A photovoltaic module paving intelligent end picker based on a dual nine-axis imu and a paving method

Abstract

The application discloses a photovoltaic module paving intelligent end picker based on a double-nine-axis IMU and a paving method, which comprises an end picker body, a double-nine-axis IMU positioning system, a posture adjusting mechanism, a vacuum adsorption system and a PLC control system. The double-nine-axis IMU positioning system comprises a photovoltaic panel IMU module installed on the photovoltaic module and an end picker IMU module fixed on the end picker body, and is used for collecting posture data of the photovoltaic module and the end picker in real time. The PLC control system calculates a posture deviation according to data of the two IMU modules, controls the posture adjusting mechanism to adjust the posture of the end picker, and starts the vacuum adsorption system to grab the module until the deviation is less than a threshold value to reach an alignment state. The application directly measures the posture through the IMU, gets rid of the dependence on illumination and surface features, has the advantages of strong anti-interference, fast response and low maintenance cost, and significantly improves the positioning accuracy, environmental adaptability and operation efficiency of photovoltaic module paving.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module installation equipment technology, specifically to a photovoltaic module installation intelligent end-feeder and installation method based on dual nine-axis IMUs. Background Technology

[0002] As a core pillar of the global clean energy transition, photovoltaic (PV) power generation relies on efficient and safe automated installation of PV modules for its large-scale application. Currently, PV module installation end-feeders generally employ a positioning scheme of "depth camera + visual algorithm," achieving attitude calibration by collecting 3D point cloud data of PV modules. However, the complex environment of outdoor PV power plants (such as strong sunlight reflection, dust cover, low temperature and humidity) poses significant limitations to visual positioning schemes: First, they are highly dependent on light conditions, easily leading to fluctuations in positioning accuracy under weak or strong light conditions; second, they have weak anti-interference capabilities, easily causing point cloud segmentation errors when the module surface is obscured or contaminated; third, maintenance costs are high, as camera lenses are easily contaminated and require frequent cleaning; fourth, response latency is high, and point cloud processing is time-consuming, affecting installation efficiency. Furthermore, PV modules are high-value and fragile products, and visual positioning deviations can easily lead to inaccurate adsorption, increasing the risk of module detachment. Therefore, there is an urgent need for a PV module installation end-feeder positioning technology that is highly adaptable to the environment, has high real-time positioning performance, and low maintenance costs to improve the reliability and economy of installation operations. Summary of the Invention

[0003] In view of the above problems, the present invention provides a photovoltaic module installation intelligent end-feeder based on dual nine-axis IMU, which aims to solve the technical problems of existing visual positioning solutions in complex outdoor environments, such as positioning accuracy affected by light interference, weak anti-shading ability, high maintenance cost and large response delay, so as to achieve high-precision, highly adaptable attitude alignment and stable grasping of photovoltaic modules.

[0004] To achieve the above objectives, in a first aspect, the present invention provides a photovoltaic module installation intelligent end-feeder based on a dual nine-axis IMU, comprising: End effector body; The dual nine-axis IMU positioning system includes a photovoltaic panel IMU module and an end effector IMU module. The photovoltaic panel IMU module is fixedly installed on the photovoltaic module, and the end effector IMU module is fixed at the center of the end effector body. When the end effector moves to the preset gripping position directly above the photovoltaic module, the sensing coordinate systems of the photovoltaic panel IMU module and the end effector IMU module are set to be parallel to each other and axially aligned, so as to collect the first attitude data of the photovoltaic module and the second attitude data of the end effector based on the same spatial reference in real time. The attitude adjustment mechanism includes a pitch adjustment servo motor, a roll adjustment servo motor, and a yaw adjustment servo motor. The pitch adjustment servo motor, roll adjustment servo motor, and yaw adjustment servo motor are connected to the end effector body through a transmission mechanism and are used to adjust the spatial attitude of the end effector body according to the attitude deviation calculated by the PLC control system. A vacuum adsorption system, installed on the end effector body, is used to adsorb the photovoltaic module in an orientation-aligned state. The PLC control system, electrically connected to the dual nine-axis IMU positioning system, attitude adjustment mechanism, and vacuum adsorption system, is used to execute the following steps: S1: Calculate the attitude deviation between the photovoltaic module and the end effector based on the first attitude data and the second attitude data, and control the attitude adjustment mechanism to adjust the attitude according to the attitude deviation; when it is determined that the current attitude deviation between the photovoltaic module and the end effector is less than the preset attitude deviation threshold, it is determined that the attitude alignment state has been reached. S2: In the posture alignment state, control the vacuum adsorption system to start so as to adsorb the photovoltaic module.

[0005] Furthermore, the attitude deviation includes roll angle deviation Δ Pitch angle deviation Δ and yaw angle deviation Δ ; Step S1 includes: S11: Calculate the roll angle deviation Δ between the first attitude data and the second attitude data. Pitch angle deviation Δ and yaw angle deviation Δ The roll angle deviation Δ Pitch angle deviation Δ and yaw angle deviation Δ Each deviation is compared with its corresponding preset attitude deviation threshold. If the absolute value of any deviation exceeds its corresponding preset attitude deviation threshold, a corresponding control command is generated to drive the corresponding servo motor in the attitude adjustment mechanism to adjust the spatial attitude of the end effector body and recalculate the attitude deviation between the photovoltaic module and the end effector. S12: Repeat step S11 until the recalculated roll angle deviation Δ is obtained. Pitch angle deviation Δ and yaw angle deviation Δ If the absolute values ​​of all values ​​are less than their corresponding preset deviation thresholds, it is determined that the end effector body and the photovoltaic module have reached an attitude alignment state.

[0006] Furthermore, the PLC control system executes a graded attitude adjustment strategy in step S11, specifically including: The roll adjustment servo motor and the pitch adjustment servo motor are driven preferentially to eliminate the roll angle deviation Δ. and the pitch angle deviation Δ ; in the roll angle deviation Δ and the pitch angle deviation Δ Once all deviations are less than their corresponding preset deviation thresholds, the yaw adjustment servo motor is then driven to eliminate the yaw angle deviation Δ. ; The PLC control system also includes: The data filtering module is used to filter the first attitude data and the second attitude data acquired by the dual nine-axis IMU positioning system; the filtering process includes a combination algorithm of Kalman filtering and moving average filtering to eliminate sensor noise and environmental interference.

[0007] Furthermore, the vacuum adsorption system includes at least two vacuum adsorption subsystems that are independent of each other in terms of both gas path and electrical circuit. Each of the aforementioned vacuum adsorption subsystems includes: The suction cup is mounted on the bottom of the end effector body via a buffer rod assembly, and is used to contact the surface of the photovoltaic module and form a sealed cavity; A vacuum generator, connected to the suction cup via an air passage, is used to generate and maintain the negative pressure required for adsorption within the sealed cavity. A vacuum sensor is installed on the gas pipeline connecting the suction cup and the vacuum generator or integrated into the vacuum generator, and is used to monitor the vacuum level in the sealed cavity in real time. A control valve is installed on the gas pipeline and controlled by the PLC control system, used to switch the connection state between the suction cup cavity and the vacuum generator, or between the suction cup cavity and the atmosphere; The suction cups of at least two sets of vacuum adsorption subsystems are distributed at the bottom of the end effector body to jointly cover and stably adsorb the photovoltaic module; In step S2, the PLC control system is configured to: after confirming that the attitude alignment state has been reached, send instructions to the control valves of all the vacuum adsorption subsystems to connect the corresponding suction cups and vacuum generators, and simultaneously or in a preset sequence start the vacuum generators of each subsystem to adsorb the photovoltaic modules.

[0008] Furthermore, in step S2, the PLC control system is also configured to: Vacuum level data is read in real time by vacuum level sensors of each vacuum adsorption subsystem, and the vacuum level data is compared with a preset safe adsorption threshold. If the vacuum level of any vacuum adsorption subsystem fails to reach or remains below the safe adsorption threshold within a preset time, the vacuum adsorption subsystem is determined to be in a fault state. At this time, the PLC control system issues a warning message containing the identifier of the vacuum adsorption subsystem in a fault state, and maintains the vacuum generators of the remaining vacuum adsorption subsystems with normal vacuum levels to continue to work and the current state of their control valves. Based on the number and layout of the remaining normal vacuum adsorption subsystems, the overall adsorption force of the vacuum adsorption system is evaluated to see if it is still higher than the preset safe redundancy threshold, and a decision is made to continue the handling operation or execute the emergency safe placement procedure accordingly.

[0009] Furthermore, the end effector body is provided with a buffer rod assembly connected to the suction cup, and the buffer rod assembly has a built-in travel sensing switch; In step S2, the PLC control system is further configured to: after determining that the posture alignment state has been reached, control the end effector body to press down at a preset speed until the travel sensing switch is triggered, confirm that the suction cup is attached to the surface of the photovoltaic module, and then start the vacuum adsorption system.

[0010] Furthermore, the photovoltaic panel IMU module has a detachable structure, and its outer shell is equipped with a strong magnetic adsorption component, which is adsorbed and fixed to the metal frame of the photovoltaic module; the photovoltaic panel IMU module has a built-in wireless communication module and battery, which are used for wireless data communication with the PLC control system. The end effector also includes: A wireless charging device is installed on the storage station or transfer rack of the photovoltaic module. When the photovoltaic module with the photovoltaic panel IMU module attached is placed on the storage station or transfer rack, the wireless charging device charges the battery of the photovoltaic panel IMU module through electromagnetic induction.

[0011] In a second aspect, the present invention provides a method for installing photovoltaic modules based on dual nine-axis IMUs, the method being applicable to the installation of intelligent end-sensors for photovoltaic modules based on dual nine-axis IMUs as described in the first aspect of the present invention, the method comprising the following steps: Receive instructions from an external motion system or based on a preset path, control the attitude adjustment mechanism to keep the end effector in a ready position, and cooperate with the external motion system to move the end effector to a preset coarse positioning area above the photovoltaic module; The dual nine-axis IMU positioning system collects in real time the first attitude data of the photovoltaic module sensed by the photovoltaic panel IMU module and the second attitude data of the end effector sensed by the end effector IMU module, based on the same spatial reference. Based on the first and second attitude data, the attitude deviation between the photovoltaic module and the end effector is calculated. According to the attitude deviation, the pitch, roll, and yaw servo motors in the attitude adjustment mechanism are controlled to dynamically adjust the spatial attitude of the end effector body. The attitude data acquisition, deviation calculation, and adjustment are repeated until the attitude deviation is determined to be less than a preset attitude deviation threshold, achieving an attitude alignment state. After confirming that the alignment state has been achieved, the vacuum adsorption system is activated to adsorb the photovoltaic module. The attitude adjustment mechanism is controlled to maintain or fine-tune the attitude of the end effector during the transportation process, and works with the external motion system to move the end effector with the adsorbed photovoltaic module to the target installation position; then the vacuum adsorption system is controlled to release, and the installation of the photovoltaic module is completed.

[0012] Furthermore, during the transportation process after the vacuum adsorption system starts and adsorbs the photovoltaic modules, and before the vacuum adsorption system is released, a fault adaptation step is also included. This fault adaptation step specifically includes: The vacuum sensor built into the vacuum adsorption system monitors and acquires the current vacuum level of each independent vacuum adsorption subsystem in the vacuum adsorption system in real time at a preset sampling frequency. The current vacuum level value of each independent vacuum adsorption subsystem is compared with its corresponding preset failure threshold. If the current vacuum level value of one or more vacuum adsorption subsystems is continuously lower than its preset failure threshold for a preset time, it is determined that the one or more vacuum adsorption subsystems have experienced vacuum failure. All remaining effective vacuum adsorption subsystems are identified, and the theoretical total adsorption force that all effective vacuum adsorption subsystems can provide is calculated. The calculated theoretical total adsorption force is compared with a preset safety redundancy threshold. If the theoretical total adsorption force is greater than the safety redundancy threshold, the system is determined to have the conditions to continue to safely execute the task, and the attitude readjustment sub-step is triggered. Otherwise, an emergency stop and alarm signal are generated. The attitude readjustment sub-step includes: Based on the physical layout of all effective vacuum adsorption subsystems on the end effector body and their respective rated adsorption forces, calculate the new force equilibrium center point of the photovoltaic module under the joint adsorption of the effective vacuum adsorption subsystems. Based on the first attitude data provided by the photovoltaic panel IMU module, the center of gravity position of the photovoltaic module is determined, and the center of gravity position is projected onto the plane where the end effector body is located to obtain the center of gravity projection point; Calculate the positional deviation between the center of gravity projection point and the new force equilibrium center point; based on the positional deviation and combined with the rigid connection model formed by the end effector and the photovoltaic module, calculate the compensation adjustment amount required for the pitch adjustment servo motor, roll adjustment servo motor and yaw adjustment servo motor in the attitude adjustment mechanism. Based on the compensation adjustment amount, control the action of the posture adjustment mechanism to drive the end effector body to perform spatial rotation and translation fine adjustment around its current posture until the center of gravity projection point coincides with the new force balance center point or the deviation is less than an allowable tolerance. After completing the attitude readjustment sub-step, the external motion system and the attitude adjustment mechanism are controlled to continue the subsequent steps of moving the photovoltaic module to the target installation location and releasing it while maintaining the adjusted attitude.

[0013] Furthermore, there are multiple intelligent end effectors, which constitute a collaborative paving system. The PLC control system of one intelligent end effector is the master control unit, and the PLC control systems of the other intelligent end effectors are slave control units. The paving method also includes: The main control unit assigns a local area to each of the participating end-effectors based on the size, shape, and structural strength information of the photovoltaic module to be transported, and generates area calibration information containing each local area and sends it to the corresponding end-effector. The area calibration information includes the coordinates of the area boundary or the coordinates of the feature points. Each end effector moves its IMU module above the assigned local area based on the received area calibration information; each end effector independently collects the first attitude data segment of the photovoltaic module corresponding to its assigned local area, as well as its own second attitude data, through its own dual nine-axis IMU positioning system; the PLC control system of each end effector uploads the collected first attitude data segment and second attitude data to the main control unit in real time through the communication network; After receiving the data uploaded by all end effectors, the main control unit performs the following operations: Based on a unified system clock and spatial coordinate system, the first attitude data segments uploaded by all end-capsule devices are time-stamped and transformed, and all first attitude data segments are merged into global first attitude data that characterizes the overall spatial attitude of the photovoltaic module. For each end effector, the attitude deviation between the second attitude data of the end effector itself and the projection of the global first attitude data onto the local area allocated to the end effector is calculated as the individual target adjustment deviation of the end effector; at the same time, the relative pose relationship between all end effectors is calculated and its compliance with the preset cooperative motion constraints is evaluated. Based on the individual target adjustment deviations of all end effectors and the cooperative motion constraints, the main control unit plans a set of cooperative motion trajectories through kinematic calculations, which enables all end effectors to synchronously and smoothly approach the overall attitude of the photovoltaic module. According to the cooperative motion trajectory, synchronous control command sequences are generated for the pitch, roll, and yaw servo motors in the attitude adjustment mechanism of each end effector. The main control unit simultaneously sends the generated sequence of synchronous control commands to the PLC control systems of all end effectors. After receiving the commands, the PLC control systems of each end effector drive their own attitude adjustment mechanisms to perform actions according to the received commands. During the adjustment process, each end effector continuously collects and feeds back real-time attitude data to the main control unit. The main control unit performs closed-loop monitoring until it is determined that the individual target adjustment deviation of all end effectors is less than the corresponding preset cooperative deviation threshold and meets the cooperative motion constraint conditions. At this point, it is confirmed that the global attitude alignment state has been achieved. After confirming that the global attitude alignment state has been achieved, the main control unit simultaneously sends an adsorption start command to the PLC control system of all end effectors; upon receiving the adsorption start command, the PLC control system of each end effector synchronously controls its respective vacuum adsorption system to start, thereby completing the coordinated adsorption of the entire photovoltaic module.

[0014] Unlike existing technologies, the above technical solution provides an intelligent end effector and installation method for photovoltaic module installation based on dual nine-axis IMUs. The method includes an end effector body, a dual nine-axis IMU positioning system, an attitude adjustment mechanism, a vacuum adsorption system, and a PLC control system. The dual nine-axis IMU positioning system comprises a photovoltaic panel IMU module mounted on the photovoltaic module and an end effector IMU module fixed on the end effector body, used to collect attitude data of the photovoltaic module and the end effector in real time. The PLC control system calculates the attitude deviation based on the data from the two IMU modules and controls the attitude adjustment mechanism to adjust the end effector attitude until the deviation is less than a threshold and alignment is achieved, then the vacuum adsorption system is activated to grasp the module. This invention directly measures attitude through IMUs, eliminating dependence on illumination and surface features, and has advantages such as strong anti-interference, fast response, and low maintenance costs, significantly improving the positioning accuracy, environmental adaptability, and operational efficiency of photovoltaic module installation.

[0015] The above description of the invention is merely an overview of the technical solution of the present invention. In order to enable those skilled in the art to better understand the technical solution of the present invention and to implement it based on the description and drawings, and to make the above-mentioned objectives and other objectives, features and advantages of the present invention easier to understand, the following description is provided in conjunction with the specific embodiments and drawings of the present invention. Attached Figure Description

[0016] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of specific embodiments of the present invention and other related contents, and should not be considered as limitations on the present invention.

[0017] In the accompanying drawings of the instruction manual: Figure 1 This is a schematic diagram of the structure of the intelligent end effector described in a specific embodiment; Figure 2 This is a schematic diagram of the attitude adjustment mechanism described in a specific embodiment; Figure 3 This is a schematic diagram of the first structure of the vacuum adsorption system described in a specific embodiment; Figure 4 This is a schematic diagram of the second structure of the vacuum adsorption system described in a specific embodiment; Figure 5 A flowchart illustrating the steps and methods performed by the PLC control system in a specific implementation embodiment; Figure 6 This is a first flowchart of the paving method described in the specific implementation embodiment; Figure 7 A flowchart of the fault adaptation steps described in the specific implementation method; Figure 8 A flowchart of the attitude readjustment sub-steps described in the specific implementation method; Figure 9 This is a second flowchart of the paving method described in the specific implementation embodiment; Figure 10 The flowchart shows the steps and methods executed by the main control unit after receiving data uploaded by all end-devices. The reference numerals used in the above figures are explained as follows: 11. Horizontal aluminum profile; 12. Vertical aluminum profile; 13. Corner bracket; 14. Suction cup guide seat; 15. Fixed connecting plate; 21. Suction cup buffer rod assembly; 22. Vacuum filter; 23. Solenoid valve; 24. Pressure gauge; 25. Vacuum tank; 26. Vacuum pump; 27. Industrial computer; 31. Pitch adjustment servo motor; 32. Roll adjustment servo motor; 33. Yaw adjustment servo motor. Detailed Implementation

[0018] To illustrate the possible application scenarios, technical principles, implementable specific solutions, and achievable objectives and effects of this invention in detail, the following description, in conjunction with the listed specific embodiments and accompanying drawings, provides a detailed explanation. The embodiments described herein are merely illustrative of the technical solutions of this invention and are therefore intended only as examples, not as limiting the scope of protection of this invention.

[0019] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this invention, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0020] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit the invention.

[0021] In the first aspect, such as Figure 1-4 As shown, this invention provides a smart end-feed device for photovoltaic module installation based on a dual nine-axis IMU, comprising: End effector body; The dual nine-axis IMU positioning system includes a photovoltaic panel IMU module and an end effector IMU module. The photovoltaic panel IMU module is fixedly installed on the photovoltaic module, and the end effector IMU module is fixed at the center of the end effector body. When the end effector moves to the preset gripping position directly above the photovoltaic module, the sensing coordinate systems of the photovoltaic panel IMU module and the end effector IMU module are set to be parallel to each other and axially aligned, so as to collect the first attitude data of the photovoltaic module and the second attitude data of the end effector based on the same spatial reference in real time. The attitude adjustment mechanism includes a pitch adjustment servo motor, a roll adjustment servo motor, and a yaw adjustment servo motor. The pitch adjustment servo motor, roll adjustment servo motor, and yaw adjustment servo motor are connected to the end effector body through a transmission mechanism and are used to adjust the spatial attitude of the end effector body according to the attitude deviation calculated by the PLC control system. A vacuum adsorption system, installed on the end effector body, is used to adsorb the photovoltaic module in an orientation-aligned state. The PLC control system is electrically connected to the dual nine-axis IMU positioning system, attitude adjustment mechanism, and vacuum adsorption system, such as... Figure 5 As shown Used to perform the following steps: S1: Calculate the attitude deviation between the photovoltaic module and the end effector based on the first attitude data and the second attitude data, and control the attitude adjustment mechanism to adjust the attitude according to the attitude deviation; when it is determined that the current attitude deviation between the photovoltaic module and the end effector is less than the preset attitude deviation threshold, it is determined that the attitude alignment state has been reached. S2: In the posture alignment state, control the vacuum adsorption system to start so as to adsorb the photovoltaic module.

[0022] In this embodiment, the end effector body adopts a rectangular basic frame constructed of 6061-T6 aluminum profiles. It is the core mounting carrier for the dual nine-axis IMU positioning system, attitude adjustment mechanism, and vacuum adsorption system. The frame is spliced ​​from horizontal aluminum profiles 11 and vertical aluminum profiles 12, and high-strength bolt connections are achieved through corner brackets 13. A suction cup guide seat 14 is provided on the frame for fixing the vacuum adsorption system components. A fixed connecting plate 15 is also welded to achieve connection with the attitude adjustment mechanism. The overall design balances lightweight (weight ≤35kg) and structural strength (load capacity ≥100kg). The diagonal error of the frame is ≤2mm, providing stable physical support for the collaborative work of each module.

[0023] Dual nine-axis IMU positioning system The photovoltaic panel IMU module and end-effector IMU module, both industrial-grade nine-axis IMUs, integrate a three-axis accelerometer, a three-axis gyroscope, and a three-axis magnetometer. Attitude angle accuracy is ≤0.1°, and zero-bias stability is ≤0.5° / h. They can acquire real-time three-dimensional attitude data (roll angle) of the equipment and photovoltaic modules. Pitch angle Yaw angle ).

[0024] Attitude adjustment mechanism The modular core component connecting the robot and the end effector body includes a pitch adjustment servo motor 31, a roll adjustment servo motor 32, and a yaw adjustment servo motor 33. The three servo motors are linked with the fixed connection plate 15 of the end effector body through a transmission mechanism to achieve high-precision dynamic correction of the end effector's spatial attitude, with a positioning accuracy of ±0.02°.

[0025] In this embodiment, the robot specifically refers to a photovoltaic module installation industrial robot (also known as a photovoltaic installation robotic arm / automated installation robot), which is the core motion execution equipment in the automated installation operation of photovoltaic power plants, and also the supporting upper-level motion system of this intelligent end effector.

[0026] This robot is an industrial-grade multi-joint robotic arm / gantry mobile robot with precise spatial displacement and posture adjustment capabilities. It can drive the intelligent end effector connected to the end of the photovoltaic power station to complete actions such as spatial movement, coarse positioning, component handling, and target placement according to the paving path planning of the photovoltaic power station. It is the basic carrier for the end effector to realize the whole process of photovoltaic module picking-handling-paving.

[0027] The connection between the robot and this intelligent end effector is as follows: the end effector flange of the robot is connected to the robot connection flange of the attitude adjustment mechanism of this end effector, and the fixed connection plate 15 of the end effector is linked with the attitude adjustment mechanism. Ultimately, the robot drives the overall movement of the end effector, while the attitude adjustment mechanism of the end effector completes fine attitude correction. The two work together to realize the integrated operation of "coarse positioning + fine attitude adjustment" for photovoltaic module installation.

[0028] Vacuum adsorption system The actuator is mounted on the suction cup guide seat 14 of the end effector body. The suction cup buffer rod assembly 21, vacuum filter 22, solenoid valve 23, pressure gauge 24, vacuum tank 25, and vacuum pump 26 achieve the gripping and release of photovoltaic modules through negative pressure adsorption. The pressure gauge 24 can monitor the vacuum level in real time, and the vacuum filter 22 ensures the cleanliness of the air path. The redundant design greatly improves the adsorption safety.

[0029] PLC control system The core control unit of the end effector can be linked with the industrial computer 27. It integrates an IMU data acquisition module, an adjustment mechanism drive module, and a vacuum system control module. It is electrically connected to the dual nine-axis IMU positioning system, attitude adjustment components such as the pitch adjustment servo motor 31, and vacuum adsorption components such as the solenoid valve 23 through the industrial bus. It realizes integrated operation of attitude data processing, deviation calculation, mechanism control, and adsorption system management, and supports mainstream industrial bus protocols such as PROFINET and Modbus.

[0030] Preset capture position The position is 1m directly above the photovoltaic module (positioning error ≤10cm), which provides a reference position for the dual IMU modules to collect attitude data and calculate deviations. At this time, the sensing coordinate systems of the photovoltaic panel IMU module and the end effector IMU module are parallel and axially aligned.

[0031] Sensing coordinate system The IMU module is used to acquire attitude data in a spatial coordinate system, including the X, Y, and Z axes and the rotation direction around these axes. The sensing coordinate systems of the photovoltaic panel IMU module and the end effector IMU module are parallel and axially aligned, ensuring that the attitude data acquired by both are based on the same spatial reference and eliminating calculation errors caused by inconsistencies in coordinate systems.

[0032] First posture data The photovoltaic panel IMU module collects real-time three-dimensional attitude data of the photovoltaic module, reflecting the current roll, pitch, and yaw angle states of the photovoltaic module; second attitude data. The end effector's IMU module collects real-time 3D attitude data of the end effector body, reflecting the current spatial attitude state of the end effector.

[0033] Attitude deviation The difference between the first attitude data of the photovoltaic module and the second attitude data of the end effector reflects the spatial attitude difference between the two, and is the core basis for the attitude adjustment of the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33. Preset attitude deviation threshold Setting it to ±0.5° is a quantitative standard for determining whether the end effector and the photovoltaic module have reached an attitude alignment state.

[0034] Attitude alignment state When the attitude deviation between the photovoltaic module and the end effector body is less than the preset attitude deviation threshold, the suction cup buffer rod assembly 21 of the vacuum adsorption system can drive the suction cup to keep parallel and in contact with the surface of the photovoltaic module, providing a stable contact basis for vacuum adsorption.

[0035] The core working principle of the intelligent end effector is an integrated operation of dual IMU collaborative positioning, PLC closed-loop control, attitude adjustment, and vacuum adsorption. Each module works collaboratively according to preset logic. The horizontal aluminum profile 11 and vertical aluminum profile 12 of the end effector body provide stable support for all components, and the corner bracket 13 ensures the strength of the frame structure. The specific execution steps are as follows: After the device is powered on, the dual nine-axis IMU module completes zero-position calibration within 3 seconds and sends reference attitude data to the PLC control system. The PLC control system and the industrial computer 27 work together to store the data and initialize each module to standby state. The external paving robot drives the end effector to the preset gripping position directly above the photovoltaic module through the fixed connection plate 15 of the end effector body. At this time, the sensing coordinate system of the photovoltaic panel IMU module and the end effector IMU module are parallel and axially consistent, establishing a unified spatial reference for subsequent attitude data acquisition.

[0036] Once in the preset grasping position, the photovoltaic panel IMU module and the end effector IMU module simultaneously start real-time data acquisition. The acquired first attitude data of the photovoltaic module and the second attitude data of the end effector are transmitted to the PLC control system through the RS485 interface (baud rate 115200bps). The data update cycle is 10ms to ensure the real-time nature of the attitude data and provide accurate raw data for subsequent deviation calculation.

[0037] After receiving the first attitude data and the second attitude data, the PLC control system calculates the attitude deviation between them using a built-in algorithm. The calculated attitude deviation is compared with a preset attitude deviation threshold (±0.5°). If the attitude deviation is greater than or equal to the threshold, an attitude adjustment control command is sent to the attitude adjustment mechanism to drive the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 to work together. If the attitude deviation is less than the threshold, it is directly determined that the attitude alignment state has been reached and the vacuum adsorption process begins.

[0038] After receiving the adjustment command from the PLC control system, the attitude adjustment mechanism uses three servo motors: pitch adjustment servo motor 31 to correct the pitch angle of the end effector around the horizontal axis, roll adjustment servo motor 32 to correct the roll angle of the end effector around the longitudinal axis, and yaw adjustment servo motor 33 to correct the yaw angle of the end effector around the vertical axis. The three servo motors are linked to the fixed connection plate 15 through the transmission mechanism to drive the end effector body to adjust its attitude. During the adjustment process, the dual IMU modules continuously update the attitude data at a period of 10ms and transmit it to the PLC. The PLC recalculates the attitude deviation in real time, forming a closed-loop control of data acquisition, deviation calculation, and mechanism adjustment, until the attitude deviation is less than the preset attitude deviation threshold.

[0039] After the PLC control system determines that the alignment state has been reached, it sends a start command to the vacuum adsorption system. The vacuum pump 26 starts, and the air path, after being filtered by the vacuum filter 22, provides negative pressure to the suction cup on the suction cup buffer rod assembly 21. The pressure gauge 24 monitors the vacuum degree of the air path in real time, the vacuum tank 25 maintains the negative pressure, and the solenoid valve 23 keeps the air path connected to the vacuum pump 26, so that the suction cup and the surface of the photovoltaic module form a sealed cavity and generate a stable negative pressure, realizing the adsorption of the photovoltaic module. The suction cup guide seat 14 ensures the installation accuracy of the suction cup buffer rod assembly 21 and ensures the adhesion between the suction cup and the module surface. After adsorption is completed, it can be used with an external robot to carry out the photovoltaic module handling operation.

[0040] The modules are connected by electrical connections to achieve real-time transmission of signals and instructions. The PLC control system and the industrial computer 27 work together as the core hub to coordinate the data acquisition of the dual nine-axis IMU positioning system, the motion control of attitude adjustment components such as the pitch adjustment servo motor 31, and the start and stop management of vacuum adsorption components such as the solenoid valve 23. The horizontal aluminum profile 11, the vertical aluminum profile 12, and the corner code 13 of the end effector body provide stable structural support for the entire operation process, ensuring the continuity and accuracy of the entire operation process.

[0041] By replacing the traditional visual positioning solution with dual nine-axis IMU collaborative positioning, the influence of complex outdoor environments such as lighting, shading, and dust accumulation on the module surface on positioning is fundamentally eliminated. This significantly improves the positioning success rate in scenarios with strong light, weak light, dust, and low temperatures, enhancing the environmental adaptability of the end effector. Real-time processing of attitude data and closed-loop control of components such as the pitch adjustment servo motor 31 are achieved through the linkage of the PLC control system and the industrial control computer 27, making the attitude alignment between the end effector and the photovoltaic module more precise. This ensures that the suction cup on the suction cup buffer rod assembly 21 is completely attached to the module surface, providing a stable foundation for vacuum adsorption and reducing the risk of damage to the module surface. The end effector body uses a horizontal aluminum profile 11 and... The longitudinal aluminum profiles 12 are spliced ​​together and reinforced with corner brackets 13, balancing lightweight design with structural strength. The fixed connecting plate 15 enables flexible connection with the robot, and the suction cup guide seat 14 ensures the installation accuracy of the vacuum adsorption components. The standardized design of each structural component makes the equipment easier to disassemble and maintain. At the same time, the modular design allows for seamless integration with mainstream paving robots, ensuring strong compatibility. The position of the suction cup guide seat 14 can be adjusted to adapt to photovoltaic modules of different sizes, meeting the automated paving requirements of large-scale photovoltaic power plants. The entire operation process requires no manual intervention, realizing the automation and precision of photovoltaic module picking, effectively shortening the time of a single paving operation and improving the overall efficiency of photovoltaic paving operations.

[0042] The attitude deviation includes roll angle deviation Δ Pitch angle deviation Δ and yaw angle deviation Δ ; Step S1 includes: S11: Calculate the roll angle deviation Δ between the first attitude data and the second attitude data. Pitch angle deviation Δ and yaw angle deviation Δ The roll angle deviation Δ Pitch angle deviation Δ and yaw angle deviation Δ Each deviation is compared with its corresponding preset attitude deviation threshold. If the absolute value of any deviation exceeds its corresponding preset attitude deviation threshold, a corresponding control command is generated to drive the corresponding servo motor in the attitude adjustment mechanism to adjust the spatial attitude of the end effector body and recalculate the attitude deviation between the photovoltaic module and the end effector. S12: Repeat step S11 until the recalculated roll angle deviation Δ is obtained. Pitch angle deviation Δ and yaw angle deviation Δ If the absolute values ​​of all values ​​are less than their corresponding preset deviation thresholds, it is determined that the end effector body and the photovoltaic module have reached an attitude alignment state.

[0043] Roll angle deviation Δ It refers to the difference in rotation angle between the photovoltaic module and the end-feeder body around the longitudinal aluminum profile 12 extension direction. It is a key attitude deviation that affects the longitudinal fit of the suction cup on the suction cup buffer rod assembly 21, and is corrected by the roll adjustment servo motor 32. Pitch angle deviation Δ It refers to the difference in rotation angle between the photovoltaic module and the end-feeder body around the extension direction of the transverse aluminum profile 11. It is a key attitude deviation that affects the lateral adhesion of the suction cup and is corrected by the pitch adjustment servo motor 31. Yaw angle deviation Δ This refers to the difference in rotation angle between the photovoltaic module and the end effector body around the vertical axis, which affects the overall alignment accuracy of the end effector and the photovoltaic module, and is corrected by the yaw adjustment servo motor 33.

[0044] The corresponding preset attitude deviation threshold refers to the attitude deviation judgment threshold set for roll angle, pitch angle and yaw angle respectively. In this embodiment, the preset thresholds for the three are all ±0.5°, which can be flexibly adjusted by the industrial control computer 27 according to the actual paving requirements to ensure that the accuracy of attitude adjustment matches the adsorption requirements of suction cup buffer rod assembly 21 and photovoltaic module.

[0045] Control commands are electrical signals generated by the PLC control system based on the type of attitude deviation and used to drive the corresponding servo motors. The command parameters can be set by the industrial computer 27 to ensure the motion accuracy of the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33.

[0046] This embodiment details the specific types of attitude deviations and the closed-loop execution steps of attitude adjustment. The core principle is angular deviation calculation + independent adjustment + cyclic verification. The horizontal aluminum profile 11 and vertical aluminum profile 12 of the end effector body provide structural references for attitude adjustment. The fixed connecting plate 15 ensures the linkage accuracy between the servo motor and the body. The detailed principle of the specific execution step S1 is as follows: The PLC control system is linked with the industrial computer 27. After receiving the first attitude data and the second attitude data transmitted by the dual nine-axis IMU positioning system, it calculates the roll angle deviation Δα, pitch angle deviation Δβ and yaw angle deviation Δγ between the two through coordinate calculation. This enables a fine breakdown of the attitude deviation and provides a precise basis for the targeted adjustment of the pitch adjustment servo motor 31, roll adjustment servo motor 32 and yaw adjustment servo motor 33.

[0047] The calculated Δα, Δβ, and Δγ are then independently compared with their respective preset attitude deviation thresholds. If the absolute value of any angle deviation exceeds its corresponding threshold, the PLC control system will generate a corresponding attitude adjustment control command based on the deviation type. If the roll angle deviation Δα exceeds the threshold, a roll adjustment command is generated; if the pitch angle deviation Δβ exceeds the threshold, a pitch adjustment command is generated; and if the yaw angle deviation Δγ exceeds the threshold, a yaw adjustment command is generated. These commands are transmitted to the corresponding servo motors via the Profibus bus, and the command parameters can be monitored in real-time by the industrial computer 27.

[0048] After receiving control commands, the attitude adjustment mechanism activates the corresponding servo motors, which are linked to the fixed connection plate 15 via a transmission mechanism (harmonic reducer / gear transmission) to drive the end effector body to perform single-angle or multi-angle combined attitude adjustments. Specifically, the roll adjustment servo motor 32 drives the end effector to rotate around the longitudinal extension direction of the aluminum profile 12 via gear transmission, correcting Δα; the pitch adjustment servo motor 31 drives the end effector to rotate around the transverse extension direction of the aluminum profile 11 via a harmonic reducer, correcting Δβ; and the yaw adjustment servo motor 33 is rigidly fixed to the robot connection flange via a flat key, driving the end effector to rotate around the vertical axis, correcting Δγ. Each servo motor operates independently and can work collaboratively, achieving a positioning accuracy of ±0.02°, ensuring precise correction of angular deviations.

[0049] While the attitude adjustment mechanism is in motion, the dual nine-axis IMU module continues to collect and transmit the first and second attitude data at a 10ms cycle. The PLC control system and the industrial computer 27 work together to recalculate the roll angle deviation Δα, pitch angle deviation Δβ, and yaw angle deviation Δγ based on the updated attitude data, completing a cycle of "calculation-comparison-adjustment-recalculation" to ensure the real-time performance and accuracy of the deviation calculation.

[0050] Repeat all operations in step S11, continuously calculate, compare, adjust and recalculate the attitude deviation to form a closed-loop adjustment mechanism for each angle. After each adjustment, the deviation of the three angles is independently verified until the absolute values ​​of the recalculated Δα, Δβ and Δγ are all less than their corresponding preset deviation thresholds. At this time, the PLC control system determines that the end effector body and the photovoltaic module have reached a complete attitude alignment state, stops the operation of the pitch adjustment servo motor 31, the roll adjustment servo motor 32 and the yaw adjustment servo motor 33, and sends a start preparation command to the vacuum adsorption system to ensure that the suction cup on the suction cup buffer rod assembly 21 maintains the best contact state with the surface of the photovoltaic module.

[0051] In this step, the deviation calculation and adjustment verification of the three angles are independent of each other but can be carried out in a coordinated manner. If the deviation of multiple angles exceeds the threshold at the same time, the pitch adjustment servo motor 31, the roll adjustment servo motor 32, and the yaw adjustment servo motor 33 can act synchronously to achieve joint attitude correction of multiple angles, effectively shortening the overall time of attitude adjustment and keeping the adjustment response time within 50-100ms. The rigidity of the end effector body structure guaranteed by the angle code 13 provides a stable structural foundation for the synchronous adjustment of multiple motors and avoids adjustment errors caused by frame deformation.

[0052] This embodiment decomposes attitude deviation into three independent dimensions: roll angle, pitch angle, and yaw angle. This enables refined calculation and targeted adjustment of attitude deviation, avoiding the problems of low adjustment accuracy and long time consumption caused by traditional overall adjustment methods. This makes the actions of the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 more precise, and the attitude adjustment efficiency of the end effector higher. Through a closed-loop adjustment mechanism with cyclic verification, it ensures that the deviation of the three angles meets the preset threshold requirements, achieving complete attitude alignment between the end effector and the photovoltaic module, further improving the suction cup buffer rod assembly 2. The improved adhesion between the suction cup and the component surface reduces the risk of air leakage and uneven force on the component during vacuum adsorption. The angle-based adjustment method makes the actions of each servo motor more targeted, reducing ineffective actions, lowering energy consumption and mechanical wear, and extending the service life of components such as the pitch adjustment servo motor 31 and the horizontal and vertical aluminum profiles 11 and 12 of the end effector body. At the same time, the design of preset thresholds for each angle allows the industrial control computer 27 to flexibly adjust the accuracy standards of each angle according to the different photovoltaic module installation requirements, improving the flexibility and adaptability of the technical solution. The waist-shaped hole design of the fixed connection plate 15 enables fine-tuning of the position of the end effector and the robot, further compensating for minor errors in posture adjustment and ensuring adsorption accuracy.

[0053] In some embodiments, the PLC control system executes a graded attitude adjustment strategy in step S11, specifically including: The roll adjustment servo motor and the pitch adjustment servo motor are driven preferentially to eliminate the roll angle deviation Δ. and the pitch angle deviation Δ ; in the roll angle deviation Δ and the pitch angle deviation Δ Once all deviations are less than their corresponding preset deviation thresholds, the yaw adjustment servo motor is then driven to eliminate the yaw angle deviation Δ. ; The PLC control system also includes: The data filtering module is used to filter the first attitude data and the second attitude data acquired by the dual nine-axis IMU positioning system; the filtering process includes a combination algorithm of Kalman filtering and moving average filtering to eliminate sensor noise and environmental interference.

[0054] In this embodiment, the graded attitude adjustment strategy refers to setting the priority of attitude adjustment based on the core requirements of vacuum adsorption of photovoltaic modules. Priority is given to adjusting the roll angle and pitch angle, which have the greatest impact on the adhesion of the suction cup on the suction cup buffer rod assembly 21, and then the yaw angle is adjusted. The attitude adjustment principle is to ensure adsorption stability as the primary goal. This strategy can be preset by the industrial control computer 27 and stored in the PLC control system.

[0055] The data filtering module is a built-in functional module of the PLC control system. It can be linked with the industrial computer 27 to adjust the algorithm parameters. It is used to process the attitude data collected by the dual nine-axis IMU positioning system to eliminate noise and interference, ensure the accuracy of the attitude data, and provide a reliable data basis for deviation calculation and motion control of pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33.

[0056] Kalman filtering is an optimal estimation algorithm integrated into the data filtering module. It can effectively eliminate random noise from the IMU sensor itself, perform optimal estimation of dynamically changing attitude data, and improve the smoothness and accuracy of the data. The algorithm's filtering parameters can be fine-tuned via an industrial control computer.

[0057] In this embodiment, a 5-point moving average filter is used, which is integrated into the data filtering module to perform secondary smoothing on the attitude data after Kalman filtering. This eliminates sudden data fluctuations caused by outdoor environmental vibrations, electromagnetic interference, etc., and further improves data reliability. It forms a combined algorithm with Kalman filtering.

[0058] Sensor noise refers to the random errors generated by the sensors inside the IMU module during data acquisition, which are inherent errors in attitude data. Environmental interference refers to the interference caused by external factors such as vibration, electromagnetic radiation, and sandstorm impact in outdoor paved environments, which can lead to abnormal fluctuations in attitude data. The corner code 13 on the end effector can mitigate the impact of vibration on the IMU module.

[0059] This embodiment adds a graded attitude adjustment strategy and attitude data filtering processing, further optimizing the logic and data foundation of attitude adjustment and reducing the impact of vibration noise on data acquisition. The specific implementation principle is as follows: Attitude data filtering: After the first and second attitude data acquired by the dual nine-axis IMU positioning system are transmitted to the PLC control system, they first enter the data filtering module for processing. The data filtering module first uses the Kalman filter algorithm to perform optimal estimation of the original attitude data to eliminate the random noise of the sensor itself. Then, it uses the 5-point moving average filter algorithm to perform secondary processing on the Kalman filtered result to eliminate sudden data fluctuations caused by outdoor environmental vibration, electromagnetic interference, etc. The parameters of the filtering algorithm can be flexibly adjusted by the industrial control computer 27 according to the actual working environment. The attitude data update cycle after filtering is still maintained at 10ms, ensuring data accuracy without sacrificing real-time performance. In addition, the corner code 13 of the end effector body is made of high-strength material, which can effectively mitigate the impact of outdoor vibration on the IMU module and further reduce data interference. The filtered attitude data will serve as the sole basis for subsequent deviation calculation, avoiding the impact of noise and interference on deviation calculation from the source, and ensuring that a precise adjustment basis is provided for the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33.

[0060] Execution of graded attitude adjustment strategy (S11): The filtered attitude data is transmitted to the PLC deviation calculation unit, and after calculating the roll angle deviation Δα, pitch angle deviation Δβ, and yaw angle deviation Δγ in conjunction with the industrial control computer 27, the PLC control system executes the adjustment operation according to the graded attitude adjustment strategy of roll / pitch priority and yaw lag. This strategy is based on the adsorption requirements of the suction cup buffer rod assembly 21 and is specifically divided into two stages: The first stage prioritizes eliminating roll and pitch angle deviations. Specifically, the PLC control system first compares Δα and Δβ with their respective preset thresholds (±0.5°). If either or both exceed the threshold, it immediately generates corresponding roll and pitch adjustment commands, driving the roll adjustment servo motor 32 and the pitch adjustment servo motor 31 to move synchronously or independently. Through linkage with the fixed connecting plate 15, it corrects the roll angle deviation Δα around the longitudinal aluminum profile 12 and the pitch angle deviation Δβ around the transverse aluminum profile 11, respectively. During this stage, the yaw angle deviation Δγ is not adjusted, but is monitored and recorded in real time by the PLC control system and the industrial computer 27. During the adjustment process, the dual IMU modules continuously collect the filtered attitude data, and the PLC recalculates Δα and Δβ in real time until their absolute values ​​are both less than their corresponding preset thresholds. The first stage of adjustment is completed, ensuring the parallelism between the suction cup on the suction cup buffer rod assembly 21 and the surface of the photovoltaic module, providing a core guarantee for the adsorption seal.

[0061] The second stage involves eliminating yaw angle deviation. Specifically, after both Δα and Δβ reach the threshold requirements, the PLC control system compares the recorded yaw angle deviation Δγ with its preset threshold (±0.5°). If Δγ exceeds the threshold, a yaw adjustment command is generated to drive the yaw adjustment servo motor 33 to correct the yaw angle deviation. During the adjustment process, closed-loop verification is also performed using filtered real-time attitude data until the absolute value of Δγ is less than its preset threshold. The second stage of adjustment is then completed, ensuring the overall alignment accuracy between the end effector and the photovoltaic module and avoiding excessive local force caused by suction cup offset.

[0062] Cyclic verification and attitude alignment determination: If, during the graded adjustment process, the actions of the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 cause Δα or Δβ, which has already reached the threshold, to exceed the threshold again, the PLC control system will immediately return to the first stage, prioritize the correction of Δα and Δβ, and then perform the second stage of yaw angle adjustment; repeat the above graded adjustment and deviation verification process until the absolute values ​​of Δα, Δβ, and Δγ are all less than their corresponding preset deviation thresholds, and finally determine that the end effector body and the photovoltaic module have reached the attitude alignment state. At this time, the suction cup of the suction cup buffer rod assembly 21 is in the best contact state with the surface of the photovoltaic module, and the vacuum adsorption process can be started.

[0063] In this embodiment, the preset thresholds for roll angle and pitch angle are both ±0.5°, which are the core precision indicators to ensure that the suction cup on the suction cup buffer rod assembly 21 is parallel to the surface of the photovoltaic module. Prioritizing adjustment can ensure the sealing of the sealed cavity during vacuum adsorption and avoid insufficient negative pressure due to loose adhesion. Yaw angle deviation affects the overall alignment accuracy. Adjustment is made after adsorption stability is ensured to balance adsorption safety and alignment accuracy. The precise installation of suction cup guide seat 14 further ensures that the suction cup can make uniform contact with the module surface after alignment.

[0064] This embodiment effectively eliminates the influence of sensor noise and outdoor environmental interference on attitude data by setting a data filtering module in the PLC control system and using a combination algorithm of Kalman filtering and moving average filtering. This significantly improves the accuracy and reliability of attitude data, providing a precise data foundation for deviation calculation and attitude adjustment of components such as the pitch adjustment servo motor 31. It avoids adjustment deviations caused by data errors and further improves the accuracy of attitude alignment. Moreover, the filtering parameters can be flexibly adjusted by the industrial control computer 27 to adapt to different outdoor operating environments. The design of the graded attitude adjustment strategy closely addresses the core requirements of vacuum adsorption of photovoltaic modules. It prioritizes the roll angle and pitch angle, which have the greatest impact on the adsorption sealing of the suction cup buffer rod assembly 21, to ensure parallel contact between the suction cup and the module surface, fundamentally guaranteeing the vacuum adsorption. The sealing and stability of the components reduce the risk of component detachment and surface damage. The yaw angle hysteresis adjustment method avoids motion interference caused by simultaneous multi-angle adjustment, making the movements of the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 smoother, effectively shortening the overall time of attitude adjustment and further improving the efficiency of paving operations. The corner code 13 of the end effector body alleviates the impact of outdoor vibration on the IMU module, and the rigid frame of the horizontal aluminum profile 11 and the vertical aluminum profile 12 provides a stable foundation for attitude adjustment, reducing the adjustment error caused by frame deformation. At the same time, the combined filtering algorithm and the hierarchical adjustment strategy are integrated into the PLC control system, which can be linked with the industrial computer 27 to realize parameter adjustment without adding additional hardware equipment, thereby improving equipment performance while controlling hardware costs.

[0065] In some embodiments, the vacuum adsorption system includes at least two vacuum adsorption subsystems that are independent of each other in terms of both gas path and electrical circuit. Each of the aforementioned vacuum adsorption subsystems includes: The suction cup is mounted on the bottom of the end effector body via a buffer rod assembly, and is used to contact the surface of the photovoltaic module and form a sealed cavity; A vacuum generator, connected to the suction cup via an air passage, is used to generate and maintain the negative pressure required for adsorption within the sealed cavity. A vacuum sensor is installed on the gas pipeline connecting the suction cup and the vacuum generator or integrated into the vacuum generator, and is used to monitor the vacuum level in the sealed cavity in real time. A control valve is installed on the gas pipeline and controlled by the PLC control system, used to switch the connection state between the suction cup cavity and the vacuum generator, or between the suction cup cavity and the atmosphere; The suction cups of at least two sets of vacuum adsorption subsystems are distributed at the bottom of the end effector body to jointly cover and stably adsorb the photovoltaic module; In step S2, the PLC control system is configured to: after confirming that the attitude alignment state has been reached, send instructions to the control valves of all the vacuum adsorption subsystems to connect the corresponding suction cups and vacuum generators, and simultaneously or in a preset sequence start the vacuum generators of each subsystem to adsorb the photovoltaic modules.

[0066] The vacuum adsorption subsystem refers to an independent component of the vacuum adsorption system. Each subsystem is completely independent in terms of gas path and circuit, and can independently realize the functions of adsorption, pressure holding and release. In this embodiment, four vacuum adsorption subsystems are used, which are evenly distributed at the bottom of the frame formed by the horizontal aluminum profile 11 and the vertical aluminum profile 12 of the end effector body, and are precisely installed through the suction cup guide seat 14.

[0067] The gas path and circuit are independent, meaning that each vacuum adsorption subsystem has its own independent gas path pipeline, vacuum pump 26, solenoid valve 23, and independent power supply line, control line and detection line. The gas path or circuit failure of any subsystem will not affect the normal operation of other subsystems. The vacuum filter 22 filters the gas path of each subsystem independently.

[0068] The suction cup is a component installed at the end of the suction cup buffer rod assembly 21. It is made of flexible and wear-resistant material and can form a sealed cavity with the surface of the photovoltaic module. It is the core component for generating negative pressure adsorption. The suction cup guide seat 14 ensures that the suction cups of multiple subsystems are distributed and uniformly arranged.

[0069] Suction cup buffer rod assembly 21: A component that connects the suction cup to the suction cup guide seat 14 of the end effector body. It has a built-in buffer structure that can buffer the impact force during the downward pressing of the end effector to avoid damage to the photovoltaic module. At the same time, the height of the suction cup can be adjusted to adapt to photovoltaic modules of different thicknesses.

[0070] In this embodiment, the vacuum pump 26 serves as a vacuum generator, providing continuous negative pressure to the sealed cavity of the suction cup in each vacuum adsorption subsystem. A single vacuum pump 26 can meet the adsorption negative pressure requirements of the corresponding suction cup, with a negative pressure value reaching -0.08MPa and above. It works in conjunction with the vacuum tank 25 to maintain negative pressure.

[0071] Pressure gauge 24 refers to the detection component that integrates a vacuum sensor. It monitors the negative pressure value in the sealed cavity of the suction cup of each vacuum adsorption subsystem in real time, and can intuitively display the vacuum value. At the same time, it transmits the vacuum electrical signal to the PLC control system through the digital output terminal, providing data basis for adsorption status determination.

[0072] The solenoid valve 23 is a control valve installed on the gas pipeline of each vacuum adsorption subsystem. It is independently controlled by the digital output terminal (DC24V) of the PLC control system, which can realize the rapid switching of the gas path and complete the connection between the suction cup cavity and the vacuum pump 26 (adsorption state) or the connection between the suction cup cavity and the atmosphere (release state).

[0073] Vacuum filter 22 is a component installed at the front end of the gas path pipeline of each vacuum adsorption subsystem. It can filter dust and impurities in the gas path, prevent them from entering the vacuum pump 26 and suction cup cavity, ensure the cleanliness of the gas path and the sealing performance of the suction cup, and extend the service life of the vacuum pump 26.

[0074] Vacuum tank 25 refers to the pressure-maintaining component connected to the vacuum pump 26 of each vacuum adsorption subsystem. It can store negative pressure gas and maintain the stability of negative pressure in the suction cup cavity when the vacuum pump 26 is briefly stopped or the gas pressure fluctuates, thereby improving the anti-interference capability of the adsorption system.

[0075] The distributed layout refers to the suction cup buffer rod assembly 21 of the four sets of vacuum adsorption subsystems being evenly distributed in the four quadrants of the frame formed by the horizontal aluminum profile 11 and the vertical aluminum profile 12 of the end-effector body through the suction cup guide seat 14, so that the adsorption force is evenly applied to the surface of the photovoltaic module, avoiding deformation or damage to the module due to uneven force. The frame rigidity guaranteed by the corner code 13 ensures that the body does not deform during distributed adsorption.

[0076] The preset timing sequence refers to the start-up order of each vacuum adsorption subsystem preset by the PLC control system and the industrial control computer 27. It can be adjusted by the industrial control computer 27 according to the structural strength and center of gravity of the photovoltaic module. In this embodiment, the simultaneous start-up method is adopted to ensure that the adsorption force acts on the module surface synchronously and avoid the module displacement caused by adsorption at a single point first.

[0077] In this embodiment, the suction cup guide seat 14 provides installation accuracy assurance for the distributed layout of multiple subsystems, and the horizontal aluminum profile 11 and the vertical aluminum profile 12 provide stable support for all vacuum adsorption components. The specific implementation principle is as follows: The vacuum adsorption system consists of at least two (four in this embodiment) vacuum adsorption subsystems. Each subsystem is independently equipped with a suction cup buffer rod assembly 21, a vacuum filter 22, a solenoid valve 23, a pressure gauge 24, a vacuum tank 25, and a vacuum pump 26. The gas path and circuit of each subsystem are completely independent. The suction cup buffer rod assembly 21 is precisely installed at the bottom of the frame formed by the horizontal aluminum profile 11 and the vertical aluminum profile 12 of the end effector body through the suction cup guide seat 14. The suction cup buffer rod assemblies 21 of the four subsystems are distributed and evenly arranged to ensure that the surface of the photovoltaic module is subjected to uniform force during adsorption. The gas path pipeline of each subsystem is independently connected to the suction cup on the suction cup buffer rod assembly 21 and the vacuum pump 26. The vacuum filter 22 is set in the gas path pipeline near the vacuum pump 26. The solenoid valve 23 is set on its respective main gas path pipeline. The pressure gauge 24 is installed in the gas path pipeline near the suction cup. The vacuum tank 25 is connected in series between the vacuum pump 26 and the solenoid valve 23. The independent configuration of each component ensures the gas path independence of the subsystem.

[0078] After the PLC control system determines that the end effector and the photovoltaic module have reached the posture alignment state, it first sends a pressing command to the end effector body, so that the end effector presses down at a preset speed (50mm / s in this embodiment). The suction cup on the suction cup buffer rod assembly 21 first contacts the surface of the photovoltaic module. Its built-in buffer structure offsets the pressing impact force and avoids damage to the photovoltaic module until the suction cup is completely attached to the surface of the module, thus establishing a sealed foundation for negative pressure adsorption.

[0079] After confirming that the suction cups are fully attached to the surface of the photovoltaic modules, the PLC control system sends a gas path switching command to the solenoid valves 23 of all vacuum adsorption subsystems, causing all solenoid valves 23 to operate synchronously, connecting their respective suction cup cavities to the vacuum pumps 26 and disconnecting them from the atmosphere. Subsequently, the PLC control system sends a start command to all vacuum pumps 26. In this embodiment, a preset timing sequence for simultaneous start is adopted to ensure that the suction cup cavities of the four subsystems start generating negative pressure at the same time. If special components need to be adapted, the timing sequence can also be adjusted to sequential start through the industrial control computer 27.

[0080] After each vacuum pump 26 is started, it evacuates the corresponding suction cup cavity through an independent gas pipeline. Dust and impurities in the gas pipeline are blocked after being filtered by the vacuum filter 22, preventing them from entering the vacuum pump 26 and affecting its working performance. During the evacuation process, the pressure gauge 24 collects the vacuum level data of its subsystem in real time and converts the data into an electrical signal, which is then transmitted to the PLC control system. The PLC monitors the vacuum level data of each subsystem in real time. The vacuum tank 25 stores negative pressure gas simultaneously during the evacuation process to provide support for subsequent pressure holding. When the vacuum level of all subsystems reaches the preset adsorption negative pressure value (≥-0.08MPa in this embodiment) and this state is maintained for a preset time (200ms in this embodiment), the PLC control system determines that the photovoltaic module has been stably adsorbed, and the adsorption process is completed.

[0081] Once the photovoltaic modules are moved to the target installation location, the PLC control system sends a reverse air path switching command to all solenoid valves 23, connecting the suction cup cavity to the atmosphere and disconnecting it from the vacuum pump 26. The negative pressure inside the cavity disappears rapidly, and all vacuum pumps 26 are shut down, allowing the photovoltaic modules to be released smoothly. After release, the solenoid valves 23 reset, the vacuum pumps 26 enter standby mode, and the entire vacuum adsorption system returns to its initial standby state, ready for the next adsorption operation.

[0082] If one or more vacuum adsorption subsystems fail to generate negative pressure during the adsorption process, the remaining normal subsystems can continue to work because the gas and circuit paths of each subsystem are independent of each other. The adsorption force on the photovoltaic module is maintained by the distributed suction cup buffer rod assembly 21, ensuring the safe handling of the module. The end-effector frame reinforced by the corner code 13 can ensure that the body does not deform when the adsorption force is uneven, further ensuring the stability of handling.

[0083] The above solution designs the vacuum adsorption system as multiple independent vacuum adsorption subsystems, achieving dual redundancy in both the gas path and the circuit. A failure in any subsystem will not affect the normal operation of other subsystems, significantly improving the reliability and safety of the vacuum adsorption system and effectively reducing the risk of photovoltaic modules detaching due to adsorption system failures. Each subsystem is independently equipped with components such as the suction cup buffer rod assembly 21 and the vacuum pump 26, making fault diagnosis more convenient. It allows for quick location and repair of faulty subsystems, reducing equipment maintenance time and costs. The suction cup buffer rod assembly 21 achieves a distributed layout through the suction cup guide seat 14, ensuring that the adsorption force is evenly applied to the surface of the photovoltaic module. This avoids damage such as deformation and cracks caused by uneven force, ensuring the integrity of high-value photovoltaic modules. Furthermore, the buffer structure of the suction cup buffer rod assembly 21 effectively counteracts downward impact forces, further reducing the probability of surface damage to the modules.

[0084] The PLC control system, in conjunction with the industrial computer 27, provides unified control over all subsystems, enabling synchronized adsorption and release operations. This ensures the photovoltaic modules remain stable during adsorption and release, preventing module displacement due to single-point actions. The preset timing sequence can be flexibly adjusted to adapt to the installation requirements of different photovoltaic module specifications. The configuration of the vacuum filter 22 and vacuum tank 25 ensures clean airflow and stable negative pressure, extending the service life of the vacuum pump 26 and improving the overall durability of the adsorption system. Furthermore, the multi-subsystem design allows for flexible adjustment of the number of subsystems and the installation position of the suction cup guide seat 14 based on the size and weight of the photovoltaic modules, adapting to different photovoltaic module specifications and enhancing the adaptability and scalability of the vacuum adsorption system to meet the installation needs of various photovoltaic power plants.

[0085] In some embodiments, in step S2, the PLC control system is further configured to: Vacuum level data is read in real time by vacuum level sensors of each vacuum adsorption subsystem, and the vacuum level data is compared with a preset safe adsorption threshold. If the vacuum level of any vacuum adsorption subsystem fails to reach or remains below the safe adsorption threshold within a preset time, the vacuum adsorption subsystem is determined to be in a fault state. At this time, the PLC control system issues a warning message containing the identifier of the vacuum adsorption subsystem in a fault state, and maintains the vacuum generators of the remaining vacuum adsorption subsystems with normal vacuum levels to continue to work and the current state of their control valves. Based on the number and layout of the remaining normal vacuum adsorption subsystems, the overall adsorption force of the vacuum adsorption system is evaluated to see if it is still higher than the preset safe redundancy threshold, and a decision is made to continue the handling operation or execute the emergency safe placement procedure accordingly.

[0086] The safe adsorption threshold refers to the minimum vacuum level value preset by the PLC control system for normal adsorption by the vacuum adsorption subsystem. In this embodiment, it is set to -0.08MPa, which is a quantitative standard for determining whether the subsystem has effective adsorption capacity. This threshold can be flexibly adjusted by the industrial computer 27 according to the weight of the photovoltaic module.

[0087] A fault status refers to a situation where the vacuum degree of the vacuum adsorption subsystem fails to reach the safe adsorption threshold within a preset time, or remains below the safe adsorption threshold after reaching it. This indicates that there is a fault in the gas path or circuit of the subsystem, which cannot provide effective adsorption force. The fault status can be displayed in real time by the industrial control computer 27.

[0088] Warning information refers to the prompt information generated by the PLC control system that includes the identifier of the faulty subsystem. It can be displayed on the industrial computer 27 or uploaded through the remote monitoring module, which makes it easy for operators to quickly locate the faulty subsystem. The identifier information corresponds one-to-one with the subsystem positions distributed on the suction cup guide seat 14 (such as front left, front right, rear left, rear right).

[0089] The safety redundancy threshold refers to the minimum effective adsorption force of the entire vacuum adsorption system preset by the PLC control system. It is determined by parameters such as the weight and size of the photovoltaic module. In this embodiment, it is set to ≥70% of the rated total adsorption force. It is the core standard for determining whether the system has the ability to continue to be safely transported. It can be adjusted as needed by the industrial computer 27.

[0090] The emergency safety placement process refers to the emergency process initiated by the PLC control system when the overall adsorption force of the vacuum adsorption system is lower than the safety redundancy threshold. This process, in conjunction with an external robot, smoothly places the photovoltaic modules in a preset safe position to prevent the modules from falling off and being damaged. The execution parameters of the process can be preset by the industrial control computer 27.

[0091] The preset sampling frequency refers to the frequency at which the pressure gauge 24 collects vacuum data as set by the PLC control system. In this embodiment, it is 100Hz to ensure real-time monitoring of vacuum changes. The sampling frequency can be adjusted by the industrial computer 27.

[0092] This embodiment relies on the real-time detection of pressure gauge 24 and the linkage control between PLC and industrial control computer 27. The specific implementation principle in step S2 is as follows: Real-time vacuum monitoring: After the PLC control system sends a start command to all vacuum adsorption subsystems, the pressure gauge 24 of each subsystem immediately collects the vacuum data of its subsystem in real time at a preset sampling frequency (preferably 100Hz) and continuously transmits the data to the vacuum system control module of the PLC control system, so as to realize independent and real-time monitoring of the vacuum of each subsystem and ensure that subtle changes in vacuum can be captured in a timely manner.

[0093] Fault Status Determination: The vacuum system control module continuously compares the real-time vacuum level data of each subsystem with the preset safe adsorption threshold (-0.08MPa) and performs independent fault determination for each subsystem. If the vacuum level of a certain subsystem fails to reach the safe adsorption threshold within a preset time (preferably 200ms), or if it remains below the safe adsorption threshold for a period of time exceeding the preset value after reaching the threshold, the PLC control system immediately determines that the subsystem is in a fault state and generates a warning message containing the unique identifier of the faulty subsystem. At the same time, the warning message is output to the industrial control computer 27 or the remote monitoring module to remind the operator to check in time. The identification information is accurately matched with the subsystem installation position corresponding to the suction cup guide seat 14, realizing rapid fault location.

[0094] Faulty subsystem isolation and normal subsystem pressure maintenance: After determining that a certain subsystem is in a faulty state, the PLC control system does not perform any additional operations on the faulty subsystem, but maintains its current air and circuit status, thereby achieving physical isolation of the faulty subsystem and preventing air pressure fluctuations in the faulty subsystem from affecting other normal subsystems. At the same time, it issues pressure maintenance commands to other subsystems with normal vacuum levels, maintaining the continuous operation of their vacuum pump 26 and the current connection state of their solenoid valve 23, ensuring the stability of the adsorption force of the normal subsystem, and continuously providing stable adsorption for the photovoltaic module through the suction cup buffer rod assembly 21, avoiding interference with the adsorption state of the normal subsystem due to fault determination.

[0095] Overall Adsorption Force Assessment: After isolating the faulty subsystem, the PLC control system calculates the overall actual adsorption force that the vacuum adsorption system can currently provide based on the number of remaining normal vacuum adsorption subsystems, the rated adsorption force of each subsystem, and the distributed layout of the suction cup guide seat 14, using a built-in algorithm. The calculated overall actual adsorption force is compared with the preset safety redundancy threshold (≥70% of the rated total adsorption force) to accurately assess whether the system has the ability to continue safely handling photovoltaic modules. The assessment results can be fed back to the industrial control computer 27 in real time.

[0096] Tiered fault handling: Based on the overall adsorption force assessment results, the PLC control system and the industrial computer 27 work together to execute two different handling strategies to ensure the safe handling of photovoltaic modules while minimizing the impact on the installation operation. Continue to complete the handling operation: If the overall actual adsorption force is higher than the safety redundancy threshold, it indicates that the adsorption force of the remaining normal subsystems can meet the safe handling requirements of the photovoltaic modules. In this embodiment, after any failure of any of the four subsystems, the remaining three subsystems can provide ≥75% of the rated total adsorption force, which is higher than the safety redundancy threshold. At this time, the PLC control system will continue to follow the preset process and cooperate with the external robot to complete the handling and release operation of the photovoltaic modules. After the operation is completed, the industrial control computer 27 will continuously issue warning information to remind the operator to check the faulty subsystem.

[0097] Execute the emergency safety placement procedure: If the overall actual adsorption force is lower than the safety redundancy threshold, it indicates that the adsorption force of the remaining normal subsystems cannot guarantee the safe handling of the photovoltaic modules. For example, if two or more subsystems fail in this embodiment, the overall adsorption force will be lower than the threshold. At this time, the PLC control system immediately sends an emergency stop command to the external robot and starts the preset emergency safety placement procedure, controlling the external robot to place the photovoltaic modules stably in the preset safe position. After placement, the vacuum pumps 26 of all normal subsystems are turned off, the solenoid valves 23 are switched to connect the suction cups to the atmosphere, and the high-frequency warning information is continuously issued through the industrial control computer 27 until the operator investigates and eliminates the fault.

[0098] The entire fault monitoring and handling process is automatically completed by the PLC control system without manual intervention. The high-frequency sampling of the pressure gauge 24 and the real-time feedback of the industrial computer 27 ensure the accuracy of fault judgment and the timeliness of handling. The distributed layout of the suction cup buffer rod assembly 21 provides a structural basis for maintaining the suction force in the fault state. The end effector body frame reinforced by the corner code 13 ensures that the body structure is stable and does not deform when the fault is absorbed.

[0099] This embodiment uses pressure gauge 24 to independently monitor the vacuum level of each vacuum adsorption subsystem at high frequency in real time, enabling accurate and rapid fault condition determination. Combined with the visual display of the industrial control computer 27, it facilitates operators to locate the fault point in a timely manner, significantly reducing fault diagnosis time and improving equipment maintenance efficiency. The physical isolation design of the faulty subsystem ensures that the faulty subsystem will not affect the operation of other normal subsystems. The suction cup buffer rod assembly 21 of the remaining normal subsystems maintains part of the system's adsorption capacity, buying time for fault handling and continued operation. Through real-time assessment of the overall adsorption force and a graded fault handling strategy, the vacuum adsorption system achieves fault self-adaptation. While ensuring the safety of photovoltaic module handling, it minimizes the impact of faults on installation operations, reduces the work interruption rate, and improves the continuous working capacity and operational efficiency of the equipment.

[0100] The emergency safety placement procedure provides reliable emergency protection in cases of insufficient system adsorption, fundamentally preventing photovoltaic modules from falling off and being damaged due to insufficient adsorption, thus significantly reducing economic losses. Simultaneously, all fault monitoring, assessment, and handling logic is automatically completed by the PLC control system, which can be linked with the industrial control computer 27 to achieve parameter adjustment and status display without manual intervention, improving the automation and intelligence level of the equipment, reducing the workload of operators, and adapting to the operational needs of large-scale outdoor automated photovoltaic installation. The redundant design and fault self-adaptive capability of the vacuum adsorption system, combined with the high environmental adaptability of dual IMU positioning, further enhance the reliability and practicality of the entire intelligent end effector, enabling the equipment to operate stably in various complex outdoor environments.

[0101] In some embodiments, the end effector body is provided with a buffer rod assembly connected to the suction cup, and the buffer rod assembly has a built-in travel sensing switch; In step S2, the PLC control system is further configured to: after determining that the posture alignment state has been reached, control the end effector body to press down at a preset speed until the travel sensing switch is triggered, confirm that the suction cup is attached to the surface of the photovoltaic module, and then start the vacuum adsorption system.

[0102] In this embodiment, the travel sensing switch refers to the detection component built into the suction cup buffer rod assembly 21. The detection distance is 2mm, which can detect the downward travel of the suction cup buffer rod assembly 21 in real time. When the suction cup is completely attached to the surface of the photovoltaic module, it is triggered and outputs a high-level signal, providing hardware basis for the PLC control system to determine the attachment status.

[0103] The preset speed refers to the pressing speed of the end effector body preset by the PLC control system. In this embodiment, it is set to 50mm / s. This speed can be flexibly adjusted by the industrial computer 27 to ensure that the suction cup can quickly adhere to the surface of the photovoltaic module, while avoiding impact damage to the module caused by excessive pressing speed.

[0104] The bonding signal is a high-level electrical signal transmitted to the PLC control system after the limit sensor switch is triggered. It is the core signal for determining that the suction cup and the surface of the photovoltaic module have completed effective bonding. The PLC will start the vacuum adsorption system only after receiving this signal, so as to avoid energy waste and invalid negative pressure establishment caused by starting the vacuum pump 26 in the absence of bonding.

[0105] The PLC control system calculates the attitude data from the dual nine-axis IMU positioning system and determines that the attitude deviation between the end effector body and the photovoltaic module is less than the preset attitude deviation threshold (±0.5°). After the attitude alignment is achieved, the system does not directly start the vacuum adsorption system, but first sends a pressing command to the external photovoltaic installation robot to start the pressing process of the end effector body.

[0106] After receiving the pressing command, the external robot, through the linkage with the robot connection flange of the attitude adjustment mechanism, drives the end effector body to slowly press down on the surface of the photovoltaic module at a preset speed (50mm / s). During the pressing process, the rigid frame composed of the horizontal aluminum profile 11, the vertical aluminum profile 12 and the corner bracket 13 maintains structural stability, avoids body shaking during pressing, and ensures that the pressing direction of the suction cup buffer rod assembly 21 is accurate.

[0107] During the pressing down of the end effector body, the suction cup at the end of the suction cup buffer rod assembly 21 first contacts the surface of the photovoltaic module. As the pressing action continues, the buffer structure of the suction cup buffer rod assembly 21 is compressed. When the suction cup is fully attached to the surface of the photovoltaic module, the built-in limit sensor switch is triggered, and a high-level attachment signal is immediately transmitted to the PLC control system. This signal is the pre-trigger condition for starting the vacuum adsorption system.

[0108] After receiving the contact signal from the limit sensor switch, the PLC control system confirms that the suction cup and the surface of the photovoltaic module have been effectively attached. At this time, it sends a formal start command to the vacuum adsorption system, controls the solenoid valve 23 to connect the suction cup cavity with the vacuum pump 26, and starts the vacuum pump 26 to perform air extraction. After the air is filtered by the vacuum filter 22, a negative pressure is established in the sealed cavity between the suction cup and the surface of the photovoltaic module.

[0109] After the vacuum pump 26 is started, the pressure gauge 24 monitors the vacuum level data in real time and transmits it to the PLC control system. When the vacuum level reaches the preset safe adsorption threshold (≥-0.08MPa) and this state lasts for 200ms, the PLC determines that the photovoltaic module has been stably adsorbed, completing the entire adsorption start-up process. Subsequently, it can cooperate with an external robot to move the module.

[0110] If, during the pressing process, the travel sensing switches of some suction cup buffer rod assemblies 21 are triggered first due to the unevenness of the photovoltaic module surface, the PLC control system will wait until all travel sensing switches of the suction cup buffer rod assemblies 21 are triggered before starting the vacuum adsorption system to ensure that all suction cups are effectively attached to the module surface and to avoid adsorption leakage caused by partial non-attachment.

[0111] This embodiment adds a contact detection step between the suction cup and the photovoltaic module surface by incorporating a travel sensing switch in the suction cup buffer rod assembly 21. This achieves precise control of "contact and re-adsorption," fundamentally avoiding energy waste and ineffective negative pressure establishment caused by starting the vacuum adsorption system without contact, thus improving the energy utilization efficiency of the equipment. The end effector body presses down at a preset speed of 50mm / s. Combined with the buffer structure of the suction cup buffer rod assembly 21 and the precise detection of the travel sensing switch, this effectively avoids impact damage to the photovoltaic module caused by excessive pressing speed, further reducing the damage rate of the module surface and ensuring the integrity of high-value photovoltaic modules.

[0112] The bonding and testing process ensures that all suction cups are effectively bonded to the surface of the photovoltaic module before negative pressure is established, improving the sealing of the vacuum adsorption and avoiding air leakage caused by partial non-bonding, further reducing the risk of module detachment. The preset pressing speed can be flexibly adjusted via the industrial control computer 27, adapting to photovoltaic modules of different thicknesses and surface flatness, thus improving the equipment's adaptability. The entire bonding and testing and adsorption start-up process is automatically completed by the PLC control system without manual intervention, improving the automation level of the equipment, ensuring the continuity of the installation operation, and further improving the efficiency of photovoltaic module installation.

[0113] In some embodiments, the photovoltaic panel IMU module has a detachable structure, and its outer shell is provided with a strong magnetic adsorption component, which is adsorbed and fixed to the metal frame of the photovoltaic module; the photovoltaic panel IMU module has a built-in wireless communication module and a battery for wireless data communication with the PLC control system; The end effector also includes: A wireless charging device is installed on the storage station or transfer rack of the photovoltaic module. When the photovoltaic module with the photovoltaic panel IMU module attached is placed on the storage station or transfer rack, the wireless charging device charges the battery of the photovoltaic panel IMU module through electromagnetic induction.

[0114] In this embodiment, the strong magnetic adsorption component refers to the magnetic component set on the outer shell of the photovoltaic panel IMU module, which allows the photovoltaic panel IMU module to be detachably fixed to the metal frame of the photovoltaic module by magnetic attraction. The installation and removal are convenient, no additional fasteners are required, and no structural damage is caused to the photovoltaic module.

[0115] The wireless communication module refers to the communication component built into the photovoltaic panel IMU module. It enables wireless data transmission between the photovoltaic panel IMU module and the PLC control system, and sends the collected first attitude data of the photovoltaic module to the PLC in real time. No wiring is required, which is suitable for the mobile operation requirements of photovoltaic modules.

[0116] The battery refers to the power supply component built into the photovoltaic panel IMU module, which provides power to the photovoltaic panel IMU module and the wireless communication module, enabling the photovoltaic panel IMU module to work independently without an external power source, thus improving its flexibility of use.

[0117] Wireless charging devices refer to charging equipment installed on photovoltaic module storage stations or transfer racks. They use standard wireless charging coils with an output power of 5W and wirelessly charge the batteries of photovoltaic panel IMU modules through the principle of electromagnetic induction, eliminating the need for manual plugging and unplugging of charging cables and achieving automated charging.

[0118] Storage station / transfer rack refers to the carrier for storing and transferring photovoltaic modules before installation. It is the charging point for the photovoltaic panel IMU module. When the photovoltaic module with the photovoltaic panel IMU module attached is placed in this position, the wireless charging device automatically aligns with the photovoltaic panel IMU module and starts charging.

[0119] In this embodiment, the photovoltaic panel IMU module housing integrates a strong magnetic adsorption component, allowing operators to directly attach it to the metal frame of the photovoltaic module. The magnetic force enables a reliable connection between the two, eliminating the need for additional fasteners during installation. This convenient operation does not damage the metal frame or surface of the photovoltaic module. Furthermore, the magnetic detachable structure allows the photovoltaic panel IMU module to be repeatedly disassembled and reassembled, adapting to the installation requirements of different photovoltaic modules. One photovoltaic panel IMU module can be used with multiple photovoltaic modules.

[0120] The photovoltaic panel IMU module has a built-in battery and wireless communication module. The battery provides independent power for the IMU sensor and wireless communication module, eliminating the need for external power lines. This allows the photovoltaic panel IMU module to work independently throughout the entire process of storage, transportation, and installation of the photovoltaic module. During operation, the photovoltaic panel IMU module collects the first attitude data of the photovoltaic module in real time and transmits the data to the PLC control system of the end effector in real time through the wireless communication module. This provides data support for attitude deviation calculation. The wireless transmission method eliminates the need for wiring, avoiding problems such as wire tangling and wear, and is suitable for complex outdoor installation environments.

[0121] A wireless charging device is pre-installed on the storage station or transfer rack of the photovoltaic module. The device uses a standard wireless charging coil (output power 5W), and its installation position precisely corresponds to the position of the photovoltaic panel IMU module after the photovoltaic module is placed. When the photovoltaic module with the attached photovoltaic panel IMU module is placed on the storage station or transfer rack, the photovoltaic panel IMU module and the charging coil of the wireless charging device are automatically aligned. The wireless charging device charges the built-in battery of the photovoltaic panel IMU module through the principle of electromagnetic induction, realizing the automation of the charging process. There is no need to manually plug and unplug the charging cable, which greatly reduces the workload of manual maintenance.

[0122] The end effector IMU module on the end effector body is fixed to the center of the longitudinal aluminum profile 12 by an L-shaped metal bracket, keeping it parallel and axially aligned with the sensing coordinate system of the photovoltaic panel IMU module. When the external robot moves the end effector body to the preset gripping position directly above the photovoltaic module, the end effector IMU module collects the second attitude data of the end effector in real time and transmits it to the PLC control system via wired connection. The PLC synchronously processes the first attitude data received wirelessly and the second attitude data collected via wired connection, calculates the attitude deviation between the two, and provides the adjustment basis for the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 of the attitude adjustment mechanism.

[0123] Once a photovoltaic module is installed, the operator can remove the photovoltaic panel IMU module from the metal frame of the module and attach it to the metal frame of the next photovoltaic module to be installed, continuing the attitude data acquisition operation. The built-in battery automatically charges at the storage station to ensure its continuous operation, eliminating the need for frequent battery replacements and enabling the photovoltaic panel IMU module to be recycled and reused.

[0124] This embodiment achieves magnetic detachable installation of the IMU module and photovoltaic module by setting a strong magnetic adsorption component on the outer shell of the photovoltaic panel IMU module. The installation and disassembly operations are convenient and do not require additional fasteners, which not only improves work efficiency but also avoids structural damage to the photovoltaic module. In addition, the IMU module can be reused, reducing equipment operating costs. The photovoltaic panel IMU module has a built-in battery and wireless communication module, which enables independent operation without external power supply and wiring. It is suitable for complex outdoor photovoltaic installation environments and avoids problems such as wire tangling, wear, and aging, thereby improving the reliability and durability of the equipment. Wireless charging devices are set up in the storage station and transfer rack to realize automatic wireless charging of the photovoltaic panel IMU module without manual intervention, which greatly reduces the workload of manual maintenance, ensures continuous power supply to the IMU module, and avoids positioning interruption problems caused by battery depletion.

[0125] The integrated design of magnetic installation, wireless communication, and automatic charging greatly enhances the flexibility of photovoltaic panel IMU modules. It can be adapted to the entire process of photovoltaic module attitude data acquisition from storage and transportation to installation, providing continuous and stable first attitude data for the dual nine-axis IMU positioning system, further ensuring positioning accuracy. This optimized design does not change the core structure of the end effector body. The original performance of components such as the horizontal aluminum profile 11, the vertical aluminum profile 12, and the corner code 13 is not affected. It works well with the attitude adjustment mechanism and the vacuum adsorption system, improving the automation and intelligence level of the intelligent end effector as a whole, and meeting the operational needs of large-scale outdoor photovoltaic automated installation.

[0126] In a second aspect, this application provides a method for installing photovoltaic modules based on a dual-nine-axis IMU, the method being applicable to the installation of intelligent end-sensors for photovoltaic modules based on a dual-nine-axis IMU as described in the first aspect of this application. Figure 6 As shown, the paving method includes the following steps: S601: Receive instructions from the external motion system or based on a preset path, control the attitude adjustment mechanism to keep the end effector in a ready posture, and cooperate with the external motion system to move the end effector to a preset coarse positioning area above the photovoltaic module. S602: Using the dual nine-axis IMU positioning system, the system collects in real time the first attitude data of the photovoltaic module sensed by the photovoltaic panel IMU module and the second attitude data of the end effector sensed by the end effector IMU module, both based on the same spatial reference. Based on the first and second attitude data, the system calculates the attitude deviation between the photovoltaic module and the end effector. According to the attitude deviation, the system controls the pitch, roll, and yaw servo motors in the attitude adjustment mechanism to dynamically adjust the spatial attitude of the end effector body. The system repeats the attitude data acquisition, deviation calculation, and adjustment until the attitude deviation is determined to be less than a preset attitude deviation threshold, thus achieving attitude alignment. S603: After confirming that the posture alignment state has been reached, control the vacuum adsorption system to start to adsorb the photovoltaic module; S604: Control the attitude adjustment mechanism to maintain or fine-tune the attitude of the end effector during the transportation process, and cooperate with the external motion system to move the end effector with the adsorbed photovoltaic module to the target installation position; then control the vacuum adsorption system to release, and complete the installation of the photovoltaic module.

[0127] In this embodiment, the external motion system, namely the photovoltaic module installation-specific industrial robot / gantry-type mobile paving equipment, is a higher-level motion device that drives the intelligent end effector to complete spatial movement, coarse positioning, module handling, and target position placement. It is connected to the end effector's attitude adjustment mechanism through a robot connection flange, and can receive instructions from the PLC control system to complete the entire paving operation.

[0128] The preparatory attitude refers to the initial working attitude of the end effector body preset by the PLC control system. At this time, the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 of the attitude adjustment mechanism are all in the zero position, and the end effector body remains horizontal, providing a reference attitude for subsequent coarse positioning and attitude adjustment.

[0129] The preset path refers to the photovoltaic module installation operation path preset in the industrial control computer 27, which is determined by the installation layout plan of the photovoltaic power station. The external motion system can drive the end-effector body to complete the entire movement from the photovoltaic module storage location to the target installation location according to the path.

[0130] The preset coarse positioning area refers to the space within 1m directly above the photovoltaic module, with a positioning error of ≤10cm. It is the position where the end effector completes coarse positioning and is also the reference area where the dual nine-axis IMU positioning system begins to collect attitude data and calculate deviations.

[0131] The target installation location refers to the pre-set installation location of photovoltaic modules in a photovoltaic power station, which is determined by the layout of the photovoltaic support. After the external motion system drives the end effector body with the photovoltaic modules attached to it to the location, the installation and release of the modules are completed.

[0132] In step S601, the intelligent end effector and external motion system are powered on and started. The PLC control system is linked with the industrial computer 27 to send instructions to the attitude adjustment mechanism, controlling the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 to reset to the zero position, so that the end effector body maintains a horizontal preparatory attitude. At the same time, the dual nine-axis IMU positioning system completes the zero-position calibration, and the photovoltaic panel IMU module is fixed to the metal frame of the photovoltaic module to be installed by magnetic attraction, and enters the working state.

[0133] In step S602, coarse positioning is first performed, which specifically includes: the PLC control system receiving the operation instructions from the external motion system, or sending motion instructions to the external motion system according to the preset paving path in the industrial control computer 27; after receiving the instructions, the external motion system drives the end effector body in the preparatory posture to move through the linkage with the robot connection flange of the attitude adjustment mechanism until the end effector body reaches the preset coarse positioning area directly above the photovoltaic module to be paved, thus completing the coarse positioning. During this process, the horizontal aluminum profile 11, the vertical aluminum profile 12 and the corner bracket 13 of the end effector body maintain structural stability to ensure no deformation during the movement.

[0134] Then, fine-tuning of the attitude is performed, specifically including: after the end effector body reaches the preset coarse positioning area, the dual nine-axis IMU positioning system starts real-time data acquisition. The photovoltaic panel IMU module transmits the acquired first attitude data of the photovoltaic module to the PLC via wireless communication, and the end effector IMU module transmits the acquired second attitude data of the end effector to the PLC via wired transmission. After filtering the two sets of attitude data, the PLC calculates the attitude deviation (Δα, Δβ, Δγ) between the two sets of attitude data and compares the deviation value with the preset threshold (±0.5°). If the deviation exceeds the threshold, the PLC sends an adjustment command to the attitude adjustment mechanism, driving the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 to work together to adjust the spatial attitude of the end effector body through linkage with the fixed connection plate 15. The closed-loop operation of "attitude data acquisition-deviation calculation-attitude adjustment" is repeated until the attitude deviation is less than the preset threshold, and the attitude alignment state is achieved.

[0135] In step S603, after the PLC determines that the posture alignment state has been reached, it controls the external motion system to drive the end effector body to press down at a preset speed of 50mm / s. When the stroke sensing switch built into the suction cup buffer rod assembly 21 is triggered and a bonding signal is sent to the PLC, the PLC immediately sends a start command to the vacuum adsorption system. The solenoid valve 23 activates to connect the suction cup cavity with the vacuum pump 26. The vacuum pump 26 starts to pump air. After the air path is filtered by the vacuum filter 22, a negative pressure is established in the sealed cavity. The vacuum tank 25 achieves negative pressure maintenance, and the pressure gauge 24 monitors the vacuum degree in real time. When the vacuum degree is ≥-0.08MPa and lasts for 200ms, it is determined that the photovoltaic module has been stably adsorbed. The suction cup guide seat 14 ensures that the suction cup is subjected to uniform force to avoid module deformation.

[0136] In step S604, after the photovoltaic module is stably adsorbed, the PLC control system sends an attitude maintenance command to the attitude adjustment mechanism, so that the pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 maintain their current state, ensuring that the attitude of the end effector body and the photovoltaic module is relatively stable. At the same time, the PLC sends a transport command to the external motion system. The external motion system drives the end effector body with the adsorbed photovoltaic module to move according to a preset path. If a slight attitude deviation occurs during the movement, the attitude adjustment mechanism can make real-time fine adjustments to ensure the stability of the module during transport.

[0137] After the external motion system moves the end effector to the target installation position of the photovoltaic bracket, it sends a positioning signal to the PLC. The PLC first controls the attitude adjustment mechanism to make fine attitude adjustments to ensure that the photovoltaic module is completely aligned with the installation surface, and then sends a release command to the vacuum adsorption system. The solenoid valve 23 activates to connect the suction cup cavity to the atmosphere, the negative pressure disappears quickly, the vacuum pump 26 is turned off, and the photovoltaic module is smoothly laid to the target position. After the release is completed, the PLC controls the external motion system to move the end effector back to the photovoltaic module storage position to prepare for the installation of the next module, thus completing a complete photovoltaic module installation process.

[0138] This embodiment achieves coordinated operation of coarse positioning by the external motion system and fine attitude adjustment by the end effector. It utilizes the large-space motion capability of the external motion system and leverages the high-precision attitude adjustment advantage of the dual nine-axis IMU positioning of the intelligent end effector, which greatly improves the positioning accuracy of the photovoltaic module and adapts to the complex outdoor paving environment. The entire paving process is automated. From coarse positioning, fine attitude adjustment, adsorption and gripping to transportation and placement, the entire process is completed by the PLC control system and the external motion system in linkage, without the need for manual intervention. This greatly reduces the workload of operators and improves the efficiency of paving operations.

[0139] The installation process incorporates steps such as adhesion detection, adsorption stability judgment, and attitude fine-tuning. Combined with the redundant design of the vacuum adsorption system and the buffer protection of the suction cup buffer rod assembly 21, the risk of photovoltaic modules falling off and surface damage is minimized. This method is adaptable to photovoltaic modules of different specifications and mainstream external motion systems. Parameters such as preset paths, pressing speeds, and attitude deviation thresholds can be flexibly adjusted via the industrial control computer 27 to meet the installation needs of different photovoltaic power plants, demonstrating strong compatibility and scalability. The transverse aluminum profile 11 and longitudinal aluminum profile 12 of the end effector body provide stable support throughout the entire operation, ensuring the reliability of the equipment during continuous operation, reducing the probability of equipment failure, and lowering maintenance costs.

[0140] In some embodiments, the handling process after the vacuum adsorption system starts and adsorbs the photovoltaic module, until the vacuum adsorption system is released, also includes a fault adaptation step, such as... Figure 7 As shown, the fault adaptation step specifically includes: S701: The vacuum sensor built into the vacuum adsorption system monitors and obtains the current vacuum level value of each independent vacuum adsorption subsystem in the vacuum adsorption system in real time at a preset sampling frequency. S702: Compare the current vacuum value of each independent vacuum adsorption subsystem with its corresponding preset failure threshold; if the current vacuum value of one or more vacuum adsorption subsystems is continuously lower than its preset failure threshold for a preset time, then determine that the one or more vacuum adsorption subsystems have experienced vacuum failure; identify all remaining effective vacuum adsorption subsystems and calculate the theoretical total adsorption force that all effective vacuum adsorption subsystems can provide; S703: Compare the calculated theoretical total adsorption force with a preset safety redundancy threshold; if the theoretical total adsorption force is greater than the safety redundancy threshold, determine that the system has the conditions to continue to safely execute the task and trigger the attitude readjustment sub-step; otherwise, generate an emergency stop and alarm signal. like Figure 8 As shown, the attitude readjustment sub-step includes: S801: Based on the physical layout of all effective vacuum adsorption subsystems on the end-effector body and their respective rated adsorption forces, calculate the new force equilibrium center point of the photovoltaic module under the joint adsorption of the effective vacuum adsorption subsystems. S802: Based on the first attitude data provided by the photovoltaic panel IMU module, determine the center of gravity position of the photovoltaic module, and project the center of gravity position onto the plane where the end effector body is located to obtain the center of gravity projection point; S803: Calculate the positional deviation between the center of gravity projection point and the new force equilibrium center point; based on the positional deviation and combined with the rigid connection model formed by the end effector and the photovoltaic module, calculate the compensation adjustment amount required for the pitch adjustment servo motor, roll adjustment servo motor and yaw adjustment servo motor in the attitude adjustment mechanism. S804: Based on the compensation adjustment amount, control the posture adjustment mechanism to drive the end effector body to perform spatial rotation and translation fine adjustment around its current posture until the center of gravity projection point coincides with the new force balance center point or the deviation is less than an allowable tolerance. S805: After completing the attitude readjustment sub-step, control the external motion system and the attitude adjustment mechanism to continue the subsequent steps of moving the photovoltaic module to the target installation position and releasing it while maintaining the adjusted attitude.

[0141] In this embodiment, the fault adaptive step refers to the integrated processing steps of fault monitoring, adsorption force assessment, attitude readjustment, and emergency protection automatically executed by the PLC control system when a subsystem failure occurs in the vacuum adsorption system during the handling of photovoltaic modules. This enables the equipment to adaptively adjust according to the fault state, ensuring the safety of module handling.

[0142] The preset sampling frequency refers to the frequency at which the pressure gauge 24 collects vacuum data as set by the PLC control system. In this embodiment, it is 100Hz to ensure that the vacuum changes of each vacuum adsorption subsystem can be captured in real time and faults can be detected in a timely manner.

[0143] The preset failure threshold refers to the critical vacuum level value for determining the failure of the vacuum adsorption subsystem. In this embodiment, it is set to <-0.08MPa. When the vacuum level of the subsystem continues to be lower than this value, it is determined to be a vacuum failure.

[0144] The theoretical total adsorption capacity refers to the sum of the rated adsorption capacities of the remaining effective vacuum adsorption subsystems. It is calculated from the number of effective subsystems and the rated adsorption capacity of a single subsystem, and is the core indicator for evaluating adsorption capacity.

[0145] The new force balance center point refers to the physical layout position of the suction cups of the remaining effective vacuum adsorption subsystems on the end effector body. It is the adsorption force balance center calculated by combining the rated adsorption force of each subsystem, and is the ideal force center for stable adsorption of photovoltaic modules.

[0146] The center of gravity projection point refers to the point on the plane where the center of gravity of the photovoltaic module is vertically projected onto the end effector body. It is the actual force center of the photovoltaic module. When this point coincides with the new force balance center point, the photovoltaic module is subjected to uniform force and there is no risk of tipping over.

[0147] The allowable tolerance refers to the permissible positional deviation between the center of gravity projection point and the new force equilibrium center point. In this embodiment, it is set to ≤0.1mm. When the deviation is within this range, the photovoltaic module is judged to be under uniform force and no further adjustment is required.

[0148] The rigid connection model refers to the rigid connection structure model formed by the end effector body and the photovoltaic module through the adsorption of the suction cup. The PLC control system calculates the compensation adjustment amount of the attitude adjustment mechanism based on this model to ensure the accuracy of attitude readjustment.

[0149] In step S701, after the vacuum adsorption system starts and adsorbs the photovoltaic module, during the entire handling process until the module is released, the PLC control system controls the pressure gauges 24 of each vacuum adsorption subsystem to collect and upload their respective vacuum level data in real time at a preset sampling frequency of 100Hz, so as to realize real-time monitoring of the vacuum level of each independent vacuum adsorption subsystem throughout the process.

[0150] In step S702, the PLC control system continuously compares the real-time vacuum level data of each subsystem with the preset failure threshold (< -0.08MPa). If the vacuum level of a certain subsystem remains below the preset failure threshold for a preset time (200ms), the subsystem is immediately determined to have failed. At the same time, the PLC identifies the status of all subsystems, marks the failed subsystems, and records the number, layout position, and rated adsorption force of the remaining effective vacuum adsorption subsystems.

[0151] In step S703, the PLC control system calculates the theoretical total adsorption force that all effective subsystems can provide based on the number of remaining effective vacuum adsorption subsystems and the rated adsorption force of a single subsystem. The theoretical total adsorption force is compared with a preset safety redundancy threshold (≥70% of the rated total adsorption force). If the theoretical total adsorption force is greater than the safety redundancy threshold, the system is determined to have the conditions to continue to safely perform the task, and the attitude readjustment sub-step is initiated. If it is less than the safety redundancy threshold, an emergency stop and alarm signal is immediately generated, and the emergency safety placement process is initiated.

[0152] The attitude readjustment sub-step is the core of fault adaptation. The PLC control system achieves uniform stress on the photovoltaic modules through precise calculation and attitude adjustment, specifically including: In step S801, based on the physical layout of all effective vacuum adsorption subsystems on the end-effector body suction cup guide seat 14, and combined with their respective rated adsorption forces, the new force balance center point of the photovoltaic module under the joint adsorption of the effective subsystems is calculated by the built-in algorithm. In step S802, based on the first attitude data transmitted in real time by the photovoltaic panel IMU module, the center of gravity position of the photovoltaic module is accurately determined, and the center of gravity position is vertically projected onto the plane where the end effector body is located to obtain the center of gravity projection point. In step S803, the positional deviation between the center of gravity projection point and the new force equilibrium center point is calculated. Combining the rigid connection model formed by the end effector and the photovoltaic module, the required compensation adjustment amount of the pitch adjustment servo motor 31, roll adjustment servo motor 32 and yaw adjustment servo motor 33 in the attitude adjustment mechanism is obtained through kinematic calculation. In step S804, the PLC sends a control command to the attitude adjustment mechanism according to the calculated compensation adjustment amount, driving the three servo motors to work together. Through linkage with the fixed connection plate 15, the end effector body is driven to rotate and translate around its current posture for fine adjustment until the center of gravity projection point coincides with the new force balance center point, or the positional deviation between the two is less than the allowable tolerance of 0.1mm.

[0153] In step S805, after the attitude readjustment is completed, the PLC control system sends instructions to the external motion system and the attitude adjustment mechanism to control the external motion system to continue moving along the preset path, and the attitude adjustment mechanism to maintain the adjusted attitude to ensure that the photovoltaic module is subjected to uniform force during the subsequent handling process; when it moves to the target installation position, the module is released smoothly according to the normal installation process.

[0154] If the theoretical total adsorption force is less than the safety redundancy threshold, the PLC immediately generates an emergency stop and alarm signal, issues a warning through the industrial control computer 27, and sends an emergency stop command to the external motion system to initiate the emergency safety placement process. This process controls the external motion system to place the photovoltaic module stably in the preset safe position to prevent the module from falling off and being damaged.

[0155] The above solution, by adding a fault adaptation step during the handling process, achieves real-time monitoring, accurate identification, and adaptive handling of faults in the vacuum adsorption system, significantly improving the reliability and safety of the equipment under fault conditions. Even if some vacuum adsorption subsystems fail, the stable handling of photovoltaic modules can still be ensured through attitude readjustment, minimizing the risk of module detachment. By calculating the new force balance center point and center of gravity projection point and performing precise attitude readjustment, the solution ensures that the photovoltaic modules are subjected to uniform force under the adsorption of the effective subsystems, avoiding damage such as module deformation and cracks caused by uneven force, and further ensuring the integrity of the photovoltaic modules.

[0156] The fault-adaptive process is fully automated by the PLC control system, requiring no manual intervention. While ensuring operational safety, it minimizes the impact of faults on paving operations, reduces downtime, and enhances the equipment's continuous working capability. Attitude readjustment relies on a high-precision servo motor in the attitude adjustment mechanism, achieving a positioning accuracy of ±0.02°. This ensures precise alignment between the center of gravity projection point and the new force balance center point, with a tolerance of less than 0.1mm, further improving handling stability under fault conditions. The emergency safety placement process provides reliable emergency protection for extreme fault situations with insufficient adsorption force, fundamentally preventing photovoltaic modules from falling off and being damaged due to insufficient adsorption force, significantly reducing economic losses. This fault-adaptive design, combined with the redundant design of the vacuum adsorption system and the high-precision adjustment of dual nine-axis IMU positioning, greatly enhances the fault resistance and environmental adaptability of the entire intelligent end effector, making it better suited to the complex and high-intensity outdoor photovoltaic paving operations.

[0157] In some embodiments, there are multiple intelligent end effectors, and the multiple intelligent end effectors constitute a collaborative paving system. The PLC control system of one intelligent end effector is the master control unit, and the PLC control systems of the other intelligent end effectors are slave control units. like Figure 9 As shown, the paving method further includes: S901: The main control unit assigns a local area to each of the participating end-effectors to adsorb based on the size, shape and structural strength information of the photovoltaic module to be transported, and generates area calibration information containing each local area and sends it to the corresponding end-effector. The area calibration information includes the coordinates of the area boundary or the coordinates of the feature points. S902: Each end effector moves its IMU module above the assigned local area according to the received area calibration information; each end effector independently collects the first attitude data segment of the photovoltaic module corresponding to its assigned local area, as well as its own second attitude data, through its own dual nine-axis IMU positioning system; the PLC control system of each end effector uploads the collected first attitude data segment and second attitude data to the main control unit in real time through the communication network; like Figure 10 As shown, after receiving the data uploaded by all end-user devices, the main control unit performs the following operations: S1001: Based on a unified system clock and spatial coordinate system, timestamp synchronization and coordinate transformation are performed on the first attitude data segments uploaded by all end-capsule devices, and all first attitude data segments are merged into global first attitude data that characterizes the overall spatial attitude of the photovoltaic module. S1002: For each end effector, calculate the attitude deviation between the second attitude data of the end effector itself and the projection of the global first attitude data onto the local area allocated to the end effector, as the individual target adjustment deviation of the end effector; at the same time, calculate the relative pose relationship between all end effectors and evaluate whether it meets the preset cooperative motion constraint conditions. S1003: Based on the individual target adjustment deviations of all end effectors and the cooperative motion constraints, the main control unit plans a set of cooperative motion trajectories that enable all end effectors to synchronously and smoothly approach the overall attitude of the photovoltaic module through kinematic calculations; according to the cooperative motion trajectory, a synchronous control command sequence is generated for the pitch, roll, and yaw servo motors in the attitude adjustment mechanism of each end effector. S1004: The main control unit simultaneously sends the generated synchronization control command sequence to the PLC control system of all end effectors; after receiving the command, the PLC control system of each end effector drives its own attitude adjustment mechanism to perform the action according to the received command; during the adjustment process, each end effector continuously collects and feeds back real-time attitude data to the main control unit, and the main control unit performs closed-loop monitoring until it is determined that the individual target adjustment deviation of all end effectors is less than the corresponding preset cooperative deviation threshold and meets the cooperative motion constraint condition. At this time, it is confirmed that the global attitude alignment state has been reached. S1005: After confirming that the global attitude alignment state has been achieved, the main control unit simultaneously sends an adsorption start command to the PLC control system of all end effectors; after receiving the adsorption start command, the PLC control system of each end effector synchronously controls its respective vacuum adsorption system to start, completing the overall coordinated adsorption of the photovoltaic module.

[0158] In this embodiment, the collaborative installation system refers to a photovoltaic module installation system composed of multiple intelligent end-capsule devices. It is suitable for the installation of large-size, heavy photovoltaic modules (such as bifacial double-glass modules and BIPV building photovoltaic modules). Through the collaborative adsorption and synchronous adjustment of multiple end-capsule devices, the stable handling and precise placement of heavy modules can be achieved.

[0159] The master control unit refers to the PLC control system of a designated intelligent end effector in the collaborative paving system. As the core control center of the entire system, it is responsible for issuing work instructions, data fusion, motion planning, and collaborative monitoring. The PLC control systems of the other end effectors are slave control units, which receive instructions from the master control unit and execute corresponding operations.

[0160] The local area refers to the area on the surface of the photovoltaic module that the main control unit allocates to each participating end effector and is responsible for adsorption. It is determined by the size, shape and structural strength of the photovoltaic module. The local areas are interconnected and do not overlap, together covering the entire surface of the photovoltaic module.

[0161] Region calibration information refers to the location information of the assigned local region generated by the master control unit for each end effector, including the coordinates of the region boundary or feature points. The slave control unit adjusts the position of the end effector based on this information to ensure accurate adsorption of the corresponding region.

[0162] The first attitude data segment refers to the attitude data of the photovoltaic module corresponding to the allocated local area collected by the photovoltaic panel IMU module of each end-capture device. It only reflects the local attitude state of the photovoltaic module and needs to be fused into global attitude data by the main control unit.

[0163] The system clock and spatial coordinate system refer to the clock and spatial coordinate system preset by the main control unit and unified by the entire collaborative paving system. This ensures that the attitude data of each end effector is synchronized in time and space, avoiding fusion errors and adjustment deviations caused by data asynchrony.

[0164] Individual target adjustment deviation refers to the attitude deviation between the projection of the second attitude data of each end effector and the global first attitude data in its assigned local area, calculated by the master control unit for each end effector. It is the specific basis for attitude adjustment of each end effector.

[0165] Cooperative motion constraints refer to the relative pose restrictions between each end effector preset by the main control unit to ensure that multiple end effectors remain synchronized and stable during attitude adjustment and handling, without mutual interference, thus ensuring the stability of cooperative operation.

[0166] Cooperative motion trajectory refers to the motion path planned by the master control unit through kinematic calculations, in which all end effectors synchronously approach attitude alignment, ensuring that the attitude adjustment actions of each end effector are synchronized and coordinated, without any sequential deviation.

[0167] The global attitude alignment state refers to the state in which the individual target adjustment deviation of all end effectors in the collaborative paving system is less than the corresponding preset collaborative deviation threshold, and the relative pose relationship between each end effector meets the collaborative motion constraint conditions. At this time, the overall attitude of all end effectors and photovoltaic modules is accurately aligned, and collaborative adsorption can be performed.

[0168] This embodiment provides a multi-endpoint pickup collaborative installation method, suitable for the installation of large-size, heavy-duty photovoltaic modules. The core principle is unified scheduling by the main control unit + zoned adsorption of multiple endpoint pickups + global positioning through data fusion + synchronous adjustment and collaborative alignment + precise placement through collaborative adsorption. The horizontal aluminum profile 11, vertical aluminum profile 12, and other structural components of each endpoint pickup remain independent and stable, and collaborative linkage is achieved through the main control unit. The specific implementation steps are as follows: In step S901, based on the size, shape, and structural strength of the photovoltaic modules to be transported, a collaborative installation system consisting of multiple intelligent end-effectors is constructed. One of the end-effectors is designated as the master control unit, and the others are slave control units. The master control unit presets a unified system clock, spatial coordinate system, collaborative motion constraints, and preset collaborative deviation threshold through the industrial control computer, and simultaneously inputs the basic parameters of the photovoltaic modules to be installed.

[0169] Based on the basic parameters of the photovoltaic modules to be installed, the main control unit assigns a local area to each participating end effector to be responsible for adsorption, ensuring that each area is interconnected, non-overlapping, and adapted to the structural strength of the module. The main control unit generates area calibration information for each end effector, including the area boundary coordinates or feature point coordinates, and sends this information to the corresponding slave control unit through the communication network, while simultaneously issuing a work start command.

[0170] In step S902, after receiving the area calibration information, the slave control unit of each end effector (including the end effector belonging to the main control unit) controls its own external motion system to move the end effector body to directly above the assigned local area to complete the coarse positioning of the area. Subsequently, each end effector starts its own dual nine-axis IMU positioning system, independently collects the first attitude data segment of the photovoltaic module corresponding to its assigned local area, as well as its own second attitude data, and uploads the collected data to the main control unit in real time through the communication network.

[0171] In step S1001, after the main control unit receives the attitude data uploaded by all end sensors, it timestamps all the data based on a unified system clock to eliminate time deviation. At the same time, it performs coordinate transformation on all first attitude data segments based on a unified spatial coordinate system, and merges the scattered local attitude data into global first attitude data that characterizes the overall spatial attitude of the photovoltaic module, thereby achieving accurate positioning of the photovoltaic module as a whole.

[0172] In step S1002, the main control unit calculates the attitude deviation between the projection of its own second attitude data and the global first attitude data onto the local area allocated to the end effector for each end effector, as the individual target adjustment deviation of the end effector; at the same time, the main control unit calculates the relative pose relationship between all end effectors and evaluates whether it meets the preset cooperative motion constraints to ensure that the motion of each end effector does not interfere with each other.

[0173] In step S1003, the main control unit, based on the individual target adjustment deviations and cooperative motion constraints of all end effectors, plans a set of cooperative motion trajectories through kinematic calculations that enable all end effectors to synchronously and smoothly approach the overall attitude of the photovoltaic module. According to the trajectory, the pitch, roll, and yaw servo motors in the attitude adjustment mechanisms of the main control unit and each slave control unit generate synchronous control command sequences, and simultaneously send the command sequences to the PLC control system of all end effectors through the communication network.

[0174] In step S1004, after receiving the synchronous control command sequence, the PLC control system of each end effector synchronously drives its own pitch adjustment servo motor 31, roll adjustment servo motor 32, and yaw adjustment servo motor 33 to perform actions according to the commands, and adjusts the attitude of the end effector body through linkage with the fixed connection plate 15. During the adjustment process, each end effector continuously collects and feeds back real-time attitude data to the main control unit. The main control unit performs closed-loop monitoring of the entire system until it is determined that the individual target adjustment deviation of all end effectors is less than the corresponding preset cooperative deviation threshold, and the relative pose relationship between each end effector meets the cooperative motion constraint conditions. At this time, it is confirmed that the global attitude alignment state has been achieved.

[0175] In step S1005, after the main control unit confirms that the global attitude alignment state has been achieved, it simultaneously sends an adsorption start command to the PLC control system of all end effectors. After receiving the command, the PLC control system of each end effector synchronously controls its respective vacuum adsorption system to start, completing the coordinated adsorption of each local area of ​​the photovoltaic module, ensuring that the adsorption force acts synchronously and uniformly on the surface of the photovoltaic module. After the adsorption stabilizes, the main control unit sends a synchronous transport command to the external motion system of all end effectors. Each external motion system drives the end effector body to move synchronously, and the attitude adjustment mechanism maintains the global alignment attitude, ensuring that the heavy photovoltaic module is stable and free from deformation during the transport process.

[0176] In step S1006, after all end effectors drive the photovoltaic modules to the target installation position synchronously, the main control unit sends a fine-tuning instruction, and each end effector performs a fine-tuning adjustment to ensure that the photovoltaic modules are fully aligned with the installation surface. Subsequently, the main control unit sends a release instruction to all end effectors at the same time, and each end effector synchronously controls its own vacuum adsorption system to release the photovoltaic modules, completing the collaborative installation of heavy photovoltaic modules. After the release is completed, each end effector returns to its initial position under the scheduling of the main control unit, ready for the next collaborative installation operation.

[0177] The multi-endpoint pickup collaborative installation method described above is suitable for the installation of large-size, heavy photovoltaic modules. By using multi-endpoint pickups for zoned adsorption and synchronous adjustment, it solves the problems of insufficient adsorption force, easy deformation, and unstable handling of heavy modules by single-endpoint pickups, thus achieving stable handling and precise placement of heavy photovoltaic modules. Through unified scheduling, data fusion, and collaborative motion planning by the main control unit, it ensures that the attitude data, adjustment actions, and adsorption and release of all pickups are synchronized, avoiding motion interference and uneven force distribution in multi-endpoint pickup collaborative operations, ensuring the integrity of photovoltaic modules, and significantly reducing the risk of module deformation and detachment.

[0178] Data fusion is achieved based on a unified system clock and spatial coordinate system, fusing local attitude data fragments into global first attitude data, realizing high-precision positioning of the entire photovoltaic module. Combined with the dual nine-axis IMU positioning of each end effector, the global attitude alignment accuracy is greatly improved, adapting to the high-precision installation requirements of heavy modules. The collaborative installation system is flexible in its construction, and the number of end effectors can be adjusted according to the size and weight of the photovoltaic module, adapting to heavy photovoltaic modules of different specifications, with strong compatibility and scalability.

[0179] The entire collaborative installation process is automatically scheduled by the main control unit, and all end effectors execute instructions synchronously without manual intervention, which greatly improves the installation efficiency of heavy photovoltaic modules and reduces the workload of operators. The core structure of each end effector (horizontal aluminum profile 11, vertical aluminum profile 12, corner bracket 13, etc.) remains independent and stable, and there is no structural interference during collaborative operation. The equipment has good reliability and durability, and meets the needs of automated installation of large-scale outdoor heavy photovoltaic modules.

[0180] Finally, it should be noted that although the above embodiments have been described in the description and drawings of this invention, this should not limit the scope of patent protection of this invention. Any technical solutions that are based on the essential concept of this invention, utilize the content described in the description and drawings of this invention to make equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this invention.

Claims

1. A photovoltaic module installation intelligent end-feeder based on dual nine-axis IMUs, characterized in that, include: End effector body; The dual nine-axis IMU positioning system includes a photovoltaic panel IMU module and an end effector IMU module. The photovoltaic panel IMU module is fixedly installed on the photovoltaic module, and the end effector IMU module is fixed at the center of the end effector body. When the end effector moves to the preset gripping position directly above the photovoltaic module, the sensing coordinate systems of the photovoltaic panel IMU module and the end effector IMU module are set to be parallel to each other and axially aligned, so as to collect the first attitude data of the photovoltaic module and the second attitude data of the end effector based on the same spatial reference in real time. The attitude adjustment mechanism includes a pitch adjustment servo motor, a roll adjustment servo motor, and a yaw adjustment servo motor. The pitch adjustment servo motor, roll adjustment servo motor, and yaw adjustment servo motor are connected to the end effector body through a transmission mechanism and are used to adjust the spatial attitude of the end effector body according to the attitude deviation calculated by the PLC control system. A vacuum adsorption system, installed on the end effector body, is used to adsorb the photovoltaic module in an orientation-aligned state. The PLC control system, electrically connected to the dual nine-axis IMU positioning system, attitude adjustment mechanism, and vacuum adsorption system, is used to execute the following steps: S1: Calculate the attitude deviation between the photovoltaic module and the end effector based on the first attitude data and the second attitude data, and control the attitude adjustment mechanism to adjust the attitude according to the attitude deviation; when it is determined that the current attitude deviation between the photovoltaic module and the end effector is less than the preset attitude deviation threshold, it is determined that the attitude alignment state has been reached. S2: In the posture alignment state, control the vacuum adsorption system to start so as to adsorb the photovoltaic module.

2. The photovoltaic module installation intelligent end-feeder based on dual nine-axis IMU as described in claim 1, characterized in that, The attitude deviation includes roll angle deviation Δ Pitch angle deviation Δ and yaw angle deviation Δ ; Step S1 includes: S11: Calculate the roll angle deviation Δ between the first attitude data and the second attitude data. Pitch angle deviation Δ and yaw angle deviation Δ The roll angle deviation Δ Pitch angle deviation Δ and yaw angle deviation Δ Each deviation is compared with its corresponding preset attitude deviation threshold. If the absolute value of any deviation exceeds its corresponding preset attitude deviation threshold, a corresponding control command is generated to drive the corresponding servo motor in the attitude adjustment mechanism to adjust the spatial attitude of the end effector body and recalculate the attitude deviation between the photovoltaic module and the end effector. S12: Repeat step S11 until the recalculated roll angle deviation Δ is obtained. Pitch angle deviation Δ If the absolute values ​​of the yaw angle deviation Δ are both less than their corresponding preset deviation thresholds, it is determined that the end effector body and the photovoltaic module have reached an attitude alignment state.

3. The photovoltaic module installation intelligent end-feeder based on dual nine-axis IMU as described in claim 2, characterized in that, The PLC control system executes a graded attitude adjustment strategy in step S11, specifically including: The roll adjustment servo motor and the pitch adjustment servo motor are driven preferentially to eliminate the roll angle deviation Δ. and the pitch angle deviation Δ ; in the roll angle deviation Δ and the pitch angle deviation Δ Once all deviations are less than their corresponding preset deviation thresholds, the yaw adjustment servo motor is then driven to eliminate the yaw angle deviation Δ. ; The PLC control system also includes: The data filtering module is used to filter the first attitude data and the second attitude data acquired by the dual nine-axis IMU positioning system; the filtering process includes a combination algorithm of Kalman filtering and moving average filtering to eliminate sensor noise and environmental interference.

4. The photovoltaic module installation intelligent end-feeder based on dual nine-axis IMU as described in claim 1, characterized in that, The vacuum adsorption system includes at least two vacuum adsorption subsystems that are independent of each other in terms of gas path and circuit; Each of the aforementioned vacuum adsorption subsystems includes: The suction cup is mounted on the bottom of the end effector body via a buffer rod assembly, and is used to contact the surface of the photovoltaic module and form a sealed cavity; A vacuum generator, connected to the suction cup via an air passage, is used to generate and maintain the negative pressure required for adsorption within the sealed cavity. A vacuum sensor is installed on the gas pipeline connecting the suction cup and the vacuum generator or integrated into the vacuum generator, and is used to monitor the vacuum level in the sealed cavity in real time. A control valve is installed on the gas pipeline and controlled by the PLC control system, used to switch the connection state between the suction cup cavity and the vacuum generator, or between the suction cup cavity and the atmosphere; The suction cups of at least two sets of vacuum adsorption subsystems are distributed at the bottom of the end effector body to jointly cover and stably adsorb the photovoltaic module; In step S2, the PLC control system is configured to: after confirming that the attitude alignment state has been reached, send instructions to the control valves of all the vacuum adsorption subsystems to connect the corresponding suction cups and vacuum generators, and simultaneously or in a preset sequence start the vacuum generators of each subsystem to adsorb the photovoltaic modules.

5. The photovoltaic module installation intelligent end-feeder based on dual nine-axis IMU as described in claim 4, characterized in that, In step S2, the PLC control system is further configured to: Vacuum level data is read in real time by vacuum level sensors of each vacuum adsorption subsystem, and the vacuum level data is compared with a preset safe adsorption threshold. If the vacuum level of any vacuum adsorption subsystem fails to reach or remains below the safe adsorption threshold within a preset time, the vacuum adsorption subsystem is determined to be in a fault state. At this time, the PLC control system issues a warning message containing the identifier of the vacuum adsorption subsystem in a fault state, and maintains the vacuum generators of the remaining vacuum adsorption subsystems with normal vacuum levels to continue to work and the current state of their control valves. Based on the number and layout of the remaining normal vacuum adsorption subsystems, the overall adsorption force of the vacuum adsorption system is evaluated to see if it is still higher than the preset safe redundancy threshold, and a decision is made to continue the handling operation or execute the emergency safe placement procedure accordingly.

6. The photovoltaic module installation intelligent end-feeder based on dual nine-axis IMU as described in claim 4, characterized in that, The end effector body is provided with a buffer rod assembly connected to the suction cup, and the buffer rod assembly has a built-in travel sensing switch; In step S2, the PLC control system is further configured to: after determining that the posture alignment state has been reached, control the end effector body to press down at a preset speed until the travel sensing switch is triggered, confirm that the suction cup is attached to the surface of the photovoltaic module, and then start the vacuum adsorption system.

7. The photovoltaic module installation intelligent end-feeder based on dual nine-axis IMU as described in claim 1, characterized in that, The photovoltaic panel IMU module has a detachable structure, and its outer shell is equipped with a strong magnetic adsorption component, which is adsorbed and fixed to the metal frame of the photovoltaic module; the photovoltaic panel IMU module has a built-in wireless communication module and battery, which are used for wireless data communication with the PLC control system. The end effector also includes: A wireless charging device is installed on the storage station or transfer rack of the photovoltaic module. When the photovoltaic module with the photovoltaic panel IMU module attached is placed on the storage station or transfer rack, the wireless charging device charges the battery of the photovoltaic panel IMU module through electromagnetic induction.

8. A method for installing photovoltaic modules based on dual nine-axis IMUs, characterized in that, The installation method is applicable to the photovoltaic module installation smart end-feeder based on dual nine-axis IMU as described in any one of claims 1-7, and the installation method includes the following steps: Receive instructions from an external motion system or based on a preset path, control the attitude adjustment mechanism to keep the end effector in a ready position, and cooperate with the external motion system to move the end effector to a preset coarse positioning area above the photovoltaic module; The dual nine-axis IMU positioning system collects in real time the first attitude data of the photovoltaic module sensed by the photovoltaic panel IMU module and the second attitude data of the end effector sensed by the end effector IMU module, based on the same spatial reference. Based on the first and second attitude data, the attitude deviation between the photovoltaic module and the end effector is calculated. According to the attitude deviation, the pitch, roll, and yaw servo motors in the attitude adjustment mechanism are controlled to dynamically adjust the spatial attitude of the end effector body. The attitude data acquisition, deviation calculation, and adjustment are repeated until the attitude deviation is determined to be less than a preset attitude deviation threshold, achieving an attitude alignment state. After confirming that the alignment state has been achieved, the vacuum adsorption system is activated to adsorb the photovoltaic module. The attitude adjustment mechanism is controlled to maintain or fine-tune the attitude of the end effector during the transportation process, and works with the external motion system to move the end effector with the adsorbed photovoltaic module to the target installation position; then the vacuum adsorption system is controlled to release, and the installation of the photovoltaic module is completed.

9. The photovoltaic module installation method based on dual nine-axis IMU as described in claim 8, characterized in that, During the transportation process from the start-up of the vacuum adsorption system and its adsorption of photovoltaic modules until the system is released, a fault adaptation step is also included. This fault adaptation step specifically includes: The vacuum sensor built into the vacuum adsorption system monitors and acquires the current vacuum level of each independent vacuum adsorption subsystem in the vacuum adsorption system in real time at a preset sampling frequency. The current vacuum level value of each independent vacuum adsorption subsystem is compared with its corresponding preset failure threshold. If the current vacuum level value of one or more vacuum adsorption subsystems is continuously lower than its preset failure threshold for a preset time, it is determined that the one or more vacuum adsorption subsystems have experienced vacuum failure. All remaining effective vacuum adsorption subsystems are identified, and the theoretical total adsorption force that all effective vacuum adsorption subsystems can provide is calculated. The calculated theoretical total adsorption force is compared with a preset safety redundancy threshold. If the theoretical total adsorption force is greater than the safety redundancy threshold, the system is determined to have the conditions to continue to safely execute the task, and the attitude readjustment sub-step is triggered. Otherwise, an emergency stop and alarm signal are generated. The attitude readjustment sub-step includes: Based on the physical layout of all effective vacuum adsorption subsystems on the end effector body and their respective rated adsorption forces, calculate the new force equilibrium center point of the photovoltaic module under the joint adsorption of the effective vacuum adsorption subsystems. Based on the first attitude data provided by the photovoltaic panel IMU module, the center of gravity position of the photovoltaic module is determined, and the center of gravity position is projected onto the plane where the end effector body is located to obtain the center of gravity projection point; Calculate the positional deviation between the center of gravity projection point and the new force equilibrium center point; based on the positional deviation and combined with the rigid connection model formed by the end effector and the photovoltaic module, calculate the compensation adjustment amount required for the pitch adjustment servo motor, roll adjustment servo motor and yaw adjustment servo motor in the attitude adjustment mechanism. Based on the compensation adjustment amount, control the action of the posture adjustment mechanism to drive the end effector body to perform spatial rotation and translation fine adjustment around its current posture until the center of gravity projection point coincides with the new force balance center point or the deviation is less than an allowable tolerance. After completing the attitude readjustment sub-step, the external motion system and the attitude adjustment mechanism are controlled to continue the subsequent steps of moving the photovoltaic module to the target installation location and releasing it while maintaining the adjusted attitude.

10. The photovoltaic module installation method based on dual nine-axis IMU as described in claim 8, characterized in that, The number of intelligent end-capsule devices is multiple, and the multiple intelligent end-capsule devices constitute a collaborative paving system. The PLC control system of one intelligent end-capsule device is the master control unit, and the PLC control systems of the other intelligent end-capsule devices are slave control units. The paving method also includes: The main control unit assigns a local area to each of the participating end-effectors based on the size, shape, and structural strength information of the photovoltaic module to be transported, and generates area calibration information containing each local area and sends it to the corresponding end-effector. The area calibration information includes the coordinates of the area boundary or the coordinates of the feature points. Each end effector moves its IMU module above the assigned local area based on the received area calibration information; each end effector independently collects the first attitude data segment of the photovoltaic module corresponding to its assigned local area, as well as its own second attitude data, through its own dual nine-axis IMU positioning system; the PLC control system of each end effector uploads the collected first attitude data segment and second attitude data to the main control unit in real time through the communication network; After receiving the data uploaded by all end effectors, the main control unit performs the following operations: Based on a unified system clock and spatial coordinate system, the first attitude data segments uploaded by all end-capsule devices are time-stamped and transformed, and all first attitude data segments are merged into global first attitude data that characterizes the overall spatial attitude of the photovoltaic module. For each end effector, the attitude deviation between the second attitude data of the end effector itself and the projection of the global first attitude data onto the local area allocated to the end effector is calculated as the individual target adjustment deviation of the end effector; at the same time, the relative pose relationship between all end effectors is calculated and its compliance with the preset cooperative motion constraints is evaluated. Based on the individual target adjustment deviations of all end effectors and the cooperative motion constraints, the main control unit plans a set of cooperative motion trajectories through kinematic calculations, which enables all end effectors to synchronously and smoothly approach the overall attitude of the photovoltaic module. According to the cooperative motion trajectory, synchronous control command sequences are generated for the pitch, roll, and yaw servo motors in the attitude adjustment mechanism of each end effector. The main control unit simultaneously sends the generated sequence of synchronous control commands to the PLC control systems of all end effectors. After receiving the commands, the PLC control systems of each end effector drive their own attitude adjustment mechanisms to perform actions according to the received commands. During the adjustment process, each end effector continuously collects and feeds back real-time attitude data to the main control unit. The main control unit performs closed-loop monitoring until it is determined that the individual target adjustment deviation of all end effectors is less than the corresponding preset cooperative deviation threshold and meets the cooperative motion constraint conditions. At this point, it is confirmed that the global attitude alignment state has been achieved. After confirming that the global attitude alignment state has been achieved, the main control unit simultaneously sends an adsorption start command to the PLC control system of all end effectors; upon receiving the adsorption start command, the PLC control system of each end effector synchronously controls its respective vacuum adsorption system to start, thereby completing the coordinated adsorption of the entire photovoltaic module.

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