configured to send an electronic signal to a controller or analyzer to signal that the solar rail 2400 is in position. In addition, the camera 2530 may provide images for use by a controller or analyzer to further control the end effector 2510. Additionally, in some aspects, the end effector 2510 may be provided with a calibration target for locating position as part of the vision and / or sensor system. When the first connector end 2430 is in position and held by the gripper 2520, the motor 2542 drives the screw driver end 2544 of the electric torquing screwdriver 2540 to thereby tighten or loosen the screw 2420 as described herein. In some aspects, the auto torquing screwdriver 2540 may automatically screw the screw 2420 to a programmed torque value, fastening the strap 2410 and securing the solar rail 2400 to the torque tube 16.

[86] Although some embodiments are illustrated with a solar rail 2400 being fastened to a torque tube 16 with a strap 2410, it should be understood that other fasteners may be used. As shown in FIGS. 36C-36D, a solar rail 2400A is illustrated without a strap. During installation, the solar rail 2400A is held in position by side frames 2600A. In some embodiments, the robot arm 2500A with a specialized drill and rivet tool set end effector 2510A is configured to drill one or more openings through solar rail 2400A and the torque tube 16, and rivet one or more fasteners through the aligned openings to secure the rail to the tube.

[87] Although some embodiments are illustrated with respect to solar rails 2300 and 2400, it should be understood that other configurations of solar rail supports may be used. For example, the robot arm 2100 may be used to position a temporary rail module on a torque tube for temporary support of a solar panel during installation or inspection. A temporary rail module 5000 is described in detail in FIGS. 54A-54D.

[88] It should be understood that the solar rail construction system 2000 may be controlled by a controller 500, either automatically based on sensor inputs and programming or based on user inputs or with a combination thereof. For example, in some aspects, the solar bay construction systems described herein may include an automated quality control system to monitor whether solar infrastructure is assembled or installed to specifications. Automated positioning systems may operate in parallel with other automated systems such as motorized positioning systems, end effector systems, conveyor systems, parts systems, sensor and / or vision systems, quality control systems, and / or computer software systems. The automated quality control system determines that all Solar parts are attached to the Solar Tube structure according to specifications, such that a Solar Bay is completely assembled.Solar Panel Construction System

[89] A solar panel construction system 3000 is described in FIGS. 37-49E. As described in detail below, connectors or fasteners, such as pins and collars or rivets and washers, are presented in a predetermined orientation by a parts presentation stand. The pins and collars are picked up and held by an end effector of a robot arm and positioned by the robot arm on the solar panel and solar rail and then fastened together, such as by swaging, to connect a solar panel or module to the solar rail to form a solar panel assembly, ultimately to build one or one or more solar bays.

[90] As illustrated in FIG. 37, a schematic diagram of the pins and collars presentation system 3100 is shown. Connectors that are configured to connect a solar panel to a solar rail include mating or cooperating pins and collars. As illustrated, the pins that are provided by a pin vibratory bowl feeder 3110 and a pin supply container 3114 and corresponding collars that are provided by a collar vibratory bowl feeder 3112 and a collar supply container 3116. The pins and collars presentation system 3100 further includes parts presentation stands 3120 that each include a pin station 3122 and a collar station 3124. As shown in FIG. 37, the pins are loaded into the pin feeder, such as a vibratory bowl feeder 3110, and the collars are loaded into the collar feeder, such as a vibratory bowl feeder 3112. Transfer lines, such as air lines, conveyors, tracks, magazines, move the collars to the collar stations 3124 and separately move the pins to the pin stations 3122 of the parts presentation stands 3120. The transfer lines and parts presentation stands 3120 may be controlled by a controller 500. The parts presentation stands 3120 are configured to hold and present the pins and collars such that the pins and collars are able to be grasped or held by a pin and collar connection robot 3200.

[91] The parts presentation stand 3120 and the pin and collar connection robot 3200 are illustrated in FIGS. 38-40. The parts presentation stand 3120 is shown in detail in FIGS. 41A-41B and the pin and collar connection robot 3200 is shown in detail in FIGS. 42A-42B. As shown in FIGS. 41A-41B, the parts presentation stand 3120 includes a pin station 3122 and a collar station 3124. More specifically, the parts presentation stand 3120 may include internal transfer lines for receiving pins and collars from the pin vibratory bowl feeder 3110 and the collar vibratory bowl feeder 3112, respectively. The collar station 3124 may include a receptacle sized and configured to receive a collar C and the pin station 3122 may include a receptacle sized and configured to receive a pin P. In some embodiments, the collar station 3124 and pin station 3122 may include magnetic components for further holding the collar C and pin P, respectively. In other embodiments, the pins and collar may share one feeding system, such as a vibratory bowl feeding system. It should be understood that separate feeding systems are depicted here, but are not required for the system to correctly transfer parts to the appropriate presentation stand stations.

[92] As illustrated in FIGS. 42A-42B, the pin and collar connection robot 3200 may include an end effector 3250 that is configured to receive the pin P and collar C from the parts presentation stand 3120. More specifically, the end effector 3250 includes a collar holder 3210 and a pin holder 3212. The end effector 3250 further includes a swage tool 3214 for connecting the pin P and collar C.

[93] As shown in FIG. 38, the pin P is positioned in the pin station 3122 and the collar C is positioned in the collar station 3124, transported via the transfer lines of FIG. 37. As shown in FIG. 39, the end effector 3250 of the pin and collar connection robot 3200 is moved to take the pin P (obscured from view) and collar C from the parts presentation stand 3120. For example, the pin holder 3212 may move over and around the pin P and the collar holder 3210 may move to be positioned around the collar C. In addition, the pin holder 3212 and the collar holder 3210 may include magnetic components to further hold and secure the pin P and collar C, respectively, as shown in FIG. 40.

[94] The solar panel construction system 3000 is further illustrated in FIGS. 43-49E. It is noted that the conveyor system that holds the torque tube 16 and solar rail 2400 is omitted from the drawings for clarity and ease of presentation.

[95] As shown in FIG. 43, the solar panel construction system 3000 includes the pin and collar connection robot 3200, which, in this configuration, is depicted adjacent to the solar rail 2400, and a solar module pick and place robot arm 3500. It should be understood that the relative positions, in X, Y, and / or Z, of the robot arms to one or more of the solar rail, solar module, and / or parts presentation stand are flexible because of the controller and sensors. The solar module pick and place robot arm 3500 includes a solar module end effector 3600 that has a base 3610 and connectors 3620 that are configured to connect to and lift a solar module 3800. As illustrated, the connectors 3620 are suction cups configured to be pressed against and create a suction connection with the solar module 3800. However, it should be understood that any suitable connector may be used. In some aspects, the solar module pick and place robot arm 3500 manipulates the solar module end effector 3600 to select and pick solar modules 3800 from corresponding module parts containers, and then position, set, hold, and fasten the solar modules 3800 to the solar rails 2400. The selection of Solar Modules is determined via sensor and / or vision system data and programmed using computer software.

[96] As shown in FIG. 44, the solar module end effector 3600 positions the solar panel 3800 adjacent to the solar rail 2400, and the end effector 3250 of the pin and collar connection robot 3200 is moved below the solar rail 2400. As shown in FIG. 45, the solar panel 3800 includes a connection ledge or frame 3810. The pin holder 3212 is mounted on a hinged connection and tilts to position the pin holder 3212 and thus pin P over the ledge 3810 as shown in FIG. 46. The ledge 3810 includes an aperture to receive the pin P and the collar C is moved by the collar holder 3210 to be adjacent the pin P as illustrated in FIG. 47. As further illustrated in FIG. 47, the swaging tool 3214 moves upward to connect the pin P and collar C such that the pin P and collar C may be released as shown in FIG. 48. As further shown in FIGS. 46-48 the pin P is positioned in an aperture of the solar module ledge 3810 and the collar C is positioned around the pin P, and the pin P and collar C are swaged to form a connection (FIG. 47). It should be understood that each solar panel 3800 may be connected to one or more solar rails 2400 on a torque tube 16 and each panel may be connected to each rail by one or more fasteners, such as pins and collars.

[97] It should be understood that there may be other methods of securing rails to panels, such as rivets and washers. In this configuration, the washers may be of a material to create electrical grounding. In FIGS. 49A-49E a washer W is depicted in the ledge 3810 of the solar panel 3800 and a rivet R is depicted underneath the rail 2400. The rivet R is affixed to the washer W using a rivet tool, not depicted, with final form seen in FIGS. 49C-49E whereby the solar panel is thereby connected to the solar rail. Accordingly, as used herein, the pin P and collar C and the swaging tool may be replaced with a washer W, rivet R, and a rivet tool, respectively. In some aspects, the washer can include a raised grounding feature used for electrical grounding. The raised grounding feature is able to penetrate an insulative oxidation or anodization layer. In some aspects, the washer can include a grounding feature attached with a blind rivet. When pulling the blind rivet, pressure forces the ridge of the washer to pierce an oxide layer, establishing an electrical path to ground.

[98] It should be further understood that the movements and placement of elements in FIGS. 37-49E may be aided by cameras and / or other sensors that may be positioned around the components of the solar panel construction system 3000. The cameras and / or sensors may communicate with the controller 500 or one or more controllers, which may control the sequence of operations as described herein. It should be understood that the solar panel construction system 3000 may be controlled by a controller 500, either automatically based on sensor inputs and programming and programming or based on user inputs or with a combination thereof.Solar Bay Output Buffer System

[99] Once the solar bay is constructed, the conveyor system 300 automatically positions the solar bay 3900 and exits the solar bay 3900 from the solar bay construction system in preparation for installation. A solar bay output buffer 7000 that is configured to receive solar bays 3900 from a conveyor system 300 is illustrated. The solar bay output buffer 7000 is configured to move solar bays 3900 from the conveyor system 300 after assembly and to facilitate moving the solar bays 3900 to an installation system.

[100] As illustrated, the solar bay output buffer 7000 includes gantries 7010 and 7020 that are configured to move along the Y axis on a frame 7030 to position the solar bay 3900 at a given location for pickup by a solar bay installation system, transported by a vehicle. Gantry arms 7050 protrude on the X axis towards the conveyor, and the gantry arms 7050 are moved under the torque tube 16 of a solar bay 3900. The gantry arms 7040 raise the gantry along the X-axis to pick up the solar bay 3900 by the torque tube 16 using grippers 7060. The solar bay 3900 is then lowered in the X-direction and retracted in the X direction to hold the solar bay 3900 and move it away from the conveyor to a solar bay installation system for installation in the field. Accordingly, the gantry arms 7040 and 7050 may be used to move a solar bay 3900 from the conveyor system 300 to an installation system for transportation into the field. It should be understood that the bay output buffer system 7000 may be controlled by a controller 500, either automatically based on sensor inputs and programming or based on user inputs or with a combination thereofSolar Bay Installation System

[101] As shown in FIGS. 50B-54D, a solar bay installation system 4000 is shown for installing a solar bay 3900 into an industrial solar array. As illustrated in FIG. 50B, the solar bay 3900 includes a torque tube 16 with solar panels or modules 3800 attached to the torque tube 16 with solar rails 2400 as described herein.

[102] The solar bay 3900 is held and transported by a solar bay transportation and installation system 4000, which includes an installation support 4100 configured to support a solar bay during transportation, and gantry(ies) 4200. The gantry 4200 is configured to move the solar bay 3900 to a side of the installation system 4000 to thereby connect a torque tube 16 of the solar bay 3900 to an array of solar bays 3900. As illustrated, a temporary rail module 5000 is positioned on an end of the solar bay 3900. The temporary rail module 5000 is described in greater detail in FIGS. 54A-54D.

[103] The installation support 4100 includes a base 4110 with side supports 4112 that are configured to be positioned on a portable structure. As illustrated, the solar bay installation system 4000 is configured to be towed or pulled by a vehicle. The supports 4112 include brackets 4114 for connecting to the torque tube 16 of the solar bay 3900. In this configuration, the installation support 4100 is configured to hold the solar bay 3900 securely during transportation, and the gantry 4200 is configured to provide additional degrees of freedom to maneuver the solar bay 3900 into position and to connect the solar torque tube 16 to installed torque tubes in an array of solar bays 3900 in an industrial solar array.

[104] The gantry 4200 includes rotatable arm(s) 4210 and vertical support arm(s) 4220. As illustrated in FIGS. 51-52, the rotatable arms 4210 may include a first portion 4210A and a second portion 4210B that overlaps with (e.g., telescoping or overlapping one another) or extends away from the first portion 4210A. In this configuration, the rotatable arm 4210 is configured to extend in the Z direction as shown in FIG. 51 or the rotatable arm 4210 may rotate to extend the solar bay 3900 to a side at an angle with respect to the solar bay installation system 4000. In operation, the rotatable arm 4210 moves upward to engage the solar bay 3900 and then rotates outward at an angle to position the solar bay to a side of the solar bay installation system. In some embodiments, the gantries 4200 are configured to maintain the solar bay 3900 at a level or horizontal position, and sensor data, such as an accelerometer, camera or other suitable sensor may be used to manipulate a position of the solar bay 3900 during movement of the gantry 4200, such as to maintain the solar bay 3900 in a level position.

[105] The vertical transportation support 4220 includes a rail or bracket connector 4230 that is configured to hold the torque tube 16 of the solar bay 3900 as shown, for example, in FIG. 52. Notably, the vertical transportation support(s) 4114 is(are) stationary immobile structure(s) for transportation whereas the extendable arm(s) 4210 and 4220 is(are) retractable and rotatable for positioning in X, Y, Z, and rotations around thereof, the solar bay away from and adjacent to the gantry, and in some embodiments, the solar bay 3900 is positioned so that a majority or all of the solar bay 3900 clears or is to a side and does not overlap the base 4110. In this configuration, the vertical support 4220 holds the solar bay 3900 such that the solar panels 3800 are held in a generally horizontal position as the solar bay 3900 is positioned onto a bracket B in the field. A sensor on the installation system such as an accelerometer may be used to detect the solar bay's position. In some embodiments, a first gantry may enable rotation in a first direction about X, the direction along the solar bay's tube, and a second gantry may enable rotation around X in the opposite direction of the first gantry's rotation, such that both gantries are controlled to maintain the solar bay at a level or horizontal position. Accordingly, as illustrated in FIGS. 53A-53B, the solar bay installation system 4000 is configured to be positioned between rows of solar bays 3900, for example, by a vehicle V. In this configuration, the rotatable arm 4210 of the gantry 4200 is configured to lower the solar bay 3900 to a position that may be lower or higher than the position of the solar bay 3900 during transportation of the solar bay 3900, or level to. As shown in FIG. 53B, the rotatable arm 420 can further facilitate alignment of solar torque tubes 16 between the solar bay 3900 being installed and a solar bay 3900 that is already positioned on the brackets B in the field (FIG. 52).

[106] In some embodiments, one or more sensors S, such as a camera or laser may be used to align the torque tubes 16 of adjacent solar bays 3900. For example, the sensor S may be in the form of a laser or light emitter and a detector or a vision system, such as a camera. A laser may be positioned on one solar bay 3900 and a detector may be positioned on the adjacent solar bay 3900 such that when the solar bays are aligned, the detector detects the light from the laser. Once the solar bay 3900 is in alignment, the vehicle may move the solar bay installation system 4000 and the solar bay 3900 so as to telescope or mount the torque tube 16 to an adjacent solar bay 3900 in the array of solar bays 3900. In this configuration, mounting occurs by inserting the narrower end of the torque tube of the transported solar bay into the wider end of the torque tube of the field installed solar bay.

[107] In some embodiments, the temporary rail module 5000 is provided as a support during installation. As shown in FIGS. 54A-54B, the temporary rail module 5000 is on an end portion of a torque tube 16A to support the solar panel 3800 as the torque tube 16 A is positioned on an adjacent torque tube 16B. As shown in FIGS. 54C-54D, the temporary rail module 5000 includes a vertical body 5010, with connectors or suction cups 5020 to affix the temporary rail module 5000 to the solar panel 3800. A semicircle 5030 configured to hold the torque tube 16 is attached to the body 5010 by a telescoping support 50442 and pin 5040. As illustrated in FIG. 54D, when the pin is removed, the support 5042 telescopes and shortens such that the suction cups may be removed from the solar panel 3900.

[108] In some aspects, the solar bay construction systems described herein can include spacing structures, or Solar Infrastructure spacers, used in Solar Infrastructure to maintain a minimum space between Solar Infrastructures during and after installation. The Solar Infrastructure spacers can withstand the force of a Solar Bay’s movement during and after installation to prevent movement of adjacent Solar Bays and / or other adjacent Solar Infrastructure. Solar Infrastructure spacers are placed on a shaft and between a handle and Solar Rails. One spacer is placed on each side of the handle to maintain a minimum spacing between the shaft and the handle. In this instantiation, the spacers withstand installation forces applied to their adjacent shafts and thus prevent the movement and / or misalignment of Solar Infrastructure.

[109] It should be understood that the solar bay installation system 4000 may be controlled by a controller 500, either automatically based on sensor inputs and programming or based on user inputs or with a combination thereof.Multi Conveyor System

[110] In some embodiments, a controlled multi conveyor system, such as the dual conveyor system 6000 as shown in FIGS. 55-57, may be used. Robot arms may be positioned so that both conveyors may be reached by the same robot arms to increase efficiency and utilization of robotic elements and parallelize solar bay construction.

[111] As shown in FIGS. 55-56, the solar rail construction system 2000, the solar panel construction system 3000, and two conveyor systems 300A may be controlled by a centralized controller / analyzer 500, location agnostic. It should be understood that the conveyor system 6000 may be controlled by a controller 500, either automatically based on sensor inputs and programming or based on user inputs or with a combination thereof. It should be understood that a torque tube dispensing system may be positioned at an edge of the conveyors 300A, 300B for positioning the torque tubes 16 on the conveyor systems 300A, 300B as described herein. The solar rail construction system 2000 may include a robot arm 2100 configured to pick, place, and attach the solar rails 2400, an imaging chamber 2700 configured to image a solar rail 2400 for determining a more exact position of the solar rail 2400, a single or multiple robot arm(s) 2500 and 2600 configured to fasten the strap of the solar rails 2400.

[112] The solar panel construction system 3000 includes a collar container 3116, a collar vibratory bowl 3112, which may feed collar(s) into one or more parts, presentation stands 3120 in preparation for attaching a module to a rail at one or more locations. A pin container 3116 and pin vibratory bowl 3110 may feed pins into the one or more parts presentation stands. The robots 3200 may pick the pins and collars and connect the solar modules or panels 3800 to the solar rails 2400 using the pins and collars, and may use a tool such as a swaging tool to permanently secure the panel to the rail.

[113] As illustrated in FIG. 55, a torque tube 16 on the conveyor system 300A may be positioned on one section of the conveyor system 300A. For example, the torque tube 16 may be positioned on the left end of the conveyor system 300 adjacent to the solar panel construction system 3000 and travel towards the solar rail construction system 2000. The solar rails 2300 and 2400 may be positioned on the torque tube 16 by the solar rail construction system 2000 by the robot arms 2100, 2500, and 2600 as described herein, and the torque tube 16 with attached solar rails 2300 and 2400 may travel to the solar panel construction system 3000. The solar panel construction system 3000 may position and connect solar panels 3800 on the solar rails 2300 and 2400 using the robot arms 3200 and 3600 as described herein.

[114] While the solar panels 3800 are being connected to the solar rails 2300 and 2400 by the solar panel construction system 3000 on the conveyor system 300A, another torque tube 16 is positioned on the conveyor system 300B. Therefore, as illustrated in FIG. 55, solar rails 2300 and 2400 may be connected on the torque tube 16 on the conveyor system 300B by the solar rail construction system 2000 in parallel or in series with the solar panels 3800 are being connected to the solar rails 2300 and 2400 by the solar panel construction system 3000. As illustrated in FIG. 56, at the same time as solar panels 3800 are connected to the solar rails 2300 and 2400 of the torque tube on the conveyor system 300B by the solar panel construction system 3000, solar rails 2300 and 2400 are being connected to the torque tube 16 on the conveyor system 300A by the solar rail construction system 2000.

[115] As illustrated in FIG. 57 a torque tube dispensing system 100 with torque tube singulator and torque tube carrier is configured to position a torque tube 16 onto one of the conveyor systems 300A and 300B. The solar rail construction system(s) 2000 and the solar panel construction system(s) 3000 operate in parallel or in series with the conveyor system 300A or the conveyor system 300B as described with respect to FIGS. 55-56. When a solar bay is finished, it is output at the solar bay output buffer 6100. In this configuration, the empty torque tubes 16 are positioned on the conveyor systems 300A, 300B at a same end as the finished solar bays are removed by the solar bay output buffer 6100. The solar bay output buffer 6100 may be a robotic or automated lifting system for positioning a solar bay onto the solar assembly installation system 4000 as described herein. However, it should be understood that the solar bay output buffer 6100 may be an area configured for manually lifting and positioning a solar bay onto the solar assembly installation system 4000.

[116] It should be understood that the multi conveyor system 6000 may be controlled by a controller 500, either automatically based on sensor inputs and programming or based on user inputs or with a combination thereof.Exemplary Methods

[117] The following examples are illustrative in purpose and are not intended to be limiting as to the systems and methods described and claimed herein.

[118] In some aspects, a method for fully or partially automating the assembly of solar infrastructure may be provided. The assembly may be performed via a fully or partially automated assembly system. The assembly may be performed by a system which intakes parts required for the hardware, assembles the parts, and outputs a complete solar bay ready for installation in a solar field. In some aspects, the assembly may be performed in a system with dimensions constrained to the dimensions of industrial shipping containers. The assembly may be performed in a mobile system. In some aspects, the assembly may be performed in a system with parallelized assembly operations. The assembly may be performed in a system with parallelized assembly of two or more solar infrastructures. In some aspects, the assembly may be performed in a system able to operate in below-freezing conditions. The assembly may be performed in a system able to operate in precipitation. In some aspects, the assembly may be performed in a remotely operated system. In some aspects, no human assembly or human intervention is required. Solar infrastructure may be moved through a fully or partially automated assembly line by means of a conveyor system. The conveyor system may move solar infrastructure to and from assembly station relative positions or precise positions. In some aspects, more than one conveyor system may assemble more than one solar infrastructure in parallel. In some aspects, the materials and / or parts for the solar infrastructure may be fully or partially automated in their delivery to the assembly system.

[119] In some aspects, a method of fastening a solar module to a rail or mounting bracket of the solar infrastructure may be provided. One or more motorized positioning systems may be used. A blind rivet and washer may be used. A washer with a ridge for electrical grounding may be used. A washer with an electrical grounding feature may be used. A washer with a feature able to penetrate an anodized aluminum coating may be used.

[120] In some aspects, a method of temporarily fastening a solar module to solar infrastructure may be provided. The temporary fastening method may include fabricated hardware, referred to as a temporary module rail. The temporary module rail may serve the place of a permanently secured module rail during solar infrastructure assembly and / or transportation. The temporary module rail may not require permanent modification to other components of the solar infrastructure. The temporary module rail may use a pin system as a means of securing attachment. The temporary module rail may be removed during or after the solar bay is installed in a solar field.

[121] In some aspects, a method of retaining, aligning, and / or stabilizing solar infrastructure on a conveyor system may be provided. The solar infrastructure may be a solar bay. The solar infrastructure may be retained on a conveyor system using structures or pins.

[122] In some aspects, a method of storing solar infrastructure parts may be provided. The parts may be magnetically secured. The parts may be retrieved from a fully or partially automated system. The parts may be identified using computer vision. The parts may be magnetically retrieved.

[123] In some aspects, a method of storing solar modules may be provided. The solar modules may be stored for retrieval by a fully or partially automated solar infrastructure assembly system.

[124] In some aspects, a method for identifying and picking solar infrastructure parts may be provided. The solar infrastructure parts may be magnetically picked. The solar infrastructure parts may be picked using motorized positioning systems. The solar infrastructure parts or their container may be identified using sensors or computer vision.

[125] In some aspects, a method of picking, transporting, and installing solar infrastructure in a solar field may be provided. The solar infrastructure may be a solar bay. The solar infrastructure may be picked, transported, and installed using a vehicle. The method for picking, transporting, and installing solar infrastructure may include an attachment system on a vehicle. The solar infrastructure may be picked, transported, and installed using a remotely operated vehicle or an autonomous vehicle. The solar infrastructure may be picked, transported, and installed using a vehicle that uses sensors, computer vision, or distance sensors to align and set the solar infrastructure to a location in the solar field.

[126] In some aspects, a method of interfacing on the web or other remotely accessible interface to control a solar infrastructure assembly or installation system may be provided.

[127] In some aspects, a method of automating a quality control system for monitoring that solar infrastructure is assembled or installed to specifications may be provided. The quality control system may monitor factory failures.

[128] In some aspects, a method of fully or partially automating location selection on solar infrastructure may be provided. Computer vision may be used to select locations. One or more sensors may be used to select locations. Location selection may be used to identify one or more drilling locations. Location selection may be used to identify alignment slots in the solar infrastructure. Location selection may be used to place a solar module onto solar infrastructure. Motorized positioning systems may be used to perform a subsequent fastening operation in alignment slots. Motorized positioning systems may be used to perform a subsequent operation based on a selected location. One or more motorized positioning systems may be used to drill.

[129] In some aspects, a method of dispensing solar infrastructure tube parts for use in a fully or partially automated solar infrastructure assembly system may be provided. One or more tubes may enter into an assembly system. Tubes may enter from a dispensing system to a conveyor system located within an assembly system.

[130] The present inventive concepts are described herein with reference to the accompanying drawings and examples, in which embodiments are shown. Additional embodiments may take on many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive concepts to those skilled in the art.

[131] Like numbers refer to like elements throughout. In the figures, the thickness of certain lines, layers, components, elements or features may be exaggerated for clarity.

[132] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting thereof. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as "between X and Y" and "between about X and Y" should be interpreted to include X and Y. As used herein, phrases such as "between about X and Y" mean "between about X and about Y." As used herein, phrases such as "from about X to Y" mean "from about X to about Y." The term "about" should be understood to include variations of up to 20%.

[133] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and / or clarity.

[134] It will be understood that when an element is referred to as being "on," "attached" to, "connected" to, "coupled" with, "contacting," etc., another element, it may be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, "directly on," "directly attached" to, "directly connected" to, "directly coupled" with or "directly contacting" another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed "adjacent" another feature may have portions that overlap or underlie the adjacent feature.

[135] Spatially relative terms, such as "under," "below," "lower," "over," "upper" and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is inverted, elements described as "under" or "beneath" other elements or features would then be oriented "over" the other elements or features. Thus, the exemplary term "under" may encompass both an orientation of "over" and "under." The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms "upwardly," "downwardly," "vertical," "horizontal" and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

[136] It will be understood that, although the terms "first," "second," etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. Thus, a "first" element discussed below could also be termed a "second" element without departing from the teachings of the present disclosure. The sequence of operations (or steps) is not limited to the order presented in the claims or figures unless specifically indicated otherwise.

[137] The foregoing is illustrative of the present inventive concept and is not to be construed as limiting thereof. Although a few example embodiments have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings of this inventive concept. Accordingly, all such modifications are intended to be included within the scope of this inventive concept as defined in the claims. Therefore, it is to be understood that the foregoing is illustrative of the present inventive concept and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. 

Claims

1) A method for automatic solar bay assembling, comprising: feeding a torque tube from a torque tube dispensing system onto a conveyor system to initiate an assembly for a solar bay, wherein the conveyor system is configured to stabilize the torque tube; positioning the torque tube via the conveyor system at one or more locations in a solar bay construction system; fastening a plurality of solar rails to the torque tube and a plurality of solar panels to the plurality of solar rails, thereby producing a complete solar bay; and exiting the solar bay from the solar bay construction system via the conveyor system in preparation for installation.2) (New) ​The method of claim 103, wherein positioning the torque tube comprises: constraining, by the conveyor system, motion of the torque tube three dimensions, and rotation of the torque tube.3) (New) ​The method of claim 103, further comprising: sensing positions of components and any surrounding objects in the solar bay construction system via one or more sensors; receiving sensor data from the one or more sensors via one or more controllers; and moving, via the one or more controllers, elements of at least one of the torque tube dispensing system and the conveyor system based on the sensor data.4) ​(New) The method of claim 103, wherein positioning the torque tube further comprises: moving, via the conveyor system, the torque tube from the dispensing system sequentially through one or more first locations of a rail attaching station and one or more second locations of a panel station, wherein the plurality of solar rails are attached to the torque tube at the one or more first locations, and the plurality of solar panels are attached to the plurality of solar rails at the one or more second locations.5) ​(New) The method of claim 103, further comprising: picking, by one or more first robot arms, each of the plurality of solar rails from one or more parts containers; and positioning, by the one or more first robot arms, each of the plurality of solar rails on the torque tube; and fastening, by the one or more first robot arms, each of the plurality of solar rails to the torque tube, wherein the one or more first robot arms include one or more first end effectors configured to position and fasten the plurality of solar rails.6) (New) The method of claim 107, further comprising: lifting, by one or more second robot arms, each of the plurality of solar panels; and positioning, by the one or more second robot arms, each of the plurality of solar panels on one or more of the plurality of solar rails; and fastening, by the one or more second robot arms, each of the plurality of solar panels to the one or more of the plurality of solar rails, wherein the one or more second robot arms include one or more second end effectors configured to position and fasten the plurality of solar panels.7) ​​(New) The method of claim 108, wherein at least part of fastening the plurality of solar rails to the torque tube and at least part of fastening the plurality of solar panels to the plurality of solar rails are performed in parallel.8) (New) ​The method of claim 108, wherein the plurality of solar rails or the one or more parts containers are identified using computer vision. 9) (New) ​The method of claim 109, wherein the plurality of solar panels are identified using computer vision. 10) (New) The method of claim 103, wherein the solar bay is exited from the solar bay construction system via the conveyor system onto a solar bay output buffer system in preparation for installation.11) (New) A system for automatic solar bay assembling, comprising: a torque tube dispensing system configured to dispense one or more torque tubes; a conveyor system configured to receive the one or more torque tube from the torque tube dispensing system and move the one or more torque tubes through a plurality of positions during an assembly of a solar bay; a solar rail construction system configured to connect a plurality of solar rails to the one or more torque tubes as the one or more torque tubes are moved through the plurality of positions; a solar panel construction system configured to connect a plurality of solar panels to the plurality of solar rails as the one or more torque tubes are moved through the plurality of positions to produce a complete solar bay; and a solar bay output buffer system configured to receive the complete solar bay from the conveyor system in preparation for installation.12) (New) The system for automatic solar bay assembling of claim 113, wherein the conveyor system is configured to constrain motion of the torque tube three dimensions, and rotation of the torque tube.13) (New) The system for automatic solar bay assembling of claim 113, further comprising: one or more sensors configured to sense positions of components and any surrounding objects in the solar bay construction system; and one or more controllers configured to receive sensor data from the one or more sensors and to move elements of at least one of the torque tube dispensing system, the conveyor system, the solar rail construction system, the solar panel construction system, and the solar bay output buffer system solar bay construction system based on the sensor data.14) (New) The system for automatic solar bay assembling of claim 113, wherein the torque tube dispensing system comprises: a frame comprising a base and one or more vertical support structures extending away from the base; a plurality of holders mounted on respective ones of the plurality of vertical support structures and configured to support one or more torque tubes extending across the plurality of holders, wherein each of the plurality of holders includes a first end that is lower than an opposing second end and a sloped intermediate portion therebetween; at least one stopper at the first end of each of the plurality of holders configured to retain the one or more torque tubes; and at least one carrier holder that is movable between a raised position and a retracted position, wherein when the at least one carrier holder is in the retracted position, the at least one stopper retains the one or more torque tubes at the first end of one or more of the plurality of holders, and when the at least one carrier holder is in the raised position, the at least stopper is at or below a surface of a respective one of the at least one carrier holders to thereby allow one of the one or more torque tubes to roll along the at least one carrier holder toward the conveyor system.15) (New) The system for automatic solar bay assembling of claim 113, wherein the conveyor system is configured to move the torque tube from the dispensing system sequentially through one or more first locations within the solar rail construction system and one or more second locations within the solar panel construction system, wherein the plurality of solar rails are attached to the torque tube at the one or more first locations, and the plurality of solar panels are attached to the plurality of solar rails at the one or more second locations.16) (New) The system for automatic solar bay assembling of claim 117, wherein the solar rail construction system comprises: one or more first robot arms configured to connect to and move each solar rail of the plurality of solar rails, position each of the plurality of solar rails on the torque tube, and fasten each of the plurality of solar rails to the torque tube, wherein the one or more first robot arms include one or more first end effectors configured to position and fasten the plurality of solar rails.17) (New) The system for automatic solar bay assembling of claim 118, wherein the one or more first end effectors include switchable magnetic components configured to magnetically pick each solar rail from one or more parts containers.18) (New) The system for automatic solar bay assembling of claim 118, wherein the solar bay construction system comprises: one or more second robot arms configured to lift each of the plurality of solar panels, position each of the plurality of solar panels on one or more of the plurality of solar rails, and fasten each of the plurality of solar panels to the one or more of the plurality of solar rails, wherein the one or more second robot arms include one or more second end effectors configured to position and fasten the plurality of solar panels.19) (New) The system for automatic solar bay assembling of claim 120, wherein at least part of fastening the plurality of solar rails to the torque tube and at least part of fastening the plurality of solar panels to the plurality of solar rails are performed in parallel.20) (New) The system for automatic solar bay assembling of claim 120, wherein at least one of the plurality of solar rails, the one or more parts containers, and the solar panels are identified using computer vision. 

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