Quickly dismountable unmanned aerial vehicle for photovoltaic panel defect detection

Abstract

The utility model relates to a quick dismounting unmanned plane for photovoltaic panel defect detection, including control unit, frame, detection pod, load cabin, battery module, data plug and detachable structure, control unit, load cabin and data plug all install on the frame, detection pod and load cabin adopt detachable structure connection, load cabin and frame adopt detachable structure connection, battery module adopts detachable structure and installs on load cabin, battery module is connected with detection pod and control unit electricity respectively, detection pod passes through data plug and is connected with control unit communication, detection pod, load cabin and battery module all are quick installation or quick dismounting. The utility model has adopted the modular installation mode, and detection pod, load cabin and battery module all are quick installation or quick dismounting, connect through data plug, have realized the hot plug in the data transmission process, and the convenient replacement.

Description

Technical Field

[0001] This utility model relates to unmanned aerial vehicles (UAVs), and more particularly to a rapid disassembly and assembly UAV for detecting defects in photovoltaic panels. Background Technology

[0002] With the continuous expansion of photovoltaic power generation, the installed capacity of photovoltaic power plants is growing exponentially. Large-scale photovoltaic arrays place higher demands on inspection platforms in terms of endurance, load capacity, and environmental adaptability. Traditional commercial drones that rely on plastic or lightweight alloy materials are prone to structural fatigue in complex environments such as high temperatures and strong winds. Their endurance is often insufficient to complete the comprehensive inspection of hundreds of photovoltaic panels, and the efficiency of on-site replacement of pods and power components is low, making it difficult to meet the dual demands of operation and maintenance cost and speed.

[0003] Existing UAV platforms mostly employ fixed battery compartments and non-modular mounting structures. The connection points between the fuselage and pods typically use conventional rivets or bolts, lacking rapid maintenance and hot-swappable capabilities. Furthermore, the design of the airframe's heat dissipation and protection levels often fails to adequately consider the comprehensive impact of prolonged high-load operation on structural materials, resulting in insufficient reliability in extreme temperature (-20℃ to 60℃) or dusty environments. Therefore, there is an urgent need for a long-endurance aviation platform based on an integrated design of carbon fiber composite materials and a high-strength aluminum alloy frame, achieving lightweight, high-strength, modular maintenance, and efficient heat dissipation and protection to meet the application requirements of photovoltaic module defect detection.

[0004] Utility model patent CN220996803U discloses a portable unmanned aerial vehicle (UAV) with a foldable and retractable powered arm. The UAV includes a powered arm compartment, with a connecting compartment, a control and payload compartment, and an optoelectronic pod sequentially connected to its lower end. A satellite navigation antenna is installed inside the powered arm compartment. The control and payload compartment contains a flight control system module, a data link module, and a mission payload module. The powered arm compartment has four powered arm placement slots, each containing a folding arm. The lower end of the folding arm is connected to a rotating shaft inside the connecting compartment. The folding arm has a hollow central structure, and a telescopic arm is located within this hollow structure. A brushless DC motor is installed at the end of the telescopic arm, and a propeller is mounted on the output shaft of the brushless DC motor. This patent does not allow for quick installation or disassembly.

[0005] Therefore, providing a modular installation method for drones that can be quickly installed or disassembled is an urgent problem to be solved. Utility Model Content

[0006] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a rapid disassembly and assembly drone for photovoltaic panel defect detection.

[0007] The objective of this utility model can be achieved through the following technical solutions:

[0008] According to one aspect of this utility model, a rapid assembly / disassembly drone for photovoltaic panel defect detection is provided, comprising a control unit, a frame, a detection pod, a payload compartment, a battery module, a data plug, and a detachable structure. The control unit, payload compartment, and data plug are all mounted on the frame. The detection pod and payload compartment are connected by a detachable structure, and the payload compartment and frame are connected by a detachable structure. The battery module is mounted on the payload compartment by a detachable structure. The battery module is electrically connected to both the detection pod and the control unit. The detection pod is communicatively connected to the control unit via the data plug.

[0009] As a preferred technical solution, the UAV also includes a quick-release interface, which is mounted on the frame, and the payload compartment is connected to the frame through the quick-release interface.

[0010] As a preferred technical solution, the load compartment includes a base plate and quick-release buckles, the base plate and quick-release buckles are connected, and the base plate is connected to the frame through the quick-release buckles.

[0011] As a preferred technical solution, the payload compartment further includes a guide rail groove, which is mounted on the base plate, and the battery module is mounted on the base plate via the guide rail groove.

[0012] As a preferred technical solution, the drone also includes a cover plate and a silicone sheet, wherein the silicone sheet is mounted on the battery module and the cover plate is mounted on the silicone sheet.

[0013] As a preferred technical solution, the detection pod includes a gimbal assembly and a camera unit, the gimbal assembly and the camera unit are connected, and the gimbal assembly and the payload compartment are connected.

[0014] As a preferred technical solution, the gimbal assembly includes a pod top cover and quick-release bolts, the quick-release bolts being installed on the pod top cover and connected to the load compartment.

[0015] As a preferred technical solution, the camera unit includes a camera and an infrared thermal imager, which are electrically connected to the battery module respectively, and both the camera and the infrared thermal imager are communicatively connected to the control unit via a data plug.

[0016] As a preferred technical solution, the frame includes a skin, support legs, a chassis, and a rotor, wherein the rotor, support legs, and skin are all mounted on the chassis.

[0017] As a preferred technical solution, the chassis is made of carbon fiber reinforced plastic injection molding.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1. This utility model adopts a modular installation method. The testing pod, payload compartment and battery module can be quickly installed or quickly disassembled and connected through a data plug, realizing hot-swapping during data transmission and facilitating replacement.

[0020] 2. This utility model is equipped with a quick-release interface, which enables quick installation or quick disassembly between the load compartment and the frame.

[0021] 3. This utility model is equipped with a quick-release buckle, which enables quick installation or quick disassembly between the base plate and the quick-release buckle.

[0022] 4. This utility model is equipped with quick-release bolts, which enables quick installation or quick disassembly between the quick-release bolts and the load chamber.

[0023] 5. This utility model adopts an integrated design of carbon fiber composite material and high-strength aluminum alloy frame to achieve lightweight, high strength and modular maintenance. Attached Figure Description

[0024] Figure 1 This is a top view of the present invention;

[0025] Figure 2 This is a schematic diagram of the overall structure of this utility model;

[0026] Figure 3 This is a schematic diagram of the structure of the testing pod of this utility model;

[0027] Figure 4 This is a schematic diagram of the detection pod of this utility model from another perspective;

[0028] 11. Skin; 12. Frame; 13. Quick-release interface; 14. Support foot; 20. Control unit; 30. Detection pod; 31. Gimbal assembly; 32. Bearing; 33. Camera; 34. Infrared thermal imager; 35. Quick-release bolt; 40. Payload compartment; 41. Quick-release clip; 42. Data connector; 50. Chassis. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of the present utility model. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present utility model.

[0030] To address the current limitations of insufficient flight time for comprehensive inspection of hundreds of photovoltaic panels and the low efficiency of on-site replacement of pods and power components, which fails to meet the dual requirements of cost-effectiveness and speed in maintenance, this invention provides a rapid-installation drone for photovoltaic panel defect inspection. This invention employs a modular installation method, allowing for quick installation and removal of the inspection pod, payload compartment, and battery module. Connections are made via data connectors, enabling hot-swapping during data transmission for convenient replacement. The invention features quick-release interfaces for rapid installation and removal between the payload compartment and the frame. Quick-release clips facilitate rapid installation and removal between the base plate and the clips. Quick-release bolts enable rapid installation and removal between the bolts and the payload compartment. Finally, the invention utilizes an integrated design of carbon fiber composite material and a high-strength aluminum alloy frame, achieving lightweight, high-strength, and modular maintenance.

[0031] Example 1

[0032] like Figures 1-4 As shown, a rapid-installation / removal UAV for photovoltaic panel defect detection includes a control unit 20, a frame 12, a detection pod 30, a payload compartment 40, a battery module, a data connector 42, and a detachable structure. The control unit 20, payload compartment 40, and data connector 42 are all mounted on the frame 12. The detection pod 30 and payload compartment 40 are connected by a detachable structure, and the payload compartment 40 and frame 12 are also connected by a detachable structure. The battery module is detachably mounted on the payload compartment 40 and electrically connected to both the detection pod 30 and the control unit 20. The detection pod 30 is communicatively connected to the control unit 20 via the data connector 42. All components—the detection pod 30, payload compartment 40, and battery module—are designed for rapid installation or removal.

[0033] The drone also includes a quick-release interface 13, which is mounted on the frame 12, and the payload compartment 40 is connected to the frame 12 via the quick-release interface 13.

[0034] In this embodiment, when installing the control unit 20, a dedicated cabin is opened on the top of the frame 12, which is fixed with aerospace-grade studs and spring washers, and connected to the wiring harness inside the frame 12 through a reserved pin connector. Subsequently, the detection pod 30 and the payload pod 40 are fixed to the quick-release interface 13 at the bottom of the frame 12 with M6 stainless steel bolts and fluororubber sealing rings, respectively. The detection pod 30 is connected to the battery module and the data plug 42, respectively, to achieve modular hot-swappable design.

[0035] The load compartment 40 includes a base plate and a quick-release buckle 41, which are connected together. The base plate is connected to the frame 12 via the quick-release buckle 41.

[0036] The payload compartment 40 also includes a guide rail groove, which is mounted on the base plate, and the battery module is mounted on the base plate through the guide rail groove.

[0037] In this embodiment, the base plate 40 of the payload compartment 40 is a 200×150mm 6061-T6 aluminum alloy CNC machined part with anodized surface and a thickness of 3mm; four corners are equipped with aerospace magnesium alloy quick-release buckles 41, with an insertion stroke of 5mm and a pull-out load ≥50N. A 20-pin hole is located at the center of the base plate 42 for inserting an aerospace-grade gold-plated connector, with a insertion / removal life ≥5000 cycles. The battery module's power supply components include two 10,000mAh lithium polymer batteries, each with a magnesium-aluminum alloy die-cast casing, 12 Φ2mm heat dissipation holes on the outer wall, and an internal PTC temperature control patch and overcurrent protection board; the battery module engages with the base plate via a guide rail groove, locking with a gentle push after installation and ejecting with a single button for disassembly.

[0038] A through hole is also provided on the base plate. The through hole and the data plug 42 are coaxial, which makes it convenient for data cables and other cables to be connected to the data plug 42 through the through hole.

[0039] The drone also includes a cover plate and a silicone sheet, the silicone sheet being mounted on the battery module and the cover plate being mounted on the silicone sheet.

[0040] In this embodiment, the battery module consists of sequentially inserted lithium polymer battery modules, covered with a magnesium-aluminum alloy cover plate and a thermally conductive silicone sheet, completing the initial assembly and wiring of the entire device.

[0041] The detection pod 30 includes a gimbal assembly 31 and a camera unit, the gimbal assembly 31 and the camera unit are connected, and the gimbal assembly 31 is connected to the payload compartment 40.

[0042] The gimbal assembly 31 includes a pod top cover and quick-release bolts 35. The quick-release bolts 35 are installed on the pod top cover and are connected to the load compartment 40.

[0043] The camera unit includes a camera 33 and an infrared thermal imager 34. The camera 33 and the infrared thermal imager 34 are electrically connected to the battery module, and both the camera 33 and the infrared thermal imager 34 are communicatively connected to the control unit 20 via a data plug 42.

[0044] The frame 12 includes a skin 11, support legs 14, a chassis 50, and a rotor. The rotor, support legs 14, and skin 11 are all mounted on the chassis 50. The chassis 50 is made of carbon fiber reinforced plastic through injection molding.

[0045] In this embodiment, the drone assembly first involves pre-processing the carbon fiber composite skin 11 and the frame 12 of the 6061-T6 aluminum alloy frame, and then completing the fuselage skeleton through precision riveting and bonding processes.

[0046] The skin 11 is made of unidirectional ply carbon fiber prepreg with a thickness of approximately 0.8 mm. After being cured in an autoclave, it is integrally bonded to the aluminum alloy frame 12 to ensure overall strength and rigidity. Each section of the aluminum alloy frame is machined using a CNC milling machine, and stress-relieving through holes are provided at the joints. The threaded hole machining tolerance is ±0.05 mm.

[0047] The support leg 14 is made of ceramic-coated stainless steel, with dimensions of Φ8×120mm. It is connected to the carbon fiber bracket by interference fit and is equipped with anti-loosening nuts to ensure structural stability in environments ranging from -20℃ to 60℃.

[0048] The outer shell of the detection pod 30 is injection molded from carbon fiber and high-temperature resistant polymer composite material, with an outer diameter of Φ150mm and a height of 120mm. The internal assembly first houses a three-axis gimbal assembly 31, whose bearings 32 and corresponding support rods are made of ceramic-coated stainless steel, with a bearing clearance ≤0.02mm. The gimbal assembly 31 is vibration-isolated from the shell of the detection pod 30 through four-point elastic support. Subsequently, a Sony IMX307 visible light camera 33 and an uncooled vanadium oxide infrared thermal imager 34 are installed. Each sensor is connected to the pod's base plate via aerospace-grade FPC cables and secured with silicone sealant. The pod's top cover is secured with four quick-release bolts 35, allowing for on-site maintenance or replacement of the camera module within 2 minutes after opening the cover.

[0049] The data processing unit chassis 50 is made of carbon fiber reinforced plastic injection molded parts, featuring a top opening and aluminum alloy rails on the front panel for mounting the embedded GPU cooling module and a 2TB NVMe SSD. The GPU cooling module consists of aluminum alloy heatsinks and thermally conductive copper pillars, with fin thickness of 0.5mm and a spacing of 1.5mm. The SSD is secured to the bottom bracket with M3 screws and equipped with rubber shock-absorbing pads, supporting ±5g vibration. All hardware interfaces adopt a standard M.2, PCIe, and USB-C pluggable layout for easy future upgrades and maintenance.

[0050] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this utility model, and these modifications or substitutions should all be covered within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.

Claims

1. A rapid assembly / disassembly drone for photovoltaic panel defect detection, characterized in that, The device includes a control unit (20), a rack (12), a detection pod (30), a payload compartment (40), a battery module, a data plug (42), and a detachable structure. The control unit (20), the payload compartment (40), and the data plug (42) are all mounted on the rack (12). The detection pod (30) and the payload compartment (40) are connected by a detachable structure. The payload compartment (40) and the rack (12) are connected by a detachable structure. The battery module is mounted on the payload compartment (40) by a detachable structure. The battery module is electrically connected to the detection pod (30) and the control unit (20) respectively. The detection pod (30) is communicatively connected to the control unit (20) through the data plug (42).

2. The rapid assembly / disassembly drone for photovoltaic panel defect detection according to claim 1, characterized in that, The UAV also includes a quick-release interface (13), which is mounted on the frame (12), and the payload compartment (40) is connected to the frame (12) through the quick-release interface (13).

3. The rapid assembly / disassembly drone for photovoltaic panel defect detection according to claim 2, characterized in that, The load compartment (40) includes a base plate and a quick-release buckle (41), the base plate and the quick-release buckle (41) are connected, and the base plate is connected to the frame (12) through the quick-release buckle (41).

4. A rapid assembly / disassembly drone for photovoltaic panel defect detection according to claim 3, characterized in that, The payload compartment (40) also includes a guide rail groove, which is mounted on the base plate, and the battery module is mounted on the base plate through the guide rail groove.

5. A rapid assembly / disassembly drone for photovoltaic panel defect detection according to claim 4, characterized in that, The drone also includes a cover plate and a silicone sheet, the silicone sheet being mounted on the battery module and the cover plate being mounted on the silicone sheet.

6. A rapid assembly / disassembly drone for photovoltaic panel defect detection according to claim 1, characterized in that, The detection pod (30) includes a gimbal assembly (31) and a camera unit, the gimbal assembly (31) and the camera unit are connected, and the gimbal assembly (31) and the payload compartment (40) are connected.

7. A rapid assembly / disassembly drone for photovoltaic panel defect detection according to claim 6, characterized in that, The gimbal assembly (31) includes a pod top cover and quick-release bolts (35), which are installed on the pod top cover and connected to the payload compartment (40).

8. A rapid assembly / disassembly drone for photovoltaic panel defect detection according to claim 7, characterized in that, The camera unit includes a camera (33) and an infrared thermal imager (34). The camera (33) and the infrared thermal imager (34) are electrically connected to the battery module, and the camera (33) and the infrared thermal imager (34) are both connected to the control unit (20) via a data plug (42).

9. A rapid assembly / disassembly drone for photovoltaic panel defect detection according to claim 1, characterized in that, The frame (12) includes a skin (11), support feet (14), a chassis (50) and a rotor, all of which are mounted on the chassis (50).

10. A rapid assembly / disassembly drone for photovoltaic panel defect detection according to claim 9, characterized in that, The chassis (50) is made of carbon fiber reinforced plastic injection molding.

Images