System and method for strut and solar module assembly

Abstract

In one aspect, the present disclosure describes systems and methods for autonomous and fast strut and solar module assembly. In some aspects, the present disclosure describes an apparatus including a delivery unit and a dispensing unit. The transport unit may be configured to support and transport the plurality of struts. The distribution unit may be configured to distribute one or more of the plurality of struts from the transport unit for mounting onto the terrain.

Description

[0001] Cross-reference

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 374,211, filed Aug. 31, 2022, which is incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION

[0003] With the recognition of the harmful effects of global warming, the use of solar power generation has become increasingly accepted. Large areas of open space can provide attractive locations for the deployment of solar panels. However, such open-area solar installations may be accompanied by significant efforts to secure the solar panels to the ground such that the solar panels can resist external loading forces such as wind. Creating separate beam and strut structures to achieve this goal also adds significant costs to the installation of solar panels. SUMMARY OF THE INVENTION

[0004] There is a recognized need for methods and systems for high-throughput post installation and rapid assembly of solar modules to posts without high-precision alignment. The present disclosure provides systems and methods for post and solar module assembly.

[0005] In some aspects, the present disclosure describes an apparatus that includes a conveyance unit and a dispensing unit. The conveyance unit can be configured to support and transport a plurality of posts. The dispensing unit can be configured to dispense one or more of the plurality of posts from the conveyance unit for installation onto a terrain.

[0006] In some embodiments, the conveying unit includes a conveying line. In some embodiments, the conveying unit is configured to support a plurality of struts by suspending the plurality of struts on the conveying line. In some embodiments, the dispensing unit includes an actuator configured to dispense one or more struts by separating or releasing the one or more struts from the conveying unit. In some embodiments, the actuator is configured to separate or release the one or more struts from the conveying unit by pushing, pulling, and / or lifting the one or more struts away from the conveying unit. In some embodiments, the dispensing unit is configured to feed one or more struts to a strut mounting machine. In some embodiments, the dispensing unit is configured to dispense one or more struts to a vehicle configured to feed the one or more struts to a strut mounting machine. In some embodiments, the dispensing unit includes a support arm configured to extend through one or more first holes in one or more of the struts to support the one or more struts, wherein the support arm is further configured to push, pull, and / or lift the one or more struts away from the conveying unit. In some embodiments, the dispensing unit is further configured to feed one or more bundles to a strut mounting machine. In some embodiments, the dispensing unit is configured to dispense one or more bundles to a vehicle configured to feed the one or more bundles to a strut mounting machine.

[0007] In some embodiments, the device may further include a transfer arm configured to extend through one or more second holes in one or more of the struts to take over the one or more struts from the support arm. In some embodiments, the transfer arm is configured to transfer the one or more struts to a vehicle configured to feed the one or more struts to a strut mounting machine. In some embodiments, the plurality of struts are provided as a plurality of bundles, where each bundle includes two or more struts. In some embodiments, the two or more struts in each bundle are held together by straps, chains, or clips. In some embodiments, each bundle includes from about three to three hundred struts. In some embodiments, the dispensing unit is configured to dispense one or more bundles from the plurality of bundles. In some embodiments, the dispensing unit includes an actuator configured to dispense the one or more bundles by separating or releasing the one or more bundles from the conveying unit. In some embodiments, the actuator is configured to separate or release the one or more bundles from the conveying unit by pushing, pulling, and / or lifting the one or more bundles away from the conveying unit.

[0008] In some embodiments, the conveying unit and the dispensing unit are operatively coupled to each other. In some embodiments, the dispensing unit is located at a fixed position relative to the conveying unit. In some embodiments, the dispensing unit is movable such that the dispensing unit can move to one or more positions along or relative to the conveying unit. In some embodiments, the conveying unit, the dispensing unit, and the plurality of struts are provided in a strut storage unit or at a strut storage location. In some embodiments, the conveying unit includes a plurality of carriers linked to each other. In some embodiments, the number and spacing of the plurality of carriers are adjustable such that the conveying unit can have different turning radii during the movement of the conveying unit. In some embodiments, each of the plurality of carriers includes one or more hooks for hanging the plurality of struts. In some embodiments, the conveying unit is inclined or angled to facilitate the dispensing of one or more struts with the aid of gravity.

[0009] In some aspects, the present disclosure describes a vehicle that includes a track and a follower. The track can be configured to support a plurality of struts, wherein the track includes a gate at a distal portion of the track. The gate can be configured to prevent the plurality of struts from sliding out of the track. The follower can be configured to move the plurality of struts along the track toward the gate or press the plurality of struts against the gate. The gate and the follower can be configured to enable each of the plurality of struts to be sequentially removed from the distal portion of the track for installation onto the terrain.

[0010] In some embodiments, the follower includes a spring. In some embodiments, each strut can be sequentially removed from the track by lifting each strut above the gate. In some embodiments, one or more tabs on each of the plurality of struts or a plurality of spacers between the plurality of struts are used to index the plurality of struts a certain distance relative to each other along the track. In some embodiments, the vehicle can further include a vibration device operatively coupled to the track, wherein the vibration device is configured to generate vibrations in the track for facilitating the movement of the plurality of struts toward the gate. In some embodiments, the track is inclined or angled to facilitate the movement of the plurality of struts toward the gate with the aid of gravity. In some embodiments, the track includes a single track. In some embodiments, the track includes two or more laterally spaced sub-tracks. In some embodiments, the two or more laterally spaced sub-tracks are configured to reduce the sway of the plurality of struts on the track. In some embodiments, the vehicle can further include one or more linear guides located below the track, wherein the one or more linear guides are configured to limit and reduce the sway of the plurality of struts on the track. In some embodiments, the vehicle is inclined or angled to facilitate the removal of each strut from the track with the aid of gravity.

[0011] In some aspects, the present disclosure describes a system that includes a stanchion mounting machine. The stanchion mounting machine can include an extraction device configured to remove one or more stanchions from a vehicle for installation onto terrain.

[0012] In some embodiments, the extraction device is configured to remove the one or more stanchions from the vehicle by lifting the one or more stanchions off a track to clear a gate. In some embodiments, the stanchion mounting machine includes a load drive mechanism, and the extraction device is configured to bring the one or more stanchions to the vicinity of the load drive mechanism. In some embodiments, the load drive mechanism is configured to drive the one or more stanchions onto the terrain.

[0013] In some aspects, the present disclosure describes a stanchion mounting machine that includes a load drive mechanism and a positioning device. The load drive mechanism can include a load head configured to drive one or more stanchions onto the terrain. The positioning device can be configured to control the position of the load head in three or more degrees of freedom with respect to the one or more stanchions and the terrain prior to driving the one or more stanchions onto the terrain.

[0014] In some embodiments, the positioning device includes a plurality of linear actuators. In some embodiments, the positioning device includes a Stewart platform or a hexapod. In some embodiments, the positioning device is configured to control the position of the load head in six degrees of freedom. In some embodiments, the load drive mechanism includes an actuator configured to control the vertical position of the load head along the Z-axis. In some embodiments, the load drive mechanism includes a chain / wire and a pulley for adjusting or controlling the ratio of (a) the linear extension of the actuator relative to (b) the travel distance of the load head. In some embodiments, the ratio is 1:2. In some embodiments, the ratio is adjustable or controllable to reduce the upward reaction force when retracting the load head after driving the one or more stanchions down onto the terrain.

[0015] In some embodiments, the machine further includes a vertical track for restricting the one or more struts when the one or more struts are driven into the terrain. In some embodiments, the vertical track is configured to allow the one or more struts to slide along the track when the one or more struts are driven into the terrain. In some embodiments, the machine may further include a bracket configured to hold the one or more struts in position relative to the load head. In some embodiments, the bracket is movable to switch between an open state and a closed state. In some embodiments, the closed state causes the bracket to hold the one or more struts in position relative to the load head. In some embodiments, the open state allows the one or more struts to be positioned in place relative to the load head. In some embodiments, the bracket is hinged to a retainer configured to hold the one or more struts. In some embodiments, the bracket includes a C-shaped or U-shaped bracket.

[0016] In some aspects, the present disclosure describes an apparatus that includes a flexible mechanism. The flexible mechanism may be operatively coupled to a distal portion of a movable arm. The flexible mechanism may be configured to (1) pick up one or more solar modules from a plurality of solar modules and (2) place the one or more solar modules onto a plurality of struts that have been installed into the terrain. The flexible mechanism may also be configured to rotate and / or bend relative to the movable arm during placement of the one or more solar modules onto the plurality of struts.

[0017] In some embodiments, the flexible mechanism enables the one or more solar modules to be placed onto the plurality of struts without positioning the one or more solar modules within a threshold tolerance relative to the plurality of struts during placement. In some embodiments, the threshold tolerance is at least based on the horizontal accuracy and vertical accuracy of a global navigation satellite system (GNSS). In some embodiments, the threshold tolerance is at least based on the inclination of the plurality of struts. In some embodiments, the inclination ranges from 0 degrees to 25 degrees. In some embodiments, the flexible mechanism includes a pair of laterally spaced-apart plates and a plurality of springs radially extending from a center between the pair of laterally spaced-apart plates. In some embodiments, the plurality of springs radially extend equidistantly from the center. In some embodiments, the plurality of springs includes three springs that radially extend from the center at 120-degree angles relative to each other. In some embodiments, the plurality of springs includes four springs that radially extend from the center at 90-degree angles relative to each other. In some embodiments, the plurality of springs includes six springs that radially extend from the center at 60-degree angles relative to each other. In some embodiments, the pair of laterally spaced-apart plates includes: (1) a first plate operatively coupled to a distal portion of the movable arm; and (2) a second plate configured to pick up the one or more solar modules from the plurality of solar modules.

[0018] In some embodiments, the flexible mechanism further includes a spherical bearing at the center between a pair of laterally spaced-apart plates. In some embodiments, the pair of laterally spaced-apart plates are operatively coupled to each other via the spherical bearing and a plurality of springs. In some embodiments, the spherical bearing is configured to allow the pair of laterally spaced-apart plates to rotate relative to each other. In some embodiments, the spherical bearing includes an additional spring configured to allow the plates to move laterally relative to each other. In some embodiments, the plurality of springs are configured to allow the pair of laterally spaced-apart plates to bend relative to each other such that the pair of plates are not parallel to each other. In some embodiments, the plurality of springs are made of metal or rubber. In some embodiments, the plurality of springs are configured to have a torsional spring force such that after placing one or more solar modules onto the plurality of struts, the flexible mechanism returns to a default position. In some embodiments, the flexible mechanism includes one or more bellows. In some embodiments, the one or more bellows are provided in a rubber housing. In some embodiments, the one or more bellows can be inflated or deflated with a fluid for controlling the spring constant of the one or more bellows, wherein the fluid includes a gas or a liquid.

[0019] In some embodiments, the device may further include a movable arm. In some embodiments, the device may further include one or more actuators operatively coupled to the movable arm. In some embodiments, the one or more actuators are configured to control the movement of the movable arm in two or more degrees of freedom. In some embodiments, the two or more degrees of freedom include translation along a vertical axis and rotation about the vertical axis. In some embodiments, the two or more degrees of freedom further include translation and / or rotation along a horizontal axis. In some embodiments, the device may further include a slide rail for supporting a plurality of solar modules in a stacked form. In some embodiments, the device may further include one or more riveting tools operatively coupled to the flexible mechanism, wherein the one or more riveting tools are configured to attach one or more solar modules to the plurality of struts via a dimpling process.

[0020] In some embodiments, the present disclosure provides a method for constructing a solar module array, the method comprising: (a) autonomously positioning a plurality of struts on a terrain; and (b) autonomously assembling a plurality of solar modules with the plurality of struts on the terrain to construct a solar module array, wherein the plurality of struts includes a row of struts, wherein two adjacent struts in the row of struts each incline towards each other, and wherein a third strut adjacent to the two adjacent struts inclines outward.

[0021] In some embodiments, the array includes a dual-tilt array. In some embodiments, a solar module among the plurality of solar modules is coupled to a post among the plurality of posts via a post-module interface. In some embodiments, the post-module interface includes a substantially non-planar surface such that the angle between the module and the post is variable. In some embodiments, the post-module interface includes a plurality of tabs. In some embodiments, the plurality of tabs are bendable or deformable. In some embodiments, the post-module interface includes a non-planar pivot feature. In some embodiments, the method includes tilting the solar module via the non-planar pivot feature. In some embodiments, the plurality of posts are mounted at alternating angles. In some embodiments, two adjacent posts are mounted at a first angle and a second angle relative to a vertical axis, and a third post is mounted at a third angle. In some embodiments, the first angle, the second angle, and the third angle are substantially the same. In some embodiments, at least two of the first angle, the second angle, and the third angle are different.

[0022] In some embodiments, the present disclosure provides a method for constructing an array of solar modules, the method comprising: (a) autonomously positioning a plurality of posts on a terrain; and (b) autonomously assembling a plurality of solar modules with the plurality of posts on the terrain to construct an array of solar modules, wherein a solar module among the plurality of solar modules is supported by a variable number of posts.

[0023] In some embodiments, one side of a solar module is supported by at least three posts. In some embodiments, one side of a solar module is supported by at least four posts. In some embodiments, the array includes a dual-tilt array. In some embodiments, a solar module among the plurality of solar modules is coupled to a post among the plurality of posts via a post-module interface. In some embodiments, the post-module interface includes a substantially non-planar surface such that the angle between the module and the post is variable. In some embodiments, the post-module interface includes a plurality of tabs. In some embodiments, the plurality of tabs are bendable or deformable. In some embodiments, the post-module interface includes a non-planar pivot feature. In some embodiments, the method includes tilting the solar module via the non-planar pivot feature. In some embodiments, the plurality of posts are mounted at alternating angles.

[0024] In some embodiments, the present disclosure provides a method for assembling solar modules, the method comprising (a) providing an algorithm configured to identify locations for autonomous positioning and assembly of a plurality of posts and a plurality of solar modules; and (b) creating a set of executable software instructions for controlling one or more mobile platforms to autonomously position and assemble the plurality of posts and the plurality of solar modules on a terrain to construct an array of solar modules without assistance or involvement of a user.

[0025] In some embodiments, the method includes determining a location using a digital surface model of the terrain. In some embodiments, the method includes determining the position of a strut by using an algorithm for the strut-clamp interface angle. In some embodiments, the method includes using an algorithm to minimize the depth of the strut. In some embodiments, the method includes using a digital surface model of the terrain to minimize the depth of the strut. In some embodiments, the algorithm uses soil properties. In some embodiments, the algorithm uses array geometry and tolerances. In some embodiments, the method includes deriving or displaying the output of the algorithm in digital representation. In some embodiments, the method includes using the digital representation to modify the position of a strut or module based on measurements of nearby struts or modules. In some embodiments, the method includes using the digital representation to predict the electricity generated by the array. In some embodiments, the method includes using the digital representation to predict the components required in the array. In some embodiments, the method includes using the digital representation to create a construction plan drawing. In some embodiments, the method includes using the digital representation to generate an analysis for construction operations. In some embodiments, the method includes providing a graphical user interface (GUI) configured to display the output of the algorithm. In some embodiments, the method includes displaying a digital representation of the output of the algorithm on the GUI. In some embodiments, the method includes using sensors to record data on the terrain, struts, and / or modules. In some embodiments, the method includes displaying the recorded data in digital representation. In some embodiments, the method includes modifying the algorithm and / or the digital surface model of the terrain based on the recorded data.

[0026] Additional aspects and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes only illustrative embodiments of the present disclosure. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modification in various obvious aspects, all without departing from the present disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive.

[0027] Incorporated by reference

[0028] All publications, patents, and patent applications mentioned in this specification are incorporated herein by reference to the same extent as if each individual publication, patent, or patent application were specifically and individually indicated to be incorporated herein by reference. In the event of a conflict between the incorporated publications and patents or patent applications and the disclosure contained herein, the specification is intended to supersede and / or take precedence over any such conflicting material. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The novel features of the present disclosure are particularly set forth in the appended claims. A better understanding of the features and advantages of the present disclosure will be obtained by reference to the following detailed description of illustrative embodiments that make use of the principles of the present disclosure, along with the accompanying drawings (also referred to herein as "figures"), in which:

[0030] Figure 1 is a simplified force diagram of a ground-mounted system for solar panels.

[0031] Figure 2 shows a simplified view of an embodiment of the ground-mounted system.

[0032] Figure 3 shows a simplified view of a conventional ground-mounted installation.

[0033] Figure 4A shows a perspective view of a ground-mounted system according to an embodiment.

[0034] Figure 4B is Figure 4B an end view of the ground-mounted system, showing the loading force.

[0035] Figure 4C shows an enlarged view of a strut according to an embodiment.

[0036] Figure 5A shows a perspective view of a ground-mounted system according to an alternative embodiment.

[0037] Figure 5B shows Figure 5A a simplified end view of an embodiment, showing the loading force.

[0038] Figure 6A is a perspective view of a solar module array generated by a ground-mounted system according to an embodiment.

[0039] Figure 6B is a perspective view of another solar module array generated by a ground-mounted system according to an embodiment.

[0040] Figure 6C shows a perspective view of an alternative embodiment of a longitudinal solar module having short ends aligned in the row direction.

[0041] Figure 7A shows a perspective view of an end clip according to an embodiment.

[0042] Figure 7B shows a perspective view of an end clip attached to two modules.

[0043] Figure 8A shows a perspective view of a corner clip according to an embodiment.

[0044] Figure 8B Shows a perspective view of a corner clip embodiment connected to two modules and a strut.

[0045] Figure 8C Shows a perspective view of a pair of corner clips connected to a strut and attached modules.

[0046] Figure 9 Shows the forces to which a ground mounting system may be subjected.

[0047] Figure 10 Shows the main tolerances of concern for a ground mounting installation.

[0048] Figure 10A Shows a perspective view of two clips riveted in place on a strut.

[0049] Figure 10B Is a side perspective view showing the effect of terrain on the installation.

[0050] Figure 10C Is an enlarged view showing the ability of a ground mounting system according to an embodiment to handle relatively high tolerances.

[0051] Figure 10D Shows a perspective view of an alternative strut embodiment.

[0052] Figure 11 Shows an enlarged perspective view of the spacing between modules.

[0053] Figure 12 Shows a simplified view of an alternative clip structure.

[0054] Figure 13 Is a simplified view showing a clip attached to the side of a module.

[0055] Figure 14 Is a simplified perspective view of a clip / module assembly adjacent an alternative embodiment of a strut.

[0056] Figure 15 Is a simplified view of a riveting tool that can be used to rivet a clip to a strut surface.

[0057] Figure 15A Shows a simplified view of the resulting riveted joint.

[0058] Figure 15B Shows a view of a strut according to an alternative embodiment.

[0059] Figure 15C Shows a manufactured strut held in a hoop structure after progressive stamping.

[0060] Figure 16Shows a simplified view of the corners of four modules joined to a post.

[0061] Figure 17 Shows a progressive stamping manufacturing process that can be used to fabricate a clip.

[0062] Figure 18 Shows how the clip can maintain its connection orientation in an integrated strap configuration after formation.

[0063] Figure 19 Shows another embodiment of a ground mounting system.

[0064] Figure 20 Shows a typical layout of standard blocks of a solar module in this connection orientation.

[0065] Figure 21 Shows Figure 20 how four blocks are connected to a central inverter.

[0066] Figure 22 Is a perspective view of a part of the block.

[0067] Figure 23 Is a simplified flowchart showing an available supply chain according to an embodiment.

[0068] Figure 24 Is a simplified top view showing the progress of an embodiment of installing a machine on site.

[0069] Figure 25 Is a simplified top view showing the progress of an alternative embodiment of installing machine 2500 on site.

[0070] Figure 26 Provides a formal coordinate system for describing a moving vehicle.

[0071] Figure 27 Shows a rear perspective view of an embodiment 2700 of an installation device.

[0072] Figure 28 Shows details of a vertical conveyor element that can be used to lower one module at a time.

[0073] Figure 29 Is a schematic diagram showing how a stacked standard package of solar modules is loaded onto a vertical conveyor and each module is lowered onto a metal plate joint.

[0074] Figure 30 Shows details of the module lowered onto the joint.

[0075] Figure 31 Shows a side view of a stack of solar modules on a vertical conveyor.

[0076] Figure 32 Shows a front perspective view of the installation device.

[0077] Figure 33 Shows a view of the load head frame connected to the actuator tip.

[0078] Figure 34 Shows a method for controlling the position of a movable platform.

[0079] Figure 35 Shows a front perspective view of the installation device according to an alternative embodiment.

[0080] Figure 36 Shows Figure 35 An enlarged side view of the device.

[0081] Figure 37A Shows a perspective view of an alternative embodiment.

[0082] Figure 37B Shows an enlarged view of the gantry.

[0083] Figure 37C Shows an enlarged view of the rotating gear.

[0084] Figure 38A Shows a perspective view of another alternative embodiment.

[0085] Figure 38B Shows movement in various directions of the Figure 38A embodiment.

[0086] Figure 39 Shows a top view of an alternative embodiment featuring a cleaning robot.

[0087] Figure 40 Shows a top view of an alternative embodiment featuring staggered module placement.

[0088] Figure 41 Shows a top view of an alternative embodiment featuring staggered module placement and strut position.

[0089] Figure 42A top view of an autonomous system for positioning and assembling solar modules according to some embodiments is shown. In some cases, the modules may be unpacked, inspected, and / or processed with or without attachments prior to on-site transportation. In some cases, the post installer may drive the posts and continuously reload from a factor bundle. In some cases, the module installer may remove a solar module from a stack and attach it to a post. In some cases, the posts may be installed on the rear of a tractor or any other type of vehicle (e.g., any type of automatic or semi-automatic towing vehicle) by a custom machine. In some cases, the modules may be installed on previously installed posts by a machine on the rear of a different tractor.

[0090] Figure 43 A top view of an autonomous system for positioning and assembling solar modules according to some embodiments is shown. In some cases, the tractor may be fully electric. In some cases, a mobile power unit may be located at or near a location where the tractor can be charged. In some cases, the mobile power unit may include solar panels and / or batteries. In some cases, the reload unit may travel between sites. In some cases, the reload unit may carry posts, solar modules, or any combination thereof. In some cases, the reload unit may travel between a preparation station and an active installer unit (e.g., a tractor).

[0091] Figure 44A - Figure 44MA vehicle for positioning and assembling solar modules according to some embodiments is shown. In some cases, the module installer can be a custom-built machine on a tractor. In some cases, the module installer can receive a stack of solar modules. In some cases, the stack of solar modules can be placed on the module installer. In some cases, the stack of solar modules can be picked up by the module installer. In some cases, the module installer can carry the stack of modules. In some cases, the module installer can separate one module from the stack of modules. In some cases, the module installer can position one module on a plurality of installed struts, e.g., two, three, or four installed struts. In some cases, the module installer can lower the module to a predetermined position on the plurality of installed struts. In some cases, the module installer can deform the metal part of the module to create a rigid connection between the module and the struts. In some cases, the module installer can release the module. In some cases, the module installer can test the strength of the connection formed between the module and the plurality of struts by lifting, pushing, twisting, or any sufficient force. In some cases, the module installer can drive to the next location to place the module. In some cases, the module installer can include 3, 4, 5, or 6 or more degrees of movement. In some cases, the module installer can include a robotic arm configured to receive modules from a flipper. In some cases, picking up modules from the stack can be achieved using the robotic arm. In some cases, a gantry can be used to tilt forward and backward to pick up modules and position the modules behind. In some cases, a dual-rotation motion manipulator including one, two, or more rotary joints can be used to position the module above one or more struts. In some cases, a trailer can include a gantry for picking up and positioning one or more modules above the struts.

[0092] Figure 45A - Figure 45D A perspective view of a machine for installing struts according to some embodiments is shown. In some cases, the machine can include 3, 4, 5, or 6 or more degrees of freedom. In some cases, the machine can autonomously position the struts, install the struts on the ground, and / or perform a force test on the struts by pulling the struts in a lateral, vertical, or any other direction and record the force test data. In some cases, the machine can be configured to carry a bundle or multiple bundles of struts on a rack. In some cases, the machine can be configured to position one or more struts in a bundle of struts and collect new struts on a driving drill bit.

[0093] Figure 46A - Figure 46BA machine for installing a post according to some embodiments is shown. In some cases, the machine can have three or more mounting interfaces for mounting to a tractor, such as using a three-point hitch. In some cases, the machine can carry a hammer for driving the post into the ground. In some cases, the hammer can be mounted on a vertical track and can slide freely in a vertical or any other suitable direction such that a sufficiently small or no vibration is transmitted from the hammer to the rest of the machine.

[0094] Figure 47A - Figure 47I A coupling mechanism between a drive bit and a post according to some embodiments is shown. In some cases, the drive bit can be connected to the hammer. In some cases, the drive bit can include a shear interface for engaging the post during impact. In some cases, the drive bit can include a retention feature that prevents the post from falling off the bit as it is positioned and driven. In some cases, the drive bit can be configured to allow the post to be impacted from a web of the post, the web of the post can be provided at a lower portion on the body of the post. In some cases, compared to an impact from the head, an impact from the web can allow the hammer to impact the post with a greater force because during the impact, the impact from the web can effectively reduce the buckling length of the post. In some cases, the drive bit can enter a larger portion of the hole in the post. In some cases, the drive bit can slide down in a configuration and remain against a chisel bit. In some cases, when the drive bit engages the post, the head of the chisel feature on the drive bit can overlap at least a portion of the post. In some cases, there can be 1, 2, 3, 4 or more shear features on the chisel bit. In some cases, the chisel bit can also serve as a retention feature. In some cases, the features on the chisel bit can hold the post. In some cases, the features on the chisel bit can be separated from the features for impacting the post. In some cases, the retention feature can be a timing element that rotates to engage the post. In some cases, the retention feature can be a timing square that rotates about 45 degrees such that once engaged, the corners hold the post. In some cases, the retention feature can hang over the hole in the post. In some cases, the shaft can not engage the bottom of the hole in the post. In some cases, the pin can engage the post without overhang.

[0095] Figures 48A - 48B show a comparison of driving a post using different coupling mechanisms according to some embodiments.

[0096] Figure 49A - Figure 49C A post according to some embodiments is shown.

[0097] Figure 50A - Figure 50C shows a coupling mechanism between a strut and a rack according to some embodiments. In some cases, the strut may include a Z-shaped cross-section or a Z-shape. In some cases, the strut may include a substantially stackable shape. In some cases, the strut may include one or more sets of inclined tabs at the top. In some cases, the tabs may include cutout features. In some cases, the cutout features may be configured to allow the strut to be suspended from a hanger or bracket. In some cases, one or more struts may be bundled and transported in a container or arranged on a machine.

[0098] Figure 51 A method for coupling a solar module and a bracket according to some embodiments is shown. In some cases, the bracket may be installed at a site through a process where the module is unpacked, inspected, and / or then placed on a tooling fixture. In some cases, one, two, three, four, or more rivet guns may install rivets to join the bracket to the solar module from below, the side, the top, or any sufficient direction. In some cases, a riveting tool or an impact driver (e.g., for torquing nuts) may be used instead of a rivet gun.

[0099] Figure 52 A method for autonomously positioning and assembling a solar module according to some embodiments is shown. In some cases, the module installer may drive to a certain location. In some cases, the module installer may pick up the module. In some cases, the module installer may position the module on one, two, three, four, or more struts. In some cases, a riveting tool may be used to form a connection between the module and one or more struts. In some cases, the riveting tool may be assembled between the ears and clips of the strut. In some cases, the riveting tool may be closed to form a joint. In some cases, the module installer may release the riveting tool. In some cases, an end effector may be used to lift the module. In some cases, the module installer may drive to the next set of one or more struts to install the next module.

[0100] Figure 53 Multiple brackets capable of coupling to one or more struts according to some embodiments are shown. In some cases, the solar module may include a bracket. The bracket may be attached or coupled to the solar module. In some cases, the bracket may include deformable metal. In some cases, a connection may be formed between the bracket and the strut. In some cases, the connection may be formed by riveting the bracket and the strut together. In some cases, the bracket may include a flat or angled metal sheet configured to be riveted to the module, for example, through mounting holes. In some cases, the bracket may be connected to the module by riveting the bracket to the frame of the module.

[0101] Figure 54A - Figure 54C shows a method for determining a lateral topology for positioning and assembling solar modules according to some embodiments. In some cases, the method may include analyzing the terrain topology and / or GIS data of a given terrain. In some cases, the method may include processing the curvature of the terrain topology or GIS data. In some cases, the method may include simulating the posts and modules installed on the given terrain. In some cases, the method may include uploading the post and module geographic locations and build data of one or more machines for installing the posts and modules.

[0102] Figure 55 A GUI for determining a lateral topology for positioning and assembling solar modules is shown according to some embodiments.

[0103] Figure 56 Modules including fixed tilt arrays are shown according to some embodiments. In some cases, the modules can be rigidly connected to two pillars. In some cases, the modules can include small support brackets that mount directly to the pillars without spanning intermediate structures. In some cases, the modules can be driven by 90 degree linkages, where each module can be driven to a desired angle, for example, without the need to drive the entire tracker "bench" together. In some cases, the modules can span two or more pillars without the need for intermediate structures between the pillars. In some cases, the modules can be connected with a continuous wire or chain. In some cases, the continuous wire or chain can be driven by a mechanism to track the solar module about one or more pivots on the pillars. In some cases, the modules can each include a separate drive or drive unit so that each module can track the sun independently.

[0104] Figure 57 A solar tracker is shown according to some embodiments.

[0105] FIG. 58 illustrates tracking units according to some embodiments. In some cases, tracking units may be deployed autonomously. In some cases, tracking units may be pre-assembled, distributed, and placed on a site. In some cases, tracking units may be autonomously connected using geolocation data and / or any of the machines disclosed herein. In some cases, installed tracking units may be expanded into a single module solar track for tracking the sun on 1, 2, or 3 axes.

[0106] Figure 59 A light curtain according to some embodiments is shown. In some cases, a machine may include one or more optical sensors configured to detect when a foreign object (eg, a person or another agent) enters a workspace defined by the light curtain.

[0107] Figure 60Shows a solar module array configuration according to some embodiments. In some cases, the solar module array can include 4 struts for each corner of the module. In some cases, the solar module array can include 2 struts along the central axis of the module.

[0108] Figure 61 Shows a computer system according to some embodiments.

[0109] Figure 62 Shows an alternative embodiment of an exemplary vehicle that can be used or configured to handle, transport, install, or deploy one or more solar modules.

[0110] Figure 63 Shows another alternative embodiment of an exemplary vehicle that can be used or configured to handle, transport, install, or deploy one or more solar modules.

[0111] Figure 64 Shows an end effector according to some embodiments having a riveting tool positioned at a corner of the end effector.

[0112] Figure 65 Shows the bottom of the riveting tool, which can be tapered to assist in positioning or engaging the module.

[0113] Figure 66A and Figure 66B Shows an alternative embodiment of a clip according to some embodiments.

[0114] Figure 67 Shows an alternative embodiment of a module installer vehicle according to some embodiments.

[0115] Figure 68 Shows an exemplary configuration for struts according to some embodiments.

[0116] Figure 69A and Figure 69B Shows an alternative embodiment of the clip described herein according to some embodiments.

[0117] Figure 70A Shows additional tab features that can be used to hold one or more leads or wires of a solar module and secure them to a particular side of the module for later handling or processing.

[0118] Figure 70B Shows an embodiment of a clip where module wires are connected to the clip, which is also connected to the module and will be connected to the strut.

[0119] Figure 70CShows the use of additional tools to autonomously retrieve solar module wires held in place by clips and connect them to each other to form an electrical connection between the modules.

[0120] Figure 71 Shows Figure 70A 、 Figure 70B and Figure 70C Alternative embodiments of the tools and methods in which the tool does not push two connectors together, but instead cuts, strips, and splices wires together in place without using connectors.

[0121] Figure 72 and Figure 73 Show an exemplary configuration in which multiple modules are oriented and positioned at 90 degrees relative to the ground.

[0122] Figure 74 Shows an embodiment of an intermediate clip according to some embodiments.

[0123] Figure 75 Shows a removable access slot that can be placed on top of a post in a valley or peak of a solar module array.

[0124] Figure 76 and Figure 77 Show a gantry on wheels that can be driven on the ground in a gap between arrays in certain configurations.

[0125] Figure 78A - Figure 78C Shows an example configuration of a conveying device for a post mounting machine according to some embodiments.

[0126] Figure 79 Shows another example configuration of a conveying device according to some embodiments.

[0127] Figure 80 Shows an example feed system for a post mounting machine according to some embodiments.

[0128] Figure 81A - Figure 81C Shows an example mechanical arrangement of a transition post according to some embodiments.

[0129] Figure 82A - Figure 82C Shows an example of a magazine and track system of a conveying device according to some embodiments.

[0130] Figure 83A and Figure 83B Shows an example detailed view of a conveying unit shown in Figure 79 according to some embodiments.

[0131] Figures 84A and 84B show another example mechanical arrangement for storing and transporting posts according to some embodiments.

[0132] Figure 85 Shows different exemplary track configurations of a track system according to some embodiments.

[0133] Figure 86A - Figure 86C Shows different exemplary configurations of the hammer and actuator of a leg-mounted machine according to some embodiments.

[0134] Figure 87 Shows an exemplary configuration of a leg-mounted machine with a loader according to some embodiments.

[0135] Figure 88A - Figure 88C Shows an exemplary integration of a leg-mounted machine with a slide rail according to some embodiments.

[0136] Figure 89 Shows an exemplary configuration of a leg-mounted machine that is mounted with crawlers or wheels at its base and is equipped with a hydraulic or power source according to some embodiments.

[0137] Figure 90A and Figure 90B Shows different views of an exemplary configuration of the hammer head of a leg-mounted machine according to some embodiments.

[0138] Figure 91 Shows different views of another exemplary configuration of the hammer head of a leg-mounted machine according to some embodiments.

[0139] Figure 92A and Figure 92B Shows the range of motion of a module-mounted machine according to some embodiments.

[0140] Figure 93A - Figure 93D Shows different exemplary configurations of a module-mounted machine according to some embodiments.

[0141] Figures 94A and 94B show an exemplary configuration of a flexible mechanism at the end of the crane of a module-mounted machine according to some embodiments.

[0142] Figure 95 Shows another exemplary configuration of a flexible mechanism at the end of the crane of a module-mounted machine according to some embodiments.

[0143] Figure 96 Shows an exemplary configuration of the end effector of the crane of a module-mounted machine according to some embodiments.

[0144] Figure 97A Shows an exemplary arrangement of a row of legs according to some embodiments.

[0145] Figure 97BShows an exemplary array of struts and solar panels / modules assembled with the struts at alternating angles.

[0146] Figure 98A Shows an exemplary assembly of a strut and a solar module according to some embodiments.

[0147] Figure 98B Shows another exemplary assembly of a strut and a solar module according to some embodiments.

[0148] Figure 98C Shows another exemplary assembly of a strut and a solar module according to some embodiments.

[0149] Figure 99A Shows an exemplary strut-module interface according to some embodiments, such as a bracket for coupling a strut and a solar module.

[0150] Figure 99B Shows a top view of bracket 9900 before bolts and clips are coupled to the bracket according to some embodiments.

[0151] Figure 99C Shows an exemplary configuration of a bracket according to some embodiments.

[0152] Figure 99D Shows another exemplary configuration of a bracket according to some embodiments.

[0153] Figure 99E Shows two adjacent solar modules 9916 and 9917 that are not on the same flat surface according to some embodiments.

[0154] Figure 99F Shows a coupling bracket 9900 with a strut 9905 according to some embodiments.

[0155] Figure 99G Shows an exemplary assembly of a strut, a bracket, and a solar module.

[0156] Figure 100A Shows a non-flat pivot feature 10000 of a bracket according to some embodiments.

[0157] Figure 100B Shows solar modules that are not tilted (10003), tilted at a positive angle (10004), and tilted at a negative angle (10005) when the solar modules are coupled to the bracket with a non-flat pivot feature according to some embodiments.

[0158] Figure 100CShows an enlarged view of a solar module 10001 tilted at a positive angle relative to a flat surface according to some embodiments.

[0159] Figure 100D Shows an enlarged view of a solar module 10002 tilted at a negative angle relative to a flat surface according to some embodiments.

[0160] Figure 101 Shows an exemplary bracket including plastic material and metal material according to some embodiments.

[0161] Figure 102 Shows a post installer according to some embodiments.

[0162] Figure 103A And Figure 103B Shows a device for post loading from a post hopper and feeder according to some embodiments.

[0163] Figure 104A And Figure 104B Shows a post loading operation according to some embodiments.

[0164] Figure 105 Shows a schematic post hopper and feeder according to some embodiments.

[0165] Figure 106 Shows a post hopper and feeding machine according to some embodiments.

[0166] Figure 107A Shows an exemplary post rammer according to some embodiments.

[0167] Figure 107B Shows a post rammer configuration after the post is grasped and transported to a vertical position according to some embodiments.

[0168] Figure 107C Is a perspective view of a post rammer configuration after the post is grasped and transported to a vertical position according to some embodiments.

[0169] Figure 108 Shows an exemplary post installation machine (post installer) according to some embodiments.

[0170] Figure 109 Shows an example of a digital representation of post and solar module assembly according to some embodiments.

[0171] Figure 110A Shows an exemplary digital surface data according to some embodiments.

[0172] Figure 110BShows a digital representation of a predicted and / or designed array component at a terrain according to some embodiments.

[0173] Figure 111 Shows an exemplary digital representation of a designed array according to some embodiments.

[0174] Figure 112A Shows sensors for recording array and terrain data during installation.

[0175] Figure 112B Shows an updated digital model with data from sensors according to some embodiments.

[0176] Figure 113A Shows example data of the electricity generated by an array according to some embodiments.

[0177] Figure 113B Shows an exemplary isometric view of a designed array derived from a digital representation according to some embodiments.

[0178] Figure 113C Shows an exemplary instruction path planning for installation / construction according to some embodiments.

[0179] Figure 113D Shows an exemplary plan view of a designed array derived from a digital representation according to some embodiments. Detailed Description

[0180] Although various embodiments of the present disclosure have been shown and described herein, it will be apparent to those skilled in the art that these embodiments are provided by way of example only. Many variations, changes, and substitutions will occur to those skilled in the art without departing from the present disclosure. It should be understood that various alternatives to the embodiments of the present disclosure described herein may be employed.

[0181] Whenever the terms "at least", "greater than", or "greater than or equal to" precede the first value in a series of two or more numerical values, the terms "at least", "greater than", or "greater than or equal to" apply to each value in the series. For example, greater than or equal to 1, 2, or 3 is equivalent to greater than or equal to 1, greater than or equal to 2, or greater than or equal to 3.

[0182] Whenever the terms "not exceeding", "less than", or "less than or equal to" precede the first value in a series of two or more numerical values, the terms "not exceeding", "less than", or "less than or equal to" apply to each value in the series. For example, less than or equal to 3, 2, or 1 is equivalent to less than or equal to 3, less than or equal to 2, or less than or equal to 1.

[0183] As used interchangeably herein, the terms “real-time” or “real-time” generally refer to an event (e.g., an operation, process, method, technique, computational process, calculation, analysis, visualization, optimization, etc.) performed using recently obtained (e.g., collected or received) data. In some cases, a real-time event can be performed almost immediately or within a sufficiently short time span, e.g., within at least 0.0001 millisecond (ms), 0.0005 ms, 0.001 ms, 0.005 ms, 0.01 ms, 0.05 ms, 0.1 ms, 0.5 ms, 1 ms, 5 ms, 0.01 second, 0.05 second, 0.1 second, 0.5 second, 1 second, or longer. In some cases, a real-time event can be performed almost immediately or within a sufficiently short time span, e.g., within at most 1 second, 0.5 second, 0.1 second, 0.05 second, 0.01 second, 5 ms, 1 ms, 0.5 ms, 0.1 ms, 0.05 ms, 0.01 ms, 0.005 ms, 0.001 ms, 0.0005 ms, 0.0001 ms, or shorter.

[0184] In one aspect, the present disclosure provides systems and methods for processing and deploying energy modules. The energy module can include a solar module or a plurality of solar modules. The solar module can include a deployable device configured to generate energy using one or more resources. In some cases, the one or more resources can include solar energy, thermal energy, radiant energy, or any other type of energy.

[0185] In one aspect, the present disclosure provides a method for processing or deploying a solar module. The method can include using at least one robot to fully autonomously locate and assemble (i) at least one solar module and (ii) its support structure at the sensed geographical location, e.g., at least one strut, without user assistance. In some cases, multiple robots can be used to autonomously locate and deploy, install, or assemble multiple solar modules and / or one or more support structures for multiple solar modules.

[0186] In some cases, a robot can refer to any machine capable of performing one or more tasks. In some cases, a robot can perform one or more tasks autonomously (e.g., without human intervention or without external intervention from another entity) or semi-autonomously (e.g., with minimal external supervision, instructions, or intervention).

[0187] In some cases, the task can include transporting various components for deploying an energy module as disclosed herein, such as the energy module or the struts. In some cases, the task can include installing various components for constructing the energy module disclosed herein, e.g., installing struts on the ground or connecting the energy module to a given strut. In some cases, the task can include handling and deploying the energy module.

[0188] In some cases, the robot can include one or more movable members. In some cases, the movable member can include an arm or an end effector. The movable member can be configured to handle, move, or deploy the energy module.

[0189] In some cases, the robot can include one or more energy storage devices (e.g., batteries). In some cases, the one or more energy storage devices can be charged by a renewable energy system. In some embodiments, one or more charging stations can be provided and distributed over the terrain to enable charging of the one or more robots. The one or more robots can include, e.g., a mobile platform, a vehicle, or any other machine described elsewhere herein. In some embodiments, the one or more charging stations can be mobile. In such cases, the charging station can be configured to travel to the robot or vehicle in need of charging. In other embodiments, the one or more charging stations can be fixed. In such cases, the one or more robots or vehicles can be configured to travel to the one or more charging stations for charging.

[0190] In some cases, the robot can include a vehicle. In some cases, the vehicle can include one or more wheels, one or more legs, or any other member configured to transport the robot over flat or uneven terrain.

[0191] In some cases, the robot can include one or more vision sensors. In some cases, the robot can perform tasks at least in part based on information provided by the one or more vision sensors.

[0192] In some cases, the robot can include one or more computers, processors, or logic circuits operatively communicating with one or more computers, processors, or logic circuits of another robot, or one or more servers (e.g., cloud servers).

[0193] In some cases, multiple robots can be used to autonomously locate and deploy support structures, e.g., multiple struts configured to support multiple solar modules. The solar modules can be fixed to one or more struts. Figure 4CShows an enlarged view of the support post 450 according to some embodiments. In some cases, the support post can include a flat top interface 452 to provide a riveting surface for the clip. In some cases, the support post can be made of a metal sheet (e.g., provided in a coil). In some cases, the lower portion of the support post can include a serrated pattern 454 that is cut to impart resistance to being pulled out of the ground. In some non-limiting embodiments, the support post can have a length ranging from about 1 foot (ft) or 0.30 meters (m) to about 10 ft (or 3.05 m). In some cases, the length of an exemplary support post can be about 3 ft (or 0.91 m), where 1 ft (or 0.30 m) is above ground and 2 ft (or 0.61 m) extends into the ground. In some cases, the length of an exemplary support post can be about 10 ft (or 3.05 m), where about 3 ft (or 0.91 m) to 5 ft (or 1.52 m) is above ground and 5 ft (or 1.52 m) to 7 ft (or 2.13 m) extends into the ground. In some cases, the length of an exemplary support post can be about 10 ft (or 3.05 m), where about 4 ft (or 1.22 m) is above ground and 6 ft (or 1.83 m) extends into the ground.

[0194] In some embodiments, the support post can include a tip 456 for effectively driving into the ground, e.g., by (hydraulic) pushing. In some cases, the degree of taper of the end can be determined to accommodate the shape of the corresponding tip of the next support post in the coil, thus saving metal sheet material and reducing costs.

[0195] In some cases, the presently disclosed embodiments can allow for vertical adjustment of the size of the support post protruding above the ground. In some cases, vertical adjustment can be achieved by pushing deeper or by adding an upper attachment to increase the height of the support post.

[0196] In some cases, a robot can install a first support post in a first position and a second support post in a second position. In some cases, the first position and the second position can be close enough such that an energy module can be installed to be supported by both the first support post and the second support post. In some cases, two separate energy modules can be installed to be supported by each of the first support post and the second support post, respectively. In some cases, the first support post can be installed first and the second support post can be installed second. In some cases, the first support post and the second support post can be installed substantially simultaneously. In some cases, a first robot can install a first support post in a first position and a second robot can install a second support post in a second position. A given robot can install various numbers of support posts. A given robot can install one or more support posts in various positions.

[0197] In some cases, multiple robots can be configured to operate as a team or group. The multiple robots can communicate with one or more servers that are configured to control the operation or movement of the multiple robots within an area or location that includes the sensed geographical location. The server can provide different commands to different robots, or command different robots to cooperate in performing one or more tasks. It should be understood that the coordination of one or more robots can be performed in various configurations to achieve similar effects, for example, by using various numbers of robots, various types of robots, various numbers of struts, and various rule sets or algorithms for coordinating the robots.

[0198] In some cases, multiple robots can be configured to operate in a coordinated manner so as to optimize the time taken to perform one or more tasks. For example, a first group of robots can coordinate to be at a first location and then immediately install one or more struts at a second location. A second group of robots can coordinate with the first group of robots to install a solar module at the first location immediately when one or more struts are installed at the first location. In some cases, the first location can be an area near the robots. In some cases, the first location can be an area near the solar module storage location. In some cases, the second location can be near the first location. In some cases, the second location can be a geosensed location (e.g., a location determined or identified using one or more position sensors and / or geographical or topological data). In some cases, the second location can be an approximate location, and the approximate location can be adjusted in real time to a more precise location.

[0199] In some cases, the method can include using at least one robot to fully autonomously position and assemble at least one solar module and its support structure in two or more different directions. The two or more different directions can include a first direction and a second direction. The first direction and the second direction can be parallel to each other. Alternatively, the first direction and the second direction can be set at an angle relative to each other. The angle can be in the range of 0 degrees to 180 degrees.

[0200] In some cases, at least one robot can use a movable member to handle a solar module or any of its components or support structures. In some cases, at least one robot can move a solar module or any of its components or support structures by translating along one, two, or three Euclidean dimensions. In some cases, at least one robot can move a solar module or any of its components or support structures by rotating the solar module about one, two, or three axes of the solar module. In some cases, at least one robot can translate and rotate the solar module simultaneously. In some cases, at least one robot can translate the solar module and then subsequently rotate the solar module, and vice versa. In some cases, for a solar module that is substantially rectangular in shape, the axes of the solar module can be defined as the normal directions from the plane of the solar module with the largest area, the plane of the solar module with the second largest area, or the plane of the solar module with the third largest area. At least one robot can move the solar module in various ways, including changing the position and / or orientation of the solar module or components of the solar module.

[0201] In some cases, the solar module, support structure, and any of its components can be repositioned and / or reoriented to be more precise and / or to ensure proper installation during deployment. In some cases, a given strut can be repositioned and / or reoriented to ensure successful insertion of the strut into the ground.

[0202] Figure 52 An exemplary method for autonomously positioning and assembling a solar module according to some embodiments is shown. In some cases, a module installer (e.g., a robot) can drive to a location. This location can be determined by a user or operator of the robot or based on sensor data. In some cases, the module installer can pick up an energy module (e.g., a solar module). In some cases, the module installer can position the module on one, two, three, four, or more struts. The struts can be autonomously installed by another robot.

[0203] In some cases, a riveting tool can be used to form a connection between the module and one or more struts, as described in more detail below. In some cases, the riveting tool can be assembled between an ear and a clip of the strut. In some cases, the riveting tool can be closed to form a joint. In some cases, the module installer can release the riveting tool. In some cases, an end effector can be used to handle tools and / or install the module. In some cases, the module installer can drive to one or more struts of another set to install another module.

[0204] In some embodiments, the method can include using at least one robot to fully autonomously locate and assemble multiple solar modules and associated support structures to construct a solar module array. In some cases, the multiple solar modules and associated support structures can include at least one solar module and a support structure for the at least one solar module.

[0205] In some cases, a module array, solar module, energy module, etc. can refer to an arrangement of multiple solar modules across a district or region. In some cases, the arrangement can be a lateral arrangement. In some cases, the arrangement can include multiple rows and / or columns. In some cases, the arrangement can include a circular pattern and / or an annular configuration. In some cases, the arrangement can include a hexagonal (e.g., honeycomb) pattern. In some cases, the arrangement can include a random configuration. In some cases, the arrangement can be at least partially based on the topography or topology of the district or region where the array is being or will be deployed.

[0206] In some cases, a solar module array and / or various support structures (e.g., struts) can be constructed, deployed, or installed on a substantially flat topography. In some cases, a solar module array can be constructed on a substantially uneven topography. The topography on which the solar module array and / or various support structures (e.g., struts) are constructed, deployed, or installed can include, for example, sandy soil, rock, water, ice, vegetation, grass, or any other artificial or natural surface. In some cases, the topography can include canyons, deserts, forests, glaciers, hills, swamps, mountains, valleys, oases, oceans or other bodies of water, open terrain, river terrain, swamp terrain, or tundra terrain.

[0207] In some cases, the topography can include one or more flat portions and / or one or more inclined portions. In some embodiments, the inclined portion can have a slope ranging from about 1 degree to about 30 degrees or greater.

[0208] Figure 60 Various solar module array configurations according to some embodiments are shown. In some cases, a solar module array can include 4 struts for each corner of the module. In some cases, a solar module array can include 2 struts along the central axis of the module. In some cases, a solar module array can be a complete wired array. In some cases, a solar module array can be a double-tilt array. In some cases, a solar module array can be a fixed-tilt array. In some cases, one or more modules of the array can include a support bracket directly mounted to a strut without requiring an intermediate structure across the struts. In some cases, one or more modules can span two or more struts without an intermediate structure between the struts. Figure 72 and Figure 73An exemplary configuration is shown where multiple modules are positioned at a 90 - degree orientation relative to the ground. In some cases, the solar modules can be tilted a full 90 degrees. In some cases, multiple struts can be fixed to one or more sides of the solar module. In some cases, the arrangement and / or configuration of the solar modules can allow access to the space between individual rows in the solar module array. In some cases, the space between individual rows in the array can be used for growing crops. The struts, clamps, and modules can be placed, installed, or deployed according to any of the embodiments, methods, and / or system configurations shown and described herein.

[0209] In some cases, the modules can be configured to independently track the sun. Tracking the sun can include moving, repositioning, or redirecting the module such that the working surface of the module can receive one or more rays of light from the sun.

[0210] In some cases, the modules can track the sun at least partially based on prediction, module position, or both. In some cases, the modules can track the sun at least partially based on a measured signal (e.g., the amount of energy or power generated by the module).

[0211] In some cases, the modules can each include a separate drive such that each module can independently track the sun. In some cases, the modules can be connected by a continuous wire or chain. The continuous wire or chain can be driven by a mechanism (e.g., one or more motors) to track the solar modules around one or more pivots on a strut. In some cases, the modules can be driven to a desired angle by a linkage (e.g., a 90 - degree linkage) without the need for a tracking unit or a tracking bench.

[0212] In some cases, one or more mechanisms can be provided at one end of the solar module array. In some cases, one or more mechanisms can be provided at two opposite ends of the solar module array. In some cases, one or more mechanisms can be provided between the solar modules in the array. Any sufficient number of mechanisms can be provided between the solar modules, and any sufficient arrangement of mechanisms can be provided between the solar modules.

[0213] Figure 57 A solar tracker according to some embodiments is shown. The solar tracker can include solar module sun - tracking capabilities and / or mechanisms for moving one or more parts or components of the solar module to track the sun.

[0214] In some cases, a solar module array can include a plurality of solar modules arranged substantially linearly in at least one direction. In some cases, the plurality of linearly arranged solar modules can be coupled to one or more cables or chains along the linear direction. In some cases, one or more cables or chains can be pulled along the linear direction such that the plurality of solar modules are reoriented and / or repositioned.

[0215] In some cases, the plurality of solar modules can be arranged substantially linearly in at least two directions. In some cases, the plurality of solar modules can be coupled to at least two sets of one or more cables or chains respectively along at least two directions. In some cases, a first set of one or more cables can be pulled along a first linear direction to reorient and / or reposition the plurality of solar modules in a first direction. In some cases, a second set of one or more cables can be pulled along a second linear direction to reorient and / or reposition the plurality of solar modules in a second direction.

[0216] In some cases, one or more cables or chains can be coupled above or below a given solar module. In some cases, one or more cables or chains can be coupled to the side of a given solar module.

[0217] Figure 58 shows a tracking unit according to some embodiments. The tracking unit can include a solar module and / or mechanism having solar tracking capabilities for moving one or more parts or components of the solar module to track the sun.

[0218] In some cases, the tracking unit can be autonomously deployed. In some cases, the tracking unit can be pre-assembled, distributed, and placed on a site. In some cases, geographical location data and / or any machine or robot disclosed herein can be used to autonomously locate, deploy, or connect the tracking unit. In some cases, the tracking unit can be extended to a single-module solar track for tracking the sun on one, two, three, or more axes.

[0219] The methods disclosed herein can be implemented using a ground mounting system for solar panels. The ground mounting system can include a system, structure, or plurality of components configured to support or stabilize the energy module when the energy module is deployed.

[0220] Figure 1FIG. 0 is a simplified force diagram of a system 100 for ground-mounted solar panels according to some embodiments. Here, the active photovoltaic (PV) material and any associated components (frames, beams, columns, superstructures, junction boxes, wiring) represent a physical load G 102 that can be safely and reliably supported above the ground 104 against at least gravity and against possible external forces (e.g., wind, earthquake).

[0221] Figure 2 FIG. 4 shows a simplified view of an embodiment 200 of a ground-mounted system for solar modules according to some embodiments. Here, a plurality of solar modules 202 are reliably supported above the ground 204 by a plurality of struts 206. In some cases, a separate and distinct superstructure may not be required. In some cases, the struts may be relatively small in size and can be installed at a high frequency f. In some cases, each strut can bear a much smaller portion of the total load. Additionally, for Figure 2 the embodiments, the installation efficiency may not require large solar modules distributed over large land areas. Thus, the load can be determined by relatively small expected local peaks. Since the load borne by each strut is reduced, the struts may penetrate the ground to a shallower depth. In some cases, additional support materials (e.g., concrete) may not be required to fix the struts in the ground. In some cases, such an installation structure can allow for simpler, cheaper, and less invasive installation techniques, such as by (hydraulic) pushing or threading as described herein.

[0222] Figure 3 FIG. 10 shows a conventional ground-mounted structure 300 for supporting solar modules 302 according to some embodiments. This is a connection structure including a separate superstructure 304 and relatively massive columns 306. These columns occur at a relatively low frequency (F), and each column bears a relatively large portion of the entire load. In some cases, they sink to a considerable depth (D) into the soil 308 and can be fixed therein with additional materials such as concrete (not shown).

[0223] Some embodiments of the present disclosure can utilize the interconnectivity between modules to provide stability rather than relying on separate, distinct, and massive superstructure components to obtain structural stability. Figure 4A FIG. 15 shows a perspective view of a ground-mounted system 400 according to some embodiments. In some cases, a number of struts 450 can support a row of solar modules 402. In some cases, a rectangular solar module including seventy-two cells is shown. Various embodiments can support various types of solar modules. At each corner, the solar module can be fixed to the corresponding strut by a clip 404.

[0224] Figure 4B is according to some embodiments Figure 4A End view of a ground-mounted system Figure 4B Shows the tilt angle 410 provided by the ground mount, which orients the solar modules to capture sunlight Figure 4B Shows that according to some embodiments, wind can penetrate the open side of the row, thereby generating wind loading forces

[0225] Although Figure 4A and Figure 4B the ground-mounted embodiments of show a single row of modules supported at the same tilt angle, alternative embodiments may be characterized by rows having different tilt angle orientations. For example Figure 5A Shows a perspective view of a ground-mounted system 500 according to some embodiments. In some cases, adjacent rows sharing a common post 502 may alternate in tilt angle to create a spike structure. In some cases, the solar modules 504 may be fixed to the posts by clips having different shapes. One type of clip may be an end clip 506, which is present on one side of a row that does not have an adjacent row on that side Figure 7A and Figure 7B Depict embodiments of an end clip according to some embodiments Figure 7A Shows a perspective view of an end clip according to an embodiment. As shown, the end clip is symmetric at both ends of the module. The end clip captures the bottom side of the frame and the top side of the frame Figure 7B Shows a perspective view of an end clip with two attached modules according to some embodiments. The center tab 700 can prevent the modules from sliding laterally. According to an embodiment, the end clip may be made of a 1 mm metal sheet. Another type of clip may be an intermediate clip 508 that is present between adjacent rows Figure 74 Shows an embodiment of an intermediate clip. The intermediate clip can be used for a solar module that docks with a post in the middle region of the side of the module. In some cases, the clip may have an angled opening to accommodate multiple tilt angles and facilitate self-positioning or alignment of the clip and / or the module. In some cases, the post may have a flat surface and a notch such that the post flange can be bent and riveted (recessed) to the module clip at a location corresponding to the green dot. The module clip can be installed with rivets or bolts, or riveted to the module frame at a standard mounting point on the bottom flange. Another type of clip may be a corner clip Figure 8A - Figure 8C Depict embodiments of a corner clip Figure 8A Shows a perspective view of a corner clip 801 connected to a frame 802 of a solar module 804 including a photovoltaic material 806 (e.g., a plurality of solar cells). The clip may include a center tab 800 Figure 8BA perspective view of a corner clip connected to two modules and a strut according to some embodiments is shown. A center tab 800 that mates with the surface of the strut tab (e.g., by riveting) can be long enough to handle tolerances and impart flexibility to accommodate tolerances at least in the row direction. Figure 8C A perspective view of a pair of corner clips connected to a strut and attached modules according to some embodiments is shown. In some cases, the clips can exhibit a single mirror-image design such that the tabs fall on opposite sides of the strut. The corner clips shown and described herein may not require or may not use fasteners to clip onto the modules.

[0226] Figure 5B Shows Figure 5A A simplified end view of an embodiment, showing a loading force. In some cases, wind cannot flow under the raised side of the module row, which can significantly reduce the wind loading force that a ground-mounted system is expected to be exposed to.

[0227] Figure 6A A perspective view of a solar module array generated by a ground-mounted system according to an embodiment is shown. In some cases, the array can include multiple short (two-module) rows separated by a small spacing S. In some cases, many rows can be closely spaced together, thus saving land area and improving installation efficiency.

[0228] Figure 6B A perspective view of another solar module array generated by a ground-mounted system according to an embodiment is shown. In some cases, the array can include longer module rows. In some cases, the corners of each row can be adjacent to the corners of the next row and supported by the same strut.

[0229] Although Figure 6A and Figure 6B show a solar array having multiple rows of lateral solar modules with long ends aligned in the row direction, this is not required. Figure 6C A perspective view of an alternative embodiment having longitudinal solar modules with short ends aligned in the row direction is shown.

[0230] Figure 9 A ground-mounted system is shown with peel and shear forces that it may be subjected to. Certain embodiments can provide a shear strength of at least about 400 pounds and / or a peel strength of at least about 200 pounds.

[0231] In some embodiments, the struts may be mounted substantially perpendicular to the flat surface. In some embodiments, the struts may be mounted at an angle relative to a vertical axis perpendicular to the flat surface. In some embodiments, the angle may be 0° to 5°, 0° to 10°, 0° to 20°, 0° to 30°, 0° to 40°, 5° to 10°, 5° to 20°, 5° to 30°, 5° to 40°, 10° to 20°, 10° to 30°, 10° to 40°, 20° to 30°, 20° to 40°, or 30° to 40°. In some embodiments, the first strut may be mounted at a first angle relative to a vertical axis perpendicular to the flat surface, and the second strut may be mounted at a second angle relative to a vertical axis perpendicular to the flat surface. In some embodiments, the first angle and the second angle may be substantially the same. In some embodiments, the first angle and the second angle may be different.

[0232] In some embodiments, the struts are not parallel. In some embodiments, the plurality of struts includes a row of struts, where two adjacent struts in the row of struts each slope towards each other, and a third strut adjacent to the two adjacent struts slopes outward. In some embodiments, the struts may be mounted at alternating angles. In some embodiments, the non-parallel configuration of the struts (e.g., the mounting at alternating angles) creates an interlocking structure of the struts in terms of the forces on the struts. Figure 97A An exemplary arrangement of a row of struts is shown. Strut 9701 is adjacent to strut 9702, strut 9702 is adjacent to struts 9701 and 9703, and strut 9703 is adjacent to struts 9702 and 9704. Strut 9701 may slope forward (in the direction of arrow 9710) at an angle θ 1 relative to the vertical axis. Strut 9702 may slope backward (opposite to the direction of arrow 9710) at an angle θ 2 relative to the vertical axis. Strut 9703 may slope forward (in the direction of arrow 9710) at an angle θ 3 relative to the vertical axis. Strut 9704 may slope backward (opposite to the direction of arrow 9710) at an angle θ 4 relative to the vertical axis. In some embodiments, the angle θ 1 -θ 4 may be substantially the same. In some embodiments, the angle θ 1 -θ 4They can be different. The interlocking structure can better engage with the soil. In some embodiments, the interlocking structure can resist greater forces. In some embodiments, at least one row of struts can be installed at alternating angles. In some embodiments, at least a portion of one row of struts can be installed at alternating angles. In some embodiments, the installation of the struts at alternating angles can be determined by the installation location, the environment of the location, the quality of the soil (e.g., soft or hard / dense soil layers), and the terrain surface (e.g., flat or non-flat).

[0233] In some embodiments, the strut-module interface spans multiple struts.

[0234] In some embodiments, the angle of the struts is determined to allow for shallow embedding.

[0235] Figure 97B An exemplary array of struts and solar panels / modules assembled with the struts at alternating angles is shown.

[0236] In some embodiments, the angles are determined before installation and loaded into the autonomous assembly system disclosed herein. The autonomous assembly system can read instructions with predefined strut angles and install the struts at these predefined angles precisely.

[0237] In some embodiments, in addition to the struts that support the solar module at the corners of the solar module, additional struts can be installed at the sides of the solar module to provide additional support. Figure 98A An exemplary assembly of a strut and a solar module is shown. The solar module 9801 is supported by struts 9802 and 9803 on one side of the solar module. Additional strut 9804 can be added at this side of the solar module. In some embodiments, more than one strut can be installed between struts 9802 and 9803 at this side of the solar module. Figure 98B An exemplary assembly of a strut and a solar module is shown. In addition to struts 9802 and 9803 at the corners of the solar module 9801, additional struts 9805 and 9806 can be installed at the sides of the solar module 9801. In some embodiments, struts 9805 and 9806 can be installed at an angle relative to the vertical axis. In some embodiments, struts 9805 and 9806 can be installed at alternating angles relative to the vertical axis, as disclosed above. Figure 98CAn exemplary assembly of struts and solar modules is shown. In addition to the struts at the corners of the solar modules (not shown in the figure) 9810, 9820, and 9830, additional struts 9811 and 9812, 9821 and 9822, and 9831 and 9832 are respectively installed for modules 9810, 9820, and 9830 to provide additional support, especially in areas or regions with higher loads and / or higher topographic tolerances.

[0238] Figure 10 The main tolerances of concern for solar array installation according to some embodiments are shown. In some cases, the spacing between struts and / or the angle of the solar modules can be adjusted along a row so that the solar array can be positioned or aligned in a desired direction. Figure 10 The tilt axis angle alignment according to some embodiments is also shown. In some cases, the angular orientation of the solar modules can be fixed or movable. In some cases, the solar modules can have a dual tilt angle. In some embodiments, the solar module array includes a dual tilt array. Figure 10 The ground-mounted installation on a slope according to some embodiments is further shown. In some cases, in addition to the angle of the slope, the tracker can adjust the angle of the solar modules from at least about 1° to about 10° or more.

[0239] Figure 10B A side perspective view showing the impact of uneven terrain on the installation according to some embodiments is shown. Figure 10C Is an enlarged view showing the capabilities of the components of some embodiments disclosed herein, which can rotate relative to each other to accommodate tolerances.

[0240] Although some embodiments have shown struts with a serrated pattern at the grounding end, this is not necessary. Alternative embodiments can use struts in the form of grounding screws. In some embodiments, the strut can include two parts, where the screw part enters first and the top (allowing vertical adjustment) is attached to the screw part.

[0241] Figure 10D A perspective view of an alternative embodiment featuring a grounding screw is shown. In some cases, the four-way clip can be fixed by a standard snap ring that snaps into a groove on the strut. In some cases, vertical tolerances can be accommodated by having multiple grooves. In some cases, angular tolerances can be accommodated by enlarging the hole size. In some cases, the assembly can withstand at least about 10 pounds, 20 pounds, 30 pounds, 40 pounds, 50 pounds, 100 pounds, 200 pounds, 300 pounds, 400 pounds, 500 pounds or more of uplift at the corner regions.

[0242] Figure 10AA perspective view is shown, in which a clip that has been riveted in place (e.g., using a tool for installing the machine) on a strut tab has been substantially rotated to accommodate tolerances. In some cases, the riveting can be done in situ (e.g., when the module is in contact with the strut tab), which can lock the position of the solar module while allowing for some additional flexibility. According to some embodiments, the riveting tool can perform at least 2 punches on the entire joint (e.g., 800 lbs shear / 400 lbs peel).

[0243] Figure 14 Is a simplified perspective view showing an embodiment of a clip / module assembly adjacent to an alternative embodiment of a strut. The strut 1400 can include two opposing large tabs 1402 and 1404 at the top, which provide large surfaces for the clip to clamp onto. Figure 15 Is a simplified view showing a riveting tool 1500 according to some embodiments, which can be used to rivet clips together to the face of a strut. Figure 15A Shows a simplified view of the resulting riveted joint according to some embodiments. Figure 15B Shows a view of a strut according to an alternative embodiment. In the case of having two large tabs at the top, a large area surface can be provided for riveting with the clip. Figure 15C Shows a manufactured strut held in a hoop structure after progressive stamping according to some embodiments.

[0244] The clips and riveting operations disclosed herein can allow for joints to be formed from two or more plates that at least partially overlap. The plates may not be parallel to each other or need not be parallel to each other, and in fact may be angled relative to each other (e.g., depending on the topography or spatial configuration of other components associated with the solar module or the support structure for such a module). The plates may be disposed at different positions or orientations relative to each other and can be uniquely deformed to accommodate a wide range of angular or positional variations of the plates, the struts, the surrounding topography, or the positioning of any solar module relative to the plates or struts. The presently disclosed systems and methods can allow for wide tolerances in the manner in which the joints are formed or shaped, to simplify the installation process and to provide additional flexibility in how various components or systems are assembled relative to each other without compromising structural integrity. The wide tolerances can also allow for the installation of struts and solar modules without the need to precisely fine-tune the position, orientation, and / or relative alignment of the struts or solar modules, especially when the struts or solar modules are installed on uneven terrain with varying profiles.

[0245] Figure 16 Is a simplified view showing the corner of four modules joined to one strut according to some embodiments. This view shows the reversibility of the clip and also demonstrates the angular tolerance of the clip relative to the strut to accommodate the tilt angle.

[0246] Figure 17 Shows a progressive stamping manufacturing process that can be used to manufacture clips according to some embodiments. Figure 18 Shows how, according to some embodiments, after the clip is formed, the clip can maintain its connection orientation in an integrated hoop configuration.

[0247] Figure 19 Shows another alternative embodiment of a ground mounting system for a solar module. In some cases, additional clips can be mounted on the ridges (square openings) of two modules and / or the lower convergence points (square solids) of the module points in the case of heavy loads. These additional clips can connect two adjacent modules. This additional clip configuration can also (but not necessarily) include struts (dashed lines) that can be pushed into the ground.

[0248] According to some embodiments, the clips can be pre-mounted on the struts at the factory. The retaining rings described herein can be installed at the factory in advance. This can leave sufficient vertical tolerance for the penetrability variability of the struts. In some embodiments, this can allow a vertical clearance of approximately 1 inch, thus facilitating installation and increasing flexibility under applied loads.

[0249] Figure 11 Shows an enlarged perspective view of the gap between adjacent modules according to some embodiments. In some cases, the size of the gap can be determined based on the availability of tolerances and allow tools to enter the gap. A particular embodiment can be characterized by a gap of approximately 2” on one side of the module, with a smaller gap on the orthogonal side of the module.

[0250] Although the previous figures show a particular embodiment of a ground mounting system for a solar panel, other embodiments are possible. For example, Figure 12 Shows a simplified view of an alternative clip structure 1200 according to some embodiments. Here, the clip can include flexible tabs 1202 and can be reversible. Figure 13 Is a simplified view of a clip embodiment attached to the side of the frame 1300 of the solar module 1302 Figure 12 In some cases, the clip can be configured to engage on the top and bottom of the module through multiple tabs.

[0251] Figure 42 Shows a top view of an autonomous system for positioning and assembling solar modules according to some embodiments. In some cases, the system can be configured to unpack, inspect, and / or process solar modules with or without attachments before transporting them around the site.

[0252] In some cases, the system can include one or more post installers. The post installers can drive the posts and continuously reload from a factor bundle. In some cases, the posts can be installed by a customized machine at the rear of a vehicle (e.g., a tractor). The vehicle can include an autonomous or semi-autonomous vehicle.

[0253] In some cases, the system can include one or more module installers. The module installers can remove solar modules from a stack and attach them to one or more deployed posts. In some cases, the modules can be installed by a machine at the rear of a different vehicle (e.g., a different tractor) on previously installed posts. The vehicle can include an autonomous or semi-autonomous vehicle.

[0254] Figure 43 A top view of an autonomous system for positioning and assembling solar modules according to some embodiments is shown. In some cases, the vehicle for deploying the posts or solar modules can be fully electric. In some cases, a mobile power unit can be provided at or near a location where the vehicle can be charged. In some cases, the mobile power unit can include one or more solar panels and / or batteries. In some cases, a reload unit can travel between sites. In some cases, the reload unit can carry posts, solar modules, or any combination thereof. In some cases, the reload unit can travel between a preparation station and an active installer unit (e.g., an autonomous vehicle or robot described elsewhere herein).

[0255] In another aspect, the present disclosure provides a method that includes providing one or more mobile platforms configured to carry a plurality of posts and a plurality of solar modules. The mobile platform can include any robot, machine, or autonomous vehicle described herein.

[0256] In some embodiments, the plurality of posts can be positioned and installed on the terrain by a first mobile platform in a predefined configuration. In some embodiments, the plurality of solar modules can be deployed on a set of posts by a second mobile platform.

[0257] In some cases, one or more mobile platforms can be equipped with one or more sensors. The one or more sensors can include, for example, position sensors (e.g., geographical location sensors), vision sensors (e.g., image sensors or cameras), GNSS units, GPS units, accelerometers, motion sensors, gyroscopes, or any combination thereof. In some cases, the one or more sensors can include stereo vision sensors, depth sensors, binocular vision sensors, or infrared sensors. In some cases, the one or more sensors can include radar units, LIDAR units, altitude sensors, proximity sensors, inertial measurement units, contact sensors, pressure sensors, piezoelectric sensors, or force sensors.

[0258] In some embodiments, the method may further include using at least one or more sensors to (i) autonomously move one or more mobile platforms, and (ii) autonomously position and assemble a plurality of struts and a plurality of solar modules on the terrain to construct a solar module array. In some embodiments, the method may further include using one or more sensors to position and move an installer load head on one or more mobile platforms relative to the solar module array as the array is being constructed. The installer load head may include a movable element that can automatically position and / or deploy one or more struts into target locations.

[0259] In some embodiments, one or more mobile platforms may include a first platform for positioning and installing a plurality of struts on the terrain, and a second platform for positioning and assembling a plurality of solar modules onto the plurality of struts. In some embodiments, the first platform may be separated from the second platform. In some embodiments, the first platform and the second platform may be integrated into a single platform. In some embodiments, one or more mobile platforms may include one or more electric vehicles.

[0260] In some embodiments, a plurality of solar modules may be pre-stacked on the second platform, and the second platform may include means for extracting a selected solar module from the stack and assembling the selected solar module onto a selected set of struts already installed on the terrain.

[0261] Figure 44A - Figure 44M A vehicle for positioning and assembling solar modules according to some embodiments is shown. In some cases, the module installer may be a custom machine built on the vehicle. In some cases, the module installer may receive a stack of solar modules. In some cases, the stack of solar modules may be placed on the module installer. In some cases, the stack of solar modules may be picked up by the module installer. In some cases, the module installer may carry the stack of modules. In some cases, the module installer may separate one module from the stack of modules. In some cases, the module installer may position one module on a plurality of installed struts, e.g., two, three, or four installed struts. In some cases, the module installer may lower the module to a predetermined position on the plurality of installed struts.

[0262] In some cases, the module installer may deform the metal portion of the module to create a rigid connection between the module and the strut. In some cases, the module installer may release the module. In some cases, the module installer may test the strength of the connection formed between the module and the plurality of struts by lifting, pushing, twisting, or any sufficient force.

[0263] In some cases, the module installer can drive to the next position to place the module. In some cases, the module installer can include 3, 4, 5, or 6 or more degrees of movement. In some cases, the module installer can include a robotic arm configured to receive the module from a flipper. In some cases, a robotic arm can be used to pick up the module from a stack. In some cases, a gantry can be used to tilt forward and backward to pick up the module and position the module behind. In some cases, a dual-rotation motion manipulator including one or more rotary joints can be used to position the module above one or more struts. In some cases, a gantry can be used to pick up one or more modules and position them on one or more installed struts.

[0264] In some embodiments, an integrated riveting tool can be provided on the installer load head to create a plurality of strut-clip interfaces between a plurality of clips and a plurality of struts. In some cases, the plurality of clips can be pre-attached to the plurality of solar modules.

[0265] In some embodiments, the strut-clip interface includes a substantially non-flat surface such that the angle between the module and the strut can be variable.

[0266] Figure 53 A plurality of brackets capable of coupling to struts are shown according to some embodiments. In some cases, the solar module can include brackets. The brackets can be attached or coupled to the solar module. In some cases, the brackets can include deformable metal. The deformable metal can include, for example, aluminum, copper, iron, steel, brass, or any metal alloy. In some cases, a connection can be formed between the bracket and the strut. In some cases, the connection can be formed by riveting the bracket and the strut together. In some cases, the bracket can include a flat or angled metal sheet configured to be riveted to the module, for example, through mounting holes. In some cases, the bracket can be connected to the module by riveting the bracket to the frame of the module. In an alternative embodiment, the module clip can be directly riveted or recessed onto the solar module frame instead of being riveted or bolted through mounting holes.

[0267] Figure 51 A method for coupling a solar module and a bracket is shown according to some embodiments. In some cases, the bracket can be installed at the site through a process in which the module is unpacked, inspected, and / or then placed on a tooling fixture. In some cases, 1, 2, 3, 4, or more rivet guns can install rivets to join the bracket to the solar module from below, from the side, from the top, or any sufficient direction. The use of rivets can avoid the need for preformed holes with precise tolerances. In some cases, a riveting tool or an impact driver (e.g., for torquing nuts) can be used instead of a rivet gun.

[0268] Figure 99A An exemplary strut-module interface is shown, such as a bracket for coupling a strut and a solar module. The bracket 9900 includes bolts 9904 for securing / connecting the bracket 9900 to the strut 9905. In some embodiments, the bolts can self-tap into a cavity of the strut without cutting threads in the strut. In some embodiments, the strut-module interface (e.g., the bracket) is pressed onto the strut without using fasteners. In some embodiments, the strut can include threads for coupling the bracket to the strut. In some embodiments, the threads are pre-installed on the strut.

[0269] The bracket 9900 can include one or two clips 9902 and one or two bolts 9901 to secure one solar module or multiple solar modules to the bracket. The bracket 9900 can include multiple tabs 9903 to engage and align the solar module(s). The bracket 9900 can have different configurations to serve as a corner bracket, an edge bracket, or a non-corner non-edge bracket, thereby holding one solar module, two solar modules, or four solar modules, respectively. For example, for a strut configured to hold one solar module (e.g., a strut at a corner of an array), the bracket can include one bolt 9901, one clip 9902, and one tab 9903. For a strut configured to hold four solar modules, the bracket can include two bolts, two clips, and four tabs to hold four solar modules. In some embodiments, clips are not required. In some embodiments, the bracket can include clip(s) without fasteners to secure the solar module. In some embodiments, the solar module is clipped onto the bracket without fasteners.

[0270] Figure 99B A top view of the bracket 9900 is shown before the bolts and clips are coupled to the bracket. The bracket 9900 includes a base plate 9913. The base plate 9913 includes holes 9914 for the bolts 9904 (see Figure 99A ) to secure the bracket to the strut. The base plate 9913 can include a pair of flanges 9915 configured to prevent the solar module from sliding or moving during installation. The bracket 9900 includes side plates 9912. The side plates 9912 include holes 9911 for the bolts 9901 (see Figure 99A ) to secure the clips 9902 and the solar module. The side plates 9912 also include tabs 9903 to engage and align the solar module. In some embodiments, the base plate and the side plates of the bracket are substantially on the same surface. In some embodiments, the plate surface of the bracket is not flat. In some embodiments, the base plate and the side plates of the bracket are arranged at an angle. In some embodiments, the angle can be from 0° to 30°. In some embodiments, the base plate can be in a valley configuration relative to the side plates (Figure 99C )。In some embodiments, the substrate may be configured in a ridge shape relative to the side plate Figure 99D ). The angled arrangement of the substrate and the side plate provides the solar module with the ability to be installed in an inclined arrangement. Figure 99E Two adjacent solar modules 9916 and 9917 that are not on the same flat surface are shown.

[0271] In some embodiments, the solar module is clamped to the uneven plate surface of the bracket. In some embodiments, the clip is bolted to the uneven plate surface of the bracket.

[0272] In some embodiments, the strut-module interface is formed by an autonomous machine. In some embodiments, the module can be positioned on the plate by an autonomous machine.

[0273] In some embodiments, the bracket has protrusions to provide electrical grounding.

[0274] Figure 99F A coupling bracket 9900 with a strut 9905 is shown.

[0275] Figure 99G An exemplary assembly of a strut, a bracket, and a solar module is shown. The bracket 9920 is bolted to the strut, and four solar modules 9921 - 9924 are fixed to the bracket 9920.

[0276] In some embodiments, the bracket allows the solar module to be installed in an angular misalignment manner. In some embodiments, the tabs on the bracket are bendable. In some embodiments, the tabs on the bracket are deformable. When installing the solar module, the tabs can be bent or deformed to accommodate the rotation or tilt of the solar module between two adjacent struts.

[0277] In some embodiments, the bracket includes a non-flat pivot feature that allows the solar module to be hinged at an angle when connected and held in place on the bracket. Figure 100A The non-flat pivot feature 10000 of the bracket is shown. Figure 100B Solar modules without tilt (10003), tilted at a positive angle (10004), and tilted at a negative angle (10005) are shown when the solar module is coupled to a bracket with a non-flat pivot feature. Figure 100C An enlarged view of a solar module 10001 tilted at a positive angle relative to a flat surface is shown. Figure 100D An enlarged view of a solar module 10002 tilted at a negative angle relative to a flat surface is shown. In some embodiments, the angle can be from 0° to 30°. In some embodiments, the angle can be 11.5°.

[0278] In some embodiments, the bracket may include a deformable metal. The deformable metal may include, for example, aluminum, copper, iron, steel, brass, or any metal alloy. In some embodiments, the bracket may include a plastic material or a reinforced plastic. The plastic material may include high-density polyethylene, polyphenylene sulfide, nylon, polyetheretherketone, polyetherimide, or polyamideimide. In some embodiments, at least a portion of the bracket includes a plastic material while the remainder is made of a metal material, such as for electrical grounding and springs. Figure 101 An exemplary bracket including a plastic material and a metal material is shown. The substrate 10102 is made of a metal material while the tab 10101 is made of a plastic material. The bracket also includes a non-flat pivot feature 10103 to accommodate the tilt of the solar module.

[0279] In some embodiments, the method may further include evaluating the structural integrity of the post-clamp interface using at least one of the measured force or deflection during and / or after the solar module is mounted to the post. In some cases, the structural integrity of the post-clamp interface can be evaluated by testing the separation force, shear force resistance, and / or tensile force resistance caused by translational or rotational movement.

[0280] In some embodiments, the method may further include obtaining images of a plurality of post-clamp interfaces during or after interface formation. In some embodiments, the method may further include determining the structural integrity of each of the plurality of post-clamp interfaces based at least on one or more images.

[0281] In some embodiments, the method may further include using test tools located on one or more mobile platforms to perform tensile strength and assembly tests on one or more of the plurality of installed posts. In some cases, the test tools can be used to apply push, pull, twist, vibration, or any suitable force to the installed posts and / or the installed solar modules to test the mechanical strength, stability, and / or stiffness of the installation.

[0282] In some cases, the method may further include performing electrical tests on one or more solar modules using test tools located on one or more mobile platforms. In some cases, the electrical tests may include testing voltage, current, connectivity, and any suitable electrical measurements to ensure proper installation of the solar modules.

[0283] In another aspect, the present disclosure provides a method for constructing a solar module array. The method may include providing a plurality of posts and a plurality of solar modules. In some cases, the plurality of solar modules may include a plurality of clips pre-attached thereto. In some embodiments, the method may include autonomously positioning and assembling the plurality of posts and the plurality of solar modules on a terrain using one or more mobile platforms to construct the solar module array.

[0284] In some embodiments, the method may include forming a plurality of post - clip interfaces between a plurality of posts and a plurality of clips to construct a solar module array on a terrain without the need for one or more pre - formed holes / features for one or more fasteners. In some embodiments, the plurality of post - clip interfaces may have tolerances that enable the array to contour to the terrain, thereby eliminating the need for terrain grading. In some embodiments, the plurality of post - clip interfaces may include a plurality of riveted joints. In some embodiments, the plurality of riveted joints may be formed by a dimpling process. In some embodiments, each of the plurality of posts may include one or more tabs. In some cases, the dimpling process may include engaging one or more tabs to corresponding clips to form the plurality of riveted joints. In some embodiments, the method may further include adding one or more fasteners to the post - clip interface after or during the dimpling process.

[0285] In some cases, the plurality of post - clip interfaces may be formed at one or more corners of a plurality of solar modules. In some cases, the plurality of post - clip interfaces may be formed at all corners of a plurality of solar modules. In some cases, the plurality of post - clip interfaces may be formed at opposite corners of a plurality of solar modules. In some cases, the plurality of post - clip interfaces may be formed at one or more lateral sides of a plurality of solar modules. In some cases, the plurality of post - clip interfaces may be formed at all lateral sides of a plurality of solar modules. In some cases, the plurality of post - clip interfaces may be formed at opposite lateral sides of a plurality of solar modules.

[0286] In some cases, the plurality of post - clip interfaces may be formed by using a riveting tool located on a load head of a post installer. In some cases, the post installer load head may be located on one or more mobile platforms configured to carry the plurality of posts and the plurality of solar modules.

[0287] In some embodiments, the plurality of post - clip interfaces may be formed without the need for one or more fasteners. In some embodiments, the plurality of post - clip interfaces may be formed by positioning one or more fasteners in place relative to corresponding tabs on each clip and each post and passing one or more fasteners through the tabs to fasten the tabs to the clips, or passing one or more fasteners through the clips to fasten the clips to the tabs.

[0288] In some embodiments, the presently disclosed method can include forming a plurality of holes in situ on at least clips and / or tabs on a solar module using a movable tool. In some embodiments, the presently disclosed method can include installing one or more fasteners through the plurality of holes formed in situ on the clips and / or tabs using the movable tool or another tool.

[0289] In another aspect, the present disclosure provides an algorithm for facilitating solar module deployment. In some embodiments, the method can include using the algorithm to identify a location suitable for autonomous positioning and assembly of at least one solar module without the assistance or involvement of a user in the autonomous positioning and assembly of the at least one solar module.

[0290] In some embodiments, the algorithm includes a machine learning (ML) algorithm. In some cases, the machine learning algorithm can include a neural network. Examples of neural networks can include, for example, a deep neural network (DNN), a convolutional neural network (CNN), a recurrent neural network (RNN), and / or a generative adversarial network (GAN).

[0291] In some embodiments, the machine learning algorithm can include a deep neural network (DNN). In other embodiments, the deep neural network can include a convolutional neural network (CNN). The CNN can be, for example, U-Net, ImageNet, LeNet-5, AlexNet, ZFNet, GoogleNet, VGGNet, ResNet18, or ResNet, etc. In some cases, the neural network can include or utilize, for example, a deep feedforward neural network, a recurrent neural network (RNN), LSTM (long short-term memory), GRU (gated recurrent unit), an autoencoder (e.g., variational autoencoder, adversarial autoencoder, denoising autoencoder, or sparse autoencoder), a Boltzmann machine (BM), a restricted BM (RBM), a deep belief network, a generative adversarial network (GAN), a deep residual network, a capsule network, or one or more attention / transformer networks. In some embodiments, the neural network can include multiple neural network layers. In some cases, the neural network can have at least about 2 to 1000 or more neural network layers.

[0292] In some cases, machine learning algorithms can include support vector machines (SVMs), classification algorithms, regression analysis algorithms, or any other type of supervised, semi-supervised, or unsupervised machine learning algorithms. In some embodiments, supervised learning algorithms can include or utilize, for example, support vector machine algorithms, linear regression algorithms, logistic regression algorithms, linear discriminant analysis algorithms, k-nearest neighbor algorithms, similarity learning, or any combination thereof. In some embodiments, unsupervised learning algorithms can include, for example, clustering algorithms, hierarchical clustering algorithms, k-means clustering algorithms, mixture models, anomaly detection, local outlier factor algorithms, autoencoders, deep belief networks, Hebbian learning, self-organizing maps, expectation-maximization algorithms (EM), principal component analysis algorithms, independent component analysis algorithms, non-negative matrix factorization, singular value decomposition, or any combination thereof. In some cases, machine learning algorithms can include or utilize random forests, decision trees (e.g., boosted decision trees), classification trees, regression trees, bagged trees, or rotation forests.

[0293] In some embodiments, the algorithm can be configured to identify locations for deploying one or more solar modules and / or posts based at least on an analysis of terrain data. In some embodiments, aerial imaging or at least one of global navigation satellite systems (GNSS) is used to obtain the terrain data.

[0294] In some embodiments, the method can further include creating a set of executable instructions in a digital medium for an autonomous system to autonomously locate, deploy, install, and / or assemble at least one solar module to build a solar module array. In some embodiments, the autonomous system includes a plurality of field machines that operate communicatively via a network. In some embodiments, the plurality of field machines includes one or more robots. In some embodiments, the method can further include creating a set of executable instructions in a digital medium for an autonomous system to autonomously locate, deploy, install, and / or assemble one or more posts or other support structures for one or more modules of a solar module array.

[0295] In some embodiments, the present disclosure provides a method for determining a location that is suitable for using an algorithm to identify locations suitable for autonomously locating and assembling posts and solar modules. In some embodiments, the method further includes creating a set of executable software instructions for controlling one or more mobile platforms to autonomously locate and assemble a plurality of posts and a plurality of solar modules on a terrain to build a solar module array without the assistance or involvement of a user.

[0296] In some embodiments, the present disclosure provides a method for constructing an array of solar modules, the method comprising: (a) autonomously positioning a plurality of struts on a terrain; and (b) autonomously assembling a plurality of solar modules with the plurality of struts on the terrain to construct an array of solar modules, wherein the plurality of struts includes a row of struts, wherein two adjacent struts in the row of struts each incline towards each other, and wherein a third strut adjacent to the two adjacent struts inclines outwards.

[0297] In some embodiments, the algorithm uses a digital representation of the array design. In some embodiments, the algorithm and executable software instructions include a digital surface model of the terrain, which can be used to determine the position.

[0298] In some embodiments, the method includes determining the position of the struts by using an algorithm for the strut-clamp interface angle. In some embodiments, the method can determine the position of the struts on flat terrain and / or substantially uneven terrain.

[0299] In some embodiments, the method includes using sensors to record the position of the struts or modules in the digital representation.

[0300] In some embodiments, the method includes using an algorithm to minimize the depth of the struts. In some embodiments, the method includes using an algorithm and a digital surface model to minimize the depth of the struts.

[0301] In some embodiments, the algorithm can use soil properties. Soil properties can include the composition of the soil, the softness or hardness of the soil, the density of the soil, the moisture content of the soil, etc.

[0302] In some embodiments, the algorithm can use the array geometry and / or tolerances.

[0303] In some embodiments, the digital surface model of the terrain is updated using measurements.

[0304] In some embodiments, sensors can be used to modify the position of the struts or modules based on measurements of nearby struts or modules. In some embodiments, the sensors can include optical sensors. In some embodiments, the sensors can include geographical location sensors.

[0305] In some embodiments, the sensors can collect various data of the terrain. The data can be saved, transmitted, and / or displayed in a digital representation. The algorithm can use the digital representation of the data to simulate or model the designed array. In some embodiments, the designed array includes design features of the struts, solar modules, the interaction between the struts and solar modules, and the relationship between the struts or solar modules and any other components of the array.

[0306] In some embodiments, a digital representation of the output of an algorithm can be exported or displayed. In some embodiments, the method further includes providing a graphical user interface (GUI) to display the output of the algorithm. In some embodiments, the method further includes displaying a digital representation of the output of the algorithm on the GUI.

[0307] Figure 109 An example of a digital representation of a strut and solar module assembly is shown. The digital representation can be used for the design, evaluation, construction, operation, and maintenance of a strut and solar module system. The digital representation can include a GUI interface for displaying parameters (e.g., number of modules, number of struts, number of inverters, total module DC, total inverter AC, and average DC:AC ratio). The GUI interface can also include input information such as project name, power plant name, revision name, and revision status.

[0308] Figure 110A Exemplary digital surface data is shown. The digital surface data can be obtained based on terrain data (e.g., surface flatness, condition, soil characteristics, and angles at different locations). The digital surface data can be used to evaluate the precise location of array components (e.g., struts, solar modules, and / or mounting / assembly components). Figure 110B A digital representation of predicting and / or designing array components at a terrain is shown.

[0309] Figure 111 An exemplary digital representation of a designed array is shown. An algorithm can use the digital representation and a terrain surface model to calculate the relationships between different array components (e.g., modules (e.g., 11104), struts (e.g., 11103), strut-module interfaces, and the ground). The digital representation can also show areas (e.g., area 11102) that meet the desired specifications and areas (e.g., area 11101) that do not meet the desired specifications of the designed array. In some embodiments, the digital representation can provide guidance and direction to adjust the position, orientation, configuration, and / or angle of the array components to optimize the design of the array. In some embodiments, the algorithm can be used to optimize the relative angle between the strut and the ground to optimize strength. In some embodiments, the algorithm can use the position of the ground and the design of the array to determine the optimal length of the strut embedded in the soil to maximize or minimize a parameter of interest, such as the height of the strut above the ground, the length of the strut below the ground, the error tolerance to the ground, and / or the strut-module angle interface. In some embodiments, the algorithm can use soil characteristics from a soil model or from soil tests to determine soil strength.

[0310] In some embodiments, during the installation of the posts and / or solar modules, sensors (e.g., a geographical location sensor) can be used to record data such as the location of the ground, the location of the posts, the number of installed posts, the height of the posts on the ground, the angle of the posts, the distance between the posts, etc. In some embodiments, the recorded data can be fed into an algorithm to update or modify a digital model, which can further be used for the analysis, design, and construction of the posts and solar modules. Figure 112A Shows sensors for recording array and terrain data during installation. Vehicle 11201 is moving on the terrain to install a plurality of posts. Vehicle 11201 can include sensors to obtain data on the terrain and / or the installed posts. Figure 112B Shows an updated digital model with data from the sensors.

[0311] In some embodiments, the digital representation can be used to predict the electricity (or electrical power) generated by the array. Figure 113A Shows example data of the electricity generated by the array. In some embodiments, the digital representation of the designed array can be used to predict the cost of the array. In some embodiments, the digital representation can be used to predict the cost of the energy generated by the array.

[0312] In some embodiments, the digital representation can be used to calculate the number of required components of the array. In some embodiments, the digital representation of the designed array is used to create a construction floor plan. In some embodiments, a 2D drawing can be derived from the digital representation to guide or direct the construction. Figure 113B Shows an exemplary isometric view of the designed array derived from the digital representation. Figure 113D Shows an exemplary floor plan of the designed array derived from the digital representation. The spacing or distance between the posts, the height of the posts on the ground, and / or the angle of the post-module interface can be shown on the 2D drawing.

[0313] In some embodiments, the digital representation can be used to generate a plan and / or analysis of the construction operations of the array. Figure 113C Shows an exemplary instruction path plan for installation / construction. Figure 113C The lines in represent an optimized construction path plan.

[0314] In another aspect, the present disclosure provides a device configured to: carry a plurality of posts on a terrain; autonomously position a selected post from the plurality of posts at a predetermined position on the terrain; and autonomously install the selected post at the predetermined position. In some cases, the selected posts and the plurality of posts can be used to support a plurality of solar modules.

[0315] Figure 45A - Figure 45DA perspective view of a machine for installing posts according to some embodiments is shown. In some cases, the machine may include 3, 4, 5, or 6 or more degrees of freedom. In some cases, the machine may autonomously position a post, install the post on the ground, and / or perform a force test on the post by pulling the post in a lateral, vertical, or any other direction and record the force test data. In some cases, the machine may be configured to carry one or more bundles of posts on a rack. In some cases, the machine may be configured to position one or more posts in a bundle of posts and collect new posts on a drive bit.

[0316] Figure 46A - Figure 46B A machine for installing posts such as Figures 49A - 49C shown is depicted. In some cases, the machine may have 3 or more mounting interfaces for mounting a tractor, such as using a three-point hitch 4601. In some cases, the machine may carry a hammer 4611 for driving a post 4612 into the ground. In some cases, the hammer may be mounted on a vertical track 4613 and may slide freely vertically or in any other sufficient direction such that a sufficiently small vibration or no vibration is transmitted from the hammer to the rest of the machine.

[0317] Figures 50A - 5 0C shows a coupling mechanism between a post and a rack according to some embodiments. In some cases, the post may include a Z-shaped cross-section or Z-shape. In some cases, the post may include a substantially stackable shape. In some cases, the post may include one or more sets of inclined tabs at the top. In some cases, the tabs may include cutout features. In some cases, the cutout features may be configured to allow the post to be suspended on a hanger or bracket. In some cases, one or more posts may be bundled and transported or provided to the machine in a container.

[0318] In some embodiments, the device may also be configured to perform a force test after a selected post has been installed at a predetermined location. In some embodiments, the force test may include applying a tensile force to the selected post in at least one of a lateral or vertical direction.

[0319] In some embodiments, a load driving mechanism may be used to install a selected post at a predetermined location, the load driving mechanism being configured to drive the selected post into the ground at the predetermined location. In some cases, the load driving mechanism includes a hammer or is coupled to a hammer. In some cases, the load driving mechanism is mounted on multiple tracks and may move vertically along the multiple tracks. In some cases, the load driving mechanism is configured to slide along the multiple tracks via bearings.

[0320] In some cases, the load driving mechanism includes a retaining mechanism that prevents a selected post from displacing or decoupling from the load driving mechanism when the selected post is installed into the ground. In some cases, the retaining mechanism includes one or more shear features.

[0321] In some cases, the load driving mechanism includes a drive bit having one or more shear features. In some cases, one or more shear features may be configured to double as retaining features. In some cases, the load driving mechanism is configured to have a driving force length that is less than the entire longitudinal length of a selected post.

[0322] Figures 47A - 47I A coupling mechanism between a drive bit and a post is shown in accordance with some embodiments. In some cases, the drive bit may be connected to a hammer. In some cases, the drive bit may include a shear interface for engaging the post during impact. In some cases, the drive bit may include a retaining feature that prevents the post from falling off the bit while it is being positioned and driven. In some cases, the drive bit may be configured to allow the post to be impacted from a web of the post, the web of the post may be provided on a lower portion of the body of the post. In some cases, compared to an impact from the head, an impact from the web may allow the hammer to impact the post with a greater force because during the impact, the impact from the web may effectively reduce the buckling length of the post. In some cases, the drive bit may enter a larger portion of a hole in the post. In some cases, the drive bit may slide down in a configuration and remain against a chisel bit. In some cases, when the drive bit engages the post, a head of a chisel feature on the drive bit may overlap at least a portion of the post. In some cases, there may be 1, 2, 3, 4 or more shear features on the chisel bit. In some cases, the chisel bit may also function as a retaining feature. In some cases, a feature on the chisel bit may retain the post. In some cases, a feature on the chisel bit may be separated from a feature that impacts the post. In some cases, the retaining feature may be a timing element that rotates to engage the post. In some cases, the retaining feature may be a timing square that rotates about 45 degrees such that once engaged, a corner retains the post. In some cases, the retaining feature may overhang a hole in the post. In some cases, the shaft may not engage the bottom of the hole in the post. In some cases, the pin may engage the post without overhang. Figures 48A - 48B show a comparison of driving a post using different coupling mechanisms in accordance with some embodiments.

[0323] In some embodiments, positioning, orienting, and / or moving components can be used to drive a post into the terrain to impact a feature located along the length of the post. The component can include a hammer, a pin, or any other rigid structural member. In some cases, a sleeve or track can be used to guide the movement of the component. The impact between the component and the feature can provide a driving force to push the post into the desired position. The impact point can be closer to the center of gravity or the centroid of the post, which can help minimize buckling forces and ensure that the post is installed in the desired orientation (e.g., perpendicular to the terrain or at any other desired angle relative to the terrain).

[0324] Figure 102 A post installer is shown. The post installer 10200 includes a sensor 10201 (e.g., a geographical location sensor), a vehicle 10202 for holding the post and other components, a post hopper and feeder 10203, a post holder and pounder 10204, a post holding mechanism 10205, and a plurality of legs 10206.

[0325] Figure 103A and Figure 103B An apparatus for loading a post from a post hopper and feeder is shown. The apparatus includes a post ram, such as a hammer 10303. The post ram 10303 includes an arm that can rotate approximately 90° from a vertical position to a horizontal position. At the distal end of the arm, the post ram includes a gripper. During the process of picking up a post, the post ram 10305 travels upward along a support (e.g., a track) to a predetermined position, the arm 10306 rotates / opens to the horizontal position, and the gripper 10307 opens. The apparatus can travel to the lateral position of the post hopper and feeder. Alternatively, the apparatus can travel to the post hopper and feeder before the post ram opens. When the apparatus is at the lateral position of the post hopper and feeder, the post ram can move to the side of the post hopper and feeder or any appropriate position to pick up a post from the post hopper and feeder 10303. After picking up, the post ram can travel upward along a support (e.g., a track) to a position that allows sufficient vertical space / length to accommodate the post. Then, the apparatus can be driven to the post installation position, and the arm can rotate to the vertical position and lower to insert the post into the post holding mechanism for subsequent installation.

[0326] Figure 104A and Figure 104B A loading operation of a post is shown. In operation 10401 ( Figure 104A ), the vehicle 10402 picks up a bundle of posts 10403. In operation 10411 ( Figure 104B ), the vehicle 10402 loads the bundle of posts 10403 into the post hopper and feeder 10412.

[0327] Figure 105Illustrates a schematic post hopper and feeder. The post hopper and feeder can individually remove one post at a time from a bundle of posts for installation. The post hopper and feeder can include a hopper 10511, a lower tray 10521, an upper tray 10531, separator fins 10541, a motor mounting tray 10551, and a kicker arm 10561. The hopper 10511 includes a chassis base mount 10512, a chassis vertical mount 10513, and a post adjustment wall 10514. The lower tray 10521 includes a plurality of lower support fins 10522, a plurality of lower chute fins 10523, and a plurality of length adjustment fins 10524. The upper tray 10531 includes a plurality of upper support plates and upper chute fins 10532. The separator fins 10541 include a plurality of key shafts, collars, and spacers. The motor mounting tray 10551 includes a motor, a gearbox, a coupling, and / or a motor shaft. The kicker arm 10561 includes four rod linkages 10563 and a post support arm 10562. The kicker arm 10561 can also include a plurality of hydraulic rotary clamps, hydraulic cylinders, bearings, bushings, proximity sensors, and / or post holders.

[0328] Figure 106 Illustrates a post hopper and feeding machine. The machine includes a rotating shaft 10601 that rotates to separate one post from a large number of unclassified posts 10604 from a hopper 10602. The rotating shaft can be connected to a plurality of fins 10605 that have openings or channels into which only one post can fall or enter. Subsequently, one post can enter the chute fins 10603.

[0329] Figure 107A Illustrates an exemplary post rammer. The post rammer 10700 includes a hammer 10701, an arm 10702, and a gripper 10703. The arm 10702 can rotate from a vertical position to a horizontal position to grasp or hold a post and transfer it to a post holding mechanism. In some embodiments, the arm 10702 can be extensible. The gripper is coupled to an actuator 10705 that drives the grasping mechanism to hold the post 10704 (only a portion of the post is shown). Figure 107B Illustrates the post rammer configuration after the post has been grasped and transported to a vertical position. Figure 107C Is a perspective view of the post rammer configuration after the post has been grasped and transported to a vertical position.

[0330] Figure 108 Illustrates an exemplary post installation device / machine (post installer). The post installer includes an actuator 10801 to enable the gripper to hold a post (see Figures 107A - 107C)). The strut is inserted into the strut holding mechanism 10803. The strut holding mechanism 10803 includes a plurality of rollers and an actuator. The rollers are actuated to hold the strut close to the ground for high precision. The rollers can be opened to facilitate movement and retraction. In some embodiments, the strut can be held perpendicular to the flat surface. In some embodiments, the strut can be held at a desired angle relative to the vertical axis.

[0331] In another aspect, the present disclosure provides an apparatus configured to carry a plurality of solar modules on a terrain; autonomously position a selected solar module from the plurality of solar modules on a set of struts mounted on the terrain; and autonomously assemble the selected solar module to the set of struts without the need for or use of fasteners.

[0332] In some cases, the apparatus can be configured to autonomously assemble the selected solar module to the set of struts by forming a plurality of strut - clip interfaces. In some cases, the plurality of strut - clip interfaces include a plurality of riveted joints.

[0333] In some cases, the selected solar module can be pre - attached with clips at one or more corners or sides of the selected solar module, and each strut in the set of struts can include a plurality of tabs. In some cases, the apparatus can be configured to autonomously position the selected solar module on the set of struts by aligning the clips with the corresponding tabs at each strut. In some cases, the apparatus can be configured to autonomously assemble the selected solar module to the set of struts by riveting the corresponding tabs to the clips at each strut.

[0334] Figure 59 A light curtain according to some embodiments is shown. In some cases, a machine can include one or more optical sensors configured to detect when a foreign object (e.g., a person or another agent) enters a workspace defined by the light curtain. When a foreign object enters the workspace, at least a portion of the light curtain may be interrupted or broken, which may trigger one or more safety procedures or protocols (e.g., shutting down the machine or restricting the operation of the machine until the foreign object leaves the workspace).

[0335] The following examples are provided to further illustrate some embodiments of the present disclosure but are not intended to limit the scope of the present disclosure; it will be understood by their exemplary nature that other procedures, methods, or techniques known to those skilled in the art can be used alternatively.

[0336] Figure 20 The layout of solar module blocks in the connection direction is shown. Figure 21 A plurality of blocks connected to a central inverter are shown.

[0337] Figure 22Perspective view of a portion of a block. Line 2200 here shows how wires from a module string to an inverter (“home run”) can be installed on the side of an array and clamped to a strut.

[0338] Figure 23 Is a simplified flow chart showing an available supply chain according to an embodiment. The simplicity of such a supply chain enables struts, connectors, and prefabricated solar modules to be shipped from the factory to the deployment location. There, these components can be installed on a machine that is configured to quickly and automatically install a ground-mounted system.

[0339] Figure 24 Is a simplified top view showing the progress of an embodiment of installing machine 2400 on site. Here, the machine is towed by a truck 2402 in a direction from right to left. After pushing the struts into the ground, the modules can be attached. In this particular embodiment, the modules can have clips pre-installed therein.

[0340] Figure 25 Is a simplified top view showing the progress of an alternative embodiment of installing machine 2500 on site from left to right. This particular embodiment utilizes a strut tooling fixture 2502 that includes a rectangle of fixed dimensions so as to always index the next pair of struts 2504 out from the previous pair of struts. Specifically, in a first stage 2505, two struts are pushed into the ground and the fixture is used to position the struts relative to each other. In a second stage 2506, two more struts are pushed into the ground and again the fixture is used to position the struts. In a third stage 2508, the module 2509 is placed directly after the next pair of struts. The fixture can grip a feature on a clip on the strut so as to index and secure the clip while pressing the module into the clip. A fourth stage 2510 places the next strut (e.g., indexed from the previous strut using the fixture). Then the process can be repeated.

[0341] In some cases, the path of the installation machine can wind through the site. When the vehicle turns and travels to the other side of the row (from right to left), everything is the same except that only the strut closest to the truck has been implanted. Figure 24 and Figure 25 The two particular installation machines shown in are merely examples, and alternative embodiments can be used.

[0342] Figure 26 A formal coordinate system for describing a moving vehicle is provided. Now refer to this coordinate system to describe another exemplary embodiment of a device configured to perform the installation of a ground-mounted solar panel.

[0343] Figure 27A rear perspective view of an embodiment 2700 of an installation device is shown. The device includes various elements mounted to a mobile vehicle 2702 (e.g., a pickup truck bed) via a platform 2704. As described in detail below, the platform can be configured to move in one or more directions. Elements of the installation machinery can include a frame 2706 and a load head 2708. A vertical conveyor 2710 can be configured to receive a stack 2712 of individual prefabricated solar panels 2714. In some cases, the installation machinery can also include a hydraulic actuator 2716 for implanting a post into the ground by pushing (rather than hammering).

[0344] Figure 28 Details of a vertical conveyor element that can be used to lower one module at a time are shown. Figure 29 Is a schematic diagram showing how a standard package of a stack 2900 of solar modules is loaded onto a vertical conveyor 2904 and then individual modules 2904 are lowered onto metal sheet clips 2906. The modules can be lowered onto the metal sheet clips 2906. The resulting combination of modules and clips can be lowered onto a tray 2910 that can slide out from the bottom of the stack.

[0345] Figure 30 Details of a module including a frame 3000 that is being lowered onto a clip 3002 are shown. During this process, the connection 3003 of a joint to its adjacent joint can be cut by a sheet 3004.

[0346] Figure 31 A side view of a stack 3100 of solar modules on a vertical conveyor 3104 is shown. Horizontal tracks 3106 can be used to slide the bottom module laterally onto a mounting load head 3108. The module can be tilted by a small linear actuator 3110.

[0347] Figure 32 A front perspective view of an installation device according to an embodiment is shown. The load head 3200 is shown sliding vertically relative to a frame 3204 connected to a truck 3206. This movement can be actuated by a hydraulic actuator 3208 mounted to the frame.

[0348] Figure 33A detailed view of the load head frame 3300 connected to the actuator tip 3302 is shown, which actuator tip 3302 is used to drive the struts 3304 (simultaneously). The joint 3306 can be seen to have been attached to the solar module 3308, which solar module 3308 is loaded into the load head. The tip 3308 of the actuator that directly pushes on the strut is also connected to the module load head. Thus, when the struts are driven into the ground, the module can be simultaneously lowered into the correct position. The connection between the actuator tip and the module load head can also have a bend to reduce the vibration transmitted to the module during installation.

[0349] In combination Figures 27 - 33 with the installation machine implementation, one or more of the various elements (e.g., frame, load head, conveyor, etc.) can be mounted on a movable platform. The platform can be actuated in any of the following directions: (i) the x-axis, y-axis, and yaw direction, or (ii) the x-axis, y-axis, yaw, pitch, and roll directions.

[0350] In some cases, a vertical actuator can control the Z-axis movement. One way to control planar movement is through a two-way worktable. Additional actuators can control the yaw direction.

[0351] Figure 34 It is further shown that the position of the movable platform can be controlled (respectively or individually) by using: (i) a differential GPS system, (ii) a camera, (iii) lidar, and / or (iv) laser tracking. In some cases, the GPS and / or camera system can allow control of how precisely each module and strut is placed in the solar array. This function can provide control of the movable machinery on the red platform, and / or the position / drive of the entire installation equipment (e.g., set in a truck, trailer, or in the form of a special vehicle).

[0352] The implementation is not limited to the above specific installation equipment, and alternatives are possible. For example, Figure 35 A front perspective view of an alternative implementation of the installation machine is shown.

[0353] Figure 36 Is shown Figure 35 An enlarged side view of the installation equipment 3600 shown in

[0354] Figure 34 A non-limiting example of a platform that can be used to facilitate the deployment and installation of solar modules is shown. In some implementations, such as Figure 37AThe mechanism of the gantry portion 3700 shown in the figure is used to control the positions of the module and the load head, and this mechanism can be attached to the frame of the platform.

[0355] Figure 37B A gantry portion is shown in the form of a gantry 3704 to control planar positioning. Figure 37C An enlarged view of the rotating gear 3702 that can be mounted below is shown. In some cases, other mechanisms such as conveyors (e.g., vertical conveyors or horizontal conveyors) can be used to control the positioning of the module.

[0356] Figure 38A A perspective view of an embodiment is shown, in which the module is lifted from a stack on a tray by a gantry with a suction cup load head, and translated onto the module slider and lowered (shown extended in Figure 31 ). During Figure 38B Action #3 shown, the gantry can press the module down onto four clips to attach the clips to the module.

[0357] Figure 39 A top view of an embodiment including a dual-tilt (between 0 degrees and 20 degrees) array 3900 of ground-mounted solar modules is shown. Such an uninterrupted module array can provide a valuable opportunity to clean the array using a robot 3902. The cleaning robot can autonomously travel in any direction on the module plane.

[0358] Figure 40 A top view of another alternative embodiment is shown. Here, the solar module arrays can be installed staggeredly between the module rows. This embodiment can increase significant stiffness in the staggered direction due to the overlapping frames. Except for consuming 50% more struts, this embodiment can function in a similar manner to that previously described.

[0359] In the module-staggered configuration, each module may have 6 struts, and the clips can be modified to clip onto the corners of two modules and the middle edge of a third module. In Figure 41 the strut positions are shown as white squares at the intersections of the module edges and the two corners of the adjacent modules.

[0360] Figures 54A - 5 4C shows a method for determining the lateral topology for positioning and assembling solar modules according to some embodiments. In some cases, the method can include analyzing the terrain topology and / or GIS data of a given terrain. In some cases, the method can include processing the curvature of the terrain topology or GIS data. In some cases, the method can include simulating the struts and modules installed on a given terrain. In some cases, the method can include uploading the strut and module geographical locations and construction data of one or more machines for installing the struts and modules.Figure 55 An exemplary GUI for determining a lateral topology for positioning and assembling a solar module in accordance with some embodiments is shown.

[0361] In some cases, one or more algorithms, machine learning algorithms, or neural networks can be configured to process terrain data and determine an optimal layout, positioning, or installation location for one or more struts or solar modules. In some cases, one or more algorithms, machine learning algorithms, or neural networks can be implemented to generate a virtual representation or simulation of the terrain and one or more candidate locations for installing the struts or solar modules. In some cases, one or more algorithms, machine learning algorithms, or neural networks can be configured to generate a blueprint or instruction set for controlling and moving a plurality of robots or mobile platforms to co-deploy and install one or more struts or solar modules in a target environment. Such a blueprint or instruction set can be generated based on the virtual representation or simulation, or other data associated with the terrain or lateral topology of the target environment. The virtual representation or simulation can include, for example, a 3D model or point cloud representation of the terrain and one or more candidate installation or deployment locations.

[0362] In some embodiments, when the robot or mobile platform of the present disclosure runs out of struts or solar modules for installation (or if the number of struts or solar modules immediately accessible to the robot or mobile platform drops below a certain threshold), the robot or mobile platform can perform a restocking or replenishment operation. In some cases, the robot or mobile platform can return to a facility or other central location for restocking or replenishing struts and / or solar modules. In other cases, one or more other restocking vehicles or robots can carry or store an inventory of additional struts and / or solar modules and can automatically travel to the robot or mobile platform that requires the additional struts or solar modules. In some cases, one or more other restocking vehicles or robots can travel along the perimeter of the terrain or idle and travel to a particular robot or mobile platform when the robot or mobile platform requires additional struts or solar modules. This can avoid additional travel by the robot or mobile platform for restocking or replenishment purposes.

[0363] Figure 62 An alternative embodiment of an exemplary vehicle is shown that can be used or configured to process, transport, install, or deploy one or more solar modules. The vehicle can acquire a new stack of modules autonomously, semi-autonomously, or with the help of manual input or intervention. The vehicle may not require or need to use or rely on a separate robot to acquire a new stack of modules. In some cases, the vehicle can include one or more front attachments that can be used to retrieve or obtain new solar modules from a storage area or another vehicle.

[0364] Figure 63 Shows another alternative embodiment of an exemplary vehicle that can be used or configured to handle, transport, install, or deploy one or more solar modules. In some embodiments, the vehicle can be configured to use a robot to remove a new solar module from a trailer of another vehicle.

[0365] Figure 64 Shows an end effector having a riveting tool positioned at a corner of the end effector. In this case, the end effector may not need or use suction cups to pick up the solar module, but instead can grasp the module from the side by a squeezing or pinching action. The size of the frame of the end effector can be adjustable such that the same end effector can be configured to pick up modules of different shapes or sizes. As Figure 65 shown, the bottom of the riveting tool can be tapered to assist in positioning the module or engaging with the module (e.g., complementary features provided on the module).

[0366] Figure 66A and Figure 66B Shows an alternative embodiment of a clip. The clip can include a hole or slot that can engage a latch that automatically rotates 90 degrees, which then engages the module and clip assembly with a load head on a module installer to hold it in place. This is another embodiment of a way to pick up a solar module without using suction cups.

[0367] Figure 67 Shows an alternative embodiment of a module installer vehicle as described elsewhere herein. Here, the riveting tool (yellow) may not need or be located on the same automated component (orange) that moves the module, but instead can be located on a separate automated component (blue) that is attached to the same mobile vehicle platform as the automated component that moves the module. The separate automated component (blue) can autonomously and releasably mate to a previously installed post. The automated component (orange) that moves the module can move the module to the location of the installed post.

[0368] Figure 68 Shows an exemplary configuration for a post as described elsewhere herein. This embodiment shows cutout flanges 6801 that bend outward in an open manner such that they allow the post to enter the soil with low resistance (left), but then when the post is pulled upward, they engage the soil and bend outward more, thereby providing increased pull-out resistance (right).

[0369] Figure 69A and Figure 69BShows an alternative embodiment of the clip described elsewhere herein. In this embodiment, the clip can have bends and tabs such that they nest and stack such that the solar modules do not contact other modules above or below them in the stack.

[0370] Figure 70A Shows additional tab features that can be used to hold one or more leads or wires of a solar module and secure them in a particular side of the module for later handling or processing. Figure 70B Shows an embodiment of a clip where module wires are connected to the clip, which is also connected to the module and will be connected to a strut. Figure 70C Shows using an additional tool (blue square) to manually obtain the solar module wires held in place by the clip and connect them to each other to form an electrical connection between the modules. Figure 71 Shows Figure 70A 、 Figure 70B and Figure 70C embodiments of the tool and method in, except that in this embodiment, the tool does not push two connectors together, but instead cuts (a), strips (a), and splices (b) the wires together in place without using connectors.

[0371] Figure 75 Shows a removable access slot that can be placed on top of a strut in the valley or peak of a module array. The slot can transfer its weight and load to the strut below it rather than to the modules and can be walked on top of to access the modules in the interior area of the array. In some cases, this slot can also be a track that a robot can ride on (e.g., to clean, water, spray, or inspect).

[0372] Figure 76 and Figure 77 Shows a gantry (blue) with wheels (black) that can be driven on the ground in the gap between arrays in certain configurations. The gantry can be equipped with automation to clean the modules with water or mechanically wipe the solar modules in the array under the gantry. The gantry can also spray water or herbicide, or sow seeds, to manage the vegetation below the array. The gantry can have a rope, tube, or other hollow structure attached to it to connect it to a water source or other liquid at the end of a row of modules.

[0373] Computer system

[0374] In one aspect, the present disclosure provides a computer system programmed or otherwise configured to implement the methods of the present disclosure, e.g., any of the subject methods for using at least one robot to fully autonomously position and assemble at least one solar module and its support structure.

[0375] In another aspect, the present disclosure provides a computer system that is programmed or otherwise configured to provide one or more mobile platforms that are configured to carry a plurality of struts and a plurality of solar modules. In some cases, one or more of the mobile platforms are equipped with one or more sensors including a geographic location sensor. In some cases, the computer system is further programmed or otherwise configured to at least partially use readings or measurements obtained using the one or more sensors to (i) autonomously move the one or more mobile platforms, and (ii) autonomously position and assemble the plurality of struts and the plurality of solar modules on a terrain to construct a solar module array. Such autonomous movement or positioning can be performed using one or more signals or commands generated by a computing unit of the computer system.

[0376] In another aspect, the present disclosure provides a computer system that is programmed or otherwise configured to provide a plurality of struts and a plurality of solar modules. In some cases, the plurality of solar modules include a plurality of clips pre-attached thereto. In some cases, the computer system is further programmed or otherwise configured to form a plurality of strut-clip interfaces between the plurality of clips and the plurality of struts to construct a solar module array on a terrain without the need for one or more prefabricated holes / features for one or more fasteners.

[0377] In another aspect, the present disclosure provides a computer system that is programmed or otherwise configured to use an algorithm to identify a location suitable for autonomously positioning and assembling at least one solar module. In some cases, using the algorithm can be performed without the assistance or involvement of a user in the autonomous positioning and assembling of at least one solar module.

[0378] Figure 61 A computer system 6101 is shown that is programmed or otherwise configured to implement a method for fully autonomously positioning and assembling at least one solar module and its support structure. In some embodiments, the computer system 6101 can be configured to, for example, use an algorithm to identify a location suitable for the autonomous positioning and assembling of at least one solar module without the assistance or involvement of a user in the autonomous positioning and assembling of at least one solar module. The computer system 6101 can be an electronic device of a user or a computer system remotely located relative to the electronic device. The electronic device can be a mobile electronic device.

[0379] The computer system 6101 may include a central processing unit (CPU, also referred to herein as “processor” and “computer processor”) 6105, which may be a single-core or multi-core processor, or may be multiple processors for parallel processing. The computer system 6101 also includes a memory or memory location 6110 (e.g., random access memory, read-only memory, flash memory), an electronic storage unit 6115 (e.g., hard disk), a communication interface 6120 for communicating with one or more other systems (e.g., network adapter), and peripheral devices 6125 (e.g., cache, other memory, data storage, and / or electronic display adapter). The memory 6110, storage unit 6115, interface 6120, and peripheral devices 6125 communicate with the CPU 6105 via a communication bus (solid lines), such as a motherboard. The storage unit 6115 may be a data storage unit (or data repository) for storing data. The computer system 6101 may be operatively coupled to a computer network (“network”) 6130 with the help of the communication interface 6120. The network 6130 may be the Internet, an intranet and / or an extranet, or an intranet and / or an extranet that communicates with the Internet. In some cases, the network 6130 is a telecommunications and / or data network. The network 6130 may include one or more computer servers, which may implement distributed computing, such as cloud computing. In some cases, with the help of the computer system 6101, the network 6130 may implement a peer-to-peer network, which may enable devices coupled to the computer system 6101 to act as clients or servers.

[0380] The CPU 6105 may execute a series of machine-readable instructions, which may be embodied in a program or software. The instructions may be stored in a memory location such as the memory 6110. The instructions may be directed to the CPU 6105, which may then program or otherwise configure the CPU 6105 to implement the methods of the present disclosure. Examples of operations performed by the CPU 6105 may include fetching, decoding, executing, and writing back.

[0381] The CPU 6105 may be part of a circuit (e.g., an integrated circuit). One or more other components of the system 6101 may be included in the circuit. In some cases, the circuit is an application specific integrated circuit (ASIC).

[0382] The storage unit 6115 can store files such as drivers, libraries, and saved programs. The storage unit 6115 can store user data such as user preferences and user programs. In some cases, the computer system 6101 can include one or more additional data storage units located outside the computer system 6101 (e.g., on a remote server communicating with the computer system 6101 via an intranet or the Internet).

[0383] The computer system 6101 can communicate with one or more remote computer systems via the network 6130. For example, the computer system 6101 can communicate with a remote computer system of a user (e.g., an end user or entity that supervises, oversees, monitors, or manages robotic operations). Examples of remote computer systems include personal computers (e.g., portable PCs), tablet computers or tablet PCs (e.g., iPad, Galaxy Tab), telephones, smart phones (e.g., iPhone, Android - enabled devices, ) or personal digital assistants. A user can access the computer system 6101 via the network 6130.

[0384] The methods described herein can be implemented by machine (e.g., computer processor) - executable code stored at an electronic storage location of the computer system 6101 (e.g., stored in the memory 6110 or the electronic storage unit 6115). The machine - executable or machine - readable code can be provided in the form of software. During use, the code can be executed by the processor 6105. In some cases, the code can be retrieved from the storage unit 6115 and stored in the memory 6110 for ready access by the processor 6105. In some cases, the electronic storage unit 6115 can be excluded and the machine - executable instructions can be stored in the memory 6110.

[0385] The code can be pre - compiled and configured to be used with a machine having a processor suitable for executing the code, or it can be compiled at runtime. The code can be provided in a programming language that can be selected to enable the code to be executed in a pre - compiled or compiled manner.

[0386] Aspects of the systems and methods provided herein, such as computer system 6101, may be embodied in programming. Aspects of the technology may be considered a "product" or "article of manufacture", typically in the form of machine (or processor) executable code and / or associated data, which is carried or embodied on a type of machine-readable medium. The machine executable code may be stored on an electronic storage unit, such as a memory (e.g., read-only memory, random access memory, flash memory) or a hard disk. A "storage" type of medium may include any or all tangible memories of a computer, processor, etc., or associated modules thereof, such as various semiconductor memories, tape drives, disk drives, etc., which may provide non-transitory storage for software programming at any time. All or part of the software may sometimes be communicated via the Internet or various other telecommunications networks. For example, such communication may enable the software to be loaded from one computer or processor to another, such as from an administrative server or a host computer to a computer platform of an application server. Thus, another type of medium that may carry software elements includes optical, electrical, and electromagnetic waves, such as used across physical interfaces between local devices, via wired and optical landline networks, and via various air links. Physical elements that carry such waves, such as wired or wireless links, optical links, etc., may also be considered media that carry software. As used herein, unless restricted to non-transitory, tangible "storage" media, terms such as computer or machine "readable media" refer to any medium that participates in providing instructions to a processor for execution.

[0387] Thus, machine-readable media, such as computer-executable code, can take many forms, including but not limited to tangible storage media, carrier media, or physical transmission media. Non-volatile storage media, including for example optical discs or magnetic disks, or any storage device in any computer etc., can be used to implement databases etc. shown in the figures. Volatile storage media includes dynamic memory, such as the main memory of such a computer platform. Tangible transmission media includes coaxial cables; copper wire and fiber optics, including the wires that make up a bus within a computer system. Carrier transmission media can take the form of electrical or electromagnetic signals, or acoustic or light waves, such as acoustic or light waves generated during radio frequency (RF) and infrared (IR) data communications. Thus, common forms of computer-readable media include for example: floppy disks, flexible disks, hard disks, magnetic tapes, any other magnetic media, CD-ROMs, DVDs or DVD-ROMs, any other optical media, punched cards, paper tapes, any other physical storage media with hole patterns, RAM, ROM, PROM and EPROM, FLASH-EPROM, any other memory chip or cartridge, carrier waves that carry data or instructions, cables or links that carry such carrier waves, or any other medium from which a computer can read programming code and / or data. Many of these forms of computer-readable media can involve carrying one or more sequences of one or more instructions to a processor for execution.

[0388] The computer system 6101 can include or communicate with an electronic display 6135 that includes a user interface (UI) 6140 for providing, for example, a portal for monitoring the installation of struts or solar modules. In some cases, the UI can allow for the input of commands such as "start installation" or "stop all robots". In some cases, the UI can provide a visualization or blueprint of multiple solar modules for the installation of a solar module array. In some cases, the UI can provide a visualization for real-time tracking of one or more robots. The portal can be provided via an application programming interface (API). A user or entity can also interact with various elements in the portal via the UI. Examples of the UI include but are not limited to graphical user interfaces (GUI) and web-based user interfaces.

[0389] The methods and systems of the present disclosure may be implemented by one or more algorithms. The algorithms may be implemented in software when executed by a central processing unit 6105. For example, the algorithms may be configured to determine one or more locations for installing one or more solar modules. In some cases, the algorithms may be configured to coordinate one or more robots during the installation of one or more solar modules. In some cases, the algorithms may be configured to process force test data of one or more solar modules to determine whether one or more solar modules are installed safely. In some cases, the algorithms may be configured to provide instructions to one or more robots to adjust one or more solar modules or their support structures at least partially based on the force test data.

[0390] High throughput post installation

[0391] In one aspect, the present disclosure provides methods and systems for high throughput post installation.

[0392] Figures 78A - 78CShows an example configuration of a conveying device 7800 for a strut mounting machine according to some embodiments. According to some embodiments, the conveying device 7800 can be configured to store, transport, and convey struts on a conveyor. The conveying device 7800 can include a conveying unit 7802 configured to support and transport a plurality of struts 7804. The plurality of struts 7804 can be bundled together. The conveying unit 7802 can include a conveying line 7806. The conveying unit 7802 can be configured to support the plurality of struts 7804 by fixing the plurality of struts 7804 to the conveying line 7806. In some embodiments, the conveying unit 7802 can be configured to support the plurality of struts 7804 by hanging the plurality of struts 7804 on the conveying line 7806. The conveying device 7800 can include a dispensing unit 7808. The dispensing unit 7808 can be configured to dispense one or more struts 7804 from the conveying unit 7802 for installation onto the terrain. The dispensing unit 7808 can include an actuator 7810 configured to dispense the one or more struts by separating or releasing the one or more struts from the conveying unit 7802. The actuator 7810 can be configured to separate or release the one or more struts from the conveying unit 7802 by pushing, pulling, and / or lifting the one or more struts away from the conveying unit 7802. The actuator 7810 can position the strut into a specific location at the conveyor to push the strut into an organized cartridge arrangement such that they can be individually removed one by one into the carrier of the strut mounting machine. The conveying unit 7802 and the dispensing unit 7808 can be operably coupled to each other. In some embodiments, the dispensing unit 7808 can be located at a fixed position relative to the conveying unit 7802. In some embodiments, the dispensing unit 7808 can be movable such that the dispensing unit 7808 can move to one or more positions along or relative to the conveying unit 7802. In some embodiments, the conveying unit 7808, the dispensing unit 7808, and / or the plurality of struts can be provided in a strut storage unit or at a strut storage location. The strut storage unit or the strut storage location can include a centralized location on the site where the plurality of struts can be stored and subsequently distributed over the terrain (e.g., a very large area) for implantation.

[0393] As Figure 78A and Figure 78BAs shown, a plurality of struts 7804 may be provided as a plurality of bundles, where each bundle includes two or more struts. In some embodiments, two or more struts in a bundle may be held together by straps, chains, or clips. According to some embodiments, a bundle may include from about three to three hundred struts. Compared to grasping a large number of individual separate struts, multiple bundles of struts may be easier to manage at the beginning of the module installation process and may save time required for transportation, separation, and / or implantation. In some embodiments, after removing a bundle, the bundle may be fed into a strut installation machine, such that the bundle is individually separated into separate struts for implantation into the ground. In some embodiments, a dispensing unit may dispense one or more bundles of struts to a vehicle. In some embodiments, the vehicle may feed one or more bundles of struts to a strut installation machine.

[0394] Figure 79 Another example configuration of a delivery device 7800 according to some embodiments is shown. The dispensing unit 7808 may be configured to feed one or more struts to a strut installation machine. In some embodiments, the conveyor of the struts may continue into the workspace of the hammer 7902 without using a cartridge-like loading mechanism.

[0395] Figure 80 An example feeding system 8000 for a strut installation machine according to some embodiments is shown. The dispensing unit 7808 may be configured to dispense one or more struts to a vehicle, which is configured to feed one or more struts to a strut installation machine. In some embodiments, one or more struts may be fed into the vehicle 8002. The struts may be presented into a position within the vehicle 8002 such that the strut installation machine may drive to that position and pick up the struts. In some embodiments, the vehicle 8002 may be transported to near the strut installation machine, and the strut installation machine may pick up the struts from the vehicle 8002.

[0396] Figures 81A - 81C An example mechanical arrangement 8100 of a transition strut according to some embodiments is shown. A bracket 8101 (e.g., the dispensing unit 7808) may include a support arm 8102, which is configured to extend through one or more first holes 8104 in one or more struts 8106 to support the struts 8106. The support arm 8102 may be configured to push, pull, and / or lift the struts 8106 away from the delivery unit 7802. In some embodiments, a transfer arm 8108 may be configured to extend through one or more second holes 8110 in the struts 8106 to allow the struts 8106 to hang thereon. Then, an actuator 8110 pushes the struts 8106 away from the support arm 8102, thereby transitioning the struts 8106 from the bracket 8101 to the actuator 8110.

[0397] In some embodiments, the transfer arm 8108 can transfer one or more bundles of struts to the vehicle. In some embodiments, the vehicle can feed one or more bundles of struts to the strut mounting machine.

[0398] Figures 82A - 82C An example of a cartridge and track system 8200 according to some embodiments is shown (e.g., Figure 80 the cartridge and track system 8200 of the example feed system 8000 shown in). The vehicle 8202 can include a track 8204. The track 8204 can be configured to support a plurality of struts 8206. The track 8204 can include a door 8208 at a distal portion of the track 8204. The door 8208 can be configured to prevent the plurality of struts 8206 from sliding out of the track 8204. The track 8204 can have a fixed position for the struts to slide thereon. The vehicle 8202 can include a follower 8210 configured to move the plurality of struts 8206 along the track 8204 toward the door 8208 or press the plurality of struts 8206 against the door 8208. The struts can be pushed by the follower 8210 to the front of the track 8204 and can be required to be lifted upward above the door 8208 for release. In some embodiments, the door 8208 and the follower 8210 can be configured to enable each of the plurality of struts 8206 to be sequentially removed from the distal portion of the track 8204 for installation onto the terrain. The follower 8210 can include a spring. By lifting the struts above the door 8208, the plurality of struts can be sequentially removed from the track 8204. One or more tabs on each of the plurality of struts 8206 and / or one or both of a plurality of spacers between the plurality of struts 8206 can be used to index the plurality of struts 8206 relative to each other along the track 8204 a certain distance. The vehicle 8202 can include a vibration device 8212 operatively coupled to the track 8204. The vibration device 8212 can be configured to generate vibrations in the track 8204 to facilitate the movement of the plurality of struts 8206 toward the door 8208. The track 8204 can be inclined or angled to facilitate the movement of the plurality of struts 8206 toward the door 8208 with the help of gravity.

[0399] Figure 83A and Figure 83B An example is shown according to some embodiments in Figure 79A detailed view of the conveying device 7800 shown. The conveying unit (e.g., the conveying unit 7808 in FIG. 78) may include a plurality of brackets linked to each other. In some embodiments, the number and spacing of the plurality of brackets may be adjustable so that the conveying unit can have different turning radii during the movement of the conveying unit. In some embodiments, one of the plurality of brackets may include one or more hooks 8302 for fixing (e.g., hanging) a plurality of struts.

[0400] FIGS. 84A and 84B show another exemplary mechanical arrangement 8400 for storing and transporting struts according to some embodiments. The conveying unit (e.g., the conveying unit 7808 in FIG. 78) may be inclined or angled to facilitate the distribution of one or more struts with the help of gravity. The conveyor belt may drive the strut forward, and the front stack may fall into a tool (e.g., a carrier) that captures it in a specific vertical orientation.

[0401] Figure 85 Different exemplary track configurations 8500, 8502, and 8504 of the track system of the strut mounting machine according to some embodiments are shown. In some embodiments, the track 8506 may include a single track (e.g., configuration 8500). In some embodiments, the track 8506 may include two or more laterally spaced sub-tracks (e.g., configurations 8502 and 8504). The two or more laterally spaced sub-tracks may be configured to reduce the sway of the plurality of struts on the track. The track system may include one or more linear guides 8508 located below the track 8506. The one or more linear guides 8508 may be configured to limit and reduce the sway of the plurality of struts 8510 on the track 8506. The track 8506 may be inclined or angled to facilitate the removal of each strut 8510 from the track 8506 with the help of gravity. For example, after removing the strut 8510 from the end of the track 8506, the strut 8510 may slide slowly down the track 8506 by gravity.

[0402] A system for post installation can include a vehicle and a post installation machine. In some embodiments, the post installation machine can include an extraction device configured to remove one or more posts from the vehicle for installation onto the terrain. The extraction device can be configured to remove one or more posts 8510 from the vehicle by lifting the one or more posts 8510 off the track 8506 to clear a door (e.g., door 8208 in FIG. 82), such that the posts 8510 can be loaded onto the post installation machine in preparation for implanting into the ground. In some embodiments, the post installation machine can include a load driving mechanism (e.g., a hammer). The extraction device can be configured to bring the one or more posts 8510 to near the load driving mechanism. For example, the extracted posts 8510 can be positioned near a hammer bit that can be used to drive the posts 8510 into the ground. The load driving mechanism can be configured to drive the one or more posts 8510 onto the terrain (e.g., implant the posts 8510 into the ground). The load driving mechanism can include a load head (e.g., a hammer bit) configured to drive the one or more posts 8510 onto the terrain. The load driving mechanism can include a positioning device. The positioning device can be configured to control the position of the load head in three or more degrees of freedom with respect to the height of the one or more posts 8510 and the terrain before the one or more posts 8510 are driven onto the terrain. The positioning device can include a plurality of linear actuators. The positioning device can include a Stewart platform or a hexapod structure (see, e.g., Figure 87 ). The positioning device can be configured to control the position of the load head in six degrees of freedom.

[0403] Figures 86A - 86C Different example configurations of a hammer 8600 and an actuator 8602 of a post installation machine are shown in accordance with some embodiments. The load driving mechanism can include an actuator 8602 configured to control the vertical position of the load head along the Z-axis. The load driving mechanism can be a chain / wire and pulley for adjusting or controlling the ratio of (a) the linear extension of the actuator 8602 relative to (b) the travel distance of the load head. In some embodiments, the ratio can be from 1:6 to 6:1. In some embodiments, the ratio can be 1:2. In some embodiments, the ratio can be adjustable or controllable to reduce the upward reaction force when retracting the load head after driving one or more posts downward onto the terrain. This configuration can prevent the load head from transmitting its reaction force vertically into the post installation machine because when the load head bounces, it can slacken the wire or chain.

[0404] Figure 87Shows an example configuration of a strut - mounted machine 8700 with a loader according to some embodiments. The strut - mounted machine 8700 may include one or more vertical sliding tracks 8702 for restricting the one or more struts when the one or more struts are driven into the terrain. The one or more vertical sliding tracks 8702 may be configured to allow the one or more struts to slide along the one or more vertical tracks 8702 when the one or more struts are driven into the terrain.

[0405] In some embodiments, the strut - mounted machine may include a bracket and an actuator configured to hold the one or more struts in place relative to a load head (e.g., a hammer head). Figure 90A and Figure 90B Shows an example configuration 9000 of a hammer head of a strut - mounted machine according to some embodiments. The bracket 9002 may be movable to switch between an open state ( Figure 90A ) and a closed state ( Figure 90B ). The open state may allow the one or more struts to be positioned in place relative to the load head. The closed state may cause the bracket 9002 to hold the one or more struts in place relative to the load head. The bracket 9002 may be hinged to a retainer configured to hold the one or more struts. Figure 91 Shows another example configuration 9100 of a hammer head of a strut - mounted machine. The bracket 9002 may be a C - shaped or U - shaped bracket. The bracket 9002 may self - cancel strut forces in a direction parallel to shear features on the hammer head, which may reduce the force transmitted to the actuator.

[0406] In some embodiments, the strut - mounted machine may be integrated into a vehicle or a machine. Figures 88A - 88C Shows an example integration of the strut - mounted machine 8700 with a slide rail according to some embodiments. The slide rail may be capable of attaching to any suitable type of vehicle, e.g., a forklift, a skid - steer machine, a tractor, or a custom vehicle.

[0407] Alternatively, the strut - mounted machine may be mounted with tracks or wheels on its base and equipped with a hydraulic or power source. The strut - mounted machine may move on its own like a vehicle without cooperating with a vehicle. Figure 89 Shows an example configuration of a strut - mounted machine 8700 mounted with tracks or wheels according to some embodiments.

[0408] With a high-throughput post installation method and system as disclosed herein, posts can be automatically and rapidly fed into a post installation machine without manual intervention. In some embodiments, posts can be rapidly fed into the post installation machine at a rate of 0.2 to 60 seconds per post. Additionally, posts can be installed rapidly. In some embodiments, posts can be installed at a rate of 20 posts per hour to 750 posts per hour.

[0409] Rapid Solar Module Assembly

[0410] In one aspect, the present disclosure provides methods and systems for rapidly assembling solar modules onto posts without high-precision alignment.

[0411] In some embodiments, a system for solar module assembly can include a module installation machine. The module installation machine can include a flexible mechanism operatively coupled to a distal portion of a movable arm. In some embodiments, the flexible mechanism can pick up one or more solar modules from a plurality of solar modules and place the one or more solar modules onto a plurality of posts that have been installed onto the terrain. In some embodiments, the flexible mechanism can rotate and / or bend relative to the movable arm during placement of the one or more solar modules onto the plurality of posts. The flexible mechanism can enable the one or more solar modules to be placed onto the plurality of posts without requiring the one or more solar modules to be precisely positioned within a threshold tolerance relative to the plurality of posts during placement.

[0412] Figure 92A and Figure 92B Shows the range of motion of a module installation machine 9200 according to some embodiments. Figure 92A Shows that the module installation machine 9200 can pick up a solar module from a stack of solar modules and rotate to position the solar module onto a plurality of posts. In some embodiments, the rotation can be 90 degrees. As Figure 92B shown, the module installation machine 9200 can include a vertical axis and a movable arm (e.g., a crane). In some embodiments, the movable arm can include a boom axis and a pitch axis. The vertical axis can be capable of moving up and down along the Z-axis to adjust the height of the module installation machine. The boom axis and the pitch axis can be capable of extending or retracting, thereby moving the solar module away from or closer to the posts. The movable arm can be capable of leveling the solar module. The module installation machine 9200 can include an end effector that includes a flexible mechanism (details will be in FIGS. 94A, 94B, and Figure 95(shown in). In some embodiments, one or more actuators may be configured to control movement of the movable arm in two or more degrees of freedom. The two or more degrees of freedom may include translation along a vertical axis and rotation about the vertical axis. The two or more degrees of freedom may include translation and / or rotation along a horizontal axis.

[0413] Figures 94A and 94B illustrate an example configuration of a compliant mechanism 9400 at the end of a movable arm (e.g., a crane) of a module installation machine 9200 according to some embodiments. The compliant mechanism 9400 may be operatively coupled to a distal portion of the movable arm. The compliant mechanism 9400 may be configured to (1) pick up one or more solar modules from a plurality of solar modules and (2) place the one or more solar modules onto a plurality of posts that have been installed onto the terrain. The compliant mechanism 9400 may be configured to rotate and / or bend relative to the movable arm during placement of the one or more solar modules onto the plurality of posts. The compliant mechanism 9400 may enable the one or more solar modules to be placed onto the plurality of posts without requiring the one or more solar modules to be positioned within a threshold tolerance relative to the plurality of posts during placement. The threshold tolerance may be based at least on horizontal and vertical accuracies of a global navigation satellite system (GNSS). The threshold tolerance may be based at least on the inclination of the plurality of posts. The range of the inclination may be from 0 degrees to 25 degrees.

[0414] As shown in FIG. 94B, the flexible mechanism 9400 can include a pair of laterally spaced-apart plates and a plurality of springs radially extending centrally between the pair of laterally spaced-apart plates. The plurality of springs can radially extend equidistantly from the center with respect to each other. The plurality of springs can include 3 springs, 4 springs, 5 springs, 6 springs, 7 springs or more springs. The angle between two adjacent springs can be equal. Alternatively, the angle between two adjacent springs can be unequal. In some embodiments, the flexible mechanism can include three springs that radially extend from the center at an angle of 120 degrees with respect to each other. In some embodiments, the flexible mechanism can include four springs that radially extend from the center at an angle of 90 degrees with respect to each other. In some embodiments, the flexible mechanism can include six springs that radially extend from the center at an angle of 60 degrees with respect to each other. In some embodiments, the pair of laterally spaced-apart plates can include (1) a first plate operatively coupled to the distal portion of the movable arm, and (2) a second plate configured to pick up one or more solar modules from a plurality of solar modules. In some embodiments, the flexible mechanism 9400 can include a spherical bearing located at the center between the pair of laterally spaced-apart plates. The pair of laterally spaced-apart plates can be operatively coupled to each other via the spherical bearing and the plurality of springs. The spherical bearing can be configured to allow the pair of laterally spaced-apart plates to rotate relative to each other. The spherical bearing can include additional springs configured to allow the plates to move laterally relative to each other. The plurality of springs can be configured to allow the pair of laterally spaced-apart plates to bend relative to each other such that the pair of plates are not parallel to each other. The plurality of springs can be made of any suitable material (e.g., metal, alloy, carbon fiber, rubber, or reinforced material). The plurality of springs can be configured to have a torsional spring force such that after placing one or more solar modules on the plurality of struts, the flexible mechanism returns to the default position.

[0415] In some embodiments, the flexible mechanism 9400 can include one or more riveting tools operatively coupled to the flexible mechanism. The one or more riveting tools can be configured to attach one or more solar modules to the plurality of struts via a recessing process (see, for example, in connection with Figure 7A , Figure 7B and / or Figure 15 the description of the riveting tools and the recessing process).

[0416] Figure 95 Another example configuration of the flexible mechanism 9400 at the end of the crane of the module installation machine 9200 is shown according to some embodiments. Figure 96 An example configuration of the end effector 9600 of the crane of the module installation machine 9200 is shown according to some embodiments.

[0417] AsFigure 95 As shown, the flexible mechanism 9400 can include one or more bellows. One or more bellows can be provided in a rubber housing. One or more bellows can be inflated or deflated with a fluid for controlling the spring constant of the one or more bellows. The fluid can include a gas or a liquid. The flexible mechanism 9400 can include and / or be attached to a movable arm. The flexible mechanism 9400 can include one or more actuators (e.g., motors) operatively coupled to the movable arm.

[0418] In some embodiments, the module mounting machine can be integrated or loaded onto a vehicle or machine. Figures 93A - 93D Different example configurations of the module mounting machine 9200 according to some embodiments are shown. The module mounting machine 9200 can be on a standard rail and towed on a rail steering machine ( Figure 93A ), a trailer ( Figure 93B ), or a tractor ( Figure 93C ). In some embodiments, the rail can be equipped with a hydraulic or electric unit and wheels or tracks for self-driving without the need to cooperate with any other vehicle ( Figure 93D ). Figure 93B and Figure 93C show that the module mounting machine 9200 can include a rail for supporting a plurality of solar modules in a stacked form.

[0419] Using the module mounting machine provided herein, solar modules can be quickly positioned and assembled onto a plurality of struts. The flexible mechanism can enable one or more solar modules to be placed onto the plurality of struts without the need to precisely position the one or more solar modules within a threshold tolerance relative to the plurality of struts during placement. The time required for positioning and assembling the solar modules can be reduced by at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50% or more.

[0420] Although the preferred embodiments of the present disclosure have been shown and described herein, it will be apparent to those skilled in the art that these embodiments are provided by way of example only. The present disclosure is not intended to be limited by the specific embodiments provided in the specification. While the present disclosure has been described with reference to the foregoing specification, the description and illustration of the embodiments herein are not meant to be construed in a limiting sense. Many variations, changes, and substitutions will now occur to those skilled in the art without departing from the present disclosure. In addition, it should be understood that all aspects of the present disclosure are not limited to the specific descriptions, configurations, or relative proportions described herein, which depend on various conditions and variables. It should be understood that various alternatives to the embodiments of the present disclosure described herein may be employed in practicing the present disclosure. Accordingly, it is contemplated that the present disclosure should also cover any such alternatives, modifications, variations, or equivalents. The appended claims are intended to define the scope of the present disclosure and are intended to cover methods and structures within the scope of these claims and their equivalents.

Claims

1. A device, comprising: a conveying unit configured to support and transport a plurality of struts; and a dispensing unit configured to dispense one or more of the plurality of struts from the conveying unit for installation onto a terrain.

2. The device according to claim 1, wherein the conveying unit comprises a conveying line.

3. The device according to claim 2, wherein the conveying unit is configured to support the plurality of struts by hanging the plurality of struts on the conveying line.

4. The device according to claim 1, wherein the dispensing unit comprises an actuator configured to dispense the one or more struts by separating or releasing the one or more struts from the conveying unit.

5. The device according to claim 4, wherein the actuator is configured to separate or release the one or more struts from the conveying unit by pushing, pulling, and / or lifting the one or more struts away from the conveying unit.

6. The device according to claim 1, wherein the dispensing unit is configured to feed the one or more struts to a strut installation machine.

7. The device according to claim 1, wherein the dispensing unit is configured to dispense the one or more struts to a vehicle configured to feed the one or more struts to a strut installation machine.

8. The device according to claim 1, wherein the dispensing unit comprises a support arm configured to extend through one or more first holes in the one or more struts to support the one or more struts, and wherein the support arm is further configured to push, pull, and / or lift the one or more struts away from the conveying unit.

9. The device according to claim 8, further comprising a transfer arm configured to extend through one or more second holes in the one or more struts to take over the one or more struts from the support arm.

10. The device according to claim 9, wherein the transfer arm is configured to transfer the one or more struts to a vehicle configured to feed the one or more struts to a strut installation machine.

11. The device according to claim 1, wherein the plurality of struts are provided as a plurality of bundles, wherein each bundle comprises two or more struts.

12. The device according to claim 11, wherein the two or more struts in each bundle are held together by a strap, a chain, or a clip.

13. The device according to claim 11, wherein each bundle comprises from about three to three hundred struts.

14. The device according to claim 11, wherein the dispensing unit is configured to dispense one or more of the plurality of bundles.

15. The device according to claim 14, wherein the dispensing unit comprises an actuator configured to dispense the one or more bundles by separating or releasing the one or more bundles from the conveying unit.

16. The apparatus according to claim 15, wherein the actuator is configured to separate or release the one or more bundles from the conveying unit by pushing, pulling, and / or lifting the one or more bundles away from the conveying unit.

17. The apparatus according to claim 14, wherein the dispensing unit is further configured to feed the one or more bundles to a post mounting machine.

18. The apparatus according to claim 14, wherein the dispensing unit is configured to dispense the one or more bundles to a carrier, the carrier being configured to feed the one or more bundles to a post mounting machine.

19. The apparatus according to claim 11, wherein the dispensing unit includes a support arm configured to extend through a plurality of first holes in the one or more bundles to support the one or more bundles, wherein the support arm is further configured to push, pull, and / or lift the one or more bundles away from the conveying unit.

20. The apparatus according to claim 19, further comprising a transfer arm configured to extend through a plurality of second holes in the one or more bundles to take over the one or more bundles from the support arm.

21. The apparatus according to claim 20, wherein the transfer arm is configured to transfer the one or more bundles to a carrier, the carrier being configured to feed the one or more bundles to a post mounting machine.

22. The apparatus according to any one of claims 1 to 21, wherein the conveying unit and the dispensing unit are operably coupled to each other.

23. The apparatus according to any one of claims 1 to 21, wherein the dispensing unit is located at a fixed position relative to the conveying unit.

24. The apparatus according to any one of claims 1 to 21, wherein the dispensing unit is movable such that the dispensing unit can move to one or more positions along or relative to the conveying unit.

25. The apparatus according to any one of claims 1 to 21, wherein the conveying unit, the dispensing unit, and the plurality of posts are provided in a post storage unit or at a post storage location.

26. The apparatus according to any one of claims 1 to 21, wherein the conveying unit includes a plurality of carriages linked to each other.

27. The apparatus according to claim 26, wherein the number and spacing of the plurality of carriages are adjustable such that the conveying unit can have different turning radii during movement of the conveying unit.

28. The apparatus according to claim 26, wherein each of the plurality of carriages includes one or more hooks for hanging the plurality of posts.

29. The apparatus according to any one of claims 1 to 21, wherein the conveying unit is inclined or angled to facilitate dispensing of the one or more posts with the aid of gravity.

30. A carrier comprising: tracks configured to support a plurality of posts, wherein the tracks include a door at a distal portion of the tracks, the door being configured to prevent the plurality of posts from sliding out of the tracks; and A follower configured to move the plurality of struts along the track towards the door or press the plurality of struts against the door. Wherein the door and the follower are configured to enable each of the plurality of struts to be sequentially removed from the distal portion of the track for installation onto the terrain.

31. The vehicle according to claim 30, wherein the follower includes a spring.

32. The vehicle according to claim 30, wherein each of the struts can be sequentially removed from the track by lifting each strut above the door.

33. The vehicle according to claim 30, wherein one or more tabs on each of the plurality of struts or a plurality of spacers between the plurality of struts are used to index the plurality of struts a certain distance relative to each other along the track.

34. The vehicle according to claim 30, further comprising a vibration device operably coupled to the track.

35. The vehicle according to claim 34, wherein the vibration device is configured to generate vibrations in the track to facilitate the movement of the plurality of struts towards the door.

36. The vehicle according to claim 30, wherein the track is inclined or angled to facilitate the movement of the plurality of struts towards the door with the aid of gravity.

37. The vehicle according to claim 30, wherein the track comprises a single track.

38. The vehicle according to claim 30, wherein the track comprises two or more laterally spaced sub-tracks.

39. The vehicle according to claim 38, wherein the two or more laterally spaced sub-tracks are configured to reduce the sway of the plurality of struts on the track.

40. The vehicle according to claim 30, further comprising one or more linear guides located below the track.

41. The vehicle according to claim 40, wherein the one or more linear guides are configured to limit and reduce the sway of the plurality of struts on the track.

42. The vehicle according to claim 30, wherein the vehicle is inclined or angled to facilitate the removal of each strut from the track with the aid of gravity.

43. A system comprising: A vehicle according to any one of claims 30 to 42; and A strut mounting machine including an extraction device configured to remove one or more struts from the vehicle for installation onto the terrain.

44. The system according to claim 43, wherein the extraction device is configured to remove the one or more struts from the vehicle by lifting the one or more struts off the track to clear the door.

45. The system according to claim 44, wherein the strut mounting machine includes a load driving mechanism, and the extraction device is configured to bring the one or more struts to the vicinity of the load driving mechanism.

46. The system according to claim 45, wherein the load driving mechanism is configured to drive the one or more struts onto the terrain.

47. A strut installation machine, comprising: a load driving mechanism including a load head configured to drive one or more struts into the terrain; and a positioning device configured to control the position of the load head in three or more degrees of freedom with respect to the one or more struts and the terrain before the one or more struts are driven into the terrain.

48. The machine according to claim 47, wherein the positioning device includes a plurality of linear actuators.

49. The machine according to claim 47, wherein the positioning device includes a Stewart platform or a hexapod structure.

50. The machine according to claim 47, wherein the positioning device is configured to control the position of the load head in six degrees of freedom.

51. The machine according to claim 47, wherein the load driving mechanism includes an actuator configured to control the vertical position of the load head along the Z-axis.

52. The machine according to claim 51, wherein the load driving mechanism includes a chain / wire and a pulley for adjusting or controlling the ratio of (a) the linear extension of the actuator relative to (b) the travel distance of the load head.

53. The machine according to claim 52, wherein the ratio is 1:

2.

54. The machine according to claim 52, wherein the ratio is adjustable or controllable to reduce the upward reaction force when retracting the load head after driving the one or more struts downward into the terrain.

55. The machine according to claim 47, further comprising a vertical track for restricting the one or more struts when the one or more struts are driven into the terrain.

56. The machine according to claim 55, wherein the vertical track is configured to allow the one or more struts to slide along the track when the one or more struts are driven into the terrain.

57. The machine according to claim 47, further comprising a bracket configured to hold the one or more struts in place relative to the load head.

58. The machine according to claim 57, wherein the bracket is movable to switch between an open state and a closed state.

59. The machine according to claim 58, wherein the closed state causes the bracket to hold the one or more struts in place relative to the load head.

60. The machine according to claim 58, wherein the open state allows the one or more struts to be placed in place relative to the load head.

61. The machine according to claim 57, wherein the bracket is hinged to a holder configured to hold the one or more struts.

62. The machine according to claim 57, wherein the bracket includes a C-shaped or U-shaped bracket.

63. The machine according to claim 47, wherein the load head includes an arm configured to rotate between a vertical position and a horizontal position.

64. The machine according to claim 63, wherein the arm includes a gripper configured to grasp the support post when the arm is in the horizontal position.

65. The machine according to claim 63, wherein the arm is configured to position the support post when the arm is in the vertical position.

66. The machine according to claim 64, wherein the gripper is coupled to an actuator configured to control the opening and closing of the gripper.

67. The machine according to claim 47, including a holding mechanism configured to position the support post.

68. The machine according to claim 67, wherein the holding mechanism includes an actuator and a plurality of rollers.

69. A device, comprising: a flexible mechanism operably coupled to a distal portion of a movable arm, wherein the flexible mechanism is configured to (1) pick up one or more solar modules from a plurality of solar modules and (2) place the one or more solar modules onto a plurality of support posts that have been installed on a terrain, wherein the flexible mechanism is further configured to rotate and / or bend relative to the movable arm during placement of the one or more solar modules onto the plurality of support posts.

70. The device according to claim 69, wherein the flexible mechanism enables the one or more solar modules to be placed onto the plurality of support posts without the need to precisely position the one or more solar modules within a threshold tolerance relative to the plurality of support posts during the placement.

71. The device according to claim 70, wherein the threshold tolerance is at least based on the horizontal accuracy and vertical accuracy of a Global Navigation Satellite System (GNSS).

72. The device according to claim 70, wherein the threshold tolerance is at least based on the inclination of the plurality of support posts.

73. The device according to claim 72, wherein the inclination ranges from 0 degrees to 25 degrees.

74. The device according to claim 69, wherein the flexible mechanism includes a pair of laterally spaced-apart plates and a plurality of springs radially extending from a center between the pair of laterally spaced-apart plates.

75. The device according to claim 74, wherein the plurality of springs radially extend equidistantly from the center.

76. The device according to claim 74, wherein the plurality of springs includes three springs that radially extend from the center at an angle of 120 degrees relative to each other.

77. The device according to claim 74, wherein the plurality of springs includes four springs that radially extend from the center at an angle of 90 degrees relative to each other.

78. The device according to claim 74, wherein the plurality of springs includes six springs that radially extend from the center at an angle of 60 degrees relative to each other.

79. The device according to claim 74, wherein the pair of laterally spaced-apart plates comprises: (1) a first plate operably coupled to the distal portion of the movable arm; and (2) a second plate configured to pick up the one or more solar modules from the plurality of solar modules.

80. The device according to claim 74 or 79, wherein the flexible mechanism further comprises a spherical bearing located at the center between the pair of laterally spaced-apart plates.

81. The device according to claim 80, wherein the pair of laterally spaced-apart plates are operatively coupled to each other via the spherical bearing and the plurality of springs.

82. The device according to claim 80, wherein the spherical bearing is configured to allow the pair of laterally spaced-apart plates to rotate relative to each other.

83. The device according to claim 80, wherein the spherical bearing comprises additional springs configured to allow the plates to move laterally relative to each other.

84. The device according to claim 74, wherein the plurality of springs are configured to allow the pair of laterally spaced-apart plates to bend relative to each other such that the pair of plates are not parallel to each other.

85. The device according to claim 74, wherein the plurality of springs are made of metal or rubber.

86. The device according to claim 74, wherein the plurality of springs are configured to have a torsional spring force such that after placing the one or more solar modules on the plurality of struts, the flexible mechanism returns to a default position.

87. The device according to claim 69, wherein the flexible mechanism comprises one or more bellows.

88. The device according to claim 87, wherein the one or more bellows are provided in a rubber housing.

89. The device according to claim 87, wherein the one or more bellows can be inflated or deflated with a fluid for controlling the spring constant of the one or more bellows, wherein the fluid comprises a gas or a liquid.

90. The device according to claim 69, further comprising the movable arm.

91. The device according to claim 86, further comprising one or more actuators operatively coupled to the movable arm.

92. The device according to claim 84, wherein the one or more actuators are configured to control the movement of the movable arm in two or more degrees of freedom.

93. The device according to claim 88, wherein the two or more degrees of freedom include translation along a vertical axis and rotation about the vertical axis.

94. The device according to claim 88, wherein the two or more degrees of freedom further include translation and / or rotation along a horizontal axis.

95. The device according to claim 69, further comprising a slide rail for supporting the plurality of solar modules in a stacked form.

96. The device according to claim 69, further comprising one or more riveting tools operatively coupled to the flexible mechanism, wherein the one or more riveting tools are configured to attach the one or more solar modules to the plurality of struts via a recessing process.

97. A method for constructing a solar module array, comprising: (a) autonomously positioning a plurality of struts on a terrain; and (b) autonomously assembling a plurality of solar modules with the plurality of struts on the terrain to construct the solar module array. Wherein the plurality of struts includes a row of struts, wherein two adjacent struts in the row of struts each incline towards each other, and wherein a third strut adjacent to the two adjacent struts inclines outwards.

98. The method according to claim 97, wherein the array includes a double-inclined array.

99. The method according to claim 97, wherein the solar modules in the plurality of solar modules are coupled to the struts in the plurality of struts via a strut-module interface.

100. The method according to claim 99, wherein the strut-module interface includes a substantially non-flat surface such that the angle between the module and the strut is variable.

101. The method according to claim 99, wherein the strut-module interface includes a plurality of tabs.

102. The method according to claim 101, wherein the plurality of tabs are bendable or deformable.

103. The method according to claim 99, wherein the strut-module interface includes a non-flat pivot feature.

104. The method according to claim 103, including tilting the solar module via the non-flat pivot feature.

105. The method according to claim 97, wherein the plurality of struts are installed at alternating angles.

106. The method according to claim 97, wherein the two adjacent struts are installed at a first angle and a second angle relative to a vertical axis, and the third strut is installed at a third angle.

107. The method according to claim 106, wherein the first angle, the second angle, and the third angle are substantially the same.

108. The method according to claim 106, wherein at least two of the first angle, the second angle, and the third angle are different.

109. A method for constructing an array of solar modules, comprising: (a) autonomously positioning a plurality of struts on a terrain; and (b) autonomously assembling a plurality of solar modules with the plurality of struts on the terrain, thereby constructing the array of solar modules, wherein the solar modules in the plurality of solar modules are supported by a variable number of struts.

110. The method according to claim 109, wherein one side of the solar module is supported by at least three struts.

111. The method according to claim 109, wherein one side of the solar module is supported by at least four struts.

112. The method according to claim 109, wherein the array includes a double-inclined array.

113. The method according to claim 109, wherein the solar modules in the plurality of solar modules are coupled to the struts in the plurality of struts via a strut-module interface.

114. The method according to claim 113, wherein the strut-module interface includes a substantially non-flat surface such that the angle between the module and the strut is variable.

115. The method according to claim 113, wherein the strut-module interface includes a plurality of tabs.

116. The method according to claim 115, wherein the plurality of tabs are bendable or deformable.

117. The method according to claim 113, wherein the strut-module interface includes a non-flat pivot feature.

118. The method according to claim 117, comprising tilting the solar module via the non-flat pivot feature.

119. The method according to claim 109, wherein the plurality of struts are mounted at alternating angles.

120. A method for assembling a solar module, comprising: (a) providing an algorithm configured to identify positions for autonomous positioning and assembly of a plurality of struts and a plurality of solar modules; and (b) creating a set of executable software instructions for controlling one or more mobile platforms to autonomously position and assemble the plurality of struts and the plurality of solar modules on a terrain to build a solar module array without the assistance or involvement of a user.

121. The method according to claim 120, comprising using a digital surface model of the terrain to determine the positions.

122. The method according to claim 120, comprising determining the positions of the struts by using the algorithm for the strut-clamp interface angles.

123. The method according to claim 120, comprising using the algorithm to minimize the depth of the struts.

124. The method according to claim 123, further comprising using a digital surface model of the terrain to minimize the depth of the struts.

125. The method according to claim 120, wherein the algorithm uses soil properties.

126. The method according to claim 120, wherein the algorithm uses the array geometry and tolerances.

127. The method according to claim 120, further comprising exporting or displaying the output of the algorithm in a digital representation.

128. The method according to claim 127, comprising using the digital representation to modify the positions of the struts or modules based on measurements of nearby struts or modules.

129. The method according to claim 127, comprising using the digital representation to predict the electricity generated by the array.

130. The method according to claim 127, comprising using the digital representation to predict the components required in the array.

131. The method according to claim 127, comprising using the digital representation to create a construction plan drawing.

132. The method according to claim 127, comprising using the digital representation to generate an analysis for construction operations.

133. The method according to claim 120, further comprising providing a graphical user interface (GUI) configured to display the output of the algorithm.

134. The method according to claim 133, further comprising displaying a digital representation of the output of the algorithm on the GUI.

135. The method according to claim 120, comprising using sensors to record data of the terrain, struts, and / or modules.

136. The method according to claim 135, further comprising displaying the recorded data in a digital representation. The method according to claim 135 further comprises modifying the algorithm and / or the digital surface model of the terrain based on the recorded data.

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