Photovoltaic module rack structure with four-way clamping protection function

Abstract

The present application belongs to the technical field of photovoltaic module storage rack, and particularly relates to a photovoltaic module rack structure with four-way clamping and protection function, which comprises a side frame connected with a mounting robot main body through a rotary connecting piece, and a bottom frame arranged on the lower side of the side frame. The present application disperses and transfers the vertical pressure between the photovoltaic modules to the rest plate, weakens the static stacking pressure between the photovoltaic modules of each layer, then the right side of the uppermost photovoltaic module slides into the stepped groove to form the preliminary limiting and pressure bearing in up-down staggered mode, finally the uppermost photovoltaic module is locked from the front and rear sides, the remaining photovoltaic modules are moved downward by the back-off of the supporting table, the physical separation between the uppermost photovoltaic module and other photovoltaic modules of the lower layer is realized, the three cooperate to greatly reduce the influence of the impact force generated when the uppermost photovoltaic module is grabbed on the lower photovoltaic modules, and the interlayer adhesion is forcedly overcome, and the locking pressure of the triangular limiting plate on the uppermost photovoltaic module is significantly reduced due to the cooperation of the inclination and the stepped groove, so that the damage of the module is avoided.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic module storage rack technology, and particularly relates to a photovoltaic module storage rack structure with four-way clamping protection function. Background Technology

[0002] Currently, automated photovoltaic module installation robots commonly employ L-shaped inclined storage racks (horizontal bottom surface + inclined back plate, tilted forward 10°–15°). This structure relies on the inclined state to disperse the static lamination pressure of the upper photovoltaic modules onto the lower layer to the back plate, reducing the risk of microcracks caused by long-term stacking. Simultaneously, the L-shaped opening facilitates manual loading and robotic arm gripping, making it the mainstream solution in the industry. Furthermore, existing gripping robots are generally equipped with compliant technologies such as spring buffers and air flotation, effectively reducing the impact between the suction cups and the module surface.

[0003] However, traditional L-shaped inclined storage racks still have two key drawbacks in practical engineering applications, which existing robotic arm buffers cannot compensate for: Firstly, there is the issue of impact transmission from the gripping mechanism to the stacking interface. During on-site construction, 20-30 photovoltaic modules are typically stacked in the storage rack. Although the robotic arm absorbs some of the downward pressure energy, the residual impact force is still transmitted sequentially from the topmost photovoltaic module to the layers below. Because the modules are in rigid contact (without a buffer layer), this transmitted impact can cause microcracks or hidden cracks in the second and third layers of photovoltaic modules. This impact accumulates layer by layer as photovoltaic modules are continuously gripped, increasing the risk of microcracks in the bottommost photovoltaic module. Furthermore, with the trend of photovoltaic modules becoming thinner (e.g., 1.6mm semi-tempered glass), this cumulative impact damage has become a significant contributing factor to the increasing breakage rate, and current technology lacks effective means to prevent this.

[0004] Secondly, there is the coupling problem between interlayer adhesion and pose instability under field conditions. Due to electrostatic adsorption, EVA surface adhesion, or vacuum effects, interlayer adhesion often occurs between upper and lower modules. When the robotic arm grasps the top photovoltaic module, even if the adhesion force is insufficient to lift the lower photovoltaic modules, it will still cause slight translation of the lower photovoltaic modules, disrupting their original stacking posture. More seriously, the L-shaped storage rack has a three-sided open structure with weak lateral constraints; when operating on uneven ground in the field (slopes, uneven roads, soft soil), the vibration caused by vehicle movement, the inertial forces of acceleration and deceleration, and the shift in the center of gravity caused by layer-by-layer material handling will further exacerbate the slippage of the remaining modules. This pose instability causes the robotic arm's next grasping point to deviate from the ideal position, increasing the difficulty of grasping and the risk of cracks appearing on the surface of the photovoltaic modules.

[0005] Therefore, there is an urgent need for a photovoltaic module rack that can achieve dynamic impact isolation, anti-adhesion, and self-stabilizing position at the storage rack level, so as to systematically improve the installation safety and accuracy of photovoltaic modules during field mobile operations. Summary of the Invention

[0006] To address the aforementioned problems, this invention provides a photovoltaic module rack structure with four-way clamping protection function, which solves the problems mentioned in the background art.

[0007] To achieve the above objectives, this application provides the following technical solution: The present invention provides a photovoltaic module rack structure with four-way clamping protection function, including a side frame connected to the main body of an installation robot via a rotating connector. A bottom frame is provided below the side frame, and a support platform capable of sliding along the side frame is provided on the bottom frame. Anti-deviation frames are also symmetrically distributed front and rear on the bottom frame. The side frame includes a side frame fixedly connected to the bottom frame. A backing plate is connected to the side frame via a movable component. A conveyor belt assembly is provided on the backing plate, and a stepped groove is provided on the backing plate near the upper end of the conveyor belt assembly. The anti-deviation frame includes a column fixedly connected to the bottom frame. Two limiting cylinders are provided on the column, distributed vertically. An H-shaped limiting plate is fixedly connected to the telescopic end of the lower limiting cylinder. Conveyor belt assemblies are provided on both vertical sections of the H-shaped limiting plate, and a flipping limiting component is provided above each conveyor belt assembly on the H-shaped limiting plate. A triangular limiting plate is fixedly connected to the telescopic end of the upper limiting cylinder, and one side of the triangular limiting plate abuts against the side of the uppermost photovoltaic module. The conveyor belt assembly one and conveyor belt assembly two are used to limit and guide the three sides of the photovoltaic module other than the left side. The flipping limiting component is used to flip and limit the upper side of the photovoltaic module. The stepped groove is used to accommodate the right side of the top photovoltaic module when the support platform lifts the stacked photovoltaic modules upward, so that the top photovoltaic module is misaligned with other photovoltaic modules. When the remaining photovoltaic modules move downward, the triangular limiting plate presses the top photovoltaic module to achieve active isolation between the remaining photovoltaic modules and the top photovoltaic module.

[0008] According to an advantageous embodiment, the rotating connector includes an outer connecting plate rotatably connected to the side frame, the outer connecting plate being fixedly connected to the installation robot, and two symmetrically distributed tilting cylinders hinged between the outer connecting plate and the side frame.

[0009] According to an advantageous embodiment, the moving assembly includes four first guide rods fixedly connected to the backing plate, and a drive motor is fixedly connected to the side frame via a bracket. The output shaft of the drive motor is fixedly connected to an adjusting screw, and one end of the adjusting screw is threadedly connected to a connecting sleeve, which is fixedly connected to the backing plate.

[0010] According to an advantageous embodiment, the depth of the stepped groove relative to the surface of the backing plate used to support the photovoltaic module is 2-3 cm, and the inner wall of the stepped groove is covered with a cushioning pad with a thickness of 0.5-1 cm.

[0011] According to an advantageous embodiment, a lifting cylinder is provided on the bottom frame, and the telescopic end of the lifting cylinder is fixedly connected to the lower side of the support platform.

[0012] According to an advantageous embodiment, two second guide rods are fixedly provided on both the front and rear sides of the bottom frame, and two extended guide blocks are fixedly provided on both the front and rear sides of the support platform, with the extended guide blocks slidably inserted into the corresponding second guide rods.

[0013] According to an advantageous embodiment, the upper ends of the two vertical sections of the H-shaped limiting plate are provided with sliding holes. The flip-limiting component includes two third guide rods fixedly disposed in the sliding holes. A guide slider is slidably disposed between the two third guide rods. The flip-limiting plate is fixedly disposed on the guide slider. The surfaces of the two third guide rods are each sleeved with a return spring. The two ends of the return spring are fixedly connected to one side of the guide slider and the lower inner wall of the sliding hole, respectively.

[0014] According to an advantageous embodiment, the bottom frame and the side frame are both fixedly provided with reinforcing plates on the same side, front and back.

[0015] According to an advantageous embodiment, a through hole is provided on the back plate below the stepped groove, and the conveyor belt assembly includes a plurality of guide rollers that are rotatably and uniformly arranged along the length of the through hole. The plurality of guide rollers are together fitted with the same synchronous conveyor belt, and the bearing surface of the synchronous conveyor belt protrudes from the side surface of the back plate near the photovoltaic module.

[0016] According to an advantageous embodiment, the H-shaped limiting plate has through holes 2 on both vertical sections, and the conveyor belt assembly 2 includes a plurality of guide rollers 2 that are evenly arranged and rotated along the length direction of the through holes 2. The plurality of guide rollers 2 are together fitted with the same synchronous conveyor belt 2, and the bearing surface of the synchronous conveyor belt 2 protrudes from the surface of the H-shaped limiting plate on the side near the photovoltaic module.

[0017] Compared with the prior art, the photovoltaic module rack structure with four-way clamping protection function provided by the embodiments of the present invention has the following beneficial effects: 1. In this invention, the photovoltaic modules are tilted by the rack to distribute and transfer the vertical pressure between the photovoltaic modules to the backing plate, thereby reducing the static stacking pressure between the photovoltaic modules of each layer. Then, the right side of the top photovoltaic module slides into the stepped groove, forming an initial limit and pressure bearing for vertical misalignment. Finally, the top photovoltaic module is locked from the front and rear sides, and the support platform retracts to move the remaining photovoltaic modules down, realizing the physical separation between the top photovoltaic module and other photovoltaic modules below. The three work together to greatly reduce the impact of the impact force generated when the top photovoltaic module is grabbed on the photovoltaic modules below, while forcibly overcoming interlayer adhesion. Moreover, the locking pressure of the triangular limiting plate on the top photovoltaic module is significantly reduced due to the synergy of tilting and stepped groove, avoiding damage to the module.

[0018] 2. In this invention, the photovoltaic module is constrained in four directions from the right side, front and back and top by the back plate, H-shaped limiting plate and flipping limiting component. Combined with the low friction guidance of conveyor belt component one and conveyor belt component two, the stacked module is stable in the tilted state. Even if there is bump in the field, acceleration or deceleration or center of gravity shift, it is not easy to slip, ensuring the accuracy of the robot arm's gripping point. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall external three-dimensional structure of the present invention.

[0020] Figure 2 This is a schematic diagram of the external three-dimensional structure of the present invention in the material storage state; Figure 3 This is a schematic diagram showing the state of the present invention when working in conjunction with an external photovoltaic installation robot; Figure 4 This is a schematic diagram of the external front structure of the backing plate in this invention; Figure 5 This is a schematic diagram of the external back structure of the backing plate in this invention; Figure 6 This is a schematic diagram of the external three-dimensional structure of the anti-deviation frame in this invention; Figure 7 This is a partial three-dimensional structural diagram of the H-shaped limiting plate in this invention.

[0021] The attached figures are labeled as follows: 1. Rotating connector; 11. External connecting plate; 12. Tilting cylinder; 2. Side frame; 21. Side frame; 22. Moving component; 221. First guide rod; 222. Drive motor; 223. Adjusting screw; 224. Connecting sleeve; 23. Backing plate; 24. Conveyor belt assembly one; 241. Synchronous conveyor belt one; 25. Stepped groove; 3. Bottom frame; 4. Support platform; 5. Anti-deviation frame; 51. Column; 52. Limiting cylinder; 53. H-shaped limiting plate; 54. Conveyor belt assembly two; 541. Synchronous conveyor belt two; 55. Tilting limiting component; 551. Third guide rod; 552. Guide slider; 553. Tilting limiting plate; 554. Return spring; 56. Triangular limiting plate; 6. Lifting cylinder; 7. Second guide rod; 8. Extended guide block; 9. Reinforcing plate. Detailed Implementation

[0022] The following is in conjunction with the appendix Figure 1 -Appendix Figure 7 This application will be described in further detail.

[0023] Please refer to the following: Figure 1A photovoltaic module rack structure with four-way clamping protection function includes a side frame 2 connected to the main body of an installation robot via a rotating connector 1, a bottom frame 3 provided under the side frame 2, a support platform 4 that can slide along the side frame 2 provided on the bottom frame 3, and anti-deviation frames 5 symmetrically distributed front and rear on the bottom frame 3.

[0024] During actual operation, when loading materials, the support platform 4 is kept horizontal, the photovoltaic modules are stacked on the support platform 4, and then the side frame 2 contacts the right side of the photovoltaic modules. At the same time, the anti-deviation frame 5 at the front and rear positions limits the photovoltaic modules in the front-to-back direction and above. Then, the entire material rack in this state drives the photovoltaic modules to tilt by rotating the connecting piece 1. When the photovoltaic installation robot grabs the photovoltaic modules, the support platform 4 pushes all the photovoltaic modules to move along the guide path formed by the back plate 23 and the two anti-deviation frames 5, so that after the top photovoltaic module reaches the predetermined position, the top photovoltaic module can be controlled to separate from other photovoltaic modules.

[0025] See Figure 1 and Figure 2 The rotating connector 1 includes an outer connecting plate 11 rotatably connected to the side frame 21. The outer connecting plate 11 is fixedly connected to the installation robot. Two symmetrically distributed tilting cylinders 12 are hinged between the outer connecting plate 11 and the side frame 21. By retracting the two tilting cylinders 12, the side frame 21 rotates relative to the outer connecting plate 11, thereby tilting the photovoltaic modules on the entire rack. Furthermore, the anti-deviation frame 5 and the side frame 2 simultaneously limit the photovoltaic modules on the front, back, right, and top of the entire rack, allowing the photovoltaic modules to tilt from horizontal to vertical as much as possible, thereby significantly reducing the pressure of the upper photovoltaic modules on the lower photovoltaic modules.

[0026] See Figure 1 A lifting cylinder 6 is installed on the bottom frame 3, and the telescopic end of the lifting cylinder 6 is fixedly connected to the lower side of the support platform 4. Two second guide rods 7 are fixedly installed on the front and rear sides of the bottom frame 3, and two extended guide blocks 8 are fixedly installed on the front and rear sides of the support platform 4. The extended guide blocks 8 are slidably inserted into the corresponding second guide rods 7.

[0027] The support platform 4 is driven by the lifting cylinder 6 and, under the guidance and support of the second guide rod 7, pushes all photovoltaic modules to move along the back plate 23.

[0028] See Figures 1-3The side frame 2 includes a side frame 21 fixedly connected to the bottom frame 3. Reinforcing plates 9 are fixedly installed on the same side, both front and rear, of the bottom frame 3 and the side frame 21 to improve the stability of the entire rack during rotation. A backing plate 23 is connected to the side frame 21 via a moving component 22. A conveyor belt assembly 24 is mounted on the backing plate 23, and a stepped groove 25 is formed on the backing plate 23 near the upper end of the conveyor belt assembly 24. The depth of the stepped groove 25 relative to the surface of the backing plate 23 used to support the photovoltaic module is 2 cm, and a 0.5 cm thick buffer pad is laid on the inner wall of the stepped groove 25. This buffer pad is preferably made of polyurethane elastomer or silicone rubber to reduce the impact when the right side of the uppermost photovoltaic module slides into the stepped groove 25.

[0029] See Figures 1-3 as well as Figure 6 The anti-deviation frame 5 includes a column 51 fixedly connected to the bottom frame 3. Two limiting cylinders 52 are provided on the column 51, which are distributed vertically. The telescopic end of the lower limiting cylinder 52 is fixedly connected to an H-shaped limiting plate 53. Conveyor belt assembly 54 is provided on both vertical sections of the H-shaped limiting plate 53, and a flipping limiting component 55 is provided on the H-shaped limiting plate 53 above each conveyor belt assembly 54. The telescopic end of the upper limiting cylinder 52 is fixedly connected to a triangular limiting plate 56, and one side of the triangular limiting plate 56 abuts against the side of the uppermost photovoltaic module.

[0030] In specific work, During loading: the photovoltaic modules are stacked on the support platform 4. Then, the moving component 22 drives the support and limiting surface of the conveyor belt component 24 to contact the right side of the photovoltaic module. The front and rear conveyor belt components 54 approach and contact the front and rear sides of the photovoltaic module. Then, the support platform 4 moves vertically upward until the upper side of the front and rear edges of the photovoltaic module contacts the limiting surface of the corresponding flipping limiting component 55 and stops, so that the front, rear, right and top sides of the photovoltaic module are limited. Then, the material rack is rotated to make the photovoltaic module tilt.

[0031] This allows a portion of the photovoltaic module's weight to act on the support plate 23, thereby reducing the vertical pressure between the photovoltaic modules. When the photovoltaic installation robot moves on rough ground, it provides a stable guiding and limiting function, restricting the photovoltaic module's deviation and making it easier for the photovoltaic installation robot to grasp the photovoltaic module.

[0032] When picking up photovoltaic modules: the support platform 4 will push the top photovoltaic module to move along the guide path formed by the first conveyor belt assembly 24 and the second conveyor belt assembly 54 until the right side of the top photovoltaic module completely crosses the bearing surface of the first conveyor belt assembly 24 and is completely aligned with the stepped groove 25 on the back plate 23. At this time, the top photovoltaic module will slide slightly relative to the other photovoltaic modules, so that the right side of the top photovoltaic module enters the stepped groove 25 and is misaligned with the other photovoltaic modules. Then, driven by their respective limiting cylinders 52, the front and rear triangular limiting plates 56 clamp the front and rear sides of the top photovoltaic module from the front-rear direction. Next, the support platform 4 moves slightly downward along the tilted guide path. Because the right side of the top photovoltaic module is limited by the stepped groove 25, and the front and rear sides are rigidly clamped by the triangular limiting plates 56, the top photovoltaic module will not move downward with the other photovoltaic modules, thus separating the other photovoltaic modules from the top photovoltaic module. Finally, the photovoltaic installation robot picks up the top photovoltaic module. At the same time as the picking is completed, the front and rear triangular limiting plates 56 reset, releasing the clamping of the top photovoltaic module.

[0033] This ensures that when the photovoltaic installation robot grabs a photovoltaic module and generates impact force, it will not affect the other photovoltaic modules, and at the same time avoids the problem of the top photovoltaic module sticking to other photovoltaic modules when it is grabbed.

[0034] In addition, it should be noted that although the separation of the top photovoltaic module from other photovoltaic modules mainly relies on the rigid clamping of the front and rear triangular limiting plates 56, the right side of the top photovoltaic module is restricted within the stepped groove 25 and is set at an angle. This greatly reduces the locking pressure required to keep the top photovoltaic module stationary relative to other photovoltaic modules. Furthermore, the greater the tilt angle of the photovoltaic module, the less pressure is required for this locking, thus ensuring that the top photovoltaic module is clamped without damage.

[0035] See Figure 2 and Figure 5 The moving component 22 includes four first guide rods 221 fixedly connected to the back plate 23, and a drive motor 222 is fixedly connected to the side frame 21 via a bracket. The output shaft of the drive motor 222 is fixedly connected to an adjusting screw 223. One end of the adjusting screw 223 is threadedly connected to a connecting sleeve 224, and the connecting sleeve 224 is fixedly connected to the back plate 23.

[0036] After the photovoltaic module is placed horizontally on the support platform 4, the drive motor 222 drives the adjusting screw 223 to rotate. This causes the connecting sleeve 224 and the backing plate 23 to move relative to the photovoltaic module under the limitation of the first guide rod 221. This drives the conveyor belt assembly 24 on the backing plate 23 to move closer to the right side of the photovoltaic module until the conveyor belt assembly 24 contacts the right side of the photovoltaic module. During subsequent clockwise tilting of the photovoltaic module, the right side of the photovoltaic module remains in contact with the conveyor belt assembly 24 to prevent improper placement of the photovoltaic module, which could result in a gap between the right side of the photovoltaic module and the conveyor belt assembly 24, causing slippage when the photovoltaic module is tilted.

[0037] See Figure 2-5To reduce friction between the photovoltaic module and the conveyor belt assembly 24, a through hole is provided on the backing plate 23 below the stepped groove 25. The conveyor belt assembly 24 includes multiple guide rollers evenly arranged and rotating along the length of the through hole. A common synchronous conveyor belt 241 is fitted around these guide rollers, and the bearing surface of the synchronous conveyor belt 241 protrudes from the surface of the backing plate 23 near the photovoltaic module. The multiple guide rollers provide stable support for the synchronous conveyor belt 241, while simultaneously preventing hard contact between the photovoltaic module and the guide rollers.

[0038] See Figure 7 The H-shaped limiting plate 53 has through holes 2 on both vertical sections. The conveyor belt assembly 2 54 includes multiple guide rollers 2 that are evenly arranged and rotated along the length direction of the through holes 2. The multiple guide rollers 2 are together fitted with the same synchronous conveyor belt 2 541. The bearing surface of the synchronous conveyor belt 2 541 protrudes from the surface of the H-shaped limiting plate 53 on the side closest to the photovoltaic module.

[0039] In actual operation, the synchronous conveyor belt 241 on the back plate 23 contacts the right side of the photovoltaic module under the drive of the moving component 22. The pressure of the photovoltaic module acts on the synchronous conveyor belt 241. When the support platform 4 drives the photovoltaic module to move along the back plate 23, the pressure of the photovoltaic module can push the bearing surface of the synchronous conveyor belt 241 to move together with the photovoltaic module. The synchronous conveyor belt 241 supports the right side of the photovoltaic module and can move together with the photovoltaic module, which avoids the photovoltaic module moving along the back plate 23 and greatly reduces the friction generated during the movement.

[0040] The front and rear sides of the photovoltaic module are in contact with the synchronous conveyor belt 541, which limits and guides the corresponding front and rear sidewalls of the photovoltaic module.

[0041] In addition, it should be noted that during actual operation, when the photovoltaic module moves, there may be a slight relative displacement between the right side of the photovoltaic module and the corresponding bearing surface of the synchronous conveyor belt 241. Since the synchronous conveyor belt 241 is made of flexible rubber, the frictional force generated by this slight displacement can be ignored.

[0042] See Figure 7 To prevent the photovoltaic modules from flipping over when moving along uneven road surfaces while tilted, the upper ends of the two vertical sections of the H-shaped limiting plate 53 are provided with sliding holes. The flipping limiting component 55 includes two third guide rods 551 fixedly installed in the sliding holes. A guide slider 552 is slidably installed between the two third guide rods 551. The flipping limiting plate 553 is fixedly installed on the guide slider 552. A reset spring 554 is sleeved on the surface of each of the two third guide rods 551. The two ends of the reset spring 554 are fixedly connected to one side of the guide slider 552 and the lower inner wall of the sliding hole, respectively.

[0043] To minimize the pressure of the upper photovoltaic modules on the lower photovoltaic modules, the photovoltaic modules need to be tilted against the support plate 23 as much as possible. To prevent the photovoltaic modules from flipping, when the H-shaped limiting plate 53 drives the synchronous conveyor belt 2 541 to contact the front and rear side walls of the photovoltaic modules, the flipping limiting plate 553 is positioned directly above the edges of all photovoltaic modules. Then, the photovoltaic modules placed horizontally on the support platform 4 can move upward with the support platform 4 until the upper edge of the top photovoltaic module contacts the lower side of the flipping limiting plate 553 and stops. When the photovoltaic modules move with the photovoltaic installation robot, the flipping limiting plate 553 restricts the rotation of the top photovoltaic module. At the same time, when the right side of the top photovoltaic module transitions from the top end of the synchronous conveyor belt 241 to the stepped groove 25 on the surface of the support plate 23, the flipping of the top photovoltaic module is also prevented.

[0044] In this design, pressure sensors are installed at the connection points of the connecting sleeve 224 and the backing plate 23, the connection points of the telescopic end of the limiting cylinder 52 and the H-shaped limiting plate 53, the connection points of the telescopic end of the limiting cylinder 52 and the triangular limiting plate 56, and the lower side of the flipping limiting plate 553. The pressure sensors are electrically connected to an external controller to help determine the pressure when the synchronous conveyor belt 241 on the backing plate 23, the synchronous conveyor belt 541 on the H-shaped limiting plate 53, the triangular limiting plate 56, and the flipping limiting plate 553 come into contact with the photovoltaic module.

[0045] All the pressure sensors mentioned above can be resistive strain gauge thin-film pressure sensors (e.g., FSR-402 or equivalent). These sensors are no more than 0.5 mm thick, have high sensitivity, and can be mounted at the contact surface between two components. The sensor's output signal is connected via wires to a programmable logic controller (PLC) or microcontroller (such as Arduino or STM32 series, not shown in the diagram). The controller pre-stores the pressure thresholds for each contact point, for example: Contact pressure threshold of the backing plate 23: 5~10 N (when this value is reached, it indicates that the synchronous conveyor belt 241 has contacted the right edge of the photovoltaic module, and the controller sends a signal to stop the drive motor 222). Lateral clamping force threshold: 30~80 N (adjustable within this range, set by the operator according to the photovoltaic module specifications; when the pressure reaches the set value, the controller closes the corresponding limit cylinder 52 air supply valve). Upper limit detection threshold: 1~3 N (only used to confirm that the flip limit plate 553 has contacted the upper edge of the photovoltaic module, not used to stop the action, only as a confirmation signal of the position).

[0046] Operating logic: When the pressure value detected by each pressure sensor reaches the corresponding threshold, the controller outputs a control signal (such as cutting off the power supply to the drive motor 222, closing the cylinder air supply solenoid valve, etc.) to avoid excessive compression or impact on the photovoltaic modules. All pressure sensors are connected in parallel with redundancy, so even if a single sensor fails, the system can still maintain basic safety protection based on the signals from other sensors.

[0047] The workflow of the entire material rack when working with the photovoltaic installation robot is as follows: Material preparation: The pallet with the photovoltaic modules is transported to the support platform 4 by a forklift. Then, the synchronous conveyor belt 241 and the two synchronous conveyor belts 541 approach the side wall of the photovoltaic modules from the right side and the front and rear sides respectively. The support platform 4 moves up so that the upper edge of the top photovoltaic module contacts the flipping limit plate 553. Then, the entire rack is flipped by the flipping cylinder 12 to control the tilting angle of the photovoltaic modules and complete the material loading.

[0048] Loading: The support platform 4 controls all photovoltaic modules to move towards the stepped groove 25. The flipping limit plate 553 slides along with the module and compresses the reset spring 554. When the right side of the top photovoltaic module is fully aligned with the stepped groove 25, the top photovoltaic module slides relative to the other photovoltaic modules and the right side of the top photovoltaic module slides into the stepped groove 25. Then, the front and rear triangular limit plates 56 clamp the front and rear sides of the top photovoltaic module. After the top photovoltaic module is clamped, the support platform 4 moves back a certain distance. The other photovoltaic modules follow the support platform 4 back under the action of gravity. Due to the clamping of the triangular limit plate 56 and the action of the stepped groove 25, the top photovoltaic module is finally separated from the other photovoltaic modules.

[0049] The robot arm of the photovoltaic installation robot picks up the top photovoltaic module. After the front and rear limit plates and the flip limit plate 553 are stabilized by the robot arm, they retract and reset. Then the robot arm drives the top photovoltaic module to be installed.

[0050] Repeated feeding can be used in conjunction with the photovoltaic installation robot to feed all photovoltaic modules.

[0051] In summary, the fundamental flaw of existing L-shaped material racks lies in the fact that the top photovoltaic modules and the lower photovoltaic modules are always in rigid contact during gripping, resulting in the downward transmission of impact force and the upward pulling of adhesive force, which exacerbates each other. This invention, before the gripping action occurs, uses the coordinated actions of the stepped groove 25 for support, the triangular limiting plate 56 for clamping, and the retraction of the support platform 4 to physically separate the top photovoltaic modules from the rest. After separation, the impact force generated by the robotic arm only acts on the isolated top photovoltaic module and cannot be transmitted to the lower layers; simultaneously, the interlayer adhesion caused by static electricity or stickiness is forcibly overcome during separation, and no further pulling occurs during gripping.

[0052] 2. Since the lower-layer photovoltaic modules are no longer subjected to impact and tension during grasping, their original stacking posture is maintained. Simultaneously, the side frame 2's backing plate 23, the anti-deviation frame 5's H-shaped limiting plate 53, and the flipping limiting component 55 form a four-way constraint guiding path. Combined with the friction reduction provided by conveyor belt assembly 1 24 and conveyor belt assembly 2 54, this prevents the remaining photovoltaic modules from slipping during vehicle vibration, acceleration / deceleration, and center of gravity shifts. This stable posture further ensures the robot arm's accurate grasping point position each time, avoiding collisions or mis-grabbing caused by module misalignment.

[0053] 3. Existing technologies heavily rely on the compliant gripping of robotic arms to absorb impacts. However, as photovoltaic modules become increasingly thinner, even minute residual impacts can cause microcracks. This invention shifts the focus of protection from the "gripping interface" to the "stacking interface," using the pre-separation mechanism of the rack itself to block the impact transmission path, thus increasing protection for photovoltaic modules during installation. Even if the robotic arm's buffering performance decreases or the module thickness is reduced, this rack can still provide reliable impact isolation, thereby reducing the overall system's reliance on high-precision force control and improving the equipment's fault tolerance and applicability under complex operating conditions.

[0054] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0055] Furthermore, the terms "first," "second," "number one," and "number two" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first," "second," "number one," or "number two" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0056] In this invention, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," "link," and "fix" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0057] The embodiments described herein are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A photovoltaic module rack structure with four-way clamping protection function, characterized in that: It includes a side frame that is connected to the main body of the installation robot via a rotating connector, a bottom frame that is provided under the side frame, a support platform that can slide along the side frame on the bottom frame, and anti-deviation frames that are symmetrically distributed front and back on the bottom frame. The side frame includes a side frame that is fixedly connected to the bottom frame. A backing plate is connected to the side frame via a movable component. A conveyor belt assembly is provided on the backing plate, and a stepped groove is provided on the backing plate near the upper end of the conveyor belt assembly. The anti-deviation frame includes a column fixedly connected to the base frame. Two limiting cylinders are arranged vertically on the column. An H-shaped limiting plate is fixedly connected to the telescopic end of the lower limiting cylinder. Conveyor belt assemblies II are arranged on both vertical sections of the H-shaped limiting plate, and a flipping limiting component is arranged on the H-shaped limiting plate above each conveyor belt assembly II. A triangular limiting plate is fixedly connected to the telescopic end of the upper limiting cylinder, and one side of the triangular limiting plate abuts against the side of the uppermost photovoltaic module. The first and second conveyor belt assemblies are used to limit and guide the photovoltaic module on the other three sides except the left side, and the flipping limiting component is used to flip and limit the upper side of the photovoltaic module. The stepped groove is used to accommodate the right side of the top photovoltaic module when the support platform lifts the stacked photovoltaic modules upward, so that the top photovoltaic module is misaligned with other photovoltaic modules. When the remaining photovoltaic modules move downward, the triangular limiting plate presses the top photovoltaic module to control the active isolation between the remaining photovoltaic modules and the top photovoltaic module.

2. The photovoltaic module rack structure with four-way clamping protection function according to claim 1, characterized in that, The rotating connector includes an outer connecting plate that is rotatably connected to the side frame. The outer connecting plate is fixedly connected to the installation robot. Two tilting cylinders that are symmetrically distributed front and back are hinged between the outer connecting plate and the side frame.

3. The photovoltaic module rack structure with four-way clamping protection function according to claim 1, characterized in that, The moving component includes four first guide rods fixedly connected to the back plate, and a drive motor is fixedly connected to the side frame via a bracket. The output shaft of the drive motor is fixedly connected to an adjusting screw, and one end of the adjusting screw is threadedly connected to a connecting sleeve, which is fixedly connected to the back plate.

4. A photovoltaic module rack structure with four-way clamping protection function according to claim 1, characterized in that, The depth of the stepped groove relative to the surface of the backing plate used to support the photovoltaic module is 2-3cm, and the inner wall of the stepped groove is covered with a cushioning pad with a thickness of 0.5-1cm.

5. A photovoltaic module rack structure with four-way clamping protection function according to claim 1, characterized in that, A lifting cylinder is installed on the bottom frame, and the telescopic end of the lifting cylinder is fixedly connected to the lower side of the support platform.

6. A photovoltaic module rack structure with four-way clamping protection function according to claim 5, characterized in that, Two second guide rods are fixedly installed on the front and rear sides of the bottom frame, and two extended guide blocks are fixedly installed on the front and rear sides of the support platform. The extended guide blocks are slidably inserted into the corresponding second guide rods.

7. A photovoltaic module rack structure with four-way clamping protection function according to claim 1, characterized in that, The upper ends of the two vertical sections of the H-shaped limiting plate are provided with sliding holes. The flip-limiting component includes two third guide rods fixedly installed in the sliding holes. A guide slider is slidably installed between the two third guide rods. The flip-limiting plate is fixedly installed on the guide slider. The surfaces of the two third guide rods are each fitted with a return spring. The two ends of the return spring are fixedly connected to one side of the guide slider and the lower inner wall of the sliding hole, respectively.

8. A photovoltaic module rack structure with four-way clamping protection function according to claim 1, characterized in that, The bottom frame and the side frame are both fixed with reinforcing plates on the same side, front and back.

9. A photovoltaic module rack structure with four-way clamping protection function according to claim 1, characterized in that, The backing plate has a through hole below the stepped groove. The conveyor belt assembly includes multiple guide rollers that are evenly arranged and rotated along the length of the through hole. The multiple guide rollers are all fitted with the same synchronous conveyor belt. The bearing surface of the synchronous conveyor belt protrudes from the side of the backing plate closest to the photovoltaic module.

10. A photovoltaic module rack structure with four-way clamping protection function according to claim 1, characterized in that, The H-shaped limiting plate has through holes 2 on both vertical sections. The conveyor belt assembly 2 includes multiple guide rollers 2 that are evenly arranged and rotated along the length of the through holes 2. The multiple guide rollers 2 are fitted together with the same synchronous conveyor belt 2. The bearing surface of the synchronous conveyor belt 2 protrudes from the surface of the H-shaped limiting plate on the side closest to the photovoltaic module.

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