A ground-mounted photovoltaic module installation vehicle

Abstract

This invention provides a ground-mounted photovoltaic module installation vehicle, comprising a mobile vehicle body and a module transport mechanism connected to the mobile vehicle body for transporting photovoltaic modules. The mobile vehicle body is equipped with a module gripping and installation robotic arm, a module fastening bolt installation robotic arm, a satellite positioning and machine vision recognition system, and a control system. The module gripping and installation robotic arm, the module fastening bolt installation robotic arm, and the satellite positioning and machine vision recognition system are respectively connected to the control system. The control system receives position signals, processes the operating signals of the joint motors of the robotic arms, and after processing, controls the movement of the vehicle and the corresponding actions of the robotic arms. This invention uses a mechanized and automated installation vehicle, improving the installation efficiency of photovoltaic modules, ensuring installation quality, and reducing labor intensity.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic equipment installation technology, and in particular to a ground-mounted photovoltaic module installation vehicle. Background Technology

[0002] With the increasing number of photovoltaic (PV) power plants being built, the installation of PV modules is a major and complex task. Currently, PV module installation relies primarily on manual labor, which is labor-intensive, inefficient, and prone to damage due to various factors during installation. Furthermore, manual installation is significantly affected by weather, terrain, and the individual's level of responsibility, resulting in inconsistent installation quality. Summary of the Invention

[0003] To address the shortcomings of the existing technologies, this invention provides a ground-mounted photovoltaic module installation vehicle to overcome the drawbacks of manual handling and installation, such as high labor intensity, low efficiency, large manpower requirements, easy damage to modules, and frequent non-standard installation, which are associated with short-distance on-site transportation of photovoltaic modules, precise automatic positioning and placement of photovoltaic modules, and tightening of fixing bolts. This promotes the transformation of photovoltaic power stations from manual installation to automated installation, and achieves automated, safe, efficient, and precise photovoltaic module installation.

[0004] The technical solution provided by this invention is as follows: A ground-mounted photovoltaic module installation vehicle includes a mobile vehicle body and a module transportation mechanism connected to the mobile vehicle body for transporting photovoltaic modules. The mobile vehicle body is equipped with a module gripping and installation robotic arm, a module fastening bolt installation robotic arm, a satellite positioning and machine vision recognition system, and a control system. The module gripping and installation robotic arm, the module fastening bolt installation robotic arm, and the satellite positioning and machine vision recognition system are respectively connected to the control system. The control system is used to receive vehicle body position signals, images captured by cameras, and process the operation signals of the joint motors of the robotic arms. After processing, it controls the movement of the vehicle body and controls the robotic arms to perform corresponding actions.

[0005] The component gripping and installation robotic arm includes a first robotic arm mounted on a mobile vehicle body and a gripping mechanism for gripping components disposed at the end of the first robotic arm. A first camera is mounted on the first robotic arm.

[0006] The component fastening bolt installation robotic arm includes a second robotic arm mounted on a mobile vehicle body and a component fastening bolt installation mechanism disposed at the end of the second robotic arm. The component fastening bolt installation mechanism includes a nut and washer compartment, a bolt compartment, and a bolt installation assembly for disassembling and assembling bolts. A second camera is mounted on the second robotic arm.

[0007] The satellite positioning and machine vision recognition system includes a positioning device and a machine vision recognition system. The positioning and machine vision recognition system is set up with two sets installed at the front and rear of the mobile vehicle respectively. The positioning device is used to determine the actual position of the installation vehicle and to determine whether it has reached the designated position. The machine vision recognition system uses optical equipment to collect target images to determine whether there are obstacles within the working range.

[0008] Furthermore, the first robotic arm is divided into three sections and has five movable joints. The first robotic arm includes a gripping and mounting robotic arm base, a first servo motor, a first joint servo motor, a first link, a second joint servo motor, a third joint servo motor, a second link, a drive motor and a harmonic gear assembly, and a first wrist. The first servo motor is mounted on the gripping and mounting robotic arm base. The output end of the first servo motor is connected to the base at the end of the first link. The two ends of the first link are respectively connected to the first joint servo motor and the second joint servo motor. The two ends of the second link are respectively connected to the third joint servo motor, the drive motor, and the harmonic gear assembly. The output end of the drive motor is connected to the harmonic gear, and the other end of the harmonic gear is connected to the first wrist.

[0009] Furthermore, the gripping mechanism includes a mounting plate fixed to the end of the first robotic arm. A fixed clamping plate is provided on one side of the mounting plate, and a movable clamping plate is slidably mounted on the mounting plate. A first guide rail is provided on the mounting plate, and a first slider is slidably connected on the first guide rail. The movable clamping plate is fixed to the first slider, and one side of the first slider is connected to the telescopic end of a first electric push rod fixed on the mounting plate.

[0010] Furthermore, the mobile vehicle body is a general tracked vehicle, the component transportation mechanism adopts an electric forklift or trailer, etc., for transporting the boxed components that have been distributed on site to the front of the photovoltaic support array, and the positioning device adopts a GPS or Beidou position locator.

[0011] Furthermore, the second robotic arm is divided into 6 segments and has 8 movable joints. The second robotic arm includes a component fastening bolt mounting base, a second servo motor, a fourth joint servo motor, a fifth joint servo motor, a sixth joint servo motor, a seventh joint servo motor, an eighth joint servo motor, a ninth joint servo motor, a third link, a fourth link, a fifth link, a sixth link, a seventh link, a second wrist, a drive motor, and a harmonic gear assembly. The second servo motor is mounted on the component fastening bolt mounting base. The output end of the second servo motor is connected to the base at the end of the third link. Both ends of each link are connected to the corresponding joint servo motor. One end of the second wrist is connected to the ninth joint servo motor, and the other end is connected to the drive motor and the harmonic gear assembly. The end of the harmonic gear assembly away from the second wrist is connected to the component fastening bolt mounting mechanism.

[0012] Furthermore, the component fastening bolt installation mechanism includes a bolt mounting bracket and a bolt compartment base fixed to the end of the second robotic arm. A nut washer compartment base is provided on the bolt mounting bracket, and a nut washer compartment is slidably disposed on the nut washer compartment base. A removable end baffle is installed at the front end of the nut washer compartment. A transverse groove is provided on the side of the nut washer compartment, and a dividing partition is movably inserted into the transverse groove. A first cylinder is provided below the bolt compartment base, and a bolt compartment slider bracket is fixedly connected to the telescopic end of the first cylinder. A bolt compartment is provided on the bolt compartment slider bracket, and the bolt compartment slider bracket is slidably connected to a fourth guide rail fixed below the bolt compartment base.

[0013] Furthermore, the nut and washer compartment has a nut groove and a washer groove inside. A nut and washer spring compression base is installed at the rear of the nut and washer compartment. A second electric push rod is installed on the side of the nut and washer compartment base. A second slider is fixedly connected to the telescopic end of the second electric push rod. The second slider is slidably connected to a second guide rail located below the nut and washer compartment base. The second slider is fixedly connected to the nut and washer compartment.

[0014] Furthermore, two sets of drive mechanisms are symmetrically arranged on both sides of the nut washer compartment, which are used to drive the end baffle and the dividing partition to move respectively. Each set of drive mechanisms includes an electric push rod, a slider connected to the telescopic end of the electric push rod, and a guide rail adapted to the slider. The corresponding slider is fixedly connected to the drive end baffle and the dividing partition respectively.

[0015] Furthermore, the bolt mounting assembly includes a bolt clamp base fixed to the bolt mounting bracket. A camera and a second cylinder are installed inside the bolt clamp base. A feed slider is fixedly connected to the telescopic end of the second cylinder. The feed slider is fixedly connected to a third servo motor and slidably connected to a third guide rail disposed on the side of the bolt clamp base. A rotating frame is fixedly connected to the output end of the third servo motor. A fourth servo motor is installed inside the rotating frame. The output end of the fourth servo motor is connected to the bolt clamp through a transmission assembly.

[0016] Furthermore, the transmission assembly includes a rotating shaft mounted on the output end of the fourth servo motor, and a U-shaped feed frame is threadedly connected to the rotating shaft. The top two sides of the U-shaped feed frame are rotatably connected to two clamping plates of the bolt clamp, respectively.

[0017] The beneficial effects of this invention are:

[0018] (1) Reduce installation personnel and reduce production costs: The transport and installation vehicle is fully functional, requiring only one person and one vehicle to complete all component installation work, reducing component installation costs by at least 40%.

[0019] (2) Improve installation efficiency: The flexible movement of the robotic arm and the fast and accurate recognition of the machine vision recognition system can install 20-30 components per hour.

[0020] (3) Reduce labor intensity and improve working environment: The automated installation process eliminates the need for heavy physical labor and high-altitude work. Ground-mounted photovoltaic module installation usually requires high-altitude work.

[0021] (4) Ensure installation quality: The ground photovoltaic module installation vehicle can accurately control the installation position of the photovoltaic module to ensure installation accuracy.

[0022] (5) Adaptable to complex environments: The excellent off-road performance of the tracked chassis enables the installation vehicle to work in various complex terrains and harsh environments, without being limited by terrain and weather conditions.

[0023] (6) Reduce component damage: The secondary handling of components in the photovoltaic area is carried out by vehicle, avoiding non-standard operation of the backsheet by manual handling, which can effectively prevent component damage and reduce the project installation cost. Attached Figure Description

[0024] Figure 1 and Figure 2 These are schematic diagrams of the structure of the present invention from different angles;

[0025] Figure 3 This is a schematic diagram of the component gripping and installation robotic arm of the present invention;

[0026] Figure 4 This is a schematic diagram of the component clamping mechanism of the present invention;

[0027] Figure 5 This is a schematic diagram of the mechanical arm for mounting component fastening bolts according to the present invention;

[0028] Figure 6 A schematic diagram of the nut and washer compartment of the present invention;

[0029] Figure 7 A schematic diagram of the bolt compartment structure of the present invention;

[0030] Figure 8 This is a schematic diagram of the component fastening bolt mounting mechanism of the present invention;

[0031] Figure 9 This is a schematic diagram of the bolt mounting mechanism of the present invention;

[0032] Figure 10 This is the invention Figure 9 A magnified view of the local structure.

[0033] In the diagram: 1-Component transport mechanism, 2-Mobile vehicle body, 3-Component gripping and installation robotic arm, 4-Component fastening bolt installation robotic arm, 5-Satellite positioning and machine vision recognition system A, 6-Satellite positioning and machine vision recognition system B;

[0034] 301 - Component gripping and mounting robotic arm base; 302 - First servo motor; 303 - First joint servo motor; 304 - First link; 305 - Second joint servo motor; 306 - Third joint servo motor; 307 - Second link; 308 - Drive motor and harmonic gear assembly; 309 - First camera; 310 - First wrist; 311 - First guide rail; 312 - First slider; 313 - Fixed clamping plate; 314 - Movable clamping plate; 315 - First electric push rod; 316 - Mounting plate.

[0035] 401 - Component fastening bolts for mounting the robotic arm base; 402 - Second servo motor; 403 - Fourth joint servo motor; 404 - Third link; 405 - Fifth joint servo motor; 406 - Fourth link; 407 - Sixth joint servo motor; 408 - Fifth link; 409 - Seventh joint servo motor; 410 - Sixth link; 411 - Eighth joint servo motor; 412 - Seventh link; 413 - Ninth joint servo motor; 414 - Second wrist; 415 - Harmonic gear assembly;

[0036] 416- Bolt mounting bracket, 417- Nut and washer compartment base, 418- Second electric push rod, 422, 423- Electric push rod, 419- Nut and washer compartment, 420- Dividing partition, 421- End baffle, 424- Bolt clamp, 425- Fourth servo motor, 426- Third servo motor, 427- Second cylinder, 428- Bolt clamp base, 429- Bolt compartment, 430- First cylinder, 431- Camera;

[0037] 4191-Nut, washer, and spring clamping base; 4192-Nut and washer; 4181-Second slider; 4182-Second guide rail; 4301-Bolt compartment base; 4302-Fourth guide rail; 4303-Bolt compartment slider bracket; 4241-U-shaped feed frame; 4251-Rotating frame; 4252-Rotating shaft; 4261-Feed slider; 4271-Third guide rail. Detailed Implementation

[0038] The present invention will be further described below with reference to specific embodiments. The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the present invention. In order to better illustrate the specific embodiments of the present invention, some parts in the drawings may be omitted, enlarged or reduced, and do not represent the actual product size. It is understandable for those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings. Based on the specific embodiments of the present invention, all other specific embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] In the description of this invention, it should be noted that the terms "front," "rear," "upper," and "lower," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0040] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0041] like Figure 1-10 The illustrated ground-mounted photovoltaic module installation vehicle includes a mobile vehicle body 2 and a module transport mechanism 1 connected to the mobile vehicle body 2 for transporting photovoltaic modules. The mobile vehicle body 2 is equipped with a module gripping and installation robotic arm 3, a module fastening bolt installation robotic arm 4, a satellite positioning and machine vision recognition system, and a control system. The module gripping and installation robotic arm 3, the module fastening bolt installation robotic arm 4, and the satellite positioning and machine vision recognition system are respectively connected to the control system. The control system is used to receive vehicle position signals, images captured by cameras, and process the operation signals of the joint motors of the robotic arms. After processing, it controls the movement of the vehicle body and controls the robotic arms to perform corresponding actions.

[0042] The component gripping and installation robotic arm 3 includes a first robotic arm mounted on the mobile vehicle body 2 and a gripping mechanism for gripping components disposed at the end of the first robotic arm. A first camera 309 is mounted on the first robotic arm.

[0043] The component fastening bolt installation robotic arm 4 includes a second robotic arm mounted on the mobile vehicle body 2 and a component fastening bolt installation mechanism disposed at the end of the second robotic arm. The component fastening bolt installation mechanism includes a nut and washer compartment 419, a bolt compartment 429, and a bolt installation assembly for disassembling and assembling bolts. A second camera 431 is mounted on the second robotic arm.

[0044] The satellite positioning and machine vision recognition system includes a positioning device and a machine vision recognition system. The positioning and machine vision recognition system is set up with two sets installed at the front and rear of the mobile vehicle respectively. The positioning device is used to determine the actual position of the installation vehicle and to determine whether it has reached the designated position. The machine vision recognition system uses optical equipment to collect target images to determine whether there are obstacles within the working range.

[0045] The first robotic arm is divided into three sections and has five movable joints. The first robotic arm includes a gripping and mounting robotic arm base 301, a first servo motor 302, a first joint servo motor 303, a first link 304, a second joint servo motor 305, a third joint servo motor 306, a second link 307, a drive motor and a harmonic gear assembly 308, and a first wrist 310. The first servo motor 302 is mounted on the gripping and mounting robotic arm base 301. The output end of the first servo motor 302 is connected to the base at the end of the first link 304. The two ends of the first link 304 are respectively connected to the first joint servo motor 303 and the second joint servo motor 305. The two ends of the second link 307 are respectively connected to the third joint servo motor 306 and the drive motor and the harmonic gear assembly 308. The output end of the drive motor is connected to the harmonic gear, and the other end of the harmonic gear is connected to the first wrist 310. The first servo motor 302 controls the entire robotic arm to rotate in a plane.

[0046] The gripping mechanism includes a mounting plate 316 fixed to the end of a first robotic arm. A fixed clamping plate 313 is provided on one side of the mounting plate 316, and a movable clamping plate 314 is slidably mounted on the mounting plate 316. A first guide rail 311 is provided on the mounting plate 316, and a first slider 312 is slidably connected to the first guide rail 311. The movable clamping plate 314 is fixed to the first slider 312, and one side of the first slider 312 is connected to the telescopic end of a first electric push rod 315 fixed on the mounting plate 316.

[0047] The mobile vehicle body 2 is a general-purpose tracked vehicle. The component transport mechanism 1 uses an electric forklift or trailer to transport the boxed components already distributed on site to the photovoltaic support array. The positioning device uses a GPS or Beidou positioning device. The tracked vehicle serves as the support and mobile foundation for the entire installation vehicle, possessing excellent off-road performance and stability, and can adapt to various complex terrains, such as sand, mud, and hillsides. The tracked vehicle can utilize a diesel engine or battery to provide power for its movement.

[0048] The second robotic arm is divided into 6 sections and has 8 movable joints. The second robotic arm includes a robotic arm base 401 mounted with component fastening bolts, a second servo motor 402, a fourth joint servo motor 403, a third link 404, a fifth joint servo motor 405, a sixth joint servo motor 407, a seventh joint servo motor 409, an eighth joint servo motor 411, a ninth joint servo motor 413, a fourth link 406, a fifth link 408, a sixth link 410, a seventh link 412, a second wrist 414, and a harmonic gear assembly 415. The second servo motor 402 is mounted on the component fastening bolt mounting base 401 of the robotic arm. The output end of the second servo motor 402 is connected to the base set at the end of the third link 404. Both ends of each link are connected to the corresponding joint servo motor. One end of the second wrist 414 is connected to the ninth joint servo motor 413, and the other end is connected to the harmonic gear assembly 415. The end of the harmonic gear assembly 415 away from the second wrist 414 is connected to the component fastening bolt mounting mechanism. The second servo motor 402 controls the entire robotic arm to rotate in the plane.

[0049] The component fastening bolt installation mechanism includes a bolt mounting bracket 416 fixed to the end of the second robotic arm and a bolt compartment base 4301. A nut washer compartment base 417 is provided on the bolt mounting bracket 416, and a nut washer compartment 419 is slidably provided on the nut washer compartment base 417. A removable end baffle 421 is installed at the front end of the nut washer compartment 419. A transverse groove is opened on the side of the nut washer compartment 419, and a dividing partition 420 is movably inserted into the transverse groove. A first cylinder 430 is provided below the bolt compartment base 4301. A bolt compartment slider bracket 4303 is fixedly connected to the telescopic end of the first cylinder 430. A bolt compartment 429 is provided on the bolt compartment slider bracket 4303. The bolt compartment slider bracket 4303 is slidably connected to a fourth guide rail 4302 fixed below the bolt compartment base 4301.

[0050] The nut and washer compartment 419 has a nut groove and a washer groove inside. A nut and washer spring compression base 4191 is installed at the rear of the nut and washer compartment 419. A second electric push rod 418 is installed on the side of the nut and washer compartment base 417. A second slider 4181 is fixedly connected to the telescopic end of the second electric push rod 418. The second slider 4181 is slidably connected to a second guide rail 4182 located below the nut and washer compartment base 417. The second slider 4181 is fixedly connected to the nut and washer compartment 419.

[0051] Two sets of driving mechanisms are symmetrically arranged on both sides of the nut washer compartment 419, which are used to drive the end baffle 421 and the dividing partition 420 to move respectively. Each set of driving mechanisms includes an electric push rod, a slider connected to the telescopic end of the electric push rod, and a guide rail adapted to the slider. The corresponding sliders are fixedly connected to the drive end baffle 421 and the dividing partition 420 respectively.

[0052] The bolt mounting assembly includes a bolt clamp base 428 fixed to a bolt mounting bracket 416. A camera 431 and a second cylinder 427 are installed inside the bolt clamp base 428. A feed slider 4261 is fixedly connected to the telescopic end of the second cylinder 427. The feed slider 4261 is fixedly connected to a third servo motor 426 and slidably connected to a third guide rail 4271 located on the side of the bolt clamp base. A rotating frame 4251 is fixedly connected to the output end of the third servo motor 426. A fourth servo motor 425 is installed inside the rotating frame 4251. The output end of the fourth servo motor 425 is connected to a bolt clamp 424 through a transmission assembly.

[0053] The transmission assembly includes a rotating shaft 4252 mounted on the output end of the fourth servo motor 425. A U-shaped feed frame 4241 is threadedly connected to the rotating shaft 4252. When the rotating shaft 4252 rotates, it drives the U-shaped feed frame 4241 to move up and down. The top two sides of the U-shaped feed frame 4241 are rotatably connected to the two clamping plates of the bolt clamp 424. The base of the bolt clamp 424 is fixedly connected to the rotating frame 4251, and the two clamping plates of the bolt clamp 424 are symmetrically hinged to its base.

[0054] The control system of this invention is the core control unit for the transport and installation vehicle to complete its tasks, and uses an industrial computer as the operating interface. The control system receives positioning information and information from the machine vision recognition system, processes operating signals such as the number of rotations and speed of each joint motor, and controls the movement of the vehicle and robotic arm according to a preset program and algorithm.

[0055] Operators can input the positioning information, installation tasks and parameters of each photovoltaic array through the operating interface. The control system controls the movement of the vehicle and the robotic arm according to the input information to realize the automated installation of photovoltaic modules.

[0056] The positioning and machine vision recognition system is installed at the front and rear of the vehicle. The positioning device is used to determine the actual position of the installation vehicle and whether it has reached the designated position. The camera system is used to determine whether there are obstacles in the working area. Installation work can only begin after safety is ensured.

[0057] The principle of machine vision recognition is to acquire target images through optical devices, process and recognize the images by combining them with computer vision algorithms, and finally achieve automated measurement and control.

[0058] The machine vision recognition system of the present invention includes a camera, control software, and a computer; the control software and the computer are installed inside the vehicle. The control software processes the images captured by the camera, continuously compares the targets (obstacles on the vehicle's movement path, component frames, photovoltaic module purlins, and component mounting elliptical holes) to extract features, and determines whether the robotic arm is in position.

[0059] The component fastening bolt installation robotic arm is mounted on the vehicle body. It is divided into 6 sections and has 8 movable joints. It can pass under the component from the side and move flexibly in three-dimensional space. The robotic arm can be customized as needed.

[0060] The robotic arm for installing component fastening bolts is equipped with a specially designed bolt installation mechanism at its end for automatically installing fastening bolts. This mechanism can store eight sets of bolts, sufficient for installing two components. Bolt storage, however, must be done entirely manually.

[0061] The end of the component fastening bolt installation robotic arm is also equipped with a camera to provide real-time feedback on the relative position between the bolt installation device and the component mounting hole; under the guidance of the vision recognition system, the fastening bolt installation work is completed.

[0062] The component gripping and installation robotic arm is mounted on the vehicle body. It is divided into 3 sections and has 5 movable joints, enabling it to move flexibly in three-dimensional space. The robotic arm can be customized as needed.

[0063] The robotic arm is equipped with grippers and a camera at its end for gripping and placing photovoltaic modules. The grippers are specially designed to fit well with the surface of the photovoltaic modules, ensuring a firm and stable grip while avoiding damage to the module surface.

[0064] The robotic arm is equipped with a camera at its end to provide real-time feedback on the positional difference between the robotic arm and the modules and photovoltaic brackets; guided by the vision recognition system, it grabs the modules from the transport device and places them in the required installation position.

[0065] The specific method of using this invention includes the following steps:

[0066] (1) Vehicle movement and positioning

[0067] Preparation: The operator inputs the positioning coordinates of the photovoltaic array to be installed into the vehicle control system, the number of the first component to be installed in the array, the component's external dimensions, and the number of components in each photovoltaic array.

[0068] The ground-mounted photovoltaic module installation vehicle is started, transporting the modules to be installed to the designated array location. Through real-time feedback from the positioning system, the control system automatically guides the installation vehicle to the optimal installation position for each module.

[0069] (2) Component capture and installation

[0070] After the ground-mounted photovoltaic module installation vehicle stops at the predetermined position, the position and azimuth of the vehicle can be obtained through the positioning and camera system installed in front of and behind the vehicle, and then the position of the base axis of the module gripping and installation robotic arm 3 can be obtained.

[0071] Starting from a fixed initial position, the component gripping and installation robotic arm 3, driven by the first servo motor 302 and the joint servo motors 303, 305, 306, and 308 of the base 301, moves the first wrist 310 above the component transport device. Under the control of the first camera 309 and the visual recognition system, the first wrist 310 places the fixed clamping plate 313 and the movable clamping plate 314 in the middle of the component, with the clamps on both sides of the middle of the long side of the component. After the fixed clamping plate 313 and the movable clamping plate 314 are positioned, under the control of the first camera 309 and the visual recognition system, the first electric push rod 315 pushes the first slider 312, causing the movable clamping plate 314 mounted on it to move towards the fixed clamping plate 313. After the clamping force of the component exceeds 63 kg, the gripping ends and the output torque of the first electric push rod 315 is locked, and the component gripping and installation robotic arm 3 picks up the component.

[0072] Each joint servo motor of the robotic arm is equipped with an encoder to record its rotation angle, and the control system calculates the real-time actual position of each link.

[0073] Based on the array positioning coordinates and the number of columns of components to be installed, the positioning coordinates of the installation target are calculated in real time. Under the assisted control of the machine recognition system, the first link 304, the second link 307, and the first wrist 310 are controlled to move the components to the installation position on the photovoltaic support. After the first wrist 310 reaches the installation position, the joint motor 303 of the first link 304 of the robotic arm controls the downward torque of the robotic arm. When the torque exceeds 18 kg and there is no displacement, the locking torque is completed, thus completing the component placement and installation process.

[0074] After the three component fastening bolts are installed, the component gripping and installation robotic arm 3 releases the component. The first electric push rod 315 pulls back the first slider 312, causing the movable clamping plate 314 mounted on it to move 20mm away from the fixed clamping plate 313. At the same time, the first servo motor 302 of the base 301 rotates, causing both the fixed clamping plate 313 and the movable clamping plate 314 to detach from the component. The component gripping and installation robotic arm 3 then moves to retrieve the next component, repeating the component retrieval process.

[0075] (3) Installation of component fastening bolts

[0076] While gripping the component, the component fastening bolt installation robot arm 4, which has initially or completed its work, returns to its initial zero position. Similarly, based on the positioning systems installed at the front and rear of the vehicle, the base axis position coordinates of the component gripping and component fastening bolt installation robot arm 5 are obtained.

[0077] After returning to the zero position, manually place 8 M8 nuts and 8 M8 flat washers into the nut and washer compartment 419; and place 8 sets of M8 bolts with spring washers and flat washers into the bolt compartment 429. One photovoltaic module requires 4 sets of M8 bolts.

[0078] The nut and washer compartment 419 has a nut groove and a washer groove inside. A nut and washer spring clamping base 4191 is installed at the rear of the compartment. The nut and washer are pushed forward by the spring in 4191.

[0079] The nut washer compartment 419 has a removable end baffle 421 installed at its front end to block the nut washer. The end baffle 421 is driven by an electric push rod 423 to move the slider bracket back and forth on the guide rail, realizing movement in the direction parallel to the end section.

[0080] The nut washer compartment 419 has a transverse groove at a distance of one bolt from the end. A dividing plate 420 can be inserted into the transverse groove. The dividing plate 420, like the end baffle 421, is moved by an electric push rod 422. After the first nut is tightened, the dividing plate 420 is inserted into the nut washer compartment 419 to block subsequent nut washers and prevent them from falling out.

[0081] After the bolts are manually installed, the component fastening bolt installation robotic arm 5 is re-initialized. Based on the array positioning coordinates and the number of columns of components to be installed, the control system calculates the target positioning coordinates in real time and controls the second servo motor 402, the fourth link 406, the fifth link 408, the sixth link 410, the seventh link 412, and the second wrist 414 of the base to rotate, moving the bolt installation bracket 416 to the vicinity of the target installation position coordinates on the photovoltaic bracket with 8 bolts.

[0082] Each joint servo motor of the robotic arm is equipped with an encoder to record its rotation angle, and the control system calculates the real-time actual position of each link.

[0083] Under the control of the second camera 431 and the visual recognition system, the precise position of the component mounting hole is first identified, and the harmonic gear of the bolt mounting bracket 416 is controlled to adjust the bolt mounting bracket 416 to be perpendicular to the bolt surface to be installed; the second servo motor 402 of the base 401 and the eighth joint motor 411 of the seventh link 412 are controlled to rotate, and the axis of the bolt mounting bracket 416 is adjusted to the waist center line of the long oval mounting hole of the bolt of the component to be installed.

[0084] Identification of the oblong mounting holes for component bolts: their dimensional characteristics are that the two ends are symmetrical semicircular arcs, and the middle is a straight line.

[0085] Under the push of the bolt magazine 429 and the bolt slider bracket 4303 and the first cylinder 430, the bolt to be installed is moved to the top of the bolt clamp 424. The fourth servo motor 425 rotates, causing the U-shaped feed frame 4241 of the lead screw and the bolt clamp 424 of the slider mechanism to move downward by 5mm, opening the bolt clamp 424.

[0086] The servo motor 426 feeds the slider 4261, which is pushed by the second cylinder 427, and the bolt clamp 424 is fed to the bolt chamber 429 where the bolt is to be installed; the fourth servo motor 425 rotates and drives the U-shaped feed frame 4241 of the bolt clamp 424 of the lead screw and slider mechanism to move upward by 5mm, and closes the bolt clamp 424 until the torque is greater than 21N.m.

[0087] The rotation of the third servo motor 426 drives the rotating frame 4251 of the bolt clamp 424 to rotate, causing the bolt clamp 424 to rotate and tighten the bolt from the bolt chamber 429. At the same time, the retraction of the second cylinder 427 causes the bolt clamp 424 to move down 16mm. After the bolt clamp 424 has moved down, the bolt chamber 429 retracts to its original zero position.

[0088] Under the control of the second camera 431 and the visual recognition system, the second servo motor 402 of the base 401 and the eighth joint motor 411 of the seventh link 412 are rotated again, adjusting the axis of the bolt mounting bracket 416 to the center line of the oblong mounting hole of the component bolt to be mounted; the bolt clamp 424 is located directly below the center of the oblong mounting hole of the component bolt, with an error within 0.2mm. The bolt clamp 424 enters the oblong mounting hole of the component bolt under the push of the second cylinder 427. After entering, the bolt clamp 424 rotates under the drive of the third servo motor 426, feeding 6mm while rotating, and then stops. The dividing plate 420 of the nut washer compartment 419 is inserted 14mm; the end baffle 421 moves away 24mm, opening the nut groove channel of the nut washer compartment 419. The nut washer compartment 419 retracts 20mm, and the end baffle 421 moves back 24mm, blocking the nut groove channel of the nut washer compartment 419. The nut washer chamber 419 advances 20mm, using the end baffle 421 to hold the nut on the bolt clamp 424. The bolt clamp 424 begins to rotate and feed upwards until the torque reaches 21 N·m. The bolt clamp 424 releases, the clamping torque is zero, and the bolt clamp 424 moves downwards 50mm, returning to its original zero position.

[0089] Under the control of the control system, the next bolt is installed, and the above process is repeated. After all 8 bolts are installed, the component fastening bolt installation robot arm 4 returns to its initial zero position.

[0090] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A ground-mounted photovoltaic module installation vehicle, characterized in that, The system includes a mobile vehicle body (2) and a component transport mechanism (1) connected to the mobile vehicle body (2) for transporting photovoltaic modules. The mobile vehicle body (2) is equipped with a component gripping and installation robotic arm (3), a component fastening bolt installation robotic arm (4), a satellite positioning and machine vision recognition system, and a control system. The component gripping and installation robotic arm (3), the component fastening bolt installation robotic arm (4), and the satellite positioning and machine vision recognition system are respectively connected to the control system. The control system is used to receive vehicle position signals, images captured by cameras, and process the operation signals of the joint motors of the robotic arm. After processing, it controls the movement of the vehicle body and controls the robotic arm to perform corresponding actions. The component gripping and installation robotic arm (3) includes a first robotic arm mounted on a mobile vehicle body (2) and a gripping mechanism for gripping components located at the end of the first robotic arm. A first camera (309) is mounted on the first robotic arm. The component fastening bolt installation robot arm (4) includes a second robot arm installed on the mobile vehicle body (2) and a component fastening bolt installation mechanism set at the end of the second robot arm. The component fastening bolt installation mechanism includes a nut and washer compartment (419), a bolt compartment (429), and a bolt installation assembly for disassembling and assembling bolts. A second camera (431) is installed on the second robot arm. The satellite positioning and machine vision recognition system includes a positioning device and a machine vision recognition system. The positioning and machine vision recognition system is set up in two sets, which are installed in front of and behind the mobile vehicle respectively. The positioning device is used to determine the actual position of the installation vehicle and to determine whether it has reached the designated position. The machine vision recognition system collects target images through optical equipment to determine whether there are obstacles within the working range. The component fastening bolt installation mechanism includes a bolt mounting bracket (416) fixed to the end of the second robotic arm and a bolt compartment base (4301). A nut washer compartment base (417) is provided on the bolt mounting bracket (416), and a nut washer compartment (419) is slidably provided on the nut washer compartment base (417). A removable end baffle (421) is installed at the front end of the nut washer compartment (419). A transverse groove is provided on the side of the nut washer compartment (419), and a dividing partition (420) is movably inserted into the transverse groove. A first cylinder (430) is provided below the bolt compartment base (4301). A bolt compartment slider bracket (4303) is fixedly connected to the telescopic end of the first cylinder (430). A bolt compartment (429) is provided on the bolt compartment slider bracket (4303). The bolt compartment slider bracket (4303) is slidably connected to a fourth guide rail (4302) fixed below the bolt compartment base (4301). The bolt mounting assembly includes a bolt clamp base (428) fixed to a bolt mounting bracket (416). A second camera (431) and a second cylinder (427) are installed inside the bolt clamp base (428). A feed slider (4261) is fixedly connected to the telescopic end of the second cylinder (427). The feed slider (4261) is fixedly connected to a third servo motor (426). The feed slider (4261) is slidably connected to a third guide rail (4271) located on the side of the bolt clamp base. A rotating frame (4251) is fixedly connected to the output end of the third servo motor (426). A fourth servo motor (425) is installed inside the rotating frame (4251). The output end of the fourth servo motor (425) is connected to a bolt clamp (424) through a transmission assembly.

2. The ground-mounted photovoltaic module installation vehicle according to claim 1, characterized in that, The first robotic arm is divided into 3 sections and has 5 movable joints. The first robotic arm includes a component gripping and mounting robotic arm base (301), a first servo motor (302), a first joint servo motor (303), a first link (304), a second joint servo motor (305), a third joint servo motor (306), a second link (307), a first harmonic gear assembly (308), and a first wrist (310). The first servo motor (302) is mounted on the component gripping and mounting robotic arm base (301). The output end of the first servo motor (302) is connected to the base at the end of the first link (304). The two ends of the first link (304) are connected to the first joint servo motor (303) and the second joint servo motor (305) respectively. The two ends of the second link (307) are connected to the third joint servo motor (306) and the first harmonic gear assembly (308) respectively. The output end of the drive motor is connected to the harmonic gear, and the other end of the harmonic gear is connected to the first wrist (310).

3. The ground-mounted photovoltaic module installation vehicle according to claim 1, characterized in that, The gripping mechanism includes a mounting plate (316) fixed to the end of the first robotic arm. A fixed clamping plate (313) is provided on one side of the mounting plate (316). A movable clamping plate (314) is slidably mounted on the mounting plate (316). A first guide rail (311) is provided on the mounting plate (316). A first slider (312) is slidably connected on the first guide rail (311). The movable clamping plate (314) is fixed to the first slider (312). One side of the first slider (312) is connected to the telescopic end of a first electric push rod (315) fixed on the mounting plate (316).

4. The ground-mounted photovoltaic module installation vehicle according to claim 1, characterized in that, The mobile vehicle body (2) is a general tracked vehicle, and the component transportation mechanism (1) adopts an electric forklift or trailer to transport the boxed components that have been distributed to the site to the front of the photovoltaic support array. The positioning device adopts a GPS or Beidou position locator.

5. A ground-mounted photovoltaic module installation vehicle according to claim 1, characterized in that, The second robotic arm is divided into 6 sections and has 8 movable joints. The second robotic arm includes a robotic arm base (401) mounted with component fastening bolts, a second servo motor (402), a fourth joint servo motor (403), a third link (404), a fifth joint servo motor (405), a sixth joint servo motor (407), a seventh joint servo motor (409), an eighth joint servo motor (411), a ninth joint servo motor (413), a fourth link (406), a fifth link (408), a sixth link (410), a seventh link (412), a second wrist (414), and a third link (405). The second harmonic gear assembly (415) and the second servo motor (402) are mounted on the assembly fastening bolt mounting robot arm base (401). The output end of the second servo motor (402) is connected to the base set at the end of the third link (404). Both ends of each link are connected to the corresponding joint servo motor. One end of the second wrist (414) is connected to the ninth joint servo motor (413), and the other end is connected to the drive motor and the second harmonic gear assembly (415). The end of the drive motor and the second harmonic gear assembly (415) away from the second wrist (414) is connected to the assembly fastening bolt mounting mechanism.

6. A ground-mounted photovoltaic module installation vehicle according to claim 1, characterized in that, The nut and washer compartment (419) has a nut groove and a washer groove inside. A nut and washer spring compression base (4191) is installed at the rear of the nut and washer compartment (419). A second electric push rod (418) is installed on the side of the nut and washer compartment base (417). A second slider (4181) is fixedly connected to the telescopic end of the second electric push rod (418). The second slider (4181) is slidably connected to the second guide rail (4182) located below the nut and washer compartment base (417). The second slider (4181) is fixedly connected to the nut and washer compartment (419).

7. A ground-mounted photovoltaic module installation vehicle according to claim 1, characterized in that, Two sets of driving mechanisms are symmetrically arranged on both sides of the nut washer compartment (419), which are used to drive the end baffle (421) and the dividing partition (420) to move respectively. Each set of driving mechanisms includes an electric push rod, a slider connected to the telescopic end of the electric push rod, and a guide rail adapted to the slider. The corresponding slider is fixedly connected to the drive end baffle (421) and the dividing partition (420) respectively.

8. A ground-mounted photovoltaic module installation vehicle according to claim 1, characterized in that, The transmission assembly includes a rotating shaft (4252) installed at the output end of the fourth servo motor (425). A U-shaped feed frame (4241) is threaded onto the rotating shaft (4252). The top two sides of the U-shaped feed frame (4241) are rotatably connected to two clamping plates of the bolt clamp (424).

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