A mobile modular photovoltaic assembly system

Abstract

This invention is a mobile modular photovoltaic (PV) assembly system. The system comprises a digital assembly platform for PV modular strings, a digital assembly vehicle for PV modular strings, and a Manufacturing Execution System (MES). The assembly platform features a modular design, equipped with flipping components, track adjustment, clamp fixing, and quality inspection mechanisms, allowing for flexible adaptation to modules of different sizes. The assembly vehicle provides mobile support and material loading, enabling flexible deployment through high-precision positioning and environmental sensing. The MES system achieves full-process process scheduling, status monitoring, and data traceability. This invention solves the problems of poor mobility, reliance on manual assembly, low informatization, and insufficient adaptability in existing PV module installations. It achieves rapid deployment, digital management, flexible movement, and efficient assembly of PV modules, significantly improving construction efficiency, quality stability, and safety, while reducing costs.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module installation technology, and more specifically to a mobile modular photovoltaic assembly system. Background Technology

[0002] With the continuous expansion of photovoltaic power plant construction, traditional manual handling and installation methods are inefficient, labor-intensive, and prone to damage to components in complex terrains such as deserts and hills. Existing photovoltaic assembly equipment is mostly fixed or semi-fixed, large in size, lacks versatility, and is difficult to move flexibly with construction progress, nor can it quickly adapt to different specifications of photovoltaic modules and support structures. Furthermore, existing systems have low modularity, requiring significant manual alignment and auxiliary operations during installation, thus limiting overall assembly efficiency. Therefore, there is an urgent need for a mobile, easily deployable, and quickly adaptable modular photovoltaic assembly system to improve installation efficiency and adaptability. Summary of the Invention

[0003] The purpose of this invention is to overcome the problems existing in the prior art and provide a mobile modular photovoltaic assembly system. The system consists of a photovoltaic modular string digital assembly platform, a MES system, and a photovoltaic modular string digital assembly vehicle for carrying and transporting the assembly platform. Through the above-mentioned collaborative structure, the system solves the problems of poor mobility, reliance on manual labor in the assembly process, low level of informatization, and difficulty in adapting to different scenarios in the installation of existing photovoltaic modules, and realizes the rapid deployment, digital management, flexible movement and efficient assembly of photovoltaic modules on site.

[0004] To achieve the above-mentioned technical objectives and effects, the present invention is implemented through the following technical solution: A mobile modular photovoltaic (PV) assembly system includes a digital assembly platform for PV modular strings, a digital assembly vehicle for PV modular strings, and a Manufacturing Execution System (MES). These three components work together to form a mobile, configurable, and traceable PV assembly unit. The photovoltaic modular string digital assembly platform includes a flipping component, photovoltaic panels, photovoltaic panel fasteners, purlins, purlin power line motors, a barcode scanning camera assembly, purlin tracks, photovoltaic panel tracks, purlin clamps, photovoltaic panel power line motors, an ultrasonic scanner, an IoT module, a lithium battery, a platform lifting mechanism, a photovoltaic panel limiting mechanism, a multimeter, and lockable casters. The flipping component is used to remove the assembled photovoltaic modules. The photovoltaic panel tracks and purlin tracks are adjusted in position via corresponding power line motors. The ultrasonic scanner and multimeter are used for surface crack detection and electrical performance testing of the photovoltaic panels, respectively, and the test data is uploaded to the MES system. The IoT module uploads the assembly progress and component information. The assembly platform is extended through modular combinations. The photovoltaic modular string digital assembly vehicle includes a vehicle platform, a platform fixing device, a detachable assembly platform lifting mechanism, an automatic lifting staircase, a purlin placement platform lifting device, a purlin placement platform, a purlin stack, a vehicle shock absorption device, a track tensioning device, a tracked or wheeled walking mechanism, a GNSS / RTK positioning antenna, a photovoltaic panel material flipping mechanism, an operating platform, a camera sensor, a lidar sensor, and a robotic arm. The platform fixing device secures the photovoltaic modular string digital assembly platform. The positioning antenna, lidar sensor, and camera sensor work together to achieve positioning, navigation, and environmental perception. The robotic arm is responsible for loading operations. The MES system communicates with the various mechanical units and sensors of the photovoltaic modular string digital assembly platform and the photovoltaic modular string digital assembly vehicle to realize process scheduling, status monitoring, data acquisition, batch binding, quality traceability and multi-vehicle collaboration.

[0005] Furthermore, the flipping component consists of a flipping mechanism, a baffle, and a push rod lifting mechanism; the photovoltaic panel fixing component adopts a pressure block installation, bolt back lock installation, or U-bolt + pressure block installation method; the purlin clamp includes a purlin power roller, a purlin clamping slider, a clamp motor, an electric push rod, an upper and lower lifting platform, and a rubber clamp head, used to clamp the purlin to prevent shaking.

[0006] Furthermore, the assembly platform lifting mechanism is a detachable structure used to move the assembly platform from the vehicle platform to the ground or other locations; the purlin placement platform lifting device includes a rack, gear motor, linear guide rail and frame assembly to realize the up and down lifting of the purlin.

[0007] Furthermore, the control flow of the MES system includes: During system initialization, communication is established with each mechanical unit and a self-test is completed, and production task parameters are loaded. During the material loading stage, the barcode information of the photovoltaic panels is collected by a barcode scanning camera to complete the material identification and batch binding; During the assembly process, actions such as control track adjustment, fixture clamping, and platform lifting are carried out in a coordinated manner, and the assembly status is monitored in real time. During the testing phase, the system receives test data from an ultrasonic scanner and a multimeter, and automatically determines the qualification of the components. During the unloading stage, the control flipping component removes qualified components and uploads full-process data through the IoT module; when multiple vehicles work together, path planning, conflict avoidance and progress management are realized.

[0008] Furthermore, the photovoltaic panel limiting mechanism of the assembly platform restricts the position of the photovoltaic modules through electric push rods to prevent slippage and mark the current assembly batch; the lithium battery powers the lifting mechanism and the track adjustment motor.

[0009] Furthermore, the automatic lifting staircase of the assembled vehicle consists of push rods, connecting rods, and foot platforms for personnel to go up and down; the vehicle shock absorption device works in conjunction with the track tensioning device and the track to reduce vibration during travel.

[0010] Furthermore, the specific process of this system includes: Step S1: The MES system starts up, establishes communication with each mechanical unit of the photovoltaic modular string digital assembly platform and the photovoltaic modular string digital assembly vehicle, completes self-inspection and loads production parameters; Step S2: The assembly vehicle uses GNSS / RTK positioning antenna and lidar to scan and locate itself. After precise parking, the digital assembly platform for photovoltaic modular strings is fixed to the vehicle platform. Step S3: An external transport vehicle places the photovoltaic panel box on the photovoltaic panel material flipping mechanism. The photovoltaic panel material flipping mechanism flips the photovoltaic panel box to a horizontal position. A robotic arm or a person picks up the panel and places it on the photovoltaic modular string digital assembly table. A barcode scanning camera collects barcode information and uploads it to the MES system to complete batch binding. Step S4: The purlins are transported to the assembly table track by the purlin placement platform lifting device. The robotic arm or manual placement of the purlins is performed. The MES system controls the clamps to clamp and adjust the track position to achieve precise docking between the photovoltaic panels and the purlins. Step S5: The platform lifting mechanism lifts the components, completing the mechanical fixing and electrical wiring of the photovoltaic panels and purlins. The ultrasonic scanner and multimeter simultaneously perform quality inspection, and the inspection data is uploaded to the MES system. Step S6: After the MES system determines that the component is qualified, it controls the flipping component to move the component to the transportation position; if the component is unqualified, an exception record is generated. Step S7: The IoT module uploads the entire process data of the components, the assembly vehicle moves to the next construction site, and the above process is repeated; when multiple vehicles are working, the MES system performs coordinated scheduling.

[0011] The beneficial effects of this invention are: 1. Significantly improved construction efficiency: Through the mechanical coordination of assembly vehicles and assembly platforms and the real-time scheduling of the MES system, the entire process of photovoltaic module loading, assembly, testing and unloading is automated or semi-automated. Multiple assembly vehicles can work together to reduce manual handling and waiting time, and greatly improve assembly efficiency.

[0012] 2. Controllable and stable component quality: The MES system uses closed-loop control and automatic judgment mechanisms to conduct full-process quality control of components, collect barcode information, test data and mechanical status in real time, and promptly detect and handle abnormalities to ensure the consistency and reliability of component quality before leaving the factory.

[0013] 3. Improved construction safety: Safety checkpoints are set up for all key mechanical operations, such as clamping torque, lifting limit, track movement range, vehicle navigation collision detection, etc. The system can monitor abnormal conditions in real time and take measures to stop the machine or provide warnings, reducing the risk of manual operation.

[0014] 4. Full-process data traceability: Through IoT modules and MES systems, the entire process of component data recording and traceability is realized from material delivery to assembly completion. Managers can query construction progress, quality data and historical records at any time, providing a reliable basis for project management and operation and maintenance.

[0015] 5. High flexibility and scalability: The modular design of the assembly platform can flexibly adapt to different sized components and layouts. The assembly vehicle supports multiple modes of movement to adapt to complex terrains. The MES system can dynamically schedule multiple vehicles to meet the needs of different construction site environments and construction plans.

[0016] 6. Reduce construction and maintenance costs: Automated and semi-automated operations reduce manual labor input, and online quality monitoring reduces the cost of later component replacement and maintenance, achieving an efficient and low-loss construction process. Attached Figure Description

[0017] Figure 1 This is the overall hardware diagram of the mobile modular photovoltaic assembly system of the present invention; Figure 2 This is a hardware structure diagram of the photovoltaic modular string digital assembly platform of the present invention; Figure 3 This is a hardware structure diagram of the photovoltaic modular string digital assembly vehicle of the present invention.

[0018] Explanation of the labels in the diagram: Figure 1 In the middle: 1-Photovoltaic panel flipping module, 2-Purlin placement platform, 3-Photovoltaic panel module flat mounting platform, 4-Assembly platform lifting mechanism, 5-Purlin placement platform lifting device, 6-Assembly vehicle, 7-Operating platform, 8-Robotic arm; Figure 2 In the middle: 1-Flipping component, 2-Photovoltaic panel, 3-Photovoltaic panel fixing component, 4-Purlin, 5-Purlin power line motor, 6-Bar scanning camera assembly, 7-Purlin track, 8-Photovoltaic panel track, 9-Purlin clamp, 10-Photovoltaic panel power line motor, 11-Ultrasonic scanner, 12-IoT module, 13-Lithium battery, 14-Platform lifting mechanism, 15-Photovoltaic panel limiting mechanism, 16-Multimeter, 17-Universal wheel; Figure 3In the middle: 1-vehicle platform, 2-platform fixing device, 3-assembly platform lifting mechanism, 4-automatic lifting staircase, 5-purlin placement platform lifting device, 6-purlin placement platform, 7-purlin stack, 8-vehicle shock absorption device, 9-track tensioning device, 10-track, 11-GNSS / RTK positioning antenna, 12-photovoltaic panel material flipping mechanism, 13-operating table, 14-camera sensor, 15-lidar sensor, 16-robotic arm. Detailed Implementation

[0019] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] like Figure 1 As shown, a mobile modular photovoltaic (PV) assembly system includes a digital assembly platform for PV modular strings, a digital assembly vehicle for PV modular strings, and a MES (Manufacturing Execution System). These three components work together to form a mobile, configurable, and traceable PV assembly unit. like Figure 2 As shown, the photovoltaic modular string digital assembly platform includes a flipping component, photovoltaic panels, photovoltaic panel fasteners, purlins, purlin power line motors, a barcode scanning camera assembly, purlin tracks, photovoltaic panel tracks, purlin clamps, photovoltaic panel power line motors, an ultrasonic scanner, an IoT module, a lithium battery, a platform lifting mechanism, a photovoltaic panel limiting mechanism, a multimeter, and lockable casters; wherein: The flipping component consists of a flipping mechanism, a baffle, and a push rod lifting mechanism. It is used to remove the assembled photovoltaic modules from the assembly area and can be transported to the installation area by a carrier. Photovoltaic panels are placed onto the assembly platform manually or by a robotic arm. They can be assembled in multiple pieces or in sections. The assembly platform can be extended modularly to meet different size requirements. Photovoltaic panel fasteners are used to fix photovoltaic panels and can be installed using pressure block installation, bolt back lock installation, or U-bolt + pressure block installation methods. Purlins are stacked on both sides of the assembly platform and placed onto the platform manually or by a robotic arm; the purlin power line motor drives the purlin track to move through the gear chain, enabling the assembly of components of different sizes; The barcode scanning camera component is used to scan the barcodes on photovoltaic panels and record information to ensure batch binding and production traceability of the components. The photovoltaic panel track and purlin track can be moved left and right by the photovoltaic panel power line moving components and the purlin power line moving components to achieve track position adjustment; Purlin clamps are used to clamp purlins during assembly to prevent them from shaking. For example, an H-type purlin clamp includes: a purlin drive roller, a purlin clamping slider, a clamp motor, an electric push rod, an upper and lower lifting platform, and a rubber clamp head. Ultrasonic scanners are used to detect cracks on the surface of photovoltaic panels, and abnormal data is uploaded to the MES system; The IoT module is used to upload assembly progress and component information to the MES system; The lithium battery powers the lifting mechanism and the track adjustment motor; The platform lifting mechanism is used to lift the photovoltaic modules to facilitate the connection of the junction box and the locking fasteners (if the fixing method requires lifting, then lift; the following explanation uses lifting as an example). The photovoltaic panel limiting mechanism uses electric push rods to restrict the position of photovoltaic modules, prevent them from slipping, and mark the current assembly batch.

[0021] The multimeter is used for electrical performance testing, and the results are uploaded to the MES system to enable component quality traceability. Casters are used for moving the platform.

[0022] like Figure 3 As shown, the photovoltaic modular string digital assembly vehicle includes a vehicle platform, a platform fixing device, a detachable assembly platform lifting mechanism, an automatic lifting staircase, a purlin placement platform lifting device, a purlin placement platform, a purlin stack, a vehicle shock absorption device, a track tensioning device, a tracked or wheeled walking mechanism, a GNSS / RTK positioning antenna, a photovoltaic panel material flipping mechanism, an operating platform, a camera sensor, a lidar sensor, and a robotic arm; wherein: The vehicle platform is the foundation for the entire vehicle. The assembly platform is fixed to the vehicle through the platform fixing device, providing installation and support for various mechanisms. The platform fixing device is used to securely fix the assembly platform to the vehicle platform to ensure the stability of the assembly platform during the assembly operation. The assembly platform lifting mechanism can move the assembly platform from the vehicle platform to the ground or other locations. The mechanism is detachable, which facilitates transportation and on-site installation.

[0023] The automatic lifting staircase consists of push rods, connecting rods, and foot platforms, which are used by personnel to go up and down the assembly vehicle, improving the convenience and safety of operation; The purlin placement platform lifting device includes a rack, gear motor, linear guide rail and frame assembly, which can realize the up and down lifting of the purlins and is used in conjunction with the platform.

[0024] The purlin placement platform is located on both sides of the vehicle and is used to store purlins to be assembled. Multiple purlins can be placed at once. It can be used in conjunction with the lifting device to facilitate loading by robotic arms or manual labor. Purlin stacks are used for temporary storage of purlins to be assembled, ensuring the continuity of assembly operations and facilitating material retrieval by operators; The vehicle shock absorption device works in conjunction with the track tensioning device and the track to reduce vibration during vehicle movement, protect the photovoltaic panels and assembled structure, and extend the equipment's lifespan. The track tensioning device is used to adjust the track tension to ensure that the vehicle travels stably under different ground conditions; Tracks provide the vehicle with driving power and terrain adaptability, supporting tracked or wheeled travel (for wheeled vehicles, refer to the shock absorption structure of off-road vehicles). GNSS / RTK positioning antennas provide high-precision real-time coordinates for autonomous vehicle navigation and positioning; The photovoltaic panel material flipping mechanism is located at the front of the vehicle and is used to flip the photovoltaic panel box to the front of the assembly table for loading by a robotic arm or manual labor. It includes a motor, a photovoltaic panel placement platform and a box support structure. The control panel and display screen work together to enable manual vehicle control, semi-automatic driving (such as remote control), and fully automatic driving (based on sensor-based autonomous navigation). It integrates MES system software for operation management and data acquisition. The camera sensor is installed under the front of the vehicle to collect images of the scene, enabling environmental perception, operation monitoring, and visual-assisted navigation; The lidar sensor is installed under the front of the vehicle to scan the surrounding environment and form a point cloud map, which is used for obstacle detection, environmental modeling and autonomous navigation. The robotic arm is used for loading photovoltaic panels and placing purlins. It can be used in conjunction with photovoltaic panel flipping mechanisms and purlin lifting platforms to achieve automated assembly operations.

[0025] The specific implementation plan for the assembly system is as follows: In this embodiment, the mobile modular photovoltaic assembly system achieves modular, mobile, and efficient assembly of photovoltaic modules through the mechanical collaboration between a photovoltaic modular string digital assembly vehicle (hereinafter referred to as the "assembly vehicle") and a photovoltaic modular string digital assembly platform (hereinafter referred to as the "assembly platform"). The assembly vehicle provides a loading platform and transportation support for photovoltaic panels and purlins, while the assembly platform is responsible for the precise assembly and unloading of the modules. The two are mechanically linked through slide rails, a flipping mechanism, and a power line mechanism.

[0026] The assembly vehicle first acquires its current location and the point cloud of the construction environment through GNSS / RTK positioning antenna and lidar scanning. It then precisely stops at the predetermined construction point and aligns with the assembly platform, securing the platform to the vehicle platform and providing a stable platform for subsequent loading and assembly of photovoltaic panels and purlins. Operators or the automatic control system confirm the position of the assembly platform and the status of the modules, preparing to proceed with the loading and assembly process.

[0027] During the photovoltaic panel loading process, if no photovoltaic panel box is placed above the material tilting mechanism at the front of the assembly vehicle, an external transport vehicle (such as a forklift) is needed to move the photovoltaic panel box and place it on the tilting mechanism. Subsequently, the material tilting mechanism flips the photovoltaic panel box to a horizontal position, transporting the photovoltaic panel to the assembly station at the front of the assembly table, where a robotic arm or operator can remove the photovoltaic panel from the box for assembly. The first photovoltaic panel is fixed by a limiting mechanism, providing a positioning reference for the sequential arrangement of subsequent photovoltaic panels.

[0028] The purlins are transported to both sides of the assembly platform by lifting devices on both sides of the assembly vehicle. A robotic arm or manual labor then grasps and places them onto the purlin tracks, where they are clamped and secured. A power line motor drives track fine-tuning to achieve precise alignment between the photovoltaic panels and purlins, ensuring the modules remain stable throughout the assembly process, preventing swaying or tipping. The track fine-tuning can automatically adjust to different photovoltaic panel sizes and arrangement methods, meeting modular assembly requirements.

[0029] During component assembly, the assembly platform's track adjustment, clamping, platform lifting, and tilting mechanisms work in tandem. A power line motor moves the track along the length and width of the photovoltaic panel, ensuring precise module positioning. The platform lifting mechanism slightly raises the entire module, facilitating the mechanical connection between the photovoltaic panel and the purlins using bolts or clamps. Clamps and limiting mechanisms continuously secure the photovoltaic panel and purlins throughout the assembly process and automatically adjust the clamping force according to the module dimensions to ensure assembly accuracy and stability.

[0030] The assembled photovoltaic modules slide along the track to the assembly vehicle's transport position via a tilting mechanism at the end of the assembly platform, or are moved to the carrier's handling area via a sliding rail mechanism. Clamps and limiting mechanisms continue to hold the modules in place during movement to prevent tipping or vibration damage. The assembly vehicle can move to the next construction site after completing one batch of modules, while the assembly platform continues assembling the next batch, enabling multi-batch, continuous operation.

[0031] This system supports modular expansion: assembly platform modules can be added to extend the assembly length, and the power line track and clamps can be controlled synchronously or in segments to adapt to the assembly of photovoltaic panels of different sizes and arrangements. The entire assembly process is cyclical, realizing continuous feeding of photovoltaic panels and purlins, track adjustment, clamping and fixing, platform lifting, and flipping for unloading, ensuring efficient, precise, and continuous mechanized assembly on the construction site. Meanwhile, the bottom of the assembly platform is equipped with lockable casters, which can be locked during assembly operations to ensure equipment stability; when the assembly platform needs to be moved, the locks can be released to allow for overall horizontal movement, thereby improving the on-site adaptability and mobility of the assembly system.

[0032] In terms of safety and operational precision, the actions of each mechanical unit on the assembly platform and assembly vehicle can be monitored in real time through the MES system, including track position, clamping status, tilting component movement, and platform lifting status. When track deviation, clamping abnormalities, or tilting instability are detected, an alarm can be triggered or operation can be automatically stopped, while simultaneously recording the component assembly status to achieve full-process data traceability. The slide rail mechanism, platform lifting mechanism, and clamps employ a combination of mechanical constraints and power coordination to ensure the safety of components during handling, assembly, and transportation.

[0033] Through the above implementation scheme, the assembly vehicle and assembly platform work together to achieve continuous mechanized operation of photovoltaic modules from loading, positioning, clamping, assembly, lifting, flipping to unloading, supporting modular, mobile operation and multi-batch cyclic assembly. Simultaneously, the system can flexibly adjust the module size, assembly sequence, and construction location according to the needs of the construction site, ensuring construction efficiency and traceability of module quality, providing an efficient, safe, and controllable overall solution for photovoltaic module assembly.

[0034] Specific implementation plan for MES system: In this embodiment, the MES system serves as the core control and data management unit for the photovoltaic modular string digital assembly platform and assembly vehicle. It is used to realize process scheduling, status monitoring, data acquisition, and multi-vehicle collaborative operation throughout the entire photovoltaic module assembly process. The MES system establishes communication connections with each modular mechanical unit of the assembly platform and assembly vehicle to achieve mechanical motion control, sensor data acquisition, construction progress management, and data traceability. The specific implementation process is as follows: First, during the system initialization phase, the MES system establishes communication connections with the various mechanical execution units, sensors, and communication modules of the assembly platform and assembly vehicle. The assembly platform module includes a power line motor, purlin clamping mechanism, platform lifting mechanism, tilting components, barcode scanning camera, ultrasonic scanner, and multimeter, while the assembly vehicle module includes a photovoltaic panel material tilting mechanism, purlin placement platform lifting device, track drive, and positioning sensors. The MES system performs status detection and self-check confirmation on each mechanical unit, loads the photovoltaic module specification parameters corresponding to the current production task, and uniformly initializes the working status of each module based on the number of assembly platform modules and the assembly length configuration.

[0035] When photovoltaic panels or purlins enter the assembly station, the MES system collects the barcode information of the photovoltaic panels through a barcode scanner and matches it with the preset production plan to achieve material identification and batch binding. The assembly table module can automatically activate the required number of assembly modules according to the number and arrangement of photovoltaic panels. At this time, the MES system controls the motor and track movement mechanism of the assembly table power line to adjust the purlin track and photovoltaic panel track to the corresponding installation position, ensuring that the assembly requirements of photovoltaic modules of different sizes and arrangements are met.

[0036] During component assembly, the MES system controls the purlin clamps in real time to perform clamping actions and monitors clamping displacement, motor feedback, and clamping status to ensure the purlins are stably fixed during assembly, preventing shaking or displacement. The platform lifting mechanism is controlled by the MES system to lift the photovoltaic modules as a whole, allowing operators or robotic arms to secure them with bolts or pressure blocks and perform electrical wiring. The MES system simultaneously collects data from ultrasonic scanners and displacement sensors to record and judge the surface quality of the photovoltaic panels, the purlin assembly status, and the assembly process of each module in real time. When microcracks, displacement, or abnormalities in the actuator are detected, the system automatically generates a process abnormality record and triggers a processing prompt.

[0037] After completing the mechanical and electrical connections between the photovoltaic panels and purlins, the MES system triggers a multimeter to test the electrical performance of the modules, collecting voltage, current, and other parameters. Based on preset judgment rules, it automatically determines whether the modules meet the exit conditions. For modules that pass the test, the MES system controls the tilting mechanism at the end of the assembly table and the power line mechanism to move the modules out of the assembly station. Simultaneously, the MES system uploads module identification information, assembly data, electrical test results, and installation records to the central management system via an IoT communication module, achieving full-process data traceability.

[0038] In multi-vehicle collaborative operations, the MES system collects sensor data from each assembly vehicle, including GNSS / RTK positioning antennas, LiDAR point clouds, and camera images. Combined with construction site maps, this data enables vehicle position verification, path planning, and operational navigation. When vehicle position deviations exceed preset thresholds or potential path conflicts exist, the MES system automatically alerts operators or adjusts vehicle work paths to ensure safe and efficient multi-vehicle collaboration. The MES system calculates the completion rate based on the operational status of each assembly vehicle and the assembly progress of the assembly platform. It periodically generates construction progress reports, displaying the number of completed sequences, remaining tasks, and vehicle positions through Gantt charts or 2D / 3D visualization interfaces, enabling real-time construction progress management.

[0039] The entire MES system also includes a data storage and traceability module, which records assembly data from the assembly platform, vehicle position and sensor data, and track adjustment and clamping actions in a database. This data is used for construction process queries, report generation, and historical analysis, providing technical support for construction management, quality control, and subsequent project optimization. The MES system is designed to eliminate the need to collect the physical location of the assembly platform or purlins. It achieves high-precision assembly and navigation through the collaboration of the assembly platform and vehicle sensors, while ensuring data traceability during the assembly process and efficient multi-vehicle collaboration on the construction site.

[0040] Through the above implementation scheme, the MES system forms a close mechanical and data collaborative control relationship with the assembly platform and assembly vehicle, realizing the whole process management of photovoltaic modules from feeding, positioning, clamping, assembly, lifting, flipping to unloading. The system supports modular expansion, assembly of photovoltaic panels of different sizes, multi-vehicle collaboration, and real-time updates of construction progress, providing an efficient, safe, and traceable overall solution for photovoltaic module assembly.

[0041] The specific implementation process of this system includes: In this embodiment, the photovoltaic modular string digital assembly system achieves continuous, modular, and traceable operation of photovoltaic modules from material loading, assembly, testing, and discharge through mechanical coordination between the assembly vehicle and the assembly platform, and control by the MES system. After the system starts, the MES system first establishes communication connections with each modular mechanical unit of the assembly platform and assembly vehicle, including the power line motor, purlin clamp, platform lifting mechanism, flipping component, barcode camera, ultrasonic scanner, multimeter, photovoltaic panel material flipping mechanism, and purlin placement platform lifting device. The MES system instructs each mechanical unit to perform self-checks to confirm that the motor, lifting mechanism, clamp, and sensor are in normal condition. At the same time, it loads the photovoltaic module specification parameters corresponding to the current production task and initializes the working status of each module according to the number of modules on the assembly platform and the assembly length.

[0042] At the construction site, the assembly vehicle uses GNSS / RTK positioning and LiDAR scanning to acquire point clouds of the construction location and surrounding environment. After precise parking, the MES system controls the sliding rail mechanism to align and fix the assembly platform with the assembly vehicle, providing a stable operating platform for the loading and assembly of photovoltaic panels and purlins. During the loading stage, if the photovoltaic panel box is not yet placed above the material tilting mechanism, an external transport tool (such as a forklift) is needed to place the photovoltaic panel box on the tilting mechanism. Subsequently, the MES system triggers the material tilting mechanism to tilt the photovoltaic panel box to a horizontal position, transporting the photovoltaic panel to the assembly station at the front of the assembly platform. The photovoltaic panel can be removed by a robotic arm or manually. A barcode scanning camera collects the barcode information of the photovoltaic panel. The MES system matches the barcode data with the production plan to complete the identification and batch binding of the photovoltaic panel, and automatically activates the corresponding assembly module according to the layout requirements.

[0043] During the purlin loading stage, the lifting devices on the purlin placement platforms on both sides of the assembly vehicle transport the purlins to be assembled to the assembly table track. A robotic arm or manual labor places the purlins onto the track. The MES system controls the clamps to clamp and monitors the clamping displacement and force feedback to ensure stable fixation of the purlins. The MES system then controls the power line motors of the photovoltaic panel track and purlin track to adjust the track position, ensuring precise alignment between the photovoltaic panels and purlins. During this process, clamping, track adjustment, and platform lifting actions can be performed in parallel. The MES system monitors safety checkpoints for each action, such as clamping torque, lifting limits, and track movement range, ensuring safe and reliable mechanical operation.

[0044] After the components are assembled, the platform lifting mechanism, under the command of the MES system, raises the components to secure them with bolts or clamps and to perform electrical wiring operations on the photovoltaic panels. During assembly, the MES system continuously collects data from the ultrasonic scanner and other actuators to monitor the surface quality of the photovoltaic panels, the assembly status of the purlins, and the assembly process. When cracks, component misalignment, or actuator abnormalities are detected, the MES system generates an anomaly record and issues a processing prompt, pausing the current operation to ensure assembly quality. After the photovoltaic panels are connected to the purlins, the MES system triggers a multimeter to perform electrical performance testing and determines whether the components are qualified according to preset rules.

[0045] For photovoltaic modules that pass inspection, the MES system controls the tilting mechanism and power line mechanism at the end of the assembly platform to slide the modules along the track to the transport position of the assembly vehicle or the slide rail exit. A robotic arm or carrier can then further transport them to the construction and installation area. The IoT module uploads module identification information, assembly data, and electrical test results to the central MES system, enabling full-process data traceability. For unqualified modules, the MES system generates an anomaly record and issues a processing prompt, preventing them from proceeding to the next process and updating the current assembly module status.

[0046] After completing a batch of components, the assembly vehicle moves to the next construction site under the navigation and path planning instructions of the MES system, entering the next round of material loading and assembly cycle. The MES system simultaneously collects sensor data from each assembly vehicle and combines it with construction site maps to perform vehicle position verification, path planning, and work navigation. When multiple vehicles are operating simultaneously and potential path conflicts exist, the MES system can automatically adjust the vehicle's work path or work sequence to ensure construction safety and efficiency. The system periodically generates construction progress reports, displaying the number of completed assemblies, remaining tasks, and vehicle status, providing managers with real-time construction information.

[0047] The entire system achieves a complete closed loop for photovoltaic modules, from material loading, positioning, clamping, assembly, lifting, inspection, and unloading to multi-vehicle collaboration and construction progress management, through close coordination between the MES system control and mechanical actions. All mechanical actions are confirmed by safety checkpoints and feedback signals to ensure safe and reliable operation. At the same time, the data storage and traceability module records module assembly data, mechanical status, and sensor information, providing technical support for construction management, quality control, and subsequent project optimization, realizing an efficient, controllable, and traceable photovoltaic modular string assembly construction process.

[0048] In addition, the bottom of the assembly platform is equipped with lockable casters, which can be locked during the assembly process to ensure the stability of the equipment; when it is necessary to move the assembly platform, the locks can be released to achieve overall horizontal movement, thereby further improving the flexibility and adaptability of the assembly system on the construction site.

[0049] Table of Mechanical Actions and MES Commands for Digital Assembly System of Modular Photovoltaic Strings:

[0050]

[0051] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A mobile modular photovoltaic assembly system, characterized in that, The system includes a digital assembly platform for modular photovoltaic strings, a digital assembly vehicle for modular photovoltaic strings, and a MES system. These three components work together to form a mobile, configurable, and traceable photovoltaic assembly unit. The photovoltaic modular string digital assembly platform includes a flipping component, photovoltaic panels, photovoltaic panel fasteners, purlins, purlin power line motors, a barcode scanning camera assembly, purlin tracks, photovoltaic panel tracks, purlin clamps, photovoltaic panel power line motors, an ultrasonic scanner, an IoT module, a lithium battery, a platform lifting mechanism, a photovoltaic panel limiting mechanism, a multimeter, and lockable casters. The flipping component is used to remove the assembled photovoltaic modules. The photovoltaic panel tracks and purlin tracks are adjusted in position via corresponding power line motors. The ultrasonic scanner and multimeter are used for surface crack detection and electrical performance testing of the photovoltaic panels, respectively, and the test data is uploaded to the MES system. The IoT module uploads the assembly progress and component information. The assembly platform is extended through modular combinations. The photovoltaic modular string digital assembly vehicle includes a vehicle platform, a platform fixing device, a detachable assembly platform lifting mechanism, an automatic lifting staircase, a purlin placement platform lifting device, a purlin placement platform, a purlin stack, a vehicle shock absorption device, a track tensioning device, a tracked or wheeled walking mechanism, a GNSS / RTK positioning antenna, a photovoltaic panel material flipping mechanism, an operating platform, a camera sensor, a lidar sensor, and a robotic arm. The platform fixing device secures the photovoltaic modular string digital assembly platform. The positioning antenna, lidar sensor, and camera sensor work together to achieve positioning, navigation, and environmental perception. The robotic arm is responsible for loading operations. The MES system communicates with the various mechanical units and sensors of the photovoltaic modular string digital assembly platform and the photovoltaic modular string digital assembly vehicle to realize process scheduling, status monitoring, data acquisition, batch binding, quality traceability and multi-vehicle collaboration.

2. The mobile modular photovoltaic assembly system according to claim 1, characterized in that, The flipping component consists of a flipping mechanism, a baffle, and a push rod lifting mechanism; the photovoltaic panel fixing component adopts a pressure block installation, bolt back lock installation, or U-bolt + pressure block installation method; the purlin clamp includes a purlin power roller, a purlin clamping slider, a clamp motor, an electric push rod, an upper and lower lifting platform, and a rubber clamp head, which are used to clamp the purlin to prevent shaking.

3. The mobile modular photovoltaic assembly system according to claim 1, characterized in that, The assembly platform lifting mechanism is a detachable structure used to move the assembly platform from the vehicle platform to the ground or other locations; the purlin placement platform lifting device includes a rack, gear motor, linear guide rail and frame assembly to realize the up and down lifting of the purlin.

4. The mobile modular photovoltaic assembly system according to claim 1, characterized in that, The control flow of the MES system includes: During system initialization, communication is established with each mechanical unit and a self-test is completed, and production task parameters are loaded. During the material loading stage, the barcode information of the photovoltaic panels is collected by a barcode scanning camera to complete the material identification and batch binding; During the assembly process, actions such as control track adjustment, fixture clamping, and platform lifting are carried out in a coordinated manner, and the assembly status is monitored in real time. During the testing phase, the system receives test data from an ultrasonic scanner and a multimeter, and automatically determines the qualification of the components. During the unloading stage, the control flipping component removes qualified components and uploads full-process data through the IoT module; when multiple vehicles work together, path planning, conflict avoidance and progress management are realized.

5. The mobile modular photovoltaic assembly system according to claim 1, characterized in that, The photovoltaic panel limiting mechanism of the assembly platform restricts the position of the photovoltaic modules through electric push rods to prevent them from slipping and to mark the current assembly batch; the lithium battery powers the lifting mechanism and the track adjustment motor.

6. The mobile modular photovoltaic assembly system according to claim 1, characterized in that, The automatic lifting staircase of the assembled vehicle consists of push rods, connecting rods, and foot platforms for personnel to go up and down; the vehicle's shock absorption device works in conjunction with the track tensioning device and the track to reduce vibration during travel.

7. The mobile modular photovoltaic assembly system according to claim 3, characterized in that, The specific process of this system includes: Step S1: The MES system starts up, establishes communication with each mechanical unit of the photovoltaic modular string digital assembly platform and the photovoltaic modular string digital assembly vehicle, completes self-inspection and loads production parameters; Step S2: The assembly vehicle uses GNSS / RTK positioning antenna and lidar to scan and locate itself. After precise parking, the digital assembly platform for photovoltaic modular strings is fixed to the vehicle platform. Step S3: An external transport vehicle places the photovoltaic panel box on the photovoltaic panel material flipping mechanism. The photovoltaic panel material flipping mechanism flips the photovoltaic panel box to a horizontal position. A robotic arm or a person picks up the panel and places it on the photovoltaic modular string digital assembly table. A barcode scanning camera collects barcode information and uploads it to the MES system to complete batch binding. Step S4: The purlins are transported to the assembly table track by the purlin placement platform lifting device. The robotic arm or manual placement of the purlins is performed. The MES system controls the clamps to clamp and adjust the track position to achieve precise docking between the photovoltaic panels and the purlins. Step S5: The platform lifting mechanism lifts the components, completing the mechanical fixing and electrical wiring of the photovoltaic panels and purlins. The ultrasonic scanner and multimeter simultaneously perform quality inspection, and the inspection data is uploaded to the MES system. Step S6: After the MES system determines that the component is qualified, it controls the flipping component to move the component to the transportation position; if the component is unqualified, an exception record is generated. Step S7: The IoT module uploads the entire process data of the components, the assembly vehicle moves to the next construction site, and the above process is repeated; when multiple vehicles are working, the MES system performs coordinated scheduling.

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