Methods for constructing a solar module array

Abstract

In one embodiment, the present invention describes a method comprising using at least one robot to autonomously locate and assemble at least one solar module and its support structure at a sensed geographic location, without the assistance of a user.

Description

Technical Field

[0001] This application relates to systems and methods for assembling solar power plants, and more specifically, to systems and methods for autonomously installing a solar module array on various terrains. Prior Technology

[0002] As we recognize the harmful effects of global warming, the generation of usable electricity from solar energy is gaining increasing acceptance. Large open spaces offer attractive locations for solar panel deployment. However, such open-area solar installations require a significant effort to secure the solar panels to the ground in a way that enables them to withstand external loads such as wind. The separate beam and support structures needed to achieve this also significantly increase the installation cost of the solar panels. Summary of the Invention

[0003] This invention provides systems and methods for autonomously installing a solar module array on various terrains. Some embodiments of the invention describe methods and systems for planning and executing the installation of a solar module array on a given terrain. In some cases, terrain data from various sources (e.g., GPS, geological survey data, cameras, etc.) can be used in a computer algorithm to prepare a blueprint or instructions for deploying solar modules on a given terrain. In some cases, one or more autonomous machines can be used and coordinated to perform various tasks related to installing a solar module array on a given landscape. Some embodiments of the invention provide systems and methods suitable for efficiently installing a solar module array on terrains with various topologies and compositional properties or characteristics.

[0004] Some embodiments of the present invention describe structural supports, solar modules, and coupling mechanisms of various shapes and forms that can be formed to connect various components in a solar array. In some cases, the structural supports and solar modules can be coupled using mechanisms that can be quickly formed and provide a stable link. Some embodiments of the present invention provide apparatus and methods for establishing and deploying such coupling mechanisms, enabling efficient and rapid installation of a solar module array without the need for additional tools or fasteners.

[0005] In one embodiment, the present invention describes a method comprising using at least one robot to autonomously locate and assemble at least one solar module and its supporting structure at a sensed geographic location, without the assistance of a user. In some embodiments, the method further comprises using the at least one robot to autonomously locate and assemble the at least one solar module and its supporting structure in two or more different directions. In some embodiments, the method further comprises using the at least one robot to autonomously locate and assemble a plurality of solar modules and associated supporting structures to construct a solar module array. In some embodiments, the plurality of solar modules and the associated supporting structures include the at least one solar module and its supporting structure.

[0006] In some embodiments, the solar module array is constructed on a substantially flat terrain. In some embodiments, the solar module array is constructed on a substantially uneven terrain.

[0007] In some embodiments, the solar module array is a fully wired array. In some embodiments, the solar module is a dual-tilt array. In some embodiments, the solar module array may be a single-tilt array capable of or configurable for tilting from 0 degrees to 90 degrees.

[0008] In some embodiments, the present invention describes a method comprising providing one or more mobile platforms configured to carry a plurality of pillars and a plurality of solar modules. In some embodiments, the one or more mobile platforms are equipped with one or more sensors including a geolocation sensor. In some embodiments, the method further comprises autonomously moving the one or more mobile platforms using at least partially the one or more sensors. In some embodiments, the method further comprises autonomously locating and assembling the plurality of pillars and the plurality of solar modules on terrain using at least partially the one or more sensors to construct a solar module array. In some embodiments, the one or more sensors further include an image sensor.

[0009] In some embodiments, the one or more operational platforms include a first platform for positioning and installing the plurality of pillars onto the terrain. In some embodiments, the one or more operational platforms include a second platform for positioning and assembling the plurality of solar modules onto the plurality of pillars. In some embodiments, the first platform and the second platform are separate. In some embodiments, the first platform and the second platform are integrated into a single platform.

[0010] In some embodiments, the plurality of pillars are positioned and installed on the terrain by the first platform according to a predefined configuration. In some embodiments, the plurality of solar modules are pre-stacked on the second platform. In some embodiments, the second platform includes a mechanism for extracting a selected solar module from the stack and assembling the selected solar module onto a selected group of pillars already installed on the terrain.

[0011] In some embodiments, the method further includes using a test tool located on one or more of the action platforms to perform tensile strength and assembly tests on one or more of the plurality of mounting supports.

[0012] In some embodiments, the method further includes using one or more sensors to position and move one of the mount heads on one or more mobile platforms relative to the solar module array during the construction of the array.

[0013] In some embodiments, the method further includes using a tool on the mounter load head (e.g., an integral molding tool or an integral crimping tool) to establish a plurality of post-mount-clip interfaces between a plurality of clips and a plurality of posts. In some embodiments, the tool may include any type of tool capable of forming, shaping, or otherwise manipulating a material (e.g., to establish one or more post-mount-clip interfaces). In some embodiments, the plurality of clips are pre-attached to the plurality of solar modules. In some embodiments, the method further includes forming a plurality of clip-module interfaces, wherein the plurality of clip-module interfaces include a plurality of crimp joints.

[0014] In some embodiments, the one or more mobile platforms include one or more electric vehicles. In some embodiments, the method further includes providing one or more charging stations distributed across the terrain for charging the one or more electric vehicles. In some embodiments, the one or more charging stations are mobile or stationary.

[0015] In some embodiments, the present invention describes a method comprising providing a plurality of supports and a plurality of solar modules. In some embodiments, the plurality of solar modules includes a plurality of clips pre-attached thereto.

[0016] In some embodiments, the method further includes forming a plurality of pillar-clamp interfaces between a plurality of clamps and a plurality of pillars to construct a solar module array on a terrain without requiring one or more pre-drilled holes / features for one or more fasteners. In some embodiments, the plurality of pillar-clamp interfaces have tolerances that allow the array to be fitted to the terrain, thereby eliminating the need for leveling the terrain. In some embodiments, the plurality of pillar-clamp interfaces include a plurality of press-fit joints. In some embodiments, the plurality of press-fit joints are formed by a denting process. In some embodiments, each of the plurality of pillars includes one or more tabs. In some embodiments, the denting process includes connecting the one or more tabs to a corresponding clamp to form the plurality of press-fit joints. In some embodiments, the plurality of pillar-clamp interfaces are formed at one or more corners of the plurality of solar modules. In some embodiments, the plurality of pillar-clamp interfaces are formed at all corners of the plurality of solar modules. In some embodiments, the plurality of support-clamp interfaces are formed at opposite corners of the plurality of solar modules. In some embodiments, the plurality of support-clamp interfaces are formed on one or more lateral sides of the plurality of solar modules. In some embodiments, the plurality of support-clamp interfaces are formed on all lateral sides of the plurality of solar modules. In some embodiments, the plurality of support-clamp interfaces are formed on opposite lateral sides of the plurality of solar modules. In some embodiments, the plurality of support-clamp interfaces are formed by using a crimping tool located on a support mount load head. In some embodiments, the support mount load head is located on a mobile platform configured to carry the plurality of supports and the plurality of solar modules.

[0017] In some embodiments, the method further includes using one or more mobile platforms to autonomously position and assemble the plurality of pillars and the plurality of solar modules on the terrain to construct the solar module array.

[0018] In some embodiments, the method further includes using at least one of a measuring force or a deflection to assess the structural integrity of one of the pillar-clamp interfaces during and / or after the solar modules are installed on the pillars.

[0019] In some embodiments, the method further includes obtaining images of the plurality of pillar-clamp interfaces during or after the formation of the interfaces.

[0020] In some embodiments, the method further includes determining the structural integrity of one of the plurality of pillar-clip interfaces based at least on one or more of the images.

[0021] In some embodiments, the plurality of pillar-clip interfaces are formed without the need for one or more fasteners.

[0022] In some embodiments, the plurality of pillar-clip interfaces are formed by positioning one or more fasteners in place relative to each clip and a corresponding tab on each pillar, and passing the one or more fasteners through the tab to secure the tab to the clip, or passing the one or more fasteners through the clip to secure the clip to the tab.

[0023] In some embodiments, the method further includes using a movable tool to form a plurality of holes in situ on at least the tabs of the clips and / or the supports on the solar modules. In some embodiments, the method further includes using the movable tool or another tool to install the one or more fasteners through the plurality of holes formed in situ on the clips and / or the tabs. In some embodiments, the method further includes adding the one or more fasteners to the support-clip interfaces after or during the punching process.

[0024] In some embodiments, the present invention describes a method comprising using an algorithm to identify a location suitable for the autonomous positioning and assembly of at least one solar module. In some embodiments, the method does not require or involve the participation of a user in the autonomous positioning and assembly of the at least one solar module.

[0025] In some embodiments, the algorithm is a machine learning (ML) algorithm. In some embodiments, the algorithm identifies the location based on at least one type of terrain data analysis. In some embodiments, the terrain location is obtained using at least one of aerial imaging or a Global Navigation Satellite System (GNSS).

[0026] In some embodiments, the method further includes establishing a set of executable instructions in a digital medium to enable an autonomous system to autonomously locate and assemble the at least one solar module to construct a solar module array.

[0027] In some embodiments, the autonomous system includes a plurality of field machines that are operationally communicated via a network. In some embodiments, the plurality of field machines includes robots.

[0028] In some embodiments, the present invention describes a device configured to carry a plurality of supports on a terrain. In some embodiments, the device may be further configured to autonomously position a selected support from the plurality of supports at a predetermined location on the terrain. In some embodiments, the device may be further configured to autonomously install the selected support at the predetermined location, wherein the selected support and the plurality of supports can be used to support a plurality of solar modules.

[0029] In some embodiments, the device may be further configured to perform a force test after the selected support is installed at the predetermined location. In some embodiments, the force test includes applying a tensile force to the selected support in at least one of a lateral or vertical direction.

[0030] In some embodiments, the selected support post is installed at a predetermined location by driving it into the ground using a load drive mechanism. In some embodiments, the load drive mechanism includes or is coupled to a hammer. In some embodiments, the load drive mechanism is mounted to a plurality of tracks and is movable along the plurality of tracks in a vertical direction. In some embodiments, the load drive mechanism is configured to slide along the plurality of tracks via bearings. In some embodiments, the load drive mechanism includes a retaining mechanism to prevent displacement or decoupling of the selected support post from the load drive mechanism when it is installed in the ground. In some embodiments, the retaining mechanism includes one or more shearing features. In some embodiments, the load drive mechanism includes a drive drill bit having one or more shearing features. In some embodiments, the one or more shearing features are configured to dually function as retaining features. In some embodiments, the load drive mechanism is configured to have a driving force length less than the total longitudinal length of one of the selected supports.

[0031] In some embodiments, the present invention describes a device configured to carry a plurality of solar modules on a terrain surface. In some embodiments, the device may be further configured to autonomously position a selected solar module from the plurality of solar modules onto a set of supports mounted on the terrain surface. In some embodiments, the device may be further configured to autonomously assemble the selected solar module onto the set of supports without the need for or use of fasteners.

[0032] In some embodiments, the device can be further configured to autonomously assemble a selected solar module onto a set of pillars by forming a plurality of pillar-clamp interfaces. In some embodiments, the plurality of pillar-clamp interfaces include a plurality of crimp joints. In some embodiments, a clip is pre-attached to one or more corners or sides of the selected solar module, and each pillar in the set of pillars includes a plurality of tabs. In some embodiments, the device is configured to autonomously position the selected solar module onto the set of pillars by aligning the clip with a corresponding tab at each pillar. In some embodiments, the device is configured to autonomously assemble the selected solar module onto the set of pillars by crimping the corresponding tab to the clip at each pillar.

[0033] In another embodiment, the present invention provides a ground-mounted system. The ground-mounted system may include a plurality of solar modules, each comprising a photovoltaic material and a frame. A plurality of clips may be connected to corners of the frame. Each corner may be supported by a post embedded at a relatively shallow depth in the ground. An upper post portion may include a facet of a tab connected to the clips. A lower post portion may include a point embedded in the ground. Increasing the frequency of vertically supporting post elements at each intersection of the solar modules avoids the need for deep digging of posts to support large amounts of horizontal weight transfer components, thereby minimizing material costs and simplifying site preparation. In some embodiments, each of the plurality of solar modules is supported above the ground solely by the clips and the post, without the need for an additional superstructure. In some embodiments, the lower portion further includes a serrated pattern. In some embodiments, the lower portion further includes a thread. In some embodiments, the lower portion may have no or no additional features other than its curvature. In some embodiments, the lower portion may include one or more cuts for making the post lighter and reducing the amount of material required to create a rigid and stable post. In some embodiments, the clip includes a central tab configured to protrude into a corresponding opening in the frame. In some embodiments, the device further includes a plurality of columns, wherein alternating columns of solar modules are oriented at opposite tilt angles to form a spike structure. In some embodiments, the surface is riveted to the tab.

[0034] In another embodiment, a portable device responsible for coordinating the assembly and installation of components on the ground is also disclosed. Depending on the specific embodiment, the portable device may be housed in a truck (e.g., on a platform in a truck bed) or a trailer, or may take the form of a specially constructed vehicle designed for this particular purpose.

[0035] In some embodiments, the present invention describes a method comprising inserting a lower portion (e.g., a tapered point) of a first support column into the ground at a first location in an installation site. In some embodiments, the lower portion of the first support column may not be tapered or may not be required to be tapered. In some embodiments, the method further comprises attaching a first clip to a frame of a first solar module. In some embodiments, the method further comprises connecting the first clip to an upper end of the first support column. In some embodiments, the method further comprises moving in a linear direction to a second location in the installation site. In some embodiments, the method further comprises inserting a lower portion of a second support column into the ground at the second location in the installation site. In some embodiments, the method further comprises attaching a second clip to a frame of a second solar module. In some embodiments, the method further comprises connecting the second clip to an upper end of the second support column. In some embodiments, the method further comprises moving in the linear direction to a third location in the installation site. In some embodiments, the portion is pushed into the ground. In some embodiments, the tapered point is pushed into the ground by a hydraulic actuator. In some embodiments, the portion is screwed into the ground. In some embodiments, the first clip is attached to the frame by lowering the first solar module. In some non-limiting embodiments, the solar modules may be raised or lowered using a conveyor (e.g., a vertical conveyor). In some embodiments, the first support is connected to the first clip by a tool (e.g., a forming tool or a riveting tool). In some embodiments, the second support is connected to the second clip by the tool. In some embodiments, the method further includes storing the first solar module, the second solar module, the first clip, and / or the second clip in a mobile mounting device. In some embodiments, the tool is secured to the mobile mounting device.

[0036] In some embodiments, the present invention describes an apparatus comprising a platform on a vehicle. In some embodiments, the apparatus further comprises an actuator fixed to the platform and configured to insert a support post into the ground at a first location in an installation site. In some embodiments, the apparatus further comprises a vertical conveyor fixed to the platform and configured to deliver a solar module having a frame to a load head. In some embodiments, the apparatus further comprises a clamp located on the platform and configured to position a clamp attached to the frame near the load head. In some embodiments, the apparatus further comprises a tool fixed to the platform and configured to connect the clamp to the support post. In some embodiments, the vehicle comprises a truck, a trailer, or a custom-built device. In some embodiments, the platform comprises a bidirectional workbench. In some embodiments, the apparatus further comprises a controller comprising at least one of a camera configured to determine the position of the bidirectional workbench and a Global Positioning System (GPS). In some embodiments, the tool comprises a riveting tool. In some embodiments, the actuator includes a hydraulic actuator configured to push a portion of the support column (e.g., a conical point) into the ground. In some embodiments, the vertical conveyor is configured to lower the solar module onto the clip to attach the clip to the frame. In another non-limiting embodiment, the invention provides a system including one or more mobile platforms. A plurality of modules may be stacked on a mobile platform (e.g., a module mounter), and one or more modules may be handled or moved by an automaton (e.g., a robotic arm, a component, or any mechanical or structural component) associated with the module mounter. The one or more modules may be moved to a location where one or more supports (e.g., via a mobile support mounter) have been placed, using geolocation data and / or machine or sensor vision. The one or more modules may then be mounted on the one or more supports.

[0037] In another embodiment, the present invention provides a support structure comprising a sheet metal shaped or bent to achieve a high-density stacking of the support structure. In some embodiments, the sheet metal includes one or more bent or angled portions or sections. In some embodiments, the support structure further includes one or more tabs providing a surface for connecting the sheet metal or a portion thereof to a solar module or a bracket to be attached to the solar module. In some embodiments, the sheet metal is shaped or bent into a Z-shape or a C-shape. In some embodiments, the one or more tabs are integrated or coupled to the sheet metal. In some embodiments, the sheet metal includes the one or more tabs. In some embodiments, the one or more tabs correspond to a portion or section of the sheet metal. In some embodiments, the sheet metal includes one or more holes allowing access to a tool. In some embodiments, the one or more holes are cut from the sheet metal to reduce the weight of the support structure. In some embodiments, the sheet metal includes the one or more tabs. In some embodiments, the one or more tabs are configured to open from a lower portion of the sheet metal. In some embodiments, at least a portion of the sheet metal is tapered to increase tip stress when driving the support structure into the ground. In some embodiments, the sheet metal includes one or more features that can be engaged by a drive unit to drive the support structure into the ground. In some embodiments, the one or more features include a hole. In some embodiments, the one or more features include a protrusion. In some embodiments, the one or more features are positioned at a predetermined location between a first end and a second end of the sheet metal. In some embodiments, the one or more features allow the drive unit to drive the support structure into the ground by applying a force at or near the predetermined location. In some embodiments, the support structure can be stacked or configured as one or more stacks or bundles. In some embodiments, the one or more tabs include a notch feature for suspending the support structure from a hanger or frame.

[0038] Another aspect of the present invention provides a non-transitory computer-readable medium comprising machine-executable code which, after being executed by one or more processors, implements any of the methods described above or elsewhere herein.

[0039] Another aspect of the present invention provides a system comprising one or more computer processors and computer memory coupled to the one or more computer processors. The computer memory includes machine-executable code that, when executed by the one or more computer processors, implements any of the methods described above or elsewhere herein.

[0040] Those skilled in the art will readily understand the additional features and advantages of the invention from the following detailed description, which only shows and describes illustrative embodiments of the invention. It should be appreciated that other and different embodiments of the invention are implemented, and certain details thereof can be significantly modified in various respects without departing from the invention. Therefore, the drawings and descriptions should be considered illustrative rather than restrictive. References merged

[0041] All publications, patents, and patent applications mentioned in this specification are incorporated herein by reference as if each individual publication, patent, or patent application were expressly and individually indicated to be incorporated by reference. This specification intends to discard and / or give precedence to any conflicting disclosure contained herein, to the extent that any incorporated publication, patent, or patent application contradicts the disclosure contained herein. Simple Explanation of the Diagram

[0042] The novel features of the invention are particularly set forth in the claims attached. One of the features and advantages of the invention will be better understood by referring to the following detailed description and accompanying drawings (also referred to herein as "Figures") illustrating illustrative embodiments utilizing the principles of the invention, wherein:

[0043] Figure 1 is a simplified force diagram of one of the systems of a ground mounting bracket for a solar panel.

[0044] Figure 2 shows a simplified diagram of one embodiment of a ground-mounted system.

[0045] Figure 3 shows a simplified diagram of one of the commonly known ground-mounted installation facilities.

[0046] Figure 4A shows a perspective view of one of the ground mounting systems according to one embodiment.

[0047] Figure 4B is a one-end view of the ground-mounted system shown in Figure 4A, illustrating the load-bearing capacity.

[0048] Figure 4C shows an enlarged view of one of the pillars according to one embodiment.

[0049] Figure 5A shows a perspective view of one of the ground installation systems according to one of the alternative embodiments.

[0050] Figure 5B is a simplified end view of one embodiment of Figure 5A showing the load capacity.

[0051] Figure 6A is a perspective view of a solar module array generated by a ground-mounted system according to an embodiment.

[0052] Figure 6B is a perspective view of another solar module array generated by a ground-mounted system according to one embodiment.

[0053] Figure 6C shows a perspective view of one of the alternative embodiments of a longitudinally oriented solar module, wherein the short ends are aligned in the column direction.

[0054] Figure 7A shows a perspective view of one end clip according to one embodiment.

[0055] Figure 7B shows a perspective view of one of the two modules attached to one end clip.

[0056] Figure 8A shows a perspective view of one of the corner clips according to one embodiment.

[0057] Figure 8B shows a perspective view of one embodiment of the corner clamp connected to two modules and a support.

[0058] Figure 8C shows a perspective view of one of the diagonal clips connected to a pillar and one of the attached modules.

[0059] Figure 9 illustrates the forces that a ground-mounted system can withstand.

[0060] Figure 10 illustrates the key tolerances of concern for a ground-mounted installation.

[0061] Figure 10A shows a perspective view of one of two clips in the appropriate position on a support.

[0062] Figure 10B is a perspective view showing the impact of terrain on installation.

[0063] Figure 10C is an enlarged view showing the ability of the ground-mounted system according to one embodiment to handle relatively high tolerances.

[0064] Figure 10D shows a perspective view of one embodiment of an alternative support.

[0065] Figure 11 shows an enlarged perspective view of one of the intervals between modules.

[0066] Figure 12 shows a simplified diagram of one of the alternative clip structures.

[0067] Figure 13 is a simplified diagram showing a clip attached to the side of a module.

[0068] Figure 14 is a simplified perspective view showing a clip / module assembly of one of the alternative embodiments adjacent to a pillar.

[0069] Figure 15 shows a simplified diagram of a riveting tool that can be used to rivet clips together to one side of a support.

[0070] Figure 15A shows a simplified diagram of one of the resulting press-fit joints.

[0071] Figure 15B shows a view of one of the pillars according to one of the alternative embodiments.

[0072] Figure 15C shows the manufacturing strut that remains in a spring-loaded structure after progressive stamping.

[0073] Figure 16 is a simplified diagram showing one corner of the four modules connected to a pillar.

[0074] Figure 17 illustrates one of the progressive stamping processes that can be used to manufacture clips.

[0075] Figure 18 illustrates how the clip can maintain its connection orientation in an integrated cartridge configuration after it has been formed.

[0076] Figure 19 illustrates another embodiment of a ground-mounted system.

[0077] Figure 20 shows a typical layout of a standard block of a solar module in this connection orientation.

[0078] Figure 21 shows how the four blocks in Figure 20 are connected to a central inverter.

[0079] Figure 22 is a perspective view of one part of a block.

[0080] Figure 23 illustrates a simplified flowchart of a supply chain available according to one of the embodiments.

[0081] Figure 24 is a simplified top view showing the progress of one embodiment of an installation machine at the site.

[0082] Figure 25 is a simplified top view showing the progress of one of the alternative embodiments of an installation machine 2500 at the site.

[0083] Figure 26 provides a form of coordinate system for describing a moving vehicle.

[0084] Figure 27 shows a rear perspective view of one embodiment 2700 of the installation equipment.

[0085] Figure 28 shows details of one of the vertical conveyor components that can be used to lower modules one at a time.

[0086] Figure 29 is a schematic diagram showing how a standard package of stacked solar modules can be loaded onto a vertical conveyor and lowered module by module onto a sheet metal connector.

[0087] Figure 30 shows details of one of the modules being lowered onto a connector.

[0088] Figure 31 shows a side view of a stack of solar modules on a vertical conveyor.

[0089] Figure 32 shows a front perspective view of one of the installed devices.

[0090] Figure 33 shows one view of the load head frame connected to the actuator tip.

[0091] Figure 34 illustrates a method for controlling the position of a movable platform.

[0092] Figure 35 shows a front perspective view of one of the installation devices according to one of the alternative embodiments.

[0093] Figure 36 shows an enlarged side view of one of the devices in Figure 35.

[0094] Figure 37A shows a perspective view of one of the alternative embodiments.

[0095] Figure 37B shows an enlarged view of one of the brackets.

[0096] Figure 37C shows an enlarged view of one of the rotating gears.

[0097] Figure 38A shows a perspective view of one of the alternative embodiments.

[0098] Figure 38B shows the movement of the embodiment of Figure 38A in various directions.

[0099] Figure 39 shows a top view of one of the alternative embodiments featuring a cleaning robot.

[0100] Figure 40 shows a top view of one of the alternative embodiments, characterized by staggered module placement.

[0101] Figure 41 shows a top view of one of the alternative embodiments, characterized by staggered module placement and pillar positioning.

[0102] Figure 42 shows a top view of one of the autonomous systems for positioning and assembling solar modules according to some embodiments. In some cases, the modules can be unpacked, inspected, and / or processed with or without accessories before being transported around the site. In some cases, the support mount can drive the support and continuously reload from the factor bundle. In some cases, the module mount can pull a solar module from a stack and attach it to the support. In some cases, the support can be mounted by a custom machine behind a tractor or any other type of vehicle (e.g., any type of autonomous or semi-autonomous tractor). In some cases, a module can be mounted onto a previously installed support by a machine behind a different tractor.

[0103] Figure 43 shows a top view of one of the autonomous systems for positioning and assembling solar modules according to some embodiments. 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, a reload unit may travel between stations. In some cases, a reload unit may carry a support pole, solar modules, or any combination thereof. In some cases, a reload unit may travel between a preparation station and a mobile mount unit (e.g., a tractor).

[0104] Figures 44A to 44M illustrate vehicles for positioning and assembling solar modules according to some embodiments. In some cases, a module mounter may be a custom machine built onto a tractor. In some cases, a module mounter may accommodate a stack of solar modules. In some cases, the stack of solar modules may be placed on the module mounter. In some cases, the stack of solar modules may be picked up by the module mounter. In some cases, the module mounter may carry the module stack. In some cases, the module mounter may detach a module from the module stack. In some cases, the module mounter may position a module on a plurality of mounting posts, such as two, three, or four mounting posts. In some cases, the module mounter may lower a module to a predetermined position on a plurality of mounting posts. In some cases, the module mounter may deform a metal portion of a module to establish a rigid connection between the module and the post. In some cases, the module mounter may release the module. In some cases, a module installer may test the strength of a connection formed between a module and a plurality of supports by lifting, pushing, twisting, or any force sufficient to do so. In some cases, a module installer may be driven to the next position to place a module. In some cases, a module installer may include three, four, five, or six or more degrees of motion. In some cases, a module installer may include a robotic arm configured to receive a module from a flipper. In some cases, a robotic arm may be used to pick up a module from a stack. In some cases, a support may be used to tilt back and forth to pick up and position the module. In some cases, a dual rotary motion manipulator including one, two, or more rotary joints may be used to position a module above one or more supports. In some cases, a trailer may include a support for picking up and positioning one or more modules above supports.

[0105] Figures 45A to 45D show perspective views of a machine for installing a support post according to some embodiments. In some cases, the machine may include three, four, five, or six or more degrees of freedom. In some cases, the machine may autonomously position a support post, install the support post in the ground, and / or force-test the support post and record force test data by pulling the support post laterally, vertically, or in any other direction. In some cases, the machine may be configured to carry one or more bundles of support posts on a rack. In some cases, the machine may be configured to position one or more support posts into a bundle and collect a new support post at a drive drill bit.

[0106] Figures 46A and 46B illustrate a machine for installing a support post according to some embodiments. In some cases, the machine may have three or more mounting interfaces for mounting a tractor, for example, using a three-point hook. In some cases, the machine may carry a hammer for driving a support post into the ground. In some cases, the hammer may be mounted on a vertical track and can slide freely vertically or in any other sufficiently wide direction, such that sufficiently little or no vibration is transferred from the hammer to the rest of the machine.

[0107] Figures 47A to 47I illustrate a coupling mechanism between a drive drill bit and a support post according to one of several embodiments. In some cases, a drive drill bit may be connected to a hammer. In some cases, a drive drill bit may include a shear interface for engaging a support post during striking. In some cases, a drive drill bit may include a retaining feature to prevent a support post from falling off the drill bit when it is positioned and driven. In some cases, a drive drill bit may be configured to allow a support post to be struck from the web of the support post, the web being positioned at a lower position on the body of the support post. In some cases, striking from the web allows the hammer to impact the support post with greater force compared to striking from the head, because striking from the web can effectively reduce the buckling length of the support post during striking. In some cases, a drive drill bit may enter a larger portion of a hole in a support post. In some cases, a drive drill bit may slide downwards and remain against a chisel-shaped drill bit in one configuration. In some cases, when a drive drill bit engages with a support, the head of a chisel feature on the drive drill bit may overlap at least a portion of the support. In some cases, a chisel drill bit may have one, two, three, four, or more shearing features. In some cases, a chisel drill bit may also function as a retaining feature. In some cases, a feature on a chisel drill bit may retain a support. In some cases, a feature on a chisel drill bit may separate from a feature that strikes the support. In some cases, a retaining feature may be a clock element that rotates to engage with a support. In some cases, a retaining feature may be rotated approximately 45 degrees such that a clock square of the support is retained at the corner after engagement. In some cases, a retaining feature may hang over a hole in the support. In some cases, a shaft may not engage the bottom of a hole in the support. In some cases, a pin may engage with a support without hanging.

[0108] Figures 48A and 48B show a comparison of driving a strut using different coupling mechanisms according to some embodiments.

[0109] Figures 49A to 49C illustrate the pillars according to some embodiments.

[0110] Figures 50A to 50C illustrate coupling mechanisms between a support column and a rack according to some embodiments. In some cases, a support column may include a Z-shaped section or a Z-shape. In some cases, a support column may include a substantially stackable shape. In some cases, a support column may include one or more sets of inclined tabs at its top. In some cases, a tab may include an opening feature. In some cases, the opening feature may be configured to allow a support column to be suspended from a hanger or a rack. In some cases, one or more supports may be bundled and shipped in a container or mounted on a machine.

[0111] Figure 51 illustrates one method for coupling a solar module and a bracket according to some embodiments. In some cases, a bracket may be installed by a procedure in which the module is unpacked, inspected, and / or then placed in a station on a tooling fixture. In some cases, one, two, three, four, or more rivet guns may be used to install rivets to connect a bracket to a solar module from below, side, top, or any sufficient direction. In some cases, a crimping tool or an impact actuator (e.g., for torsion nuts) may be used instead of a rivet gun.

[0112] Figure 52 illustrates one method for autonomously positioning and assembling a solar module according to some embodiments. In some cases, a module mounter can be driven to a position. In some cases, a module mounter can pick up a module. In some cases, a module mounter can position a module onto one, two, three, four, or more supports. In some cases, a crimping tool can be used to form a connection between the module and one or more supports. In some cases, the crimping tool can be fitted between an ear of a support and a clamp. In some cases, the crimping tool can be closed to form a joint. In some cases, the module mounter can release the crimping tool. In some cases, an end effector can be used to lift a module. In some cases, a module mounter can be driven to the next group of one or more supports to install the next module.

[0113] Figure 53 illustrates a plurality of brackets that can be coupled to one or more pillars according to some embodiments. In some cases, a solar module may include a bracket. The bracket may be attached to or coupled to the solar module. In some cases, the bracket may include a deformable metal. In some cases, a connection may be formed between the bracket and a pillar. In some cases, the connection may be formed by crimping the bracket and the pillar together. In some cases, the bracket may include a flat or angled metal piece configured to be riveted to a module, for example, through mounting holes. In some cases, the bracket may be connected to a module by crimping the bracket to a frame of the module.

[0114] Figures 54A to 54C illustrate a method for determining a landscape topology for locating and assembling solar modules according to some embodiments. In some cases, the method may include analyzing a 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 supports and modules installed on the given terrain. In some cases, the method may include uploading the geographic location and construction data of the supports and modules for installing one or more machines.

[0115] Figure 55 illustrates a GUI for determining a landscape topology for locating and assembling solar modules according to some embodiments.

[0116] Figure 56 illustrates one of the modules comprising a fixed tilt array according to some embodiments. In some cases, the module may be rigidly connected to two pillars. In some cases, the module may include a small support bracket directly mounted to a pillar without an intermediate structure. In some cases, a module may be driven by a 90-degree linkage, wherein each module can be driven to a desired angle, for example, without driving the entire tracker "stage" together. In some cases, a module may span two or more pillars without an intermediate structure between the pillars. In some cases, the modules may be connected by a continuous wire or chain. In some cases, the continuous wire or chain may be driven by a mechanism to track the solar modules around one or more pivots on the pillars. In some cases, each module may include a separate drive or actuation unit, allowing each module to track the sun independently.

[0117] Figure 57 illustrates a solar tracker according to one of some embodiments.

[0118] Figure 58 illustrates a tracking unit according to one of several embodiments. In some cases, a tracking unit can be deployed autonomously. In some cases, a tracking unit can be pre-assembled, distributed, and placed in a field. In some cases, a tracking unit can autonomously wire using geographic location data and / or any of the machines disclosed herein. In some cases, the installed tracking unit can be expanded to track a single module solar orbit on one, two, or three axes.

[0119] Figure 59 illustrates a light curtain according to one of some embodiments. In some cases, a machine may include one or more optical sensors configured to detect when an object (e.g., a person or another agent) enters a workspace defined by a light curtain.

[0120] Figure 60 illustrates a solar module array configuration according to some embodiments. In some cases, a solar module array may include four supports for each corner of a module. In some cases, a solar module array may include two supports along one central axis of a module.

[0121] Figure 61 illustrates a computer system according to one of some embodiments.

[0122] Figure 62 illustrates an alternative embodiment of an exemplary vehicle that can be used or configured to handle, transport, install or deploy one or more solar modules.

[0123] Figure 63 illustrates another alternative embodiment of an exemplary vehicle that can be used or configured to handle, transport, install or deploy one or more solar modules.

[0124] Figure 64 illustrates an end effector according to one of some embodiments and a riveting tool positioned at the corner of the end effector.

[0125] Figure 65 illustrates the bottom portion of a riveting tool that can be tapered to help position a module or engage with a module.

[0126] Figures 66A and 66B illustrate one alternative embodiment of the clip according to one of some embodiments.

[0127] Figure 67 illustrates an alternative embodiment of a module mounter vehicle according to one of some embodiments.

[0128] Figure 68 illustrates an exemplary configuration of one of the pillars according to one of some embodiments.

[0129] Figures 69A and 69B illustrate one alternative embodiment of the clip described herein according to some embodiments.

[0130] Figure 70A illustrates an additional sheet metal feature that can be used to hold one or more leads or wires of a solar module and keep them fixed in a particular side of the module for later disposal or processing.

[0131] Figure 70B illustrates one embodiment of a clip, wherein a module wire is connected to the clip, the clip is also connected to the module and will be connected to the support.

[0132] Figure 70C illustrates the use of an additional tool to independently obtain the solar module wires held in place by clips and connect them to each other to form an electrical connection between the modules.

[0133] Figure 71 illustrates an alternative embodiment of one of the tools and methods in Figures 70A, 70B and 70C, wherein the tool does not push the two connectors together, but cuts, strips and twists the wires together without using one connector.

[0134] Figures 72 and 73 illustrate an exemplary configuration in which multiple modules are oriented and positioned at a 90-degree angle relative to the ground.

[0135] Figure 74 illustrates an example of an intermediate clip according to one of some embodiments.

[0136] Figure 75 illustrates a removable access slot that can be placed on top of a support pillar in the valley or peak of a solar module array.

[0137] Figures 76 and 77 illustrate a bracket on a wheel that can be driven on the ground in the gaps between arrays in certain configurations. Implementation

[0138] Cross-reference

[0139] This application claims the rights of U.S. Provisional Application No. 63 / 155,193, filed March 1, 2021, and U.S. Provisional Application No. 63 / 308,045, filed February 8, 2022, the entire contents of which are incorporated herein by reference for all purposes.

[0140] Although various embodiments of the invention have been shown and described herein, those skilled in the art will understand that these embodiments are merely illustrative. Many variations, modifications, and substitutions will arise in the mind of those skilled in the art without departing from the invention. It should be understood that various substitutions may be made for the embodiments of the invention described herein.

[0141] Whenever the terms "at least," "greater than," or "greater than or equal to" precede the first value in a series of two or more 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.

[0142] Whenever the terms "not exceeding," "less than," or "less than or equal to" precede the first value in a series of two or more 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.

[0143] As used interchangeably in this document, the term "immediate" generally refers to an event (e.g., an operation, a procedure, a method, a technique, an operation, a calculation, an analysis, a visualization, an optimization, etc.) performed using recently acquired (e.g., collected or received) information. In some cases, an immediate event may be performed almost immediately or within a sufficiently short time span, such as within at least 0.0001 milliseconds (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 seconds, 0.05 seconds, 0.1 seconds, 0.5 seconds, 1 second, or longer. In some cases, an instantaneous event may be performed almost immediately or within a sufficiently short time span, such as within 1 second, 0.5 seconds, 0.1 seconds, 0.05 seconds, 0.01 seconds, 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 less.

[0144] In one embodiment, the present invention provides systems and methods for handling and deploying energy modules. The energy module may include one or more solar modules. The solar module may include a deployable device configured to use one or more resources to generate energy. In some cases, the one or more resources may include solar energy, thermal energy, radiant energy, or any other type of energy.

[0145] In one embodiment, the present invention provides a method for handling and deploying a solar module. The method may include using at least one robot to autonomously locate and assemble (i) at least one solar module and (ii) its support structure at a sensed geographic location, without the assistance of a user. In some cases, multiple robots may be used to autonomously locate and deploy, install, or assemble multiple solar modules and / or one or more support structures of multiple solar modules.

[0146] In some contexts, a robot can refer to any machine capable of performing one or more tasks. In others, a robot can perform one or more tasks autonomously (e.g., without human intervention or external intervention from another entity) or semi-autonomously (e.g., with minimal external supervision, instructions, or intervention).

[0147] In some cases, a task may include transporting various components for deploying one of the energy modules disclosed herein (e.g., an energy module or a support pillar). In some cases, a task may include installing various components for constructing one of the energy modules disclosed herein, such as mounting a support pillar on the ground or connecting an energy module to a given support pillar. In some cases, a task may include disposing of and deploying an energy module.

[0148] In some cases, a robot may include one or more movable components. In some cases, the movable components may include an arm or an end effector. The movable components may be configured to handle, move, or deploy energy modules.

[0149] In some cases, a robot may include one or more energy storage devices (e.g., a battery). In some cases, one or more energy storage devices may be charged by a renewable energy system. In some embodiments, one or more charging stations may be provided and distributed across a terrain to enable charging of one or more robots. One or more robots may include, for example, a mobile platform, a vehicle, or any other machine described elsewhere herein. In some embodiments, one or more charging stations may be mobile. In these cases, the charging station may be configured to travel to one of the robots or vehicles that needs charging. In other embodiments, one or more charging stations may be stationary. In these cases, one or more robots or vehicles may be configured to travel to one or more charging stations for charging.

[0150] In some cases, the robot may include a vehicle. In some cases, the vehicle may include one or more wheels, one or more legs, or any other component configured to transport the robot on flat or uneven terrain.

[0151] In some cases, a robot may include one or more vision sensors. In some cases, a robot may perform a task based at least in part on information provided by one or more vision sensors.

[0152] In some cases, a robot may include one or more computers, processors, or logic circuits that are operable in communication with another robot or one or more servers (e.g., a cloud server).

[0153] In some cases, multiple robots can be used to autonomously locate and deploy multiple supports configured to support multiple solar modules. Solar modules can be attached to one or more supports. Figure 4C shows an enlarged view of one support 450 according to one embodiment. In some cases, the support may include a flat-top interface 452 providing a crimping surface for a clamp. In some cases, the support may be made of sheet metal (e.g., provided in a coil). In some cases, a lower portion of the support may include a serrated pattern 454 cut to provide resistance to pull-out from the ground. In some cases, an exemplary support may be about 3 ft long, with 1 ft exposed from the ground and 2 ft extending into the ground. In some non-limiting embodiments, the support may have a length ranging from about 1 ft to about 10 ft.

[0154] In some embodiments, the strut may include a tip 456 for efficient driving into the ground (e.g., by (hydraulic) actuation). In some cases, the taper of this end may be determined to accommodate the shape of a corresponding tip of a next strut in the coil, thereby saving sheet metal material and reducing costs.

[0155] In some cases, the embodiments disclosed herein allow for vertical adjustment of the dimensions of the support protruding above the ground. In some cases, vertical adjustment can be achieved by pushing it in deeper or by adding an upper attachment to increase the height of the support.

[0156] In some cases, a robot may install a first pillar at a first location and a second pillar at a second location. In some cases, the first and second locations may be close enough that an energy module may be installed to be supported by both the first and second pillars. In some cases, two separate energy modules may be installed to be supported by either the first or second pillar. In some cases, the first pillar may be installed first, followed by the second pillar. In some cases, the first and second pillars may be installed substantially at approximately the same time. In some cases, a first robot may install a first pillar at a first location and a second robot may install a second pillar at a second location. Various numbers of pillars may be installed by a given robot. One or more pillars may be installed by a given robot at various locations.

[0157] In some cases, multiple robots can be configured to operate as a fleet or a group. Multiple robots can communicate with one or more servers configured to control the operation or movement of one of the robots within an area or location, including sensing a geographic location. Servers 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 implemented in various configurations to achieve a similar effect, for example, by using various numbers of robots, various types of robots, various numbers of supports, and various sets of rules or algorithms for coordinating the robots.

[0158] In some cases, multiple robots can be configured to operate in a coordinated manner to optimize the time spent performing one or more tasks. For example, a first group of robots can coordinate to install one or more supports at a first location and then immediately install one or more supports at a second location. A second group of robots can coordinate with the first group to immediately install a solar module at the first location while one or more supports are installed. In some cases, the first location may be an area near the robot. In some cases, the first location may be an area near the location where the solar module is stored. In some cases, the second location may be close to the first location. In some cases, the second location may be a geographically sensed location (e.g., using one or more location sensors and / or geographic or topological data to determine or identify a location). In some cases, the second location may be a general location, and the general location can be adjusted in real time to a more precise location.

[0159] In some cases, the method may include using at least one robot to 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 may include a first direction and a second direction. The first and second directions may be parallel to each other. Alternatively, the first and second directions may be positioned at an angle relative to each other. The angle may be in the range of 0 degrees to 180 degrees.

[0160] In some cases, at least one robot may use a movable component to handle a solar module or any of its components or supporting structures. In some cases, at least one robot may move a solar module or any of its components or supporting structures by translating along one, two, or three Euclidean dimensions. In some cases, at least one robot may move a solar module or any of its components or supporting structures by rotating the solar module about one, two, or three axes of the solar module. In some cases, at least one robot may simultaneously translate and rotate the solar module. In some cases, at least one robot may translate the solar module and then subsequently rotate it, or vice versa. In some cases, for a solar module that is substantially rectangular in shape, one axis of the solar module may be defined as the normal direction 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 may move the solar module in various ways, including changing the position and / or orientation of the solar module or one of its components.

[0161] In some cases, solar modules, support structures, and any of their components may be repositioned and / or reoriented for more precise and / or to ensure proper installation during deployment. In some cases, a given support column may be repositioned and / or reoriented to ensure successful insertion into the ground.

[0162] Figure 52 illustrates an exemplary method for autonomously positioning and assembling a solar module according to some embodiments. In some cases, a module installer (e.g., a robot) can be driven to a location. The location can be determined by a user or operator of the robot or based on sensor data. In some cases, a module installer can pick up an energy module (e.g., a solar module). In some cases, a module installer can position the module on one, two, three, four, or more supports. The supports can be autonomously installed by another robot.

[0163] In some cases, a crimping tool can be used to form a connection between a module and one or more supports, as will be described in more detail below. In some cases, the crimping tool can be fitted between a lug of a support and a clamp. In some cases, the crimping tool can be closed to form a joint. In some cases, a module installer can release the crimping tool. In some cases, an end effector can be used to dispose of the tool and / or install the module. In some cases, a module installer can be driven to one or more supports in another group to install another module.

[0164] In some embodiments, the method may include using at least one robot to autonomously locate and assemble a plurality of solar modules and associated support structures to construct a solar module array. In some cases, the plurality of solar modules and associated support structures may include at least one solar module and a support structure for one of the at least one solar module.

[0165] In some cases, an array of modules, solar modules, energy modules, and the like may refer to a plurality of solar modules configured across an area or region. In some cases, the configuration may be a lateral configuration. In some cases, the configuration may include a plurality of columns and / or rows. In some cases, the configuration may include a circular pattern and / or a ring configuration. In some cases, the configuration may include a hexagonal (e.g., honeycomb) pattern. In some cases, the configuration may include a random configuration. In some cases, the configuration may be at least partially based on the terrain or topology of the area or region where the array is deployed or will be deployed.

[0166] In some cases, the solar module array and / or various supporting structures (e.g., pillars) may be constructed, deployed, or installed on a substantially flat terrain. In other cases, the solar module array may be constructed on a substantially uneven terrain. The terrain on which the solar module array and / or various supporting structures (e.g., pillars) are constructed, deployed, or installed may include, for example, sand, rock, water, ice, vegetation, grassland, or any other man-made or natural surface. In some cases, the terrain may include a canyon, a desert, a forest, a glacier, a hill, a swamp, a mountain range, a valley, an oasis, an ocean or other body of water, open terrain, riverine terrain, swampy terrain, or tundra terrain.

[0167] In some cases, the terrain may include one or more flat sections and / or one or more sloping sections. In some embodiments, the sloping sections may have a slope ranging from about 1 degree to about 30 degrees or greater.

[0168] Figure 60 illustrates various solar module array configurations according to some embodiments. In some cases, the solar module array may include four supports for each corner of a module. In some cases, the solar module array may include two supports along one central axis of a module. In some cases, the solar module array may be a fully wired array. In some cases, the solar module array may be a double-tilted array. In some cases, the solar module array may be a fixed-tilt array. In some cases, one or more modules in the array may be directly mounted to a support without a support bracket spanning an intermediate structure. In some cases, one or more modules may span two or more supports without an intermediate structure between the supports. Figures 72 and 73 illustrate an exemplary configuration in which a plurality of modules are oriented at a 90-degree angle relative to the ground. In some cases, the solar modules may be tilted to a full 90 degrees. In some cases, a plurality of supports may be attached to one or more sides of the solar module. In some cases, the configuration and / or arrangement of solar modules may allow access to the space between various columns in a solar module array. In some cases, the space between various columns in the array may be used for crop growth. Supports, clips, and modules may be placed, installed, or deployed according to any of the embodiments, methods, and / or system configurations shown and described herein.

[0169] In some cases, modules can be configured to independently track the sun. Tracking the sun may include moving, repositioning, or reorienting the module so that one of the module's working surfaces can receive light from one or more of the sun's rays.

[0170] In some cases, the module may track the sun based at least in part on a forecast, the module's position, or both. In other cases, the module may track the sun based at least in part on a measurement signal (such as energy or electrical charge generated by the module).

[0171] In some cases, each module may include an individual drive, allowing each module to track the sun independently. In other cases, the modules may be connected to a continuous wire or chain. The continuous wire or chain may be driven by a mechanism (e.g., one or more motors) to track the solar modules around one or more pivots on a support. In some cases, the modules may 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 platform.

[0172] In some cases, one or more mechanisms may be installed at one end of a solar module array. In some cases, one or more mechanisms may be installed at two opposite ends of a solar module array. In some cases, one or more mechanisms may be installed between the solar modules in the array. Any sufficient number of mechanisms may be installed between solar modules, and any sufficient arrangement of mechanisms may be installed between solar modules.

[0173] Figure 57 illustrates a solar tracker according to one of some embodiments. The solar tracker may include a solar module with sun tracking capability and / or a mechanism for moving one or more parts or components of a solar module to track the sun.

[0174] In some cases, a solar module array may include a plurality of solar modules substantially linearly arranged in at least one direction. In some cases, the linearly arranged plurality of solar modules may be coupled to one or more cables or chains along the linear direction. In some cases, one or more cables or chains may be pulled along the linear direction, thereby reorienting and / or repositioning the plurality of solar modules.

[0175] In some cases, a plurality of solar modules may be substantially linearly arranged in at least two directions. In some cases, a plurality of solar modules may be coupled to at least two sets of cables or chains in at least two directions. In some cases, one or more cables in a first set may be pulled along a first linear direction to reorient and / or reposition the plurality of solar modules in that first direction. In some cases, one or more cables in a second set may be pulled along a second linear direction to reorient and / or reposition the plurality of solar modules in that second direction.

[0176] In some cases, one or more cables or chains may be coupled above or below a given solar module. In some cases, one or more cables or chains may be coupled to the side of a given solar module.

[0177] Figure 58 illustrates a tracking unit according to one of some embodiments. The tracking unit may include a solar module with solar tracking capability and / or a mechanism for moving one or more parts or components of a solar module to track the sun.

[0178] In some cases, the tracking unit can be deployed autonomously. In others, it can be pre-assembled, distributed, and placed in a field. In still others, it can be located, deployed, or autonomously wired using geolocation data and / or any machine or robot disclosed herein. In some cases, the tracking unit can be expanded to be used for single-module solar tracking to track the sun on one, two, three, or more axes.

[0179] The methods disclosed herein can be implemented using a ground-mounted system for solar panels. The ground-mounted system may include a system, a structure, or a plurality of components configured to support or stabilize an energy module when it is deployed.

[0180] Figure 1 is a simplified force diagram of a system 100 for ground-mounted solar panels according to some embodiments. Here, the active photovoltaic (PV) materials and any associated components (frame, beam, column, superstructure, junction box, wiring) represent a physical load G 102 that is safely and reliably supported above the ground 104 against at least gravity and possible external forces (e.g., wind, earthquake).

[0181] Figure 2 shows a simplified diagram of one 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 ground 204 by a plurality of supports 206. In some cases, separate and different superstructures are not required. In some cases, these supports can be relatively small and can be installed at a high frequency f. In some cases, each support can bear a much smaller portion of the total load. Furthermore, for the embodiment of Figure 2, the installation efficiency does not need to be distributed across a large area of ​​solar modules. Therefore, the load can be determined by a smaller expected local peak. Due to the reduced load that each support needs to bear, the supports can penetrate the ground to a shallower depth. In some cases, no additional support material (e.g., concrete) is required to secure the supports to the ground. In some cases, this mounting structure allows for simpler, cheaper, and less intrusive installation techniques, such as by (hydraulic) push or screwing as described herein.

[0182] Figure 3 illustrates a conventional ground-mounted structure 300 for supporting a solar module 302 according to some embodiments. This is a connecting structure comprising a separate superstructure 304 and relatively large columns 306. These columns appear at a relatively low frequency (F) and each bears a relatively large portion of the entire load. In some cases, they are recessed to a considerable depth (D) below the ground 308 and can be secured therein with additional materials such as concrete (not shown in the figure).

[0183] Some embodiments of the present invention utilize the interconnectivity between modules to provide stability, rather than relying on individual, distinct, and large upper-level structural components to achieve structural stability. Figure 4A shows a perspective view of a ground-mounted system 400 according to one embodiment. In some cases, a plurality of supports 450 can support a row of solar modules 402. In some cases, a rectangular solar module comprising 72 cells is shown. Various embodiments can support various types of solar modules. At each corner, the solar module can be secured to its respective support by a clip 404.

[0184] Figure 4B is an end view of the ground-mounted system of Figure 4A according to some embodiments. Figure 4B shows the tilt angle 410 provided by the ground-mounted frame, which orients the solar modules to capture sunlight. Figure 4B shows that, according to some embodiments, wind can penetrate the open side of the column to generate wind load force.

[0185] Although the ground-mounted embodiments of Figures 4A and 4B show a single-row module supported by the same tilt angle, alternative embodiments may feature rows with 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 support 502 may alternate in tilt angle to create a peak structure. In some cases, the solar module 504 may be secured to the support by clips of different shapes. One type of clip may be an end clip 506 present on one side of a row that does not have adjacent rows on one side. Figures 7A and 7B depict examples of end clips according to some embodiments. Figure 7A shows a perspective view of an end clip according to one embodiment. As shown, the end clips are symmetrical at both ends of the module. The end clips grip the bottom and top sides of the frame. Figure 7B shows a perspective view of an end clip with two modules attached according to some embodiments. The central protrusion 700 prevents the module from sliding laterally. According to one embodiment, the end clip may be made of 1 mm sheet metal. Another type of clip can be an intermediate clip 508 existing between adjacent columns. Figure 74 illustrates one example of an intermediate clip. The intermediate clip can be used for a solar module that interfaces with a support in a central region of the lateral side of the module. In some cases, the clip may have an angled opening to accommodate multiple tilt angles and facilitate autonomous positioning or alignment of the clip and / or the module. In some cases, the support may have a flat surface and a notch, such that the support flange can be bent in and crimped (punched) to the module clip at a position corresponding to the green dot. The module clip can be mounted with a rivet or bolt, or crimped to the module frame at its standard mounting point on the bottom flange. Another type of clip can be a corner clip. Figures 8A to 8C depict examples of corner clips. Figure 8A shows a perspective view of a corner clip 801 connected to a frame 802 of a solar module 804 that includes photovoltaic material 806 (e.g., a plurality of solar cells). The clip may include a central tab 800. Figure 8B shows a perspective view of a corner clip connected to two modules and a support according to some embodiments. A central tab 800, which mates with the face of the support tab (e.g., by crimping), may be long enough to accommodate tolerances and provide flexibility to accommodate tolerances in at least one direction. Figure 8C shows a perspective view of a diagonal clip connected to a support and an attached module according to some embodiments. In some cases, the clip may exhibit a single mirror design, such that the tab lands on the opposite side of the support. The corner clips shown and described herein may be attached to a module without or without the use of a fastener.

[0186] Figure 5B is a simplified end view illustrating one embodiment of the load-bearing capacity of Figure 5A. In some cases, the inability of wind to flow beneath the raised sides of the module array can substantially reduce the wind load-bearing capacity expected to be experienced by the ground-mounted system.

[0187] Figure 6A is a perspective view of a solar module array generated by a ground-mounted system according to one embodiment. In some cases, the array may include a plurality of short (two-module) columns spaced apart by a small interval S. In other cases, multiple columns may be closely spaced together to save floor space and improve installation efficiency.

[0188] Figure 6B is a perspective view of another solar module array generated by a ground-mounted system according to one embodiment. In some cases, the array may include long columns of modules. In some cases, the corners of each column may be adjacent to the corners of the next column and supported by the same pillars.

[0189] Although Figures 6A and 6B show solar arrays with rows of laterally oriented solar modules aligned in the column direction, this is not necessary. Figure 6C shows a perspective view of one alternative embodiment with longitudinally oriented solar modules whose short ends are aligned in the column direction.

[0190] Figure 9 illustrates the peel and shear forces that the ground-mounted system can withstand. Certain embodiments can provide a shear strength of at least about 400 lbs and / or a peel strength of at least about 200 lbs.

[0191] Figure 10 illustrates the key tolerances of concern for a solar array installation according to one of some embodiments. In some cases, the spacing between the supports and / or the angle of the solar modules can be adjusted along a column, allowing the solar array to be positioned or aligned to a desired orientation. Figure 10 also illustrates tilt axis angular alignment according to one of some embodiments. In some cases, the angular orientation of the solar modules can be fixed or movable. In some cases, the solar modules can have a double tilt angle. Figure 10 further illustrates a ground-mounted installation on a slope according to one of some embodiments. In some cases, in addition to the slope angle, a tracker can also adjust the angle of a solar module from at least about 1° to about 10° or greater.

[0192] Figure 10B shows a side perspective view illustrating the impact of uneven terrain on installation according to some embodiments. Figure 10C is an enlarged view showing the capabilities of components of some embodiments disclosed herein, which can be rotated relative to each other to accommodate tolerances.

[0193] While some embodiments have shown a post with a grounding terminal having a serrated pattern, this is not necessary. Alternative embodiments may utilize a post in the form of a grounding screw. In some embodiments, the post may include two sections, with a screw portion entering first and a top portion (allowing vertical adjustment) attached to the screw portion.

[0194] Figure 10D shows a perspective view of one of the alternative embodiments, featuring a grounding screw as one of its characteristics. In some cases, a four-way clip may be held by a standard retaining ring snapping into a groove on the support. In some cases, vertical tolerance may be accommodated by having multiple grooves. In some cases, corner tolerance may be accommodated by enlarged holes. In some cases, an assembly may withstand at least about 10 lbs, 20 lbs, 30 lbs, 40 lbs, 50 lbs, 100 lbs, 200 lbs, 300 lbs, 400 lbs, 500 lbs, or greater lift in a corner region.

[0195] Figure 10A shows a perspective view of a clamp that has been substantially rotated to accommodate tolerances in its proper position on a strut tab (e.g., using a tool from an installation machine). In some cases, the crimping can be performed in situ (e.g., when the module contacts the strut tab), locking it in place while accommodating some additional flexibility. According to some embodiments, a crimping tool can perform at least two punching operations (e.g., 800 lbs shearing / 400 lbs peeling) on ​​the entire joint.

[0196] Figure 14 is a simplified perspective view of one embodiment of a clip / module assembly adjacent to an alternative embodiment of a support column. The support column 1400 may include two opposing large tabs 1402 and 1404 at its top, which provide large surfaces for press-fitting the clips. Figure 15 is a simplified diagram of a press-fitting tool 1500 according to some embodiments, which can be used to press-fit the clips together to one side of the support column. Figure 15A shows a simplified diagram of a press-fitting joint obtained according to one embodiment. Figure 15B shows a view of one support column according to an alternative embodiment. The two large tabs at the top provide large surfaces for press-fitting the clips. Figure 15C shows a manufacturing support column maintained in a spring-loaded structure after progressive stamping according to some embodiments.

[0197] The clamping and riveting operations disclosed herein allow for the formation of a joint from two or more plates that at least partially overlap. The plates may not be parallel to each other, and in fact may be at an angle relative to each other (e.g., depending on the terrain or the spatial configuration of the solar module or other components associated with its support structure). The plates can be provided in different relative positions or orientations and can be uniquely deformed to accommodate a wide range of angular or positional variations in the plates, supports, surrounding terrain, or the positioning of any solar module relative to the plates or supports. The systems and methods disclosed herein allow for tolerances in shaping or forming a joint to simplify installation procedures and provide additional flexibility for assembling various components or systems relative to each other without compromising structural integrity. These tolerances also allow for the installation of supports and solar modules without requiring precise fine-tuning of the position, orientation, and / or relative alignment of supports or solar modules, especially when such supports or solar modules are installed on uneven terrain with varying profiles.

[0198] Figure 16 is a simplified diagram showing one corner of four modules connected to a support pillar according to some embodiments. This view illustrates the reversibility of the clip and also demonstrates the angular tolerance of the clip relative to the support pillar to accommodate tilt angles.

[0199] Figure 17 illustrates one of the progressive stamping processes that can be used to manufacture a clip according to some embodiments. Figure 18 illustrates how a clip can maintain its connection orientation in an integrated cartridge configuration after it has been formed, according to some embodiments.

[0200] Figure 19 illustrates another alternative embodiment of a ground-mounted system for one of the solar modules. In some cases, if a heavy load is present, several additional clips may be installed on the ridges (hollow squares) of the two modules and / or the lower junctions (solid squares) of the module points. These additional clips can connect two adjacent modules. This configuration of additional clips may also (but not necessarily) include a support column (dashed line) that can be pushed into the ground.

[0201] According to some embodiments, the clip can be pre-installed on a post at the factory. The retaining ring described herein can be pre-installed at the factory. This allows sufficient vertical tolerance for penetration variations in the post. In some embodiments, this allows for approximately 1 inch of vertical clearance, thereby facilitating installation and increasing flexibility under applied load.

[0202] Figure 11 shows an enlarged perspective view of one of the gaps between adjacent modules according to some embodiments. In some cases, the gap can be sized to allow for tool access based on tolerance availability. A particular embodiment may be characterized by a gap of approximately 2'' on one side of the module, wherein the gap on the orthogonal side of the module is smaller.

[0203] Although the foregoing figures illustrate one particular embodiment of a ground-mounted solar panel system, other embodiments are possible. For example, Figure 12 shows a simplified diagram of one alternative clip structure 1200 according to one of some embodiments. Here, the clip may include flexible tabs 1202 and may be reversible. Figure 13 is a simplified diagram showing an embodiment of the clip of Figure 12 attached to the side of a frame 1300 of a solar module 1302. In some cases, the clip may be configured to engage with both the top and bottom of the module via multiple tabs.

[0204] Figure 42 shows a top view of one of the autonomous systems for locating and assembling solar modules according to some embodiments. In some cases, the system can be configured to unpack, inspect, and / or process the solar modules with or without accessories prior to transport around a location.

[0205] In some cases, the system may include one or more strut mounters. The strut mounters can drive the struts and continuously reload the bundles. In some cases, the struts may be mounted by a custom machine behind a vehicle (e.g., a tractor). The vehicle may be an autonomous or semi-autonomous vehicle.

[0206] In some cases, the system may include one or more module mounters. A module mounter can pull a solar module from a stack and attach it to one or more deployment posts. In some cases, a module may be mounted on a previously installed post by a machine behind a different vehicle (e.g., a different tractor). The vehicle may be an autonomous or semi-autonomous vehicle.

[0207] Figure 43 shows a top view of one of the autonomous systems for positioning and assembling solar modules according to some embodiments. In some cases, the vehicle used to deploy the support pillar or solar module may be fully electric. In some cases, a mobile power unit may be located at or near a location where the vehicle can be charged. In some cases, the mobile power unit may include one or more solar panels and / or batteries. In some cases, a reloading unit may operate between stations. In some cases, a reloading unit may carry the support pillar, solar module, or any combination thereof. In some cases, a reloading unit may travel between a preparation station and a mobile installer unit (such as an autonomous vehicle or robot described elsewhere herein).

[0208] In another embodiment, the invention provides a method comprising providing one or more mobile platforms configured to carry a plurality of pillars and a plurality of solar modules. The mobile platform may include any of the robots, machines, or autonomous vehicles described herein.

[0209] In some embodiments, a plurality of support pillars may be positioned and installed on the terrain by a first mobile platform according to a predefined configuration. In some embodiments, a plurality of solar modules may be deployed onto a set of support pillars by a second mobile platform.

[0210] In some cases, one or more operational platforms may be equipped with one or more sensors. These sensors may include, for example, a location sensor (e.g., a geolocation sensor), a vision sensor (e.g., an image sensor or a camera), a GNSS unit, a GPS unit, an accelerometer, a motion sensor, a gyroscope, or any combination thereof. In some cases, the sensors may include a stereo vision sensor, a depth sensor, a binocular vision sensor, or an infrared sensor. In some cases, the sensors may include a radar unit, a LiDAR unit, an altitude sensor, a proximity sensor, an inertial measurement unit, a contact sensor, a pressure sensor, a piezoelectric sensor, or a force sensor.

[0211] 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 supports and a plurality of solar modules on a terrain to construct a solar module array. In some embodiments, the method may further include using one or more sensors to position and move one of the mounter load heads on one or more mobile platforms relative to the solar module array during array construction. The mounter load head may include a movable element capable of automatically positioning and / or deploying one or more supports to a target location.

[0212] In some embodiments, one or more mobility platforms may include a first platform for positioning and mounting a plurality of struts onto 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 separate 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 mobility platforms may include one or more electric vehicles.

[0213] In some embodiments, a plurality of solar modules may be pre-stacked on a second platform, and the second platform may include a mechanism for extracting a selected solar module from the stack and assembling the selected solar module onto a selected set of supports already installed on the terrain.

[0214] Figures 44A to 44M illustrate vehicles for positioning and assembling solar modules according to some embodiments. In some cases, a module mounter may be a custom machine built into a vehicle. In some cases, a module mounter may accommodate a stack of solar modules. In some cases, the stack of solar modules may be placed on the module mounter. In some cases, the stack of solar modules may be picked up by the module mounter. In some cases, the module mounter may carry the module stack. In some cases, the module mounter may detach a module from the module stack. In some cases, the module mounter may position a module on a plurality of mounting posts, such as two, three, or four mounting posts. In some cases, the module mounter may lower a module to a predetermined position on one of the plurality of mounting posts.

[0215] In some cases, the module installer can deform a metal portion of a module to form a rigid connection between the module and the supports. In some cases, the module installer can release the module. In some cases, the module installer can test the strength of a connection formed between the module and multiple supports by lifting, pushing, twisting, or any sufficient force.

[0216] In some cases, a module mounter can be driven to the next position to place a module. In some cases, a module mounter may include three, four, five, or six or more degrees of motion. In some cases, a module mounter may include a robotic arm configured to receive a module from a flipper. In some cases, a robotic arm may be used to reach and pick up a module from a stack. In some cases, a support may be used to tilt back and forth to pick up a module and position it rearward. In some cases, a dual rotary motion manipulator including one or more rotary joints may be used to position a module above one or more supports. In some cases, a support may be used to pick up and position one or more modules onto one or more mounting supports.

[0217] In some embodiments, an integrated crimping tool may be provided on a mounter load head to establish multiple post-clip interfaces between multiple clips and multiple posts. In some cases, the multiple clips may be pre-attached to multiple solar modules.

[0218] Figure 53 illustrates a plurality of brackets that can be coupled to a support column according to some embodiments. In some cases, a solar module may include a bracket. The bracket may be attached to or coupled to the solar module. In some cases, 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 cases, a connection may be formed between the bracket and a support column. In some cases, the connection may be formed by crimping the bracket and the support column together. In some cases, the bracket may include a flat or angled metal piece configured to, for example, be riveted to a module through mounting holes. In some cases, the bracket may be connected to a module by crimping the bracket to the frame of a module. In an alternative embodiment, the module clip may be directly crimped or punched to the solar module frame instead of being riveted or bolted through mounting holes.

[0219] Figure 51 illustrates one method for coupling a solar module and a bracket according to some embodiments. In some cases, a bracket may be installed in a station where the module has been unpacked, inspected, and / or subsequently placed on a tooling fixture. In some cases, one, two, three, four, or more rivet guns may be used to install rivets to connect a bracket to a solar module from below, side, top, or any sufficient direction. Using rivets eliminates the need for pre-drilled holes with precise tolerances. In some cases, a press-fit tool or an impact actuator (e.g., for torsion nuts) may be used instead of a rivet gun.

[0220] In some embodiments, the method may further include assessing the structural integrity of a post-clamp interface using at least one of a measuring force or a deflection during and / or after the solar module is mounted onto the post. In some cases, the structural integrity of the post-clamp interface may be assessed by testing separation forces, resistance to shear forces attributable to translational or rotational motion, and / or resistance to tensile forces.

[0221] In some embodiments, the method may further include acquiring images of a plurality of pillar-clip interfaces during or after interface formation. In some embodiments, the method may further include determining the structural integrity of one of the plurality of pillar-clip interfaces based at least on one or more of the images.

[0222] In some embodiments, the method may further include performing tensile strength and assembly tests on one or more of a plurality of mounting posts using a testing tool located on one or more operational platforms. In some cases, the testing tool may be used to apply thrust, tension, torsional force, vibration force, or any suitable force to a mounting post and / or a mounting solar module to test the mechanical strength, stability, and / or stiffness of a mounting.

[0223] In some cases, the method may further include performing electrical tests on one or more solar modules using a test tool located on one or more operational platforms. In some cases, electrical testing may include testing voltage, current, connectivity, and any appropriate electrical quantities to ensure proper installation of the solar modules.

[0224] In another embodiment, the present invention provides a method for constructing a solar module array. The method may include providing a plurality of supports 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 using one or more mobile platforms to autonomously position and assemble the plurality of supports and the plurality of solar modules onto terrain to construct the solar module array.

[0225] In some embodiments, the method may include forming a plurality of pillar-clamp interfaces between a plurality of clamps and a plurality of pillars to construct a solar module array on a terrain without requiring one or more pre-drilled holes / features for one or more fasteners. In some embodiments, the plurality of pillar-clamp interfaces may have tolerances that allow the array to be fitted to the terrain, thereby eliminating the need for terrain leveling. In some embodiments, the plurality of pillar-clamp interfaces may include a plurality of press-fit joints. In some embodiments, the plurality of press-fit joints may be formed by a punching process. In some embodiments, each of the plurality of pillars may include one or more tabs. In some cases, the punching process includes attaching one or more tabs to a corresponding clamp to form the plurality of press-fit joints. In some embodiments, the method may further include adding one or more fasteners to the pillar-clamp interfaces after or during the punching process.

[0226] In some cases, multiple support-clamp interfaces may be formed at one or more corners of multiple solar modules. In some cases, multiple support-clamp interfaces may be formed at all corners of multiple solar modules. In some cases, multiple support-clamp interfaces may be formed at opposite corners of multiple solar modules. In some cases, multiple support-clamp interfaces may be formed on one or more lateral sides of multiple solar modules. In some cases, multiple support-clamp interfaces may be formed on all lateral sides of multiple solar modules. In some cases, multiple support-clamp interfaces may be formed on opposite lateral sides of multiple solar modules.

[0227] In some cases, multiple strut-clamp interfaces can be formed using a crimping tool located on a strut mount load head. In other cases, the strut mount load head can be located on one or more mobile platforms configured to carry multiple struts and multiple solar modules.

[0228] In some embodiments, a plurality of pillar-clip interfaces may be formed without the need for one or more fasteners. In some embodiments, a plurality of pillar-clip interfaces may be formed by positioning one or more fasteners in place relative to each clip and a corresponding tab on each pillar, and by passing one or more fasteners through the tab to secure the tab to the clip, or by passing one or more fasteners through the clip to secure the clip to the tab.

[0229] In some embodiments, the method disclosed herein may include using a movable tool to form a plurality of holes in situ on at least the tabs of the clips and / or the supports of the solar module. In some embodiments, the method disclosed herein may include using a movable tool or another tool to install one or more fasteners through the plurality of holes formed in situ on the clips and / or the tabs.

[0230] In another embodiment, the present invention provides an algorithm for facilitating the deployment of a solar module. In some embodiments, the method may include using an algorithm to identify a location suitable for the autonomous positioning and assembly of at least one solar module, without the aid of or involving a user in the autonomous positioning and assembly of at least one solar module.

[0231] In some embodiments, the algorithm includes a machine learning (ML) algorithm. In some cases, the machine learning algorithm may include a neural network. Examples of neural networks may 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).

[0232] In some embodiments, the machine learning algorithm may include a deep neural network (DNN). In other embodiments, the deep neural network may include a convolutional neural network (CNN). CNN may be, for example, U-Net, ImageNet, LeNet-5, AlexNet, ZFNet, GoogleNet, VGGNet, ResNet18, or ResNet, etc. In some cases, the neural network may include or utilize, for example, a deep feedforward neural network, a recurrent neural network (RNN), LSTM (Long Short-Term Memory), GRU (Gate-Controlled Recurrent Unit), an autoencoder (e.g., variational autoencoder, adversarial autoencoder, de-cluttered autoencoder, or sparse autoencoder), a Boltzmann machine (BM), an RBM (Restricted BM), 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 may include a plurality of neural network layers. In some cases, the neural network may have at least about 2 to about 1000 or more neural network layers.

[0233] In some cases, machine learning algorithms may include a Support Vector Machine (SVM), a classification algorithm, a regression analysis algorithm, or any other type of supervised, semi-supervised, or unsupervised machine learning algorithm. In some embodiments, supervised learning algorithms may 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, supervised learning algorithms may include, for example, clustering algorithms, hierarchical clustering algorithms, k-means clustering algorithms, mixture models, anomaly detection, local anomaly factor algorithms, autoencoders, deep belief networks, Hebbian learning, self-organizing maps, expectation-maximizing algorithms (EM), principal component analysis algorithms, independent component analysis algorithms, nonnegative matrix factorization, singular value decomposition, or any combination thereof. In some cases, machine learning algorithms may include or utilize a random forest, a decision tree (e.g., an augmented decision tree), a classification tree, a regression tree, a bagging tree, or a rotating forest.

[0234] In some embodiments, the algorithm may be configured to identify locations for deploying one or more solar modules and / or supports based on at least one type of terrain data analysis. In some embodiments, the terrain data is obtained using at least one of aerial imaging or a Global Navigation Satellite System (GNSS).

[0235] In some embodiments, the method may further include establishing a set of executable instructions in a digital medium to enable an autonomous system to autonomously locate, deploy, install, and assemble at least one solar module to construct a solar module array. In some embodiments, the autonomous system includes a plurality of field machines connected via a network for operational communication. In some embodiments, the plurality of field machines includes one or more robots. In some embodiments, the method may further include establishing a set of executable instructions in a digital medium to enable an autonomous system to autonomously locate, deploy, install, and assemble one or more pillars or other support structures for one or more modules in a solar module array.

[0236] In another embodiment, the present invention provides a device configured to: carry a plurality of supports on a terrain; autonomously position a selected support from the plurality of supports at a predetermined location on the terrain; and autonomously install the selected support at the predetermined location. In some cases, the selected support and the plurality of supports can be used to support a plurality of solar modules.

[0237] Figures 45A to 45D show perspective views of a machine for installing a support post according to some embodiments. In some cases, the machine may include three, four, five, or six degrees of freedom or more. In some cases, the machine may autonomously position a support post, install the support post in the ground, and / or test the force on the support post by pulling it laterally, vertically, or in any other direction and record the force test data. In some cases, the machine may be configured to carry one or more bundles of support posts on a rack. In some cases, the machine may be configured to position one or more of the support posts in a bundle and collect a new support post on a drive drill bit.

[0238] Figures 46A and 46B illustrate a machine for installing a support post, such as those depicted in Figures 49A and 49C. In some cases, the machine may have three or more mounting interfaces for mounting a tractor, for example, using a three-point hook. In some cases, the machine may carry a hammer for driving a support post into the ground. In some cases, the hammer may be mounted on a vertical track and can slide freely vertically or in any other sufficiently wide direction, allowing for sufficiently minimal or no vibration to transfer from the hammer to the rest of the machine.

[0239] Figures 50A to 50C illustrate coupling mechanisms between a support column and a rack according to some embodiments. In some cases, a support column may include a Z-shaped section or a Z-shape. In some cases, a support column may include a substantially stackable shape. In some cases, a support column may include one or more sets of inclined tabs at its top. In some cases, a tab may include an opening feature. In some cases, the opening feature may be configured to allow a support column to be suspended from a hanger or a rack. In some cases, one or more supports may be bundled and shipped in a container or provided to a machine.

[0240] In some embodiments, the device may be further configured to perform a force test after the selected support is installed at a predetermined location. In some embodiments, the force test may include applying a tensile force to the selected support in at least one of a lateral or vertical direction.

[0241] In some embodiments, a selected support post may be mounted at a predetermined location using a load drive mechanism configured to drive the selected support post into the ground at the predetermined location. In some cases, the load drive mechanism includes or is coupled to a hammer. In some cases, the load drive mechanism is mounted to a plurality of rails and is movable along the plurality of rails in a vertical direction. In some cases, the load drive mechanism is configured to slide along the plurality of rails via bearings.

[0242] In some cases, the load drive mechanism includes a retaining mechanism that prevents the selected strut from displacing from or decoupling from the load drive mechanism when it is installed in the ground. In some cases, the retaining mechanism includes one or more shear features.

[0243] In some cases, the load drive mechanism includes a drive bit having one or more shear features. In some cases, the one or more shear features can be configured to dual-act as holding features. In some cases, the load drive mechanism is configured to have a drive force length less than the total longitudinal length of one of the selected struts.

[0244] Figures 47A to 47I illustrate a coupling mechanism between a drive drill bit and a support post according to one of several embodiments. In some cases, a drive drill bit may be connected to a hammer. In some cases, a drive drill bit may include a shear interface for engaging a support post during striking. In some cases, a drive drill bit may include a retaining feature to prevent a support post from falling off the drill bit when it is positioned and driven. In some cases, a drive drill bit may be configured to allow a support post to be struck from the web of the support post, the web being positioned at a lower position on the body of the support post. In some cases, striking from the web allows the hammer to impact the support post with greater force compared to striking from the head, because striking from the web can effectively reduce the buckling length of the support post during striking. In some cases, a drive drill bit may enter a larger portion of a hole in a support post. In some cases, a drive drill bit may slide downwards and remain against a chisel-shaped drill bit in one configuration. In some cases, when a drive drill bit engages with a support, the head of a chisel feature on the drive drill bit may overlap at least a portion of the support. In some cases, a chisel drill bit may have one, two, three, four, or more shearing features. In some cases, a chisel drill bit may also function as a retaining feature. In some cases, a feature on a chisel drill bit may retain a support. In some cases, a feature on a chisel drill bit may separate from a feature that strikes the support. In some cases, a retaining feature may be a clock element that rotates to engage with a support. In some cases, a retaining feature may be rotated approximately 45 degrees such that a clock square of the support is retained at the corner after engagement. In some cases, a retaining feature may hang over a hole in the support. In some cases, a shaft may not engage the bottom of a hole in the support. In some cases, a pin may engage with a support without hanging. Figures 48A and 48B illustrate a comparison of driving a support using different coupling mechanisms according to some embodiments.

[0245] In some embodiments, a strut can be driven into terrain using an assembly positioned, oriented, and / or moved to impact a feature located along one length of the strut. The assembly may include a hammer, a pin, or any other rigid structural member. In some cases, the movement of the assembly may be guided by a sleeve or a track. The impact between the assembly and the feature provides a driving force to propel the strut into a desired location. The point of impact may be closer to one of the strut's centers of gravity or mass, which helps minimize buckling forces and ensures the strut is mounted in a desired orientation (e.g., perpendicular to the terrain or forming any other desired angle relative to the ground).

[0246] In another embodiment, the present invention provides a device configured to: carry a plurality of solar modules on a terrain; autonomously position a selected solar module from the plurality of solar modules onto a set of supports mounted on the terrain; and autonomously assemble the selected solar module onto the set of supports without the need for or without the use of fasteners.

[0247] In some cases, the device can be configured to autonomously assemble selected solar modules onto a set of pillars by forming multiple pillar-clamp interfaces. In some cases, the multiple pillar-clamp interfaces include multiple press-fit joints.

[0248] In some cases, a clip may be pre-attached to one or more corners or sides of the selected solar module, and each support column in the set of supports may include a plurality of tabs. In some cases, the device may be configured to autonomously position the selected solar module onto the set of supports by aligning the clip with a corresponding tab at each support column. In some cases, the device may be configured to autonomously assemble the selected solar module onto the set of supports by crimping the corresponding tabs to the clips at each support column.

[0249] Figure 59 illustrates a light curtain according to one of some embodiments. In some cases, a machine may 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 a light curtain. When a foreign object enters the workspace, at least a portion of the light curtain may be interrupted or interfered with, which may trigger one or more safety procedures or protocols (e.g., shutting down a machine or restricting the operation of one of the machines until the foreign object leaves the workspace).

[0250] The following examples are provided to further illustrate some embodiments of the invention, but are not intended to limit the scope of the invention; other procedures, methods or techniques known to those skilled in the art can be used alternatively by way of their illustrative nature.

[0251] Figure 20 shows one layout of the solar module blocks in a connection orientation. Figure 21 shows multiple blocks connected to a central inverter.

[0252] Figure 22 is a perspective view of a portion of a block. Line 2200 here shows how the wires from the module string to the inverter ("home run") can be mounted on the side of an array and clipped to the support.

[0253] Figure 23 is a simplified flowchart illustrating one possible supply chain according to an embodiment. This simplified supply chain allows supports, connectors, and prefabricated solar modules to be shipped from the factory to a deployment location. Here, these components can be mounted onto a machine configured for a rapid and automated ground-mounted system.

[0254] Figure 24 is a simplified top view illustrating the progress of one embodiment of an installation machine 2400. Here, the machine is towed by a truck 2402 in a right-to-left direction. After the support column is pushed into the ground, the module can be attached. In this particular embodiment, the module may have pre-installed clips.

[0255] Figure 25 is a simplified top view showing the progress of an alternative embodiment of an installation machine 2500 on-site, from left to right. This particular embodiment utilizes a support tool jig 2502, including a rectangle of fixed size, to always rotate the next pair of supports 2504 from the previous pair. Specifically, in a first stage 2505, two supports are pushed into the ground, where the jig is used to position the supports relative to each other. In a second stage 2506, two more supports are pushed into the ground, where the jig is also used to position the supports. In a third stage 2508, the module 2509 is placed directly after the next pair of supports. The jig can grasp features on the clips on the supports to rotate and hold the clips, while pressing the module into them. In a fourth stage 2510, the next support is placed (e.g., rotated from the previous support using the jig). The procedure can then be repeated.

[0256] In some cases, the installation machine's path can be maneuvered on-site. When the vehicle turns around and proceeds to the other side of the column (from right to left), everything is the same except for implanting the support closest to the truck. The two specific installation machines shown in Figures 24 and 25 are merely examples, and alternative embodiments may be used.

[0257] Figure 26 provides a coordinate system for describing one form of a mobile vehicle. This coordinate system is now referenced to describe another exemplary embodiment of an apparatus configured to perform the installation of ground-mounted solar panels.

[0258] Figure 27 shows a rear perspective view of one embodiment 2700 of the installation equipment. The equipment includes various components mounted to a mobile vehicle 2702 (e.g., a pickup truck bed) via a platform 2704. As described in detail below, this platform can be configured to move in one or more directions. Components of the installation machinery may 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 may further include a hydraulic actuator 2716 for driving the support post into the ground by pushing (rather than hammering).

[0259] Figure 28 shows a detail of a vertical conveyor component that can be used to lower modules one at a time. Figure 29 is a schematic diagram showing how a standard package of a stack 2900 of solar modules can be loaded onto a vertical conveyor 2904 and how individual modules 2902 are then lowered onto sheet metal clips 2906. The modules can be lowered onto sheet metal clips 2906. The resulting combination of modules and clips can be lowered onto a tray 2910, which can slide out from the bottom of the stack.

[0260] Figure 30 shows details of a module comprising a frame 3000 lowered onto a clip 3002. During this process, the connection 3003 from the connector to its adjacent connector can be interrupted by component 3004.

[0261] Figure 31 shows a side view of a stack 3100 of solar modules on a vertical conveyor 3104. A horizontal rail 3106 is used to slide the bottom module laterally onto the mounting load head 3108. The module can be tilted by a small linear actuator 3110.

[0262] Figure 32 shows a front perspective view of one of the mounting devices according to one embodiment. The load head 3200 is shown to slide 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.

[0263] Figure 33 shows a detailed view of the load head frame 3300 connected to the actuator tip 3302 for (simultaneously) driving the support column 3304. A connector 3306 can be seen attached to the solar module 3308 loaded into the load head. The actuator tip 3302, which directly drives the support column, is also connected to the module load head. Therefore, the module can be simultaneously lowered into the correct position while driving the support column into the ground. The connection between the actuator tip and the module load head can also have a deflection mechanism to reduce vibrations transferred to the module during installation.

[0264] Referring to the installation machine embodiments shown in Figures 27 to 33, one or more of various components (e.g., frame, load head, (several) conveyors, etc.) can be mounted on a movable platform. The platform can be actuated in any of the following: (i) the x-axis, y-axis, and yaw direction; or (ii) the x-axis, y-axis, yaw, pitch, and roll directions.

[0265] In some cases, a vertical actuator can control Z-axis movement. One method of controlling planar movement is via a two-way stage. An additional drive can control the yaw direction.

[0266] Figure 34 further illustrates that the position of the mobile platform can be controlled (individually or individually) using: (i) a differential GPS system, (ii) a camera, (iii) LiDAR and / or (iv) laser tracking. In some cases, a GPS and / or camera system can allow control over how precisely the modules and supports in the solar array are positioned. This functionality provides control over the mobile machinery on the red platform and / or the position / drive of the entire installation (e.g., mounted in a truck, a trailer, or in the form of a custom-built vehicle).

[0267] The embodiments are not limited to the specific installation equipment described above, and alternative systems are feasible. For example, Figure 35 shows a front perspective view of one alternative embodiment of an installation machine.

[0268] Figure 36 shows an enlarged side view of one of the mounting devices 3600 illustrated in Figure 35. Here, the load head 3601 can slide inside a retaining frame 3602 to mount a single solar module 3604 in a vertical linear motion. The load head can be captured inside a rigid frame to constrain the motion to vertical only (shown by arrow 3606).

[0269] Figure 34 illustrates a non-limiting example of a platform that can be used to facilitate the deployment and installation of solar modules. In some embodiments, the position of the modules and load heads can be controlled using a mechanism such as the overhead component 3700 shown in Figure 37A (which can be attached to a frame of the platform).

[0270] Figure 37B shows the overhead component in the form of a bracket 3704 for controlling planar positioning. Figure 37C shows an enlarged view of a rotating gear 3702 that can be mounted below. In some cases, other mechanisms, such as a conveyor (e.g., a vertical or horizontal conveyor), can be used to control the positioning of the module.

[0271] Figure 38A shows a perspective view of one embodiment in which the module is lifted, translated, and lowered from its stack on a tray onto a module slider (shown as an extension in Figure 31) by a bracket having a suction cup load head. This bracket can press the module down onto four clips to install the clips onto the module during movement #3 shown in Figure 38B.

[0272] Figure 39 shows a top view of one embodiment of a double-tilted (between 0 and 20 degrees) array 3900, including one of the ground-mounted solar modules. This uninterrupted module array provides a valuable opportunity to clean the array using a robot 3902. This cleaning robot can move autonomously in any direction on the module plane.

[0273] Figure 40 shows a top view of another alternative embodiment. Here, the solar module array can be staggered between the module rows. Due to the overlapping frames, this embodiment can significantly increase stiffness in the staggered direction. Apart from consuming 50% more support pillars, this embodiment can operate in a manner similar to one of the previously described methods.

[0274] In the configuration where modules are interleaved, each module can have 6 supports, and the clips can be modified to clamp onto the corners of two modules and the middle edge of a third module. In Figure 41, the support positions are shown as a white square at the intersection of a module edge and two corners of an adjacent module.

[0275] Figures 54A to 54C illustrate a method for determining a landscape topology for locating and assembling solar modules according to some embodiments. In some cases, the method may include analyzing topographic topology and / or GIS data of a given terrain. In some cases, the method may include processing the curvature of the topographic topology or GIS data. In some cases, the method may include simulating supports and modules installed on a given terrain. In some cases, the method may include uploading the geographic location and construction data of supports and modules for installing one or more machines. Figure 55 illustrates an exemplary GUI for determining a landscape topology for locating and assembling solar modules according to some embodiments.

[0276] In some cases, one or more algorithms, machine learning algorithms, or neural networks can be configured to process terrain data and determine the optimal layout, positioning, or installation location for one or more support pillars 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 a terrain and one or more candidate locations for installing support pillars or solar modules. In some cases, one or more algorithms, machine learning algorithms, or neural networks can be configured to generate a blueprint or set of instructions for controlling and moving multiple robots or mobile platforms to jointly deploy and install one or more support pillars or solar modules in a target environment. This blueprint or set of instructions can be generated based on the virtual representation or simulation or other data associated with the terrain or landscape topology of the target environment. The virtual representation or simulation may include, for example, a 3D model or point cloud representation of the terrain and one or more candidate installation or deployment locations.

[0277] In some embodiments, when the robot or mobile platform of the present invention runs out of support pillars or solar modules for installation (or if the number of support pillars or solar modules that the robot or mobile platform can immediately access drops below a certain threshold), the robot or mobile platform may undergo repeated replenishment or supplementation operations. In some cases, the robot or mobile platform may return to a facility or other central location to replenish or supplement the support pillars and / or solar modules. In other cases, one or more other replenishment vehicles or robots may carry or store an inventory of additional support pillars and / or solar modules and may automatically travel to a robot or mobile platform that requires additional support pillars or solar modules. In some cases, one or more other replenishment vehicles or robots may travel along a perimeter of the terrain or remain idle and travel to a specific robot or mobile platform when the robot or mobile platform requires additional support pillars or solar modules. This avoids requiring the robot or mobile platform to undertake an additional journey for replenishment or supplementation.

[0278] Figure 62 illustrates one alternative embodiment of an exemplary vehicle that can be used or configured to handle, transport, install, or deploy one or more solar modules. The vehicle can acquire new module stacks autonomously, semi-autonomously, or with human input or intervention. The vehicle may acquire new module stacks without or without the use of a separate robot. In some cases, the vehicle may include front accessories that can be used to retrieve or acquire one or more new solar modules from a storage area or another vehicle.

[0279] Figure 63 illustrates 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 new solar modules from a trailer of another vehicle.

[0280] Figure 64 illustrates an end effector and a crimping tool positioned at a corner of the end effector. In this configuration, the end effector can pick up a solar module without or without using a suction cup; instead, it can grip the module from the side using a squeezing or pinching action. The size of the end effector's frame can be adjusted, allowing the same end effector to be configured to pick up modules of different shapes or sizes. As shown in Figure 65, the bottom portion of the crimping tool can be tapered to help position or engage the module (e.g., a complementary feature mounted on the module).

[0281] Figures 66A and 66B illustrate an alternative embodiment of a clip. The clip may include a hole or slot that interfaces with a latch that rotates 90 degrees automatically. The latch engages the module and clip assembly with a load head on the module mounter to hold it in place. This is another embodiment of a method for picking up a solar module without using a suction cup.

[0282] Figure 67 illustrates an alternative embodiment of a module mounter vehicle described elsewhere herein. Here, the riveting tool (yellow) may not be located on the same automaton as the moving module (orange), but may instead be located on a separate automaton (blue) of a vehicle platform attached to the same automaton as the moving module. The separate automaton (blue) can autonomously and releasably engage with the previously mounted support. The module moving automaton (orange) can then move a module to the position where the support is mounted.

[0283] Figure 68 illustrates an exemplary configuration of one of the supports described elsewhere in this document. This embodiment shows a cut flange that bends outward in an open manner, allowing the support to enter the soil with low resistance (left), but when the support is pulled upward, it engages with the soil and bends further outward to provide increased upward resistance (right).

[0284] Figures 69A and 69B illustrate one alternative embodiment of the clip described elsewhere herein. In this embodiment, the clip may have bends and tabs such that they are nested and stacked so that the solar module does not contact other modules in the stack above or below it.

[0285] Figure 70A illustrates an additional sheet metal feature that can be used to hold one or more leads or wires of a solar module and keep them fixed in a particular side of the module for later handling or processing. Figure 70B illustrates one embodiment of a clip, wherein the module wires are connected to the clip, the clip is also connected to the module and will be connected to the support. Figure 70C illustrates the use of an additional tool (blue square) to autonomously 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 illustrates one embodiment of the tools and methods in Figures 70A, 70B and 70C, except that in this embodiment, the tool does not push the two connectors together, but rather properly cuts (a), strips (b) and twists (c) the wires together, without the use of a connector.

[0286] Figure 75 illustrates a removable receiving slot that can be placed on top of a support pillar in the valley or peak of a module array. This slot transfers its weight and load to the support pillar below rather than to the module, and can move on top to retrieve modules within the array's interior area. In some cases, this slot can also serve as a track that a robot can ride on (e.g., for cleaning, watering, spraying, or inspection).

[0287] Figures 76 and 77 illustrate a bracket (blue) mounted on a ground-driven wheel (black) in the gaps between arrays, which can be configured in certain ways. This bracket can be equipped with an automatic mechanism to clean the modules with water or mechanically wipe the solar modules in the array below the bracket. The bracket can also spray water, herbicides, or aquatic seeds to manage the vegetation below the array. The bracket can be attached with a rope, pipe, or other hollow structure to connect it to a water source or other liquid at the end of a row of modules.

[0288] Computer system

[0289] In one embodiment, the present invention provides a computer system, either programmed or otherwise configured, to implement the method of the present invention, such as any of the methods for using at least one robot to autonomously locate and assemble at least one solar module and its support structure.

[0290] In another embodiment, the present invention provides a computer system, either programmed or otherwise configured, to provide a mobile platform configured to carry a plurality of supports and a plurality of solar modules. In some cases, the mobile platforms are equipped with one or more sensors including a geolocation sensor. In some cases, the computer system is further programmed or otherwise configured to at least partially utilize readings or measurements obtained using one or more sensors to (i) autonomously move one or more mobile platforms and (ii) autonomously position and assemble the plurality of supports and the plurality of solar modules on a terrain to construct a solar module array. This autonomous movement or positioning can be performed using one or more signals or commands generated by a processing unit of the computer system.

[0291] In another embodiment, the invention provides a computer system, either programmed or otherwise configured, to provide a plurality of supports and a plurality of solar modules. In some cases, the plurality of solar modules includes a plurality of clips pre-attached thereto. In some cases, the computer system is further programmed or otherwise configured to form a plurality of support-clip interfaces between the plurality of clips and the plurality of supports to construct a solar module array on a terrain without requiring one or more pre-drilled holes / features for one or more fasteners.

[0292] In another embodiment, the invention provides a computer system, either programmed or otherwise configured, to use an algorithm to identify a suitable location for autonomously locating and assembling at least one solar module. In some cases, the algorithm can be used without the aid of or involving a user in the autonomous location and assembly of at least one solar module.

[0293] Figure 61 illustrates a computer system 6101, either programmed or otherwise configured, to implement a method for fully autonomously locating and assembling at least one solar module and its support structure. In some embodiments, the computer system 6101 may be configured to, for example, use an algorithm to identify a suitable location for the autonomous positioning and assembly of at least one solar module, without the aid of or involvement of a user in the autonomous positioning and assembly of at least one solar module. The computer system 6101 may be an electronic device of a user or a computer system for remote positioning relative to an electronic device. The electronic device may be a mobile electronic device.

[0294] Computer system 6101 may include a central processing unit (CPU, also referred to herein as a "processor" and "computer processor") 6105, which may be a single-core or multi-core processor or a plurality of processors for parallel processing. Computer system 6101 also includes memory or memory locations 6110 (e.g., random access memory, read-only memory, flash memory), electronic storage units 6115 (e.g., hard disks), communication interfaces 6120 (e.g., network adapters) for communicating with one or more other systems, and peripheral devices 6125, such as caches, other memories, data storage devices, and / or electronic display adapters. Memory 6110, storage units 6115, interface 6120, and peripheral devices 6125 communicate with CPU 6105 via a communication bus (solid line) such as a motherboard. Storage unit 6115 may be a data storage unit (or database) for storing data. Computer system 6101 can be operatively coupled to a computer network ("network") 6130 via communication interface 6120. Network 6130 may be the Internet, an Internet and / or an extranet, or an intranet and / or extranet communicating with the Internet. In some cases, network 6130 is a telecommunications and / or data network. Network 6130 may include one or more computer servers that enable distributed computing such as cloud computing. In some cases, network 6130, through computer system 6101, can implement an inter-platform network that allows devices coupled to computer system 6101 to function as a client or a server.

[0295] CPU 6105 can execute a series of machine-readable instructions that can be embodied in a program or software. The instructions can be stored in a memory location (such as memory 6110). The instructions can be directed to CPU 6105, which can then be programmed or otherwise configured to implement the methods of the present invention. Examples of operations performed by CPU 6105 may include fetching, decoding, executing, and writing back.

[0296] The CPU 6105 may be part of a circuit (such as an integrated circuit). One or more other components of the system 6101 may be included in the circuit. In some cases, the circuit is a special-purpose integrated circuit (ASIC).

[0297] Storage unit 6115 may store files such as drivers, libraries, and savers. Storage unit 6115 may store user instructions, such as user preferences and user programs. In some cases, computer system 6101 may include one or more additional data storage units located outside computer system 6101 (e.g., on a remote server communicating with computer system 6101 via an intranet or the Internet).

[0298] Computer system 6101 can communicate with one or more remote computer systems via network 6130. For example, computer system 6101 can communicate with a remote computer system that is a user (e.g., an end user or entity monitoring, supervising, monitoring, or managing the operation of a robot). Examples of remote computer systems include personal computers (e.g., portable PCs), tablet PCs (e.g., Apple® iPad, Samsung® Galaxy Tab), telephones, smartphones (e.g., Apple® iPhone, Android-enabled devices, Blackberry®), or personal digital assistants. The user can access computer system 6101 via network 6130.

[0299] The methods described herein can be implemented by machine-executable code (e.g., a computer processor) stored in an electronic storage location of computer system 6101 (such as, for example, in memory 6110 or electronic storage unit 6115). The machine-executable or machine-readable code may be provided in software form. During use, the code can be executed by processor 6105. In some cases, the code may be retrieved from storage unit 6115 and stored in memory 6110 for access by processor 6105. In some cases, electronic storage unit 6115 may be excluded and machine-executable instructions may be stored in memory 6110.

[0300] The code can be pre-compiled and configured for use with a machine having a processor adapted to execute the code, or it can be compiled during runtime. The code can be selected to be provided in a programming language that can be executed in a pre-compiled or pre-compiled manner.

[0301] The forms of systems and methods provided herein (such as computer system 6101) can be embodied in programming. Various forms of technology can be considered as "products" or "articles of manufacture" typically presented as machine (or processor) executable code and / or associated data carried or embodied in a type of machine-readable medium. The machine executable code can be stored in an electronic storage unit, such as memory (e.g., read-only memory, random access memory, flash memory) or a hard disk. "Storage" media can include any or all tangible memory or associated modules of a computer, processor, or the like, such as various semiconductor memories, magnetic tape drives, disk drives, and the like, which can provide non-transitory storage for software programming at any time. All or part of the software can sometimes communicate via the Internet or various other telecommunications networks. Such communication (e.g.) enables the loading of software from one computer or processor to another computer or processor, such as from a management server or host computer to an application server computer platform. Therefore, another type of media capable of carrying software components includes optical, electrical, and electromagnetic waves, such as those used at physical interfaces between local devices, through wired and optical terrestrial networks, and through various air links. Physical components carrying these waves (such as wired or wireless links, optical links, or the like) can also be considered media carrying software. As used herein, unless limited to non-transitory, tangible "storage" media, the term "computer or machine-readable media" refers to any media that participates in providing instructions to a processor for execution.

[0302] Therefore, a machine-readable medium (such as computer executable code) can take many forms, including (but not limited to) a tangible storage medium, a carrier medium, or a physical transmission medium. Non-volatile storage media, including, for example, optical discs or magnetic disks, or any storage device in any computer(s) or the like, can be used to implement the databases shown in the diagrams, etc. Volatile storage media include dynamic memory, such as the main memory of a computer platform. Tangible transmission media include: coaxial cables; copper wires and optical fibers, which include conductors comprising a bus within a computer system. Carrier transmission media can take the form of electrical or electromagnetic signals or sound or light waves (such as sound or light waves generated during radio frequency (RF) and infrared (IR) data communications). Therefore, common forms of computer-readable media include (for example): a floppy disk, a hard disk, magnetic tape, any other magnetic media, a CD-ROM, a DVD or DVD-ROM, any other optical media, punched paper tape, any other physical storage media with a perforated pattern, a RAM, a ROM, a PROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave for transmitting data or instructions, a cable or link for transmitting such carrier wave, or any other media from which a computer can read programmed code and / or data. Many of these forms of computer-readable media may involve loading one or more sequences of instructions to a processor for execution.

[0303] Computer system 6101 may include or communicate with an electronic display 6135, the electronic display 6135 including a user interface (UI) 6140 for providing, for example, an entry point for monitoring the installation of a support column or solar module. In some cases, the UI may allow input of commands such as "Start Installation" or "Pause All Robots". In some cases, the UI may provide a visualization or blueprint of one or more solar modules for installing a solar module array. In some cases, the UI may provide a visualization for real-time tracking of one or more robots. The entry point may be provided through an application programming interface (API). A user or entity may also interact with various elements in the entry point via the UI. Examples of UIs include, but are not limited to, a graphical user interface (GUI) and a web-based user interface.

[0304] The method and system of this invention can be implemented by one or more algorithms. An algorithm can be implemented by software after execution by the central processing unit 6105. For example, the algorithm can be configured to determine one or more locations for installing one or more solar modules. In some cases, the algorithm can be configured to coordinate one or more robots during the installation of one or more solar modules. In some cases, the algorithm can be configured to process force test data of one or more solar modules to determine whether one or more solar modules are safely installed. In some cases, the algorithm can be configured to provide instructions to one or more robots, at least in part based on force test data, to adjust one or more solar modules or their support structures.

[0305] Although preferred embodiments of the invention have been shown and described herein, those skilled in the art will understand that these embodiments are merely illustrative. The invention is not intended to be limited to the specific examples provided in the specification. Although the invention has been described with reference to the foregoing description, the description and illustration of embodiments herein are not intended to be construed as limiting. Those skilled in the art will now conceive of numerous variations, modifications, and substitutions without departing from the invention. Furthermore, it should be understood that all forms of the invention are not limited to the specific description, configuration, or relative proportions set forth herein, as they depend on various conditions and variables. It should be understood that various substitutions to the embodiments of the invention described herein may be employed in the practice of the invention. Therefore, it is contemplated that the invention should also cover any such substitutions, modifications, variations, or equivalents. The following claims are intended to define the scope of the invention and thereby cover methods and structures within the scope of the claims and their equivalents.

[0306] 100: System 102: Physical Load G 104: Ground 200: Example of a ground-mounted system 202: Solar Module 204: Ground 206: Pillar 300: Familiar Ground Installation Structure 302: Solar module 304: Upper structure 306: column 308: Ground 400: Ground-mounted system 402: Solar Module 404: Card holder 410: Inclination angle 450: Pillar 452: Flat-top interface 454: Serrated pattern 456: Tip 500: Ground-mounted system 502: Common Pillar 504: Solar module 506: End Clamp 508: Middle Sandwich 700: Central protrusion 800: Central protuberance 801: Angle Clip 802: Frame 804: Solar Module 806: Photovoltaic Materials 1200: Clip structure 1202: Flexible protrusion 1300: Frame 1302: Solar module 1400: Pillar 1402: Protrusion 1404: protrusion 1500: Riveting tools 2200: Line 2400: Installation machine 2402: Truck 2500: Installation machine 2502: Support tool clamp 2504: Pillar 2505: Phase One 2506: Phase Two 2508: Phase Three 2509: Module 2510: Phase Four 2700: Example of Installing Equipment 2702: Moving vehicle 2704: Platform 2706: Framework 2708: Load Head 2710: Vertical Conveyor 2712: Stacking 2714: Solar Panel 2716: Hydraulic actuator 2900: Stacking 2904: Vertical Conveyor 2906:Plate metal card holder 2910: Pallet 3000: Framework 3002: Card Holder 3003: Connection 3004: Component 3100: Stacking 3104: Vertical Conveyor 3106: Horizontal track 3108: Install load head 3110: Small linear actuator 3200: Load Head 3204: Frame 3206: Truck 3208: Hydraulic actuator 3300: Load Header Frame 3302: Actuator tip 3304: Pillar 3306: Connector 3308: Solar Module 3600: Install equipment 3601: Load Head 3602: Retaining Frame 3604: Solar Module 3606: Vertical only 3700: Overhead components 3702: Rotary Gear 3704: Stent 3900: Dual-tilt array 3902: Robot 6101: Computer System 6105: Central Processing Unit (CPU) / Processor 6110: Memory 6115: Storage Unit 6120: Communication Interface 6125: Peripheral Devices 6130: Computer Network 6135: Electronic Display 6140: User Interface (UI) D: Depth f: Frequency F: Frequency S: Interval

Claims

1. A method for constructing a solar module array, comprising: (a) Provide a mobile platform configured to carry a plurality of posts and a plurality of solar modules, wherein the mobile platform is equipped with one or more sensors including a geolocation sensor; and (b) use at least part of the one or more sensors to (i) autonomously move the mobile platform and (ii) autonomously position and assemble the plurality of posts and the plurality of solar modules on a terrain to construct the solar module array.

2. The method of claim 1, wherein the one or more sensors further include an image sensor.

3. The method of claim 1, wherein the one or more operating platforms include a first platform for positioning and installing the plurality of pillars onto the terrain and a second platform for positioning and assembling the plurality of solar modules onto the plurality of pillars.

4. The method of claim 3, wherein the first platform and the second platform are separate or integrated into a single platform.

5. The method of request item 3, which includes positioning and installing the plurality of pillars onto the terrain by means of the first platform according to a predefined configuration.

6. The method of claim 3, wherein the plurality of solar modules are pre-stacked on the second platform, and wherein the second platform includes a mechanism for extracting a selected solar module from one stack of solar modules and assembling the selected solar module onto a selected group support already installed on the terrain.

7. The method of claim 1, further comprising: Tensile strength and assembly tests are performed on one or more sections of the solar module array constructed in (b) using one of the test tools located on one or more of the operational platforms.

8. The method of claim 1, further comprising: Using one or more sensors to position and move one of the installer load heads on one or more mobile platforms relative to the solar module array during its construction.

9. The method of claim 1, further comprising: Establish multiple post-clip interfaces between multiple clips and multiple supports, wherein the multiple clips are pre-attached to the multiple solar modules.

10. The method of claim 1, wherein the one or more mobile platforms include one or more electric vehicles, and wherein the method further includes providing one or more charging stations distributed across the terrain for charging the one or more electric vehicles, wherein the one or more charging stations are mobile or stationary.

11. The method of claim 1, comprising using a load driving mechanism to drive a pillar into the ground at a predetermined location on the terrain.

12. The method of claim 11, wherein (i) the load drive mechanism includes or is coupled to a hammer and / or (ii) the load drive mechanism is mounted to a plurality of tracks and is movable along the plurality of tracks in a vertical direction.

13. The method of claim 11, wherein the load drive mechanism includes a retention mechanism that prevents the column from displacing or decoupling from the load drive mechanism when the column is installed in the ground.

14. The method of claim 13, wherein the retaining mechanism includes one or more shear features.

15. The method of claim 11, wherein the load drive mechanism includes a driving bit having one or more shearing features.

16. The method of claim 15, wherein the one or more shearing features dually act as retaining features.

17. The method of claim 9, wherein the plurality of pillar-clip interfaces have a tolerance that allows the solar module array to be adjusted to the terrain without leveling the terrain.

18. The method of claim 9, wherein the plurality of pillar-clamp interfaces include a plurality of press-fit joints.

19. The method of claim 18, wherein the plurality of press-fit joints are formed by a dimming process, wherein each of the plurality of supports includes one or more tabs, and wherein the dimming process includes connecting the one or more tabs to a corresponding clip to form the plurality of press-fit joints.

20. The method of claim 19, further comprising: One or more fasteners are added to the plurality of support-clip interfaces after or during the punching process.

21. The method of claim 9, wherein the plurality of pillar-clip interfaces are formed at one or more corners of the plurality of solar modules.

22. The method of claim 9, wherein the plurality of pillar-clip interfaces are formed on one or more lateral sides of the plurality of solar modules.

23. The method of claim 9, wherein the plurality of pillar-clip interfaces are formed on the opposing lateral sides of the plurality of solar modules.

24. The method of claim 9, wherein the plurality of strut-clamp interfaces are established by using a riveting tool located on a strut mount load head, wherein the strut mount load head is located on at least one of the one or more mobile platforms.

25. The method of claim 9, further comprising: The structural integrity of one of the plurality of pillar-clamp interfaces is evaluated using at least part of the following: (i) a measured force or a deflection during and / or after the plurality of solar modules are installed on the plurality of pillars, or (ii) one or more images of the plurality of pillar-clamp interfaces during or after the formation of the plurality of pillar-clamp interfaces.

26. The method of claim 9, wherein the plurality of pillar-clip interfaces are formed without the need for one or more fasteners.

27. The method of claim 9, wherein the plurality of pillar-clip interfaces are formed by positioning one or more fasteners in place relative to each clip and a corresponding tab on each pillar, and passing the one or more fasteners through the tab to secure the tab to the clip, or passing the one or more fasteners through the clip to secure the clip to the tab.

28. The method of claim 1, wherein the solar module array is constructed on a substantially flat terrain or a substantially uneven terrain.

29. The method of claim 1, wherein the solar module array is a fully wired array.

30. The method of claim 1, wherein the solar module is a double-tilted array.

31. The method of claim 1, further comprising: Identify a location suitable for the autonomous positioning and assembly of at least one of the plurality of solar modules; And control the one or more operational platforms to autonomously position and assemble at least one of the plurality of pillars and at least one of the plurality of solar modules on the terrain to construct the solar module array without the assistance or participation of the user.

32. The method of claim 31 further includes identifying the location based on at least one analysis of topographic data.

Images