A photovoltaic module installation method and system

Abstract

The present application relates to the technical field of photovoltaic automation installation, in particular to a kind of installation method and control system of photovoltaic module, system includes mobile chassis, material jacking mechanism, operating mechanism and control system, method includes the following steps: S1, global parameter pre-input;S2, high consistency physical supply positioning;S3, based on the reference of physical consistency, material taking;S4, current array station first piece demonstration calibration;S5, array station subsequent photovoltaic module blind installation without identification;S6, the cycle of marching transfer of large-area construction;The present application can reduce visual hardware and computing power cost, improve the system anti-interference ability and operation stability under the adverse conditions of field, effectively improve photovoltaic module installation efficiency, and can eliminate the disturbance error generated in the process of supply, improve installation precision;Adopt flexible protection and kinematics algorithm high integration in whole process, avoid the risk of hidden crack of heavy load large size photovoltaic module from bottom.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic automated installation technology, and in particular to an installation method and control system for photovoltaic modules. Background Technology

[0002] With the global energy structure adjustment and the advancement of "dual carbon" goals, the installed capacity of photovoltaic power generation is growing rapidly. Large-scale ground-mounted photovoltaic power plants and distributed photovoltaic projects require a massive number of photovoltaic modules. Currently, the installation of photovoltaic modules mainly relies on traditional manual handling and alignment. This method is not only labor-intensive and inefficient, but also, as photovoltaic modules become larger and heavier, manual handling is prone to uneven stress, leading to microcracks in the fragile monocrystalline silicon cells, resulting in extremely unstable installation quality.

[0003] To address the shortcomings of manual installation, the industry has attempted to introduce automated installation equipment. However, existing automated installation technologies mostly focus on purely mechanical structure design or directly apply industrial-grade fully automated addressing solutions (such as relying on high-precision 3D vision systems and real-time laser positioning). This fully automated approach has fatal flaws in practical applications: on the one hand, the equipment is extremely dependent on expensive vision sensors and high-performance chips, resulting in a single unit costing millions, making it difficult to promote in large-scale ordinary power plants; on the other hand, the construction environment of outdoor photovoltaic power plants is harsh, often accompanied by strong sunlight, backlight, strong winds, and sandstorms. Precision vision sensors are prone to frequent recognition failures and target loss due to drastic changes in ambient light or surface contamination, leading to extremely unstable system operation.

[0004] Therefore, the industry urgently needs an automated continuous installation method and system for photovoltaic modules that can overcome interference from harsh outdoor working conditions, reduce the cost of expensive visual sensors, and balance high efficiency and high installation quality. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing fully automated photovoltaic installation equipment, which relies heavily on expensive 3D vision systems and is prone to failure under harsh field conditions. This invention provides a highly efficient and low-cost semi-automated photovoltaic module installation method and system that achieves blind assembly without visual interference by combining highly consistent front-end physical material supply with back-end relative coordinate matrix calculation.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A photovoltaic module installation method, which uses a control system to control photovoltaic installation equipment to install photovoltaic modules onto a photovoltaic support structure, is characterized by the following steps:

[0008] S1, Global Parameter Pre-input: Input the geometric dimensions of the photovoltaic modules and the relative spacing of the photovoltaic support array into the control system;

[0009] S2. High-consistency physical feeding and positioning: After completing step S1, the X-direction boundary of the photovoltaic module in the hopper coordinate system of the photovoltaic installation equipment and the reference height in the Y-direction are locked by driving the fork teeth and the material lifting mechanism, respectively.

[0010] S3. Material picking based on physical consistency: After completing step S2, the position and attitude information of each joint of the telescopic arm and the end effector are collected. Combined with the position information obtained in step S2, the initial pose of the photovoltaic module relative to the end vacuum suction cup is calculated. Based on the initial pose, the end effector is controlled to adjust the spatial pose so that the vacuum suction cup is aligned with the surface of the photovoltaic module and adsorbed.

[0011] S4. First piece teaching and calibration at the current array station: After completing step S3, in the current array station, the end effector is controlled by manual remote control to accurately place the first adsorbed photovoltaic module at the predetermined position of the target photovoltaic bracket; after placement, the control system locks the position encoder parameters of each joint of the telescopic arm and the end effector at this time, and converts them into the spatial local relative origin reference of the current array station.

[0012] S5. Blind installation of subsequent photovoltaic modules in the array station without identification: After completing step S4, the control system calculates the target installation pose matrix for the remaining photovoltaic modules in the current array station based on the pre-input photovoltaic module geometric parameters and the relative spacing parameters of the photovoltaic support array in step S1, and automatically drives each mechanical joint of the photovoltaic installation equipment to perform spatial trajectory interpolation along the planned smooth speed curve, thereby completing the automatic installation of subsequent photovoltaic modules in sequence.

[0013] S6. Large-scale construction site transfer cycle: After the installation of all photovoltaic modules in the current array station is completed, the control system controls the mobile chassis of the photovoltaic installation equipment to automatically move along the preset straight route to the next target array station and park and lock it. Then, the current local relative origin reference is cleared and steps S2 to S5 are repeated until the installation of all photovoltaic modules is completed.

[0014] Preferably, the specific process of step S2, high-consistency physical feeding and positioning, includes:

[0015] After inserting and flipping the entire box of photovoltaic modules, the drive fork tooth stop is placed against the edge of the photovoltaic module to prevent lateral movement and lock the photovoltaic module's X-direction boundary in the hopper coordinate system;

[0016] The photovoltaic modules are lifted upward by the material lifting mechanism until the photoelectric sensor set above the material lifting mechanism is triggered, locking the top photovoltaic module to be grabbed at the reference height in the Y direction, thereby establishing the physical pose consistency reference of the top photovoltaic module in the hopper coordinate system.

[0017] Preferably, in step S3, which is based on the physical consistency benchmark for material handling, after each photovoltaic module is removed, the material lifting mechanism automatically pushes the photovoltaic module stack upwards to raise the height of a single module according to the photovoltaic module thickness parameters pre-input in step S1. When the upper surface of the top photovoltaic module is blocked again and triggers the detection beam of the photoelectric sensor, the drive motor brakes and locks, so that the height coordinate of the newly exposed top photovoltaic module remains consistent with the initial Y-direction height coordinate when the previous photovoltaic module was grabbed, and returns to the physical pose consistency benchmark obtained in step S2.

[0018] Preferably, the specific process of converting the spatial local relative origin reference in step S4, the first piece teaching calibration of the current array station, includes:

[0019] Define the mobile chassis as the base coordinate system The center of the end-effector's suction cup is in the tool coordinate system. ;

[0020] After the first photovoltaic module is precisely placed manually, the tool coordinate system in the current state is calculated using forward kinematics. Relative to the base coordinate system The initial homogeneous transformation matrix It is saved as a local spatial relative origin reference.

[0021] Preferably, in step S5, during the blind installation of subsequent photovoltaic modules at the array station without identification, the target installation pose matrix of each subsequent photovoltaic module is automatically calculated using a relative coordinate space translation operator. The specific process includes:

[0022] For the first in a set of photovoltaic module arrays Block photovoltaic modules, their target installation pose matrix By initial homogeneous transformation matrix Obtained by right multiplication by the corresponding spatial translation operator matrix;

[0023] Among them, if the first If the photovoltaic module is located laterally adjacent to the first photovoltaic module, then the derivation formula for the target installation pose matrix is: If the first If the photovoltaic module is located in a vertically adjacent position to the first photovoltaic module, then the derivation formula for the target installation pose matrix is:

[0024] in, The length of the photovoltaic module is the pre-input value in step S1. Width of the photovoltaic module; The horizontal spacing of the photovoltaic support structure pre-input in step S1, This refers to the longitudinal spacing of the photovoltaic support structure.

[0025] Preferably, the specific process of automatically driving the mechanical joints of the photovoltaic installation equipment to perform spatial trajectory interpolation along the planned smooth speed curve during the subsequent blind splicing installation of photovoltaic modules at the array station in step S5 includes:

[0026] Based on the target installation pose matrix obtained by the control system, the inverse kinematics algorithm is used to calculate the required telescopic displacement of the telescopic arm and the target angular displacement of each rotary joint of the end effector.

[0027] A quintic polynomial or S-curve velocity curve planning algorithm is used to generate a smooth motion trajectory from the current material picking position to the target angular displacement.

[0028] The servo motors driving the telescopic arm and the end effector are synchronized along a smooth motion trajectory to perform spatial pose interpolation with continuous acceleration, avoiding microcracks in the photovoltaic modules caused by motion impact.

[0029] Preferably, in step S5, during the blind installation of photovoltaic modules at the array station without identification, when driving each mechanical joint to perform spatial trajectory interpolation, the spatial installation path specifically includes four spatial pose transformations executed sequentially:

[0030] First transformation: Raise the end effector to a safe height, changing the photovoltaic module from a material handling posture to an intermediate transport posture to avoid interference with surrounding obstacles;

[0031] Second transformation: The horizontally rotating end effector aligns the long side of the photovoltaic module with the docking direction of the target photovoltaic support;

[0032] Third transformation: Extend the telescopic arm, move the photovoltaic module directly above the target photovoltaic bracket, and adjust its posture to make it parallel to the bracket's mounting plane;

[0033] Fourth transformation: By combining the pitch and roll angle data in the target installation pose matrix, fine-tuning the downward pressure is performed to precisely align the positioning point on the lower surface of the photovoltaic module with the mating surface of the target photovoltaic bracket, and then the vacuum suction cup is released.

[0034] Preferably, in step S5, during the blind installation of photovoltaic modules at the array station without identification, a safety verification is performed before the fourth transformation. The specific process includes:

[0035] Before lowering the multi-degree-of-freedom end effector and releasing the vacuum suction cup, the contact pressure and flatness between the photovoltaic module and the photovoltaic support are confirmed by a laser rangefinder configured on the end effector. Only after all values ​​meet the set safety thresholds can the system execute the vacuum release command.

[0036] A photovoltaic module installation system for implementing any of the above-described photovoltaic module installation methods includes:

[0037] The mobile chassis is used to carry other components of the installation system and to perform movement and parking lock-up between array workstations according to control commands;

[0038] The material lifting mechanism is mounted on a mobile chassis. The material lifting mechanism includes a hopper, a fork tooth guard, and a scissor lift photovoltaic module with photoelectric sensors. The fork tooth guard is used to physically lock the X-direction boundary of the photovoltaic module, and the scissor lift photovoltaic module is used to automatically compensate for the thickness and height of the photovoltaic module after each material retrieval to maintain the physical pose consistency benchmark of the photovoltaic module to be retrieved.

[0039] The operating machinery mechanism includes a telescopic boom mounted on a mobile chassis and an end effector connected in series at the front end of the telescopic boom; the end effector includes a multi-degree-of-freedom end effector, the far end of which is equipped with a vacuum suction cup for gripping photovoltaic modules and a laser rangefinder for safety verification.

[0040] The control system is communicatively connected to the mobile chassis, material lifting mechanism, and operating machinery mechanism. It controls the operation of each photovoltaic module in the installation system and records various data. The control system includes a processor and a memory storing a computer program. When executed by the processor, the computer program is used for:

[0041] Record the encoder parameters of each joint during the first manual remote placement and establish them as the spatial local relative origin reference.

[0042] Using the spatial local relative origin as the mathematical origin, the target installation pose matrix of each photovoltaic module in the current array position is automatically calculated by the relative coordinate space translation operator.

[0043] Based on the target installation pose matrix, the driving mechanism performs spatial trajectory interpolation along a smooth speed curve to complete the blind installation of subsequent photovoltaic modules at the array station without visual interference.

[0044] Preferably, the control system includes:

[0045] The pose calculation module is used to establish the homogeneous transformation matrix between the base coordinate system of the mobile chassis, the hopper coordinate system of the material lifting mechanism, and the tool coordinate system of the multi-degree-of-freedom end effector. It also solves the spatial local relative origin reference and the target installation pose matrix of each photovoltaic module through a forward kinematics algorithm.

[0046] The path planning module is used to calculate and generate a smooth motion trajectory with continuous acceleration for the working mechanical mechanism to move from the material picking position to the target installation position matrix using a fifth-order polynomial or S-shaped velocity curve planning algorithm.

[0047] The motion control module is used to use inverse kinematics algorithm to decompose the smooth motion trajectory into the extension and retraction of the telescopic arm and the angular displacement of each rotary joint, and send drive commands to the corresponding servo drive device in real time to realize closed-loop tracking control of the trajectory.

[0048] The beneficial effects of this invention are:

[0049] (1) Significantly reduce the cost of vision hardware and computing power, and significantly improve the system's anti-interference capability and operational stability under harsh field conditions: Traditional fully automated photovoltaic installation schemes rely heavily on expensive 3D vision systems and high AI computing power chips. In strong sunlight, backlight, strong winds, and dust storms in the field, image recognition is prone to frequent failures and target loss due to drastic changes in ambient light or damage to the sensor surface. This invention adopts the control logic of "first-piece manual-assisted positioning benchmark + subsequent automatic identification-free calculation of photovoltaic module array". It only requires the use of highly reliable industrial basic sensors such as encoders and proximity switches, combined with control algorithms, to achieve large-area accurate and continuous laying. This method completely eliminates expensive vision addressing and computing hardware, which not only significantly reduces the overall system cost, but also fundamentally solves the technical bottleneck of low electrical recognition rate and easy false alarms in extreme field construction environments.

[0050] (2) Proposes array-based continuous recognition-free installation to break the efficiency bottleneck of repeated addressing of single modules: Existing installation equipment mostly adopts the operation logic of "independent addressing of single modules and independent alignment of each module". Each photovoltaic module installation requires a complex re-scanning and pose comparison, which is cumbersome and time-consuming. This invention is based on the same "grid" for array-based continuous installation: After the first photovoltaic module is accurately positioned by manual remote control, the control system can lock the pose parameters of the current multi-degree-of-freedom mechanical joints as a local spatial relative origin reference with one click; the target position of subsequent photovoltaic modules is directly based on this reference and the pre-input photovoltaic panel length, width, spacing and other size parameters, and the target installation pose matrix is ​​automatically calculated by the relative coordinate space translation operator (matrix right multiplication). This process eliminates the cumbersome scanning time of repeated addressing and realizes high-efficiency, seamless pipeline continuous operation between multiple photovoltaic modules.

[0051] (3) Eliminate random disturbance errors in the initial gripping posture, achieve material supply and installation coordination, and realize cumulative error control in long cantilever blind assembly: In long-stroke, heavy-load arrayed relative coordinate blind assembly installation, since the end actuator pushes the long cantilever without visual secondary correction, its final positioning accuracy depends heavily on the consistency of the initial posture of the photovoltaic module relative to the vacuum suction cup during each gripping. Small deviations in the initial gripping position will be amplified by the long forward extension of the telescopic arm, causing the end installation tolerance to increase geometrically, which can easily lead to rigid misalignment and collision between the photovoltaic module and the bracket, resulting in hidden cracks in the panel.

[0052] This invention integrates a front-end fork-tooth edge-blocking mechanism and a bottom scissor-lifting mechanism on the feeding side, respectively locking the boundary of the photovoltaic module in the X direction and locking the newly exposed top-layer photovoltaic module at the reference height in the Y direction. The essence of this precise coordination between physical constraints and a closed-loop photoelectric sensor lies in its ability to forcibly lock the initial spatial pose tolerance at a fixed known value during each grab at the bottom layer of the mechanical structure. Furthermore, for each photovoltaic module grabbed, the feeding mechanism performs a dynamic recalibration of the physical zero point. Through this precise coordination of physical constraints and a closed-loop photoelectric sensor, it ensures that the initial pose of the photovoltaic module to be grabbed is under a highly consistent physical reference each time the robotic arm blindly picks up a component from the hopper. This cuts off the path of accumulating spatial tolerances with the increase in the number of installed modules, effectively reducing the cumulative error under fully automated continuous installation of multiple photovoltaic modules, and achieving "blind assembly installation without identification," eliminating the need for secondary visual correction.

[0053] (4) The high integration of full-process flexible protection and kinematic algorithms effectively prevents the risk of microcracks in heavy-duty large-size photovoltaic modules from the bottom layer: Since photovoltaic modules are brittle and heavy-duty panels, they are prone to mechanical vibration or impact during long-stroke linear displacement pushing and cantilever pressing contact, which can lead to microcracks in monocrystalline silicon. This invention uses a fifth-order polynomial or S-shaped velocity curve to plan the spatial installation path (including four spatial pose transformations executed in sequence) at the control bottom layer, ensuring that the acceleration of each joint of the telescopic arm and the robotic arm is continuous and impact-free during the servo linkage process; at the same time, before vertically pressing down and releasing the vacuum suction cup, the laser ranging sensor configured at the end dynamically confirms the contact pressure and flatness between the photovoltaic module and the photovoltaic support, and releases only when the set safety threshold is met. This series of organic integration of hardware and software safety controls not only significantly reduces sensor costs, but also transforms rigid impacts into flexible pressing, maximizing the safety of photovoltaic modules during large-area assembly line operations. Attached Figure Description

[0054] Figure 1 This is a schematic diagram of the overall structure of the photovoltaic module installation system according to Embodiment 1 of the present invention;

[0055] Figure 2 This is an overall flowchart of the photovoltaic module installation method according to Embodiment 2 of the present invention;

[0056] Figure 3 This is a coordinate system topology diagram of the photovoltaic module installation system according to Embodiment 2 of the present invention;

[0057] Figure 4 This is a diagram showing the installation sequence of a set of photovoltaic modules according to Embodiment 2 of the present invention;

[0058] Figure 5 This is a front view of the photovoltaic module infeeding state in Embodiment 2 of the present invention;

[0059] Figure 6 This is a top view of the photovoltaic module receiving state in Embodiment 2 of the present invention;

[0060] Figure 7 This is a front view of the first photovoltaic module being manually installed in Embodiment 2 of the present invention;

[0061] Figure 8 This is a top view of the first photovoltaic module being manually installed in Embodiment 2 of the present invention;

[0062] Figure 9 This is a front view of the automatic installation of subsequent photovoltaic modules in Embodiment 2 of the present invention;

[0063] Figure 10 This is a top view of Embodiment 2 of the present invention when the system is in the automatic installation state of subsequent photovoltaic modules.

[0064] In the diagram: 1. Electrical control box; 2. Scissor lift mechanism; 3. Fork tooth guard; 4. Photovoltaic module; 5. Mobile chassis; 6. Boom rotating base; 7. Warning light; 8. Anemometer; 9. Telescopic boom; 10. Telescopic boom connector; 11. Telescopic end column; 12. Vacuum suction cup; 13. Photoelectric sensor. Detailed Implementation

[0065] Example 1

[0066] This embodiment is a further explanation and illustration of the present invention in conjunction with specific embodiments, such as... Figure 1 As shown, this embodiment is a photovoltaic module 4 installation system, including:

[0067] The mobile chassis 5 is used to carry other components of the installation system and to perform movement and parking lock between array workstations according to control commands. In this embodiment, a tracked chassis structure is adopted, which can better adapt to various terrains.

[0068] The material lifting mechanism, mounted on the mobile chassis 5, includes a hopper, fork-tooth guards 3, and a scissor lift photovoltaic module 42 equipped with a photoelectric sensor 14. The fork-tooth guards 3 are used to physically lock the X-direction boundary of the photovoltaic module 4, and the scissor lift photovoltaic module 42 is used to automatically compensate for the thickness and height of the photovoltaic module 4 after each material retrieval to maintain the physical posture consistency benchmark of the photovoltaic module 4 to be retrieved. The material lifting mechanism and the mobile chassis 5 are in a rotating fit. It can be rotated to a parallel fork tooth state for loading the photovoltaic module 4, and when performing installation work, it can be rotated to a vertical fork tooth state to cooperate with the operating machinery mechanism for installing the photovoltaic module 4.

[0069] The operating machinery mechanism includes a telescopic boom mounted on a mobile chassis and an end effector connected in series at the front end of the telescopic boom. The telescopic boom includes a telescopic boom 9 and a telescopic boom 10 that work together. The telescopic boom 9 is connected to the mobile chassis 5 via a boom rotating base 6, and the telescopic boom 10 is connected to the end effector via a boom connecting seat. The end effector includes a multi-degree-of-freedom end effector. The far end of the multi-degree-of-freedom end effector is connected to a vacuum suction cup 13 for gripping photovoltaic modules 4 via an end telescopic column 12, as well as a laser rangefinder sensor for safety verification.

[0070] The control system includes an electrical control box 1 fixedly mounted on the mobile chassis 5, which is communicatively connected to the mobile chassis 5, the material lifting mechanism, and the operating machinery mechanism, and is used to control the operation of each photovoltaic module 4 in the installation system and record various data; the control system includes a processor and a memory storing a computer program, which, when executed by the processor, is used for:

[0071] Record the encoder parameters of each joint during the first manual remote placement and establish them as the spatial local relative origin reference.

[0072] Using the spatial local relative origin as the mathematical origin, the target installation pose matrix of each photovoltaic module 4 in the current array position is automatically calculated by the relative coordinate space translation operator.

[0073] Based on the target installation pose matrix, the operating machinery is driven to perform spatial trajectory interpolation along a smooth speed curve, completing the blind installation of the subsequent photovoltaic modules 4 at the array station without visual interference.

[0074] Specifically, the control system includes the following modules:

[0075] The pose calculation module is used to establish the homogeneous transformation matrix between the base coordinate system of the mobile chassis, the hopper coordinate system of the material lifting mechanism, and the tool coordinate system of the multi-degree-of-freedom end effector. It also solves the spatial local relative origin reference and the target installation pose matrix of each photovoltaic module 4 through the forward kinematics algorithm.

[0076] The path planning module is used to calculate and generate a smooth motion trajectory with continuous acceleration for the working mechanical mechanism to move from the material picking position to the target installation position matrix using a fifth-order polynomial or S-shaped velocity curve planning algorithm.

[0077] The motion control module is used to use inverse kinematics algorithm to decompose the smooth motion trajectory into the extension and retraction of the telescopic arm and the angular displacement of each rotary joint, and send drive commands to the corresponding servo drive device in real time to realize closed-loop tracking control of the trajectory.

[0078] An alarm light 7 is also installed on the electrical control box 1 to indicate the working status and warn bystanders that they may be injured if they get too close during construction. An anemometer 8 is also installed on the electrical control box 1 to detect wind speed in real time. When the wind speed is too high, the operation will stop immediately and an alarm will be triggered by the alarm light 7 to prevent the photovoltaic module 4 from falling off and being damaged due to excessive wind speed.

[0079] Example 2

[0080] This embodiment describes a method for installing photovoltaic modules 4 based on the photovoltaic module 4 installation system proposed in Embodiment 1. Figure 2 As shown, the specific steps include:

[0081] System initialization: such as Figure 3 As shown, in order to realize the blind stitching algorithm of relative coordinate space translation without visual intervention, the system first constructs a global spatial geometric chain topology structure by the control system during the initialization phase, and establishes the following mutually independent physical coordinate systems:

[0082] Base coordinate system (Base Frame): The origin of the coordinate system is set at the geometric center of the mobile chassis or the center reference point of the main turntable's rotation axis. The axle travels in the straight direction along the chassis. The axis is perpendicular to the direction of travel and points to the left. The axis is perpendicular to the chassis plane and points upwards, serving as the reference source for the movement of the entire machine and the inverse kinematics solution of the robotic arm.

[0083] Hopper coordinate system (Hopper Frame): Set the origin of the coordinate system at the lower left physical boundary point of the material lifting mechanism with the hopper. The axis is parallel to the length of the hopper. The axis is parallel to the width direction of the hopper. The axis is vertically upward and parallel to the lifting direction of the stacked photovoltaic modules 4, and is used to calculate the tolerance-free initial gripping point of the photovoltaic modules 4 inside the hopper.

[0084] Tool coordinate system (Tool Frame): Set the origin of the coordinate system at the center point of the geometric normal of the vacuum suction cup assembly at the very end of the multi-degree-of-freedom end effector (a five-degree-of-freedom tandem end effector is used in this embodiment). The axis extends outward along the normal to the suction cup's adsorption surface, and is used to characterize the six-degree-of-freedom pose of the robotic arm's end effector in space.

[0085] S1. Global Parameter Pre-input: Input the geometric dimensions of photovoltaic module 4 and the relative spacing parameters of the photovoltaic support array into the control system. The specific process includes:

[0086] Before construction, the operator writes the physical geometric dimensions of the photovoltaic module 4 to be installed and the arrangement spacing parameters of the target photovoltaic support array into the non-volatile memory of the control system through a human-machine interface (such as an in-vehicle industrial touch screen) connected to the electrical control box.

[0087] Specifically, the input parameters are stored in the form of a structure, including: the length of a single photovoltaic module 4. (millimeters), width (millimeters), standard thickness (mm); and the lateral installation spacing of the "grid" brackets within the current array workstation. (mm) and longitudinal installation spacing (mm). After configuration, the motion control card of the control system performs zero-point calibration and gain parameter initialization for each joint servo driver.

[0088] S2. High-consistency physical feeding and positioning: After completing step S1, the X-direction boundary of the photovoltaic module 4 in the hopper coordinate system of the photovoltaic installation equipment, and the reference height in the Y-direction are locked by the drive fork and the material lifting mechanism, respectively; the specific process includes:

[0089] After inserting and flipping the entire box of photovoltaic modules 4, the drive fork tooth stop edge rests against the edge of the photovoltaic module 4 to prevent lateral movement and lock the X-direction boundary of the photovoltaic module 4 in the hopper coordinate system.

[0090] The photovoltaic modules 4 are lifted upward by the material lifting mechanism until the photoelectric sensor 14 set above the material lifting mechanism is triggered, locking the top photovoltaic module 4 to be grabbed at the reference height in the Y direction, thereby establishing the physical pose consistency reference of the top photovoltaic module 4 in the hopper coordinate system.

[0091] The essence of this step lies in using physical hardware to limit the photovoltaic module 4 before the robotic arm grabs it from the hopper. The random tolerances in the coordinate system are "forced to zero" to maintain an extremely high consistency benchmark. The specific actions are as follows:

[0092] First, the front-end fork mechanism picks up and flips the entire box of photovoltaic modules 4 (typically 20-30 modules stacked together) into the hopper. After unloading, the electrical control box 1 sends a bus command to start the lateral stepper motor located on the side of the hopper, pushing the fork stop 3 to move laterally inward until it abuts against the outer edge of the aluminum alloy frame of the photovoltaic module 4. At this point, the lateral movement is physically locked, and the motor driver is braked due to current overload. The control system reads the feedback pulse count from the absolute encoder of the lateral motor, directly latches and acquires the position of the photovoltaic module 4. Absolute boundary coordinates in the direction (length direction of the hopper).

[0093] Subsequently, the scissor lift mechanism 2, installed at the bottom of the hopper, starts its drive motor, pushing the scissor arms at the bottom to open in a crisscross pattern, thereby slowly lifting the entire stack of photovoltaic modules 4 vertically upwards. A set of through-beam photoelectric sensors 14 (or infrared proximity switches) is fixedly positioned directly above the upper edge of the hopper, emitting a beam of light horizontally across the top of the hopper. When the upper surface of the top photovoltaic module 4 reaches the predetermined working height as lifted by the scissor lift mechanism 2, this upper surface physically blocks and cuts off the detection beam of the photoelectric sensor 14. The photoelectric sensor 14 instantly generates a high-level transition signal and inputs it to the microprocessor's GPIO interface in the form of a hard interrupt. Upon receiving this interrupt signal, the electrical control box 1 immediately sends a high-priority dynamic braking lock command to the servo driver of the lifting motor, causing the scissor lift mechanism 2 to instantly apply the brakes, thereby locking the vertical height of the currently top photovoltaic module 4 to be grabbed at the specified position. On the working position reference in the direction (hopper height direction).

[0094] Through the above Steering fork tooth edge physical lock and The precise coordination between the directional photoelectric sensor and the brake interruption allows the control system to automatically calculate the position of the uppermost photovoltaic module 4 in the hopper coordinate system directly based on the known dimensions of the structural components, without requiring complex visual image processing. The three-dimensional center point coordinates and surface normal vectors are used to reduce the physical error of subsequent grasping actions.

[0095] S3. Material selection based on physical consistency: such as Figure 5 and Figure 6 As shown, the position and attitude information of each joint of the telescopic arm and end effector are collected. Combined with the position information obtained in step S2, the initial pose of the photovoltaic module 4 relative to the end vacuum suction cup is calculated. Based on the initial pose, the end effector is controlled to adjust its spatial pose so that the vacuum suction cup is aligned with the surface of the photovoltaic module 4 and adsorbed. The specific process includes:

[0096] Each time a photovoltaic module 4 is removed, the material lifting mechanism automatically pushes the photovoltaic module 4 stack upwards to raise the height of a single module according to the photovoltaic module 4 thickness parameters pre-input in step S1. When the upper surface of the top photovoltaic module 4 is blocked again and triggers the detection beam of the photoelectric sensor, the drive motor brakes and locks, so that the height coordinate of the newly exposed top photovoltaic module 4 remains consistent with the initial Y-direction height coordinate when the previous photovoltaic module 4 was grabbed, and returns to the physical pose consistency benchmark obtained in step S2.

[0097] The control system's built-in pose calculation module first establishes a spatial relative matrix chain. Since the material lifting mechanism is fixed on the mobile chassis 5, the hopper coordinate system... Relative to the base coordinate system homogeneous transformation matrix Given a known constant matrix, the control system reads the current linear displacement sensor values ​​of the telescopic boom. And the absolute encoder angle values ​​of each rotary joint of the multi-degree-of-freedom end effector. ( The current tool coordinate system is solved in real time using a forward kinematics algorithm. Relative to the base coordinate system pose matrix Combined with the uppermost photovoltaic module 4 locked in step S2, The three-dimensional center point coordinates in the system are used by the control system to calculate the center point of the photovoltaic module 4 surface relative to the current vacuum chuck assembly (i.e., ... The initial relative distance and normal vector deviation of the coordinate system.

[0098] like Figure 5 As shown, the multi-degree-of-freedom end effector drives the vacuum chuck assembly to descend smoothly in the vertical direction, adjusting the pitch angle to ensure that the plane of the vacuum chuck 13 is strictly parallel to the surface of the photovoltaic module 4; simultaneously, as... Figure 6 As shown, the multi-degree-of-freedom end effector finely adjusts its yaw angle in the horizontal plane to precisely align the geometric center of the vacuum suction cup assembly with the physical center of the photovoltaic module 4 on the projection plane. The multi-degree-of-freedom end effector then presses down to bring the vacuum suction cup assembly into contact with the surface of the photovoltaic module 4, and the electrical control box 1 activates the vacuum solenoid valve assembly to evacuate the air. When the negative pressure sensor in the air circuit detects that the vacuum level has reached the set safety threshold (e.g., ...), ... When the system determines that "the first material adsorption is successful", the multi-degree-of-freedom end effector will vertically lift the first photovoltaic module 4 and remove it from the interference zone of the hopper.

[0099] S4. First-piece teaching and calibration at the current array station: Within the current array station, the end effector is manually remotely controlled to precisely place the first adsorbed photovoltaic module 4 at the predetermined position on the target photovoltaic bracket. Figure 4The position marked by the number 1 in the diagram; after placement, the control system latches the position encoder parameters of each joint of the telescopic arm and end effector, and converts them into a spatial local relative origin reference for the current array position; such as Figure 7 and Figure 8 As shown, the specific process includes:

[0100] The operator switches to manual control mode using a handheld remote control and visually operates the machinery. For example... Figure 7 As shown, the multi-stage telescopic arm extends horizontally to the left of the target bracket, while the multi-degree-of-freedom end effector adjusts downwards, smoothly moving the first adsorbed photovoltaic module 4 to directly above the target photovoltaic bracket in the lower left corner and pressing it down to adhere; simultaneously, as Figure 8 As shown, the operator fine-tunes the end joints to ensure that the edge of the first photovoltaic module 4 is aligned and parallel to the boundary line of the bracket in the horizontal projection plane.

[0101] Once the first photovoltaic module 4 in the lower left corner is physically aligned, the operator presses the "One-Click Latch / Baseline Establishment" button on the control panel. Upon receiving this trigger signal, the electrical control box 1 interrupts the current motion command and reads and latches the absolute pulse count of the linear displacement of the multi-stage telescopic arm, as well as the absolute encoder angle pulses of the five rotary joints of the robotic arm. The pose calculation module then calls the built-in robot forward kinematics algorithm equations to inversely solve for the tool coordinate system under the current perfect positioning state. Relative to the base coordinate system of An initial homogeneous transformation matrix is ​​used, which is defined as representing the local spatial coordinates of the "absolute spatial coordinates of the lower left workstation" relative to the origin. :

[0102]

[0103] In the formula, the upper left corner The rotation matrix represents the three-dimensional spatial orientation of the vacuum chuck assembly when the photovoltaic module 4 is positioned, where: These are the components of the normal vector of the attitude matrix along the X, Y, and Z axes of the base coordinate system. These are the components of the direction vector along the X, Y, and Z axes; To approximate the components of the vector on the X, Y, and Z axes. (Top right corner) Position vector This matrix represents the absolute position coordinates of the suction cup center point relative to the chassis origin on the X, Y, and Z axes. The control system will use this matrix... The data is written to the temporary cache of the current workstation, serving as the mathematical reference origin for the blind assembly of all subsequent photovoltaic modules 4 without identification. The control system then cuts off the vacuum, the suction cup assembly is released, and the first photovoltaic module 4 in the lower left corner is installed.

[0104] S5. Blind installation of subsequent photovoltaic modules 4 at the array station without identification: Based on the geometric parameters of photovoltaic modules 4 pre-input in step S1 and the relative spacing parameters of the photovoltaic support array, the control system calculates the target installation pose matrix for the remaining photovoltaic modules 4 in the current array station, and automatically drives each mechanical joint of the photovoltaic installation equipment to perform spatial trajectory interpolation along the planned smooth speed curve, thereby completing the automatic installation of subsequent photovoltaic modules 4 in sequence; the specific process includes:

[0105] After the first photovoltaic module 4 in the lower left corner is manually positioned and its origin is locked, the control system closes the manual interface and automatically switches to fully automatic continuous paving mode. The operating machinery first drives the multi-degree-of-freedom end effector to return unloaded to directly above the hopper to perform the second spatial material retrieval operation.

[0106] As the robotic arm returns unloaded, the scissor lift mechanism 2 at the bottom of the hopper starts synchronously; the control system, based on the standard thickness of the single photovoltaic module 4 pre-input in step S1... The system controls the vertical upward lifting of the entire stack of photovoltaic modules 4. During this process, a through-beam photoelectric sensor fixed above the hopper performs high-frequency dynamic monitoring: when the surface of the newly exposed second photovoltaic module 4 blocks the light beam again and triggers an interrupt signal, the lifting motor instantly executes the highest-priority servo brake. This closed-loop action ensures that the height and three-dimensional boundary coordinates of the newly inserted second photovoltaic module 4 are perfectly aligned in space with the initial physical pose of the first photovoltaic module 4 before it was grasped (repeatedly called and completely conforming). Figure 5 and Figure 6 (The physical reference posture for material picking is shown); the robotic arm descends according to the same control path described in step S3, automatically aligns, picks up and vertically pulls up the second photovoltaic module 4, completing the second material picking.

[0107] After the second material handling is completed, the control system does not need to rely on any 3D vision addressing or image correction, and directly uses the homogeneous transformation matrix of the first piece in the lower left corner of the cache. Using the mathematical origin and combining the geometric structure parameters pre-input in step S1, offline algebraic operations are performed using the relative coordinate space translation operator matrix. According to... Figure 4 As shown in the installation sequence diagram, the second photovoltaic module 4 is located longitudinally adjacent to the first photovoltaic module 4 (i.e., the upper left corner, position 2). Therefore, the pose calculation module calculates the initial homogeneous transformation matrix... Right multiplication based on the length of the photovoltaic module 4 and longitudinal spacing of the bracket The constructed longitudinal translation operator matrix automatically calculates the target installation pose matrix of the second photovoltaic module 4. The specific derivation and expansion formulas are as follows:

[0108]

[0109]

[0110] In the formula, This indicates a translation along the positive Y-axis of the base coordinate system. Homogeneous translation operator matrix of distance; The length of photovoltaic module 4 is the pre-input value in step S1. The longitudinal spacing of the photovoltaic support structure; These are the absolute position coordinate components of the second photovoltaic module 4 target installation position relative to the origin of the base coordinate system on the X, Y, and Z axes, respectively.

[0111] After precisely calculating the target installation pose matrix of the second photovoltaic module 4 Subsequently, the path planning module and motion control module of electrical control box 1 are linked in a closed loop. To ensure vibration prevention and safety during the movement of heavy-duty panels, the system forces the operating machinery to automatically execute four spatial pose transformations and flexible control in sequence according to the optimal anti-interference path:

[0112] First transformation (vertical lifting): Based on the current material picking posture, the motion control module uses a fifth-order polynomial speed curve planning algorithm to drive the servo motors of each joint to vertically lift the vacuum suction cup assembly with the second photovoltaic module 4 attached to it to the preset safe overload height (300mm from the upper edge of the hopper), so that the photovoltaic module 4 can be smoothly transformed into a middle high-altitude transport posture and completely get out of the mechanical interference zone of the hopper.

[0113] Second transformation (high-altitude alignment): The path planning module generates a rotation trajectory and controls the boom rotating base and end effector to synchronously perform angle transformation, so that the long side of the second photovoltaic module 4 is aligned with the tilting assembly direction of the target photovoltaic bracket in the air.

[0114] The third transformation (cantilever forward extension and fine-tuning of rotation): as follows Figure 9 and Figure 10 As shown, electrical control box 1 sends bus commands to the servo system, driving the multi-stage telescopic boom to extend smoothly and at high speed, performing a linear forward movement. (Comparison) Figure 8 (Manual installation of the first piece) and Figure 10 The top view (of the automatically installed second piece) clearly shows the qualitative change in the spatial posture of the robotic arm: such as Figure 10As shown, in order to accurately reach the upper left corner workstation 2, the boom rotating base 6 controls the multi-stage telescopic boom to perform a specific angle of yaw rotation in the horizontal plane in a counterclockwise direction (slightly upward). The extension stroke and pitch attitude of the telescopic boom 9 and telescopic flying boom 10 in space are adaptively changed, thereby quickly and accurately pushing the second photovoltaic module 4 directly above the calculated second target workstation (the critical stop point 150mm away from the bracket mounting surface), and adjusting the end joint to keep its plane parallel to the bracket mounting surface in the air.

[0115] Fourth transformation (quintic polynomial flexible downward positioning and safe release): The control system uses inverse kinematics algorithms to transform the final target matrix. The inverse kinematics is calculated as the target endpoint angular displacement of each moving joint. Subsequently, the system switches to a low-speed, high-precision S-curve speed control mode, driving the robotic arm to slowly and finely adjust the downward pressure of the second photovoltaic module 4. For example... Figure 9 As shown in the front view, at the instant of downward contact, a laser rangefinder located at the end and torque sensors installed at each rotating joint perform dynamic closed-loop real-time monitoring. The control system continuously reads multi-point flatness values ​​and vertical contact pressure. Flatness deviation is considered to be within a certain range if and only if it is less than a certain value. When the contact pressure reaches the set safe pressure threshold, the system determines that the second photovoltaic module 4 has been flexibly attached to the mounting surface of the bracket. The electrical control box 1 then sends a positive pressure venting command to break the vacuum, and the vacuum suction cup assembly is quickly released, completing the installation of the second photovoltaic module 4.

[0116] Derivation of automatic blind splicing and lateral translation of the third photovoltaic module 4 (bottom right corner):

[0117] After the second photovoltaic module 4 (top left station 2) is installed, the robotic arm returns empty again to perform the third spatial material handling operation. The scissor lifting mechanism at the bottom of the hopper and the photoelectric sensor perform dynamic closed-loop compensation again to forcibly lock the grabbing height of the third photovoltaic module 4 at the physical zero reference.

[0118] After the material is collected, according to Figure 4 As shown in the installation sequence diagram, the third photovoltaic module 4 is located laterally adjacent to the first photovoltaic module 4 (i.e., lower right corner station 3). The pose calculation module calls the cached lower left corner homogeneous transformation matrix of the first piece. Multiply it by the width of the photovoltaic module on the right. Horizontal spacing of the bracket The constructed lateral translation operator matrix automatically calculates the target installation pose matrix of the third photovoltaic module 4. :

[0119]

[0120]

[0121] In the formula, This indicates a translation along the positive X-axis of the base coordinate system. Homogeneous translation operator matrix of distance; The width of photovoltaic module 4 is the value pre-input in step S1. The horizontal spacing of the photovoltaic support structure; These are the absolute position coordinate components of the third photovoltaic module 4 target installation position relative to the origin of the base coordinate system on the X, Y, and Z axes, respectively.

[0122] The system controls the operating machinery to continue to perform four spatial pose transformations: after lifting overload and high-altitude alignment, the boom rotating base controls the multi-stage telescopic boom to rotate clockwise (to the right) in the horizontal plane, performing yaw trajectory changes across the array; the multi-stage telescopic boom performs a straight extension based on the distance obtained from the inverse kinematics solution, pushing the third photovoltaic module 4 to the top of the lower right corner workstation 3, and performs the same five polynomial flexible downward pressing and safe release as described above.

[0123] The composite blind splicing and long cantilever seismic control of the fourth photovoltaic module 4 (top right corner extreme position):

[0124] After the third photovoltaic module 4 is installed, the robotic arm returns to perform the fourth spatial material retrieval operation, and the feeding mechanism completes the final height benchmark compensation.

[0125] according to Figure 4 As shown, the fourth photovoltaic module 4 is located at the upper right corner of the "grid" array, which is both laterally offset and longitudinally distant. This position is the extreme position with the longest cantilever forward distance and the greatest gravity overturning moment in the current array workstation of the entire equipment.

[0126] The pose calculation module will initialize the matrix. By multiplying by the composite spatial translation operator matrix on the right, the target installation pose matrix of the fourth photovoltaic module 4 is calculated. :

[0127]

[0128]

[0129] In the formula, This represents a composite homogeneous translation operator matrix that simultaneously causes spatial offsets along the X and Y axes of the base coordinate system. These are the absolute position coordinate components of the fourth photovoltaic module 4 (i.e., the farthest extreme position) relative to the origin of the base coordinate system on the X, Y, and Z axes, respectively.

[0130] After solving this target matrix containing the maximum displacement component... Subsequently, because heavy-duty cantilever arms with large aspect ratios are prone to end-effector mechanical flutter during high-speed extension and retraction, the system automatically invokes a more stringent anti-seismic control strategy during the third transformation (cantilever extension) and the fourth transformation (cantilever lowering) of the four spatial pose transformations:

[0131] Electrical control box 1 not only utilizes a fifth-order polynomial velocity curve to ensure continuous and abrupt jerk changes, but also further limits the maximum feed rate of the telescopic arm's slide rail. After the end effector carrying photovoltaic module 4 extends to directly above station 4 with its longest cantilever stroke, the control system monitors the load data of the torque sensors of each rotary joint in real time; during the fine-tuning and pressing contact phase, it relies heavily on the flatness value fed back by the end effector's laser rangefinder for flexible compensation. When it is confirmed that the flatness deviation of photovoltaic module 4 is less than [value missing] at the farthest limit station, [further details are needed]. After the contact pressure is qualified, the system releases the vacuum suction cup, and the four photovoltaic modules in the current "grid" array are fully assembled automatically.

[0132] Before lowering the multi-degree-of-freedom end effector and releasing the vacuum suction cup, the contact pressure and flatness between the photovoltaic module 4 and the photovoltaic support are confirmed by a laser rangefinder configured on the end effector. Only after all values ​​meet the set safety thresholds can the system execute the vacuum release command.

[0133] S6. Large-area construction relocation cycle: After the installation of all photovoltaic modules in the current array position is completed, the control system controls the mobile chassis of the photovoltaic installation equipment to automatically move along the preset straight route to the next target array position and park and lock. Then, the current local relative origin reference is cleared, and steps S2 to S5 are repeated until the installation of all photovoltaic modules is completed. The specific process includes:

[0134] Once the control system confirms that the fourth photovoltaic module 4 (top right corner extreme position) in the current "grid" array has been safely released and installed successfully, the system determines that the installation task for the current position group is complete, and then triggers the transition loop logic:

[0135] First, the electrical control box 1 sends a reset command, controlling the multi-stage telescopic arm and the five-degree-of-freedom end effector to fully retract and fold into a safe transport posture above the tracked chassis 5, avoiding physical collisions during travel. Then, the control system sends a travel command to the track drive module of the mobile chassis 5. The mobile chassis 5 automatically travels forward a predetermined step distance along a pre-set straight route (such as parallel to the arrangement direction of the photovoltaic support columns) until it reaches the next target array workstation. Upon reaching the target workstation, the track drive module engages parking lock (or mechanical parking via hydraulic outriggers) to ensure the stability of the entire machine on slopes or uneven ground.

[0136] After the parking lock is engaged, the control system actively erases the previous spatial local relative origin reference (i.e., the previous one) from the temporary dynamic buffer. The matrix completely eliminates the accumulated spatial error between two adjacent "grid" arrays, preventing spatial errors generated during the transition from affecting the automatic installation process. After clearing, the system status is initialized, and steps S2 (high-consistency physical material supply and positioning) to S5 (subsequent component blind assembly installation without identification) are executed again in a loop, thereby starting the automated construction of the next array.

[0137] The above description is merely a further explanation of the present invention in conjunction with specific embodiments. All descriptions made do not imply any limitation on the scope of protection of the present invention. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for installing photovoltaic modules, comprising controlling photovoltaic installation equipment via a control system to install photovoltaic modules onto a photovoltaic support structure, characterized in that, Includes the following steps: S1, Global Parameter Pre-input: Input the geometric dimensions of the photovoltaic modules and the relative spacing of the photovoltaic support array into the control system; S2. High-consistency physical feeding and positioning: After completing step S1, the X-direction boundary of the photovoltaic module in the hopper coordinate system of the photovoltaic installation equipment and the reference height in the Y-direction are locked by driving the fork teeth and the material lifting mechanism, respectively. S3. Material picking based on physical consistency: After completing step S2, the position and attitude information of each joint of the telescopic arm and the end effector are collected. Combined with the position information obtained in step S2, the initial pose of the photovoltaic module relative to the end vacuum suction cup is calculated. Based on the initial pose, the end effector is controlled to adjust the spatial pose so that the vacuum suction cup is aligned with the surface of the photovoltaic module and adsorbed. S4. First piece teaching and calibration at the current array station: After completing step S3, in the current array station, the end effector is controlled by manual remote control to accurately place the first adsorbed photovoltaic module at the predetermined position of the target photovoltaic bracket; after placement, the control system locks the position encoder parameters of each joint of the telescopic arm and the end effector at this time, and converts them into the spatial local relative origin reference of the current array station. S5. Blind installation of subsequent photovoltaic modules in the array station without identification: After completing step S4, the control system calculates the target installation pose matrix for the remaining photovoltaic modules in the current array station based on the pre-input photovoltaic module geometric parameters and the relative spacing parameters of the photovoltaic support array in step S1, and automatically drives each mechanical joint of the photovoltaic installation equipment to perform spatial trajectory interpolation along the planned smooth speed curve, thereby completing the automatic installation of subsequent photovoltaic modules in sequence. S6. Large-scale construction site transfer cycle: After the installation of all photovoltaic modules in the current array station is completed, the control system controls the mobile chassis of the photovoltaic installation equipment to automatically move along the preset straight route to the next target array station and park and lock it. Then, the current local relative origin reference is cleared and steps S2 to S5 are repeated until the installation of all photovoltaic modules is completed.

2. The photovoltaic module installation method according to claim 1, characterized in that: The specific process of step S2, high-consistency physical material feeding and positioning, includes: After inserting and flipping the entire box of photovoltaic modules, the drive fork tooth stop is placed against the edge of the photovoltaic module to prevent lateral movement and lock the photovoltaic module's X-direction boundary in the hopper coordinate system; The photovoltaic modules are lifted upward by the material lifting mechanism until the photoelectric sensor set above the material lifting mechanism is triggered, locking the top photovoltaic module to be grabbed at the reference height in the Y direction, thereby establishing the physical pose consistency reference of the top photovoltaic module in the hopper coordinate system.

3. The photovoltaic module installation method according to claim 2, characterized in that: In step S3, which is based on the physical consistency benchmark for material handling, after each photovoltaic module is removed, the material lifting mechanism automatically pushes the photovoltaic module stack upwards to raise the height of a single module according to the photovoltaic module thickness parameters pre-input in step S1. When the upper surface of the top photovoltaic module is blocked again and triggers the detection beam of the photoelectric sensor, the drive motor brakes and locks, so that the height coordinate of the newly exposed top photovoltaic module remains consistent with the initial Y-direction height coordinate when the previous photovoltaic module was grabbed, and returns to the physical pose consistency benchmark obtained in step S2.

4. The photovoltaic module installation method according to claim 3, characterized in that: The specific process of converting the spatial local relative origin reference in step S4, the first piece teaching calibration of the current array station, includes: Define the mobile chassis as the base coordinate system The center of the end-effector's suction cup is in the tool coordinate system. ; After the first photovoltaic module is precisely placed manually, the tool coordinate system in the current state is calculated using forward kinematics. Relative to the base coordinate system The initial homogeneous transformation matrix It is saved as a local spatial relative origin reference.

5. The photovoltaic module installation method according to claim 4, characterized in that: In step S5, the blind installation of subsequent photovoltaic modules at the array station without identification is carried out by automatically calculating the target installation pose matrix of each subsequent photovoltaic module using a relative coordinate space translation operator. The specific process includes: For the first in a set of photovoltaic module arrays Block photovoltaic modules, their target installation pose matrix By initial homogeneous transformation matrix Obtained by right multiplication by the corresponding spatial translation operator matrix; Among them, if the first If the photovoltaic module is located laterally adjacent to the first photovoltaic module, then the derivation formula for the target installation pose matrix is: If the first If the photovoltaic module is located in a vertically adjacent position to the first photovoltaic module, then the derivation formula for the target installation pose matrix is: in, The length of the photovoltaic module is the pre-input value in step S1. Width of the photovoltaic module; The horizontal spacing of the photovoltaic support structure pre-input in step S1, This refers to the longitudinal spacing of the photovoltaic support structure.

6. The photovoltaic module installation method according to claim 5, characterized in that: The specific process of automatically driving the mechanical joints of the photovoltaic installation equipment to perform spatial trajectory interpolation along the planned smooth speed curve in the subsequent blind splicing installation of photovoltaic modules at the array station in step S5 includes: Based on the target installation pose matrix obtained by the control system, the inverse kinematics algorithm is used to calculate the required telescopic displacement of the telescopic arm and the target angular displacement of each rotary joint of the end effector. A quintic polynomial or S-curve velocity curve planning algorithm is used to generate a smooth motion trajectory from the current material picking position to the target angular displacement. The servo motors driving the telescopic arm and the end effector are synchronized along a smooth motion trajectory to perform spatial pose interpolation with continuous acceleration, avoiding microcracks in the photovoltaic modules caused by motion impact.

7. The photovoltaic module installation method according to claim 6, characterized in that: In step S5, during the blind installation of photovoltaic modules at the array station without identification, when driving each mechanical joint to perform spatial trajectory interpolation, the spatial installation path specifically includes four spatial pose transformations executed sequentially: First transformation: Raise the end effector to a safe height, changing the photovoltaic module from a material handling posture to an intermediate transport posture to avoid interference with surrounding obstacles; Second transformation: The horizontally rotating end effector aligns the long side of the photovoltaic module with the docking direction of the target photovoltaic support; Third transformation: Extend the telescopic arm, move the photovoltaic module directly above the target photovoltaic bracket, and adjust its posture to make it parallel to the bracket's mounting plane; Fourth transformation: By combining the pitch and roll angle data in the target installation pose matrix, fine-tuning the downward pressure is performed to precisely align the positioning point on the lower surface of the photovoltaic module with the mating surface of the target photovoltaic bracket, and then the vacuum suction cup is released.

8. The photovoltaic module installation method according to claim 7, characterized in that: In step S5, during the subsequent blind installation of photovoltaic modules at the array station without identification, a safety verification is performed before the fourth transformation. The specific process includes: Before lowering the multi-degree-of-freedom end effector and releasing the vacuum suction cup, the contact pressure and flatness between the photovoltaic module and the photovoltaic support are confirmed by a laser rangefinder configured on the end effector. Only after all values ​​meet the set safety thresholds can the system execute the vacuum release command.

9. A photovoltaic module installation system for implementing the photovoltaic module installation method according to any one of claims 1-8, characterized in that, include: The mobile chassis is used to carry other components of the installation system and to perform movement and parking lock-up between array workstations according to control commands; The material lifting mechanism is mounted on the mobile chassis. The material lifting mechanism includes a hopper, a fork tooth guard, and a scissor lift photovoltaic module with a photoelectric sensor. The fork tooth guard is used to physically lock the X-direction boundary of the photovoltaic module. The scissor lift photovoltaic module is used to automatically compensate for the thickness and height of the photovoltaic module after each material retrieval to maintain the physical pose consistency benchmark of the photovoltaic module to be retrieved. The working machinery mechanism includes a telescopic arm mounted on the mobile chassis and an end effector connected in series at the front end of the telescopic arm; the end effector includes a multi-degree-of-freedom end manipulator, the far end of which is equipped with a vacuum suction cup for gripping photovoltaic modules and a laser rangefinder for safety verification. The control system is communicatively connected to the mobile chassis, material lifting mechanism, and operating machinery mechanism, and is used to control the operation of each photovoltaic module in the installation system and record various data.

10. The photovoltaic module installation system according to claim 9, characterized in that: The control system includes: The pose calculation module is used to establish the homogeneous transformation matrix between the base coordinate system of the mobile chassis, the hopper coordinate system of the material lifting mechanism, and the tool coordinate system of the multi-degree-of-freedom end effector. It also uses a forward kinematics algorithm to solve the spatial local relative origin reference and the target installation pose matrix of each subsequent photovoltaic module. The path planning module is used to calculate and generate a smooth motion trajectory with continuous acceleration for the working mechanical mechanism to move from the material picking position to the target installation position matrix using a fifth-order polynomial or S-shaped velocity curve planning algorithm. The motion control module is used to use inverse kinematics algorithm to decompose the smooth motion trajectory into the extension and retraction of the telescopic arm and the angular displacement of each rotary joint, and send drive commands to the corresponding servo drive device in real time to realize trajectory closed-loop tracking control.

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