Solar Panel Handling System

Abstract

A system for installing solar panels may include an arm assembly tool end and a linear guide assembly coupled to the arm assembly tool end. The arm assembly tool end includes a frame and a plurality of attachment devices, such as suction cups, coupled to the frame. The linear guide assembly includes a linearly movable fastener including an engagement member configured to engage a slidably coupled clamp assembly with an installation structure, and a force-torque transducer configured to move the fastener along the installation structure. A controller is configured to control the force-torque transducer and the plurality of attachment devices. The arm assembly tool end is coupled to a robotic arm and is part of an assembly robot, including autonomous and non-autonomous vehicles. Various components may be operated by a control system based on operation commands received from a neural network.

Description

[Technical Field]

[0001] The present disclosure relates generally to solar panel handling systems, and more particularly to systems for installing solar panels on installation structures. [Background technology]

[0002] In the discussion that follows, reference will be made to certain structures and / or methods. However, such reference should not be construed as an admission that these structures and / or methods constitute prior art. Applicant expressly reserves the right to demonstrate that such structures and / or methods do not qualify as prior art against the present invention.

[0003] Solar array installation typically involves mounting solar panels to a mounting structure. This support provides mounting points for the individual solar panels and also assists with routing of electrical systems and, if applicable, any mechanical components. Due to the fragile nature and large size of solar panels, the process of mounting solar panels to a mounting structure poses unique challenges. For example, in many instances, solar panels in a solar array are mounted on a rotatable structure that may rotate the solar panels about an axis, allowing the array to track the sun. In such instances, it is difficult to ensure that all of the solar panels in the array are coplanar and level with respect to the axis of the rotating structure. Furthermore, the installation costs of a solar array can be a significant portion of the total construction cost of the solar array. Therefore, there is a need for a more effective and reliable solar panel handling system for installing solar panels into a solar array. Summary of the Invention [Problem to be solved by the invention]

[0004] SUMMARY OF THE INVENTION Accordingly, the present invention is directed to a solar panel handling system that substantially obviates one or more of the problems due to limitations and disadvantages of the related art. [Means for solving the problem]

[0005] The solar panel handling system disclosed herein facilitates installation of solar panels of a solar array on existing installation structures, such as torque tubes, etc. Installing the solar panels can be made more efficient and reliable by combining tooling for handling the solar panels with components that enable coupling of the solar panels to the solar panel support structure.

[0006] Additional features and advantages of the invention will be set forth in the following description, and in part will be obvious from the description, or may be learned by the practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof, as well as the appended drawings.

[0007] To achieve these and other advantages and in accordance with the purposes of the present invention, as embodied and broadly described, a system for installing solar panels may include a frame and an arm assembly tool end including a suction cup coupled to the frame, and a linear guide assembly coupled to the arm assembly tool end, the linear guide assembly including a linearly movable fastener including an engagement member configured to engage a clamp assembly slidably coupled to a installation structure, a force-torque transducer configured to move the fastener along the installation structure, a controller coupled to the frame and configured to control the force-torque transducer and the suction cup, and a junction box including a power source.

[0008] In another aspect, a method of installing a solar panel may include engaging an arm assembly tool end with a solar panel, the arm assembly tool end including a frame and a suction cup coupled to the frame; positioning the solar panel against a mounting structure having a clamp assembly slidably coupled thereto; engaging a linear guide assembly coupled to the arm assembly tool end with a clamp assembly, the linear guide assembly including a linearly movable fastener including an engagement member configured to engage the clamp assembly and a force-torque converter configured to move the linearly movable fastener along the mounting structure; and actuating the force-torque converter to move the clamp assembly along the mounting structure to engage a side of the solar panel, thereby securing the solar panel to the mounting structure.

[0009] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

[0010] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate the invention and, together with the description, further serve to explain the principles of the invention and enable one skilled in the art to make and use the invention. Illustrative embodiments are best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, dimensions of the various features have been arbitrarily enlarged or reduced for clarity. The following figures are included in the drawings: [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a perspective view of a solar panel handling system with a solar panel container according to an embodiment of the present disclosure. [Figure 2A]FIG. 2 is a top view of the solar panel handling system and solar panel container of FIG. 1. [Figure 2B] FIG. 2 is a front view of the solar panel handling system and solar panel container of FIG. 1. [Figure 2C] FIG. 2 is a side view of the solar panel handling system and solar panel container of FIG. 1. [Figure 3A] FIG. 1 illustrates a top view of a solar panel handling system coupled to a single solar panel, according to an embodiment of the present disclosure. [Figure 3B] FIG. 1 is a side view of a solar panel handling system coupled to a single solar panel, according to an embodiment of the present disclosure. [Figure 3C] FIG. 1 is a front view of a solar panel handling system coupled to a single solar panel, according to an embodiment of the present disclosure. [Figure 4A] FIG. 1 is a perspective view of a solar panel handling system according to an embodiment of the present disclosure. [Figure 4B] FIG. 1 is a perspective view of a solar panel handling system according to an embodiment of the present disclosure. [Figure 5A] FIG. 1 illustrates a top view of a solar panel handling system according to an embodiment of the present disclosure. [Figure 5B] FIG. 1 is a front view of a solar panel handling system according to an embodiment of the present disclosure. [Figure 5C] FIG. 1 is a side view of a clamp of a solar panel handling system in a stowed position according to an embodiment of the present disclosure. [Figure 5D] FIG. 1 is a side view of a clamp of a solar panel handling system in an extended or advanced position, according to an embodiment of the present disclosure. [Figure 6A] FIG. 1 is a perspective view of a fastener of a solar panel handling system engaged with a clamp assembly coupled to a mounting structure, according to an embodiment of the present disclosure. [Figure 6B]FIG. 1 is a perspective view of a fastener of a solar panel handling system engaged with a clamp assembly coupled to a mounting structure, according to an embodiment of the present disclosure. [Figure 7A] FIG. 10 is a top view of a fastener of a solar panel handling system engaging with a clamp assembly coupled to a mounting structure according to an embodiment of the present disclosure. [Figure 7B] FIG. 1 is a front view of a fastener of a solar panel handling system engaged with a clamp assembly coupled to a mounting structure, according to an embodiment of the present disclosure. [Figure 7C] FIG. 1 is a side view of a fastener of a solar panel handling system engaging with a clamp assembly coupled to a mounting structure according to an embodiment of the present disclosure. [Figure 7D] FIG. 10 is a rear view of a fastener of a solar panel handling system engaged with a clamp assembly coupled to a mounting structure according to an embodiment of the present disclosure. [Figure 8] FIG. 1 is a schematic overhead view of a solar panel handling system during the process of installing a solar panel, according to an embodiment of the present disclosure. [Figure 9] FIG. 1 is a diagram of a solar panel handling system including an assembly tool coupled with an assembly mobile robot using a robotic arm. [Figure 10] FIG. 1 is a diagram of a solar panel handling system with two robotic arms, in which two assembly tools are coupled with an assembly mobile robot using their respective robotic arms. [Figure 11A] FIG. 1 is a diagram illustrating the process of installing solar panels. [Figure 11B] FIG. 1 is a diagram illustrating the process of installing solar panels. [Figure 11C] FIG. 1 is a diagram illustrating the process of installing solar panels. [Figure 12A] FIG. 1 is a diagram of an arrangement of a mobile robotic system including two modular vehicles and a ground vehicle with two robotic arms. [Figure 12B]FIG. 1 is a diagram of an arrangement of a mobile robotic system including two modular vehicles and a ground vehicle with two robotic arms. [Figure 13] FIG. 1 is a schematic diagram of placement achieved using computer vision registration. [Figure 14] 1 is a schematic diagram of an arrangement in which a modular vehicle is replaced with a new modular vehicle having additional supplemental solar panels. [Figure 15] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 16] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 17] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 17CONT] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 18] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 18CONT] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 19] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 20] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 21] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 21CONT] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 22] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 23]FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 23CONT] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 24] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 24CONT] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 25] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 26] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 27] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 27CONT] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 28] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 29] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 29CONT] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 30] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 31] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 31CONT] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 32] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 33] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 34] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. [Figure 34CONT] FIG. 2 is a detailed view of an exemplary structure of a system for installing solar panels, according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] The features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the drawings, in which like reference characters identify associated elements throughout, in which like reference numbers generally indicate identical, functionally similar, and / or structurally similar elements.

[0013] Reference will now be made in detail to the present embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

[0014] 1 shows a perspective view of a solar panel handling system together with a solar panel box according to an embodiment of the present disclosure, which may include an end of arm assembly tool 100 capable of coupling individual solar panels 120 from the solar panel box and moving them into position relative to a mounting structure for installation.

[0015] The end of the arm assembly tool 100 may include a frame 102 and one or more mounting devices 104 attached to the frame 102. Exemplary mounting devices 104 include suction cups or other structures that can releasably attach to the surface of the solar panel 120 and, at least in aggregate, maintain attachment during manipulation of the solar panel 120 by the end of the arm assembly tool 100. The frame 102 may be comprised of several trusses 102-A to provide structural strength and stability to the frame 102. The frame 102 also serves as a base for the end of the arm assembly tool 100 and other associated components of the solar panel handling system disclosed herein.

[0016] Other relevant components of the solar panel handling system disclosed herein may be coupled to the frame 102 to fix the relative positions of the components on the end of the arm assembly tool 100. One or more of the various components of the solar panel handling system may be coupled to one or more of the trusses 102-A to fix the relative positions of the components on the end of the arm assembly tool 100.

[0017] The mounting device 104 is configured to securely attach to a flat surface, such as the surface of a solar panel, such as by using a vacuum. In suction cup embodiments, the suction cup may operate by pressing the cup against the flat surface, thereby forcing air out of the cup and creating a vacuum seal with the flat surface. As a result, the flat surface adheres to the suction cup, with the adhesive strength and seal integrity with the flat surface determined by the size of the suction cup. In some embodiments, an air inlet (not shown) delivers air onto the flat surface when the flat surface is sealed against the suction cup to release the vacuum and release the flat surface from the suction cup.

[0018] The system may further include a linear guide assembly 106 coupled to the end of the arm assembly tool 100. The linear guide assembly 106 includes a linearly movable fastener 108 with an engagement member 108-A configured to engage a clamp assembly coupled to the installation structure. The linear guide assembly 106 may be operable to move the fastener 108 along an axis, for example, between an extended position and a retracted position. The axis of movement of the fastener 108 may be parallel to the axis of the installation structure. Thus, the linear guide assembly 106 may move the fastener 108 and the engagement member 108-A along the installation structure.

[0019] In some embodiments, the engaging member 108-A may include an electromagnet that may be actuated to grip the clamping assembly 602 (see FIGS. 6A, 6B). Alternatively, or in addition, the engaging member 108-A may include a gripping portion that prevents disengagement between the clamping assembly 602 and the engaging member 108-A when the linear guide assembly 106 is actuated to move the fastener relative to the installation structure, as described in more detail elsewhere herein.

[0020] The linear guide assembly 106 is actuated using a force-torque transducer 110. In some embodiments, the linear guide assembly 106 and the force-torque transducer 110 may form a rack-and-pinion arrangement such that rotation of the force-torque transducer 110 results in advancement or retraction of the fastener 108. In some embodiments, the linear guide assembly 106 may be a hydraulic assembly including a telescoping shaft coupled to the fastener 108. In such embodiments, the force-torque transducer 110 may be configured in the form of a pump for pumping hydraulic fluid. In other embodiments, the force-torque transducer 110 may be configured in the form of or coupled to a linear drive motor that engages a surface of a telescoping shaft coupled to the fastener 108.

[0021] In some embodiments, the linear guide assembly 106 may include an electric rod actuator that moves the fastener 108 parallel to the axis of the installation structure.

[0022] In some embodiments, the guide assembly 106 may include rollers 606 that facilitate movement of the fastener 108 along the mounting structure 604. The rollers may include bearings or other components designed, for example, to reduce friction while the fastener 108 moves relative to the mounting structure. The rollers may be coupled with sensors to provide feedback to the controller, such as through force or rotation sensors.

[0023] In some embodiments, the guide assembly may include a spring mechanism 608 that allows for a small amount of tilt (up to 15 degrees) of the clamp 108 relative to the mounting structure 604. Such tilt may occur when the orienting assembly 804 tilts the end of the arm assembly tool 100 relative to the mounting structure 604 to properly level the solar panel.

[0024] The system may further include a junction box 112 coupled to the frame 102. The junction box 112 may include a controller configured to control the force-torque transducer 110 and the mounting device 104. In some embodiments, the junction box 112 may also include a power supply or power controller for controlling the power supply to the various components.

[0025] In some embodiments, the controller 112 may include a processor operably coupled to a memory. The controller 112 may receive inputs from sensors associated with the solar panel handling system (e.g., optical sensors or proximity sensors 108-B described elsewhere herein). The controller 112 may then process the received signals and output control instructions for controlling one or more components (e.g., the linear guide assembly 106, the fasteners 108, or the mounting device 104). For example, in some embodiments, the controller 112 may receive a signal from a proximity sensor that determines that the clamp assembly is approaching the trailing edge of an installed solar panel and therefore slows down the speed of the linear guide assembly 106 to reduce excessive force and impact on the solar panel.

[0026] Referring to FIG. 8 , in some embodiments, the solar panel handling system may further include an optical sensor 802, such as a camera, a photodetector, or any other optical imaging or light-sensing device. The optical sensor is suitably positioned on the frame 102, for example, on the outer or underside of an edge member, as shown at position 802-A in FIG. 8 , or at an interior position of the frame 102 having a field of view that includes the leading edge of the solar panel, such as shown at position 802-B in FIG. 8 . The optical sensor may be configured to sense the orientation of the solar panel relative to the installation structure during operation of the end of the arm assembly tool 100. In some embodiments, the optical sensor may be configured in the form of one or more light guided levels (not shown). In such embodiments, one or more light beams (e.g., laser beams) may be projected along or parallel to the axis of the installation structure 604 from one end of the end of the arm assembly tool 100, such as a first position on the frame 102. One or more photodetectors may be located at another end of the arm assembly tool 100, such as at a second location on the frame 102, to detect one or more laser beams. Thus, if the installed solar panel 120 is not properly oriented or properly leveled relative to the installation structure 604, the solar panel 120 may block some or all of one or more laser beams, resulting in an altered signal from one or more photodetectors, which may indicate that the solar panel 120 is not properly oriented or leveled relative to the mounting structure 604.

[0027] In some embodiments, one or more sensors, such as optical sensor 802, may be used to detect and identify objects to position and control installation with improved accuracy. The sensors may be implemented, for example, using a neural network in an artificial intelligence (AI) system. For example, the neural network may include acquiring and correcting images related to the solar panel handling system, the solar panels (both installed and to be installed), and the installation environment (both the natural environment, such as topography, and the installed equipment, such as structures associated with the solar array). Also, for example, the neural network may include acquiring and correcting position information or proximity information. The corrected images and / or the corrected position or proximity information are input into the neural network and processed to estimate movement and positioning of equipment in the solar panel handling system, such as that associated with autonomous vehicles, storage vehicles, robotic equipment, and installation equipment. The estimated movement and positioning are issued to control systems associated with individual equipment in the solar panel handling system or to a main controller for the solar panel handling system as a whole.

[0028] In some embodiments, signals from the optical sensors may be input to a controller. In some embodiments, the solar panel handling system may further include an orienting assembly 804 (see FIG. 8 ) configured to tilt the end of the arm assembly tool 100 relative to the mounting structure 604. In such embodiments, the controller 112 may control the orientation in response to input from an optical signal that indicates that the solar panel being installed is not properly oriented or properly level with respect to the mounting structure, such as the torque tube 604. Of course, while the orienting assembly 804 is shown as being coupled to the force-torque transducer 110, one skilled in the art will readily recognize other means of implementing the orienting assembly 804.

[0029] In some embodiments, the controller 112 may also be configured to control the mounting device 104 to activate or deactivate the mounting / detachment of the mounting device 104. In embodiments where the mounting device 104 is a suction cup, a vacuum may enable coupling or decoupling of the solar panel 120 to the end of the arm assembly tool 100.

[0030] In some embodiments, the mounting structure 604 may have an octagonal cross-section, as shown, for example, in Figures 6A, 6B, and 7A-7D, to form a torque tube that prevents inadvertent slippage of the clamp assembly 602. However, other cross-sectional shapes, such as square, oval, or other shapes, may also be used. Additionally, the mounting structure 604 may use a circular cross-sectional shape.

[0031] In some embodiments, the assembly tool 100 can be configured to couple with an assembly mobile robot 903 (examples of which are shown in FIGS. 9 and 10 ). The assembly mobile robot 903 can be configured to position the end of the arm assembly tool 100 relative to a stack of solar panels or a storage container 905, move a selected solar panel, and place the selected solar panel relative to an installation structure 604. In some embodiments, the assembly mobile robot 903 can be operably coupled to the end of the arm assembly tool 100 via a force-torque transducer 110 (or an orienting assembly 804, if applicable). In some embodiments, the assembly mobile robot can also be operably coupled to a controller, allowing an operator of the assembly mobile robot to control various functions of the end of the arm assembly tool 100, such as activating and / or deactivating the attachment device 104, advancing and / or retracting a fastener, and / or activating and / or deactivating an engagement member relative to a clamp assembly.

[0032] 1, 6A, 6B, 7A-7D, 9, and 10, during operation, a solar panel 120 is obtained and placed on the mounting structure 60. The solar panel is then tilted relative to the mounting structure 604 so that the leading edge of the solar panel (i.e., the edge adjacent to the edge of the previously installed solar panel, or, for a first solar panel, the edge adjacent the fastener attached to the mounting structure 604) is oriented closer to the mounting structure 604 than the opposing trailing edge. The leading edge is then placed into a receiving channel (either a receiving channel positioned along the edge of the previously installed solar panel, i.e., as part of a clamp assembly, or within a fastener), and the tilt of the solar panel is reduced to an installed position on the mounting structure. In the installed position, the tilt angle is reduced while the solar panel is urged into the receiving channel so that an edge region of the solar panel's upper plane (i.e., the photovoltaic active surface oriented toward the sun) is captured within the receiving channel. An exemplary embodiment of a receiving channel 610 on a clamp assembly 602 is shown in Figures 6A and 6B.

[0033] Once the solar panel is in place on the installation structure, the force-torque actuator 110 actuates the guide assembly 106 on the end of the arm assembly tool 100 to bring the engagement member 108-A of the fastener 108 into contact with the clamp assembly 602. This clamp assembly was originally positioned on the installation structure outside the area occupied by the solar panel being installed, but close enough to be reached by the associated components on the end of the arm assembly tool 100. The surfaces and features of the engagement member 108-A can be positioned and sized to mate with complementary features on the clamp assembly 602. After this contact, the force-torque actuator 110 is actuated (either continues to actuate or acts in a second mode) to slide the clamp assembly 602 axially along a portion of the length of the installation structure 604. The axial sliding of the clamp assembly 602 causes the receiving channel of the clamp assembly 602 to engage the trailing edge of the solar panel that was just installed. A sensor, such as in the force-torque actuator 110 or in the fastener 108, may provide feedback to the controller indicating full engagement of the receiving channel of the clamp assembly 602 with the trailing edge of the solar panel. Once the clamp assembly 602 is positioned, the guide assembly 106 is retracted and installation of the next solar panel can occur.

[0034] In some embodiments, the linear guide assembly 106 may include a proximity sensor 108-B configured to sense the distance between the engagement member 108 and the trailing edge of the solar panel 120 during operation of the solar panel 120. The output from the proximity sensor 108-B may be used to appropriately control the speed of the fastener 108 during operation of the linear guide assembly 106 to avoid excessive force and impact on the solar panel 120. In some embodiments, the proximity sensor 108-B may be, for example, an optical sensor or an audio sensor (e.g., sonar) that detects the distance between the leading edge of the solar panel 120 and the engagement member 108, while in other embodiments, the proximity sensor 108-B may be a limit switch that is retracted by contact.

[0035] 9 and 10 , the assembly mobile robot 903 may be implemented using a ground vehicle 907. For example, the ground vehicle 907 may be implemented as an electric vehicle (EV). The ground vehicle 907 may move autonomously adjacent to the installation structure 604. Although not shown, the ground vehicle 907 may move along tracks or rails attached to or away from the installation structure. In some embodiments, the ground vehicle 907 may be controlled using sensors or based on input or feedback from sensors. The sensors may be, for example, optical sensors or proximity sensors. In further embodiments, a neural network using artificial intelligence may be used to control the movement of the ground vehicle 907, such as by analyzing the operating environment and generating commands for movement of the ground vehicle.

[0036] FIG. 10 shows an embodiment of a solar panel handling system with two robotic arms, in which two assembly tools are coupled with an assembly mobile robot using their respective robotic arms.

[0037] As shown in FIG. 9 , a storage container 905 containing solar panels to be installed can be disposed on a ground vehicle. Here, FIG. 9 illustrates a solar panel handling system including an arm assembly tool 100 coupled to an assembly mobile robot using a robotic arm. Alternatively, as shown in FIG. 10 , one or more storage containers 905 can be disposed on each of one or more modular vehicles 1005 adjacent to a ground vehicle 907. Thus, FIG. 10 illustrates a solar panel handling system having two robotic arms, with two assembly tools coupled to an assembly mobile robot using respective robotic arms. In embodiments of the present disclosure, the robotic arm can be an articulated arm having two or more sections coupled with joints, or alternatively, can be a truss arm. The examples herein are intended to disclose the use of any type of arm in accordance with the present disclosure.

[0038] Referring to FIG. 9 , for example, a robotic arm such as an arm assembly tool 100 having an upper portion 908 and a lower portion 909 can exhibit increased flexibility during operation while maintaining light weight and simple operation. As additionally shown in FIG. 9 , a second robotic arm 911 can be provided with the arm assembly tool 100 having a nut runner or nut driver at its end to secure the solar panel to the installation structure 604. While any type of robotic arm can be used for the second robotic arm 911, FIG. 9 illustrates an example of using an articulated arm with a nut runner or nut driver at its end. Here, the robotic arms 100 and 911 can be automatically operated using computer vision with neural networks and artificial intelligence control. Alternatively, the robotic arms 100 and 911 can be manually operated or remotely operated.

[0039] In some embodiments, the ground vehicle 907 may be an autonomous vehicle with neural networks and artificial intelligence controlling its movement and manipulation, and the modular vehicle 1005 is towed by or coupled to the ground vehicle 907. In other embodiments, the modular vehicle 1005 may be an autonomous vehicle with neural networks and artificial intelligence controlling its movement and manipulation, and the ground vehicle 907 is towed by or coupled to the modular vehicle 1005. Also, in some embodiments, the assembly mobile robot 903 is attached to one of the ground vehicle 907 and the modular vehicle 1005. In other embodiments, the assembly mobile robot 903 may be attached to a dedicated robotic vehicle.

[0040] A process for installing solar panels is shown in FIGS. 11A through 11C. As shown in FIG. 11A, pallets of solar panels can be delivered by truck. In some embodiments, the pallets can constitute solar panel storage containers 905. The pallets can include machine-readable indicia, such as barcodes, QR codes, or other manufacturing references, that can be read to provide information about the solar panels, installation instructions, or other information used in the installation process, particularly information used by neural network and artificial intelligence control. Such information can include, for example, the number of solar panels, the type of solar panel, physical characteristics of the solar panels, such as size, installation-related characteristics, such as hardware type and location, installation instructions, or other characteristics of the solar panels, storage of the solar panels on the pallet, and information related to installation. Furthermore, by using machine-readable indicia, the system can control the delivery or replenishment of panel boxes in the correct order and / or ensure that panels with similar impedance from the factory are used.

[0041] As shown in FIG. 11B, mechanical equipment such as a forklift may be used to move and place the pallet on the ground vehicle. Here, the forklift may be manually operated, remotely operated, or automated. In FIG. 11B, the pallet is placed on the ground vehicle. Alternatively, the pallet may be placed on a modular vehicle. Next, as shown in FIG. 11C, a robotic arm is used to install the solar panels. In the illustrated example, two arms are used to handle each solar panel to be installed on each installation structure. Here, the ground vehicle moves between two respective installation structures. Additionally, one modular vehicle may be provided that is separate from the ground vehicle.

[0042] Those skilled in the art will recognize that modifications and variations in implementation may be used. For example, as shown in Figures 12A and 12B, two modular vehicles may be provided for each robotic arm. In a further alternative, the modular vehicles may be connected to the ground vehicle instead of being separate. Thus, as shown in Figure 12A, the robotic arms may engage with respective solar panels that are installed as shown in Figure 12B.

[0043] In some embodiments, placement may be accomplished using computer vision registration, as shown in Figure 13. For example, as previously described, optical sensors and the like may be utilized in conjunction with neural networks for artificial intelligence.

[0044] In some embodiments, when a modular vehicle is used with a ground vehicle, as shown in Figure 14, once all of the solar panels on the modular vehicle are installed, the modular vehicle can be replaced with a new modular vehicle. Here, computer vision processes can be used to communicate with and control an autonomous vehicle, such as a forklift, to bring in additional solar panel boxes. Thus, the supply of solar panels can be replenished.

[0045] In a replenishment operation using the forklift example, the forklift (whether automatic, remote-controlled, or manually operated) can be used to return empty boxes or containers of solar panels to a disposal area, remove straps, open lids, or cut box faces from delivered boxes, pick up boxes to correct rotation / orientation of solar panels, or for other functions. Additionally, the forklift can be maintained near the ground vehicle and wait for the system to empty the next solar panel box. Thus, the forklift can manually or automatically discard the empty box, place the next box on the ground vehicle or module vehicle, open the box (including removing straps, opening lids, or cutting box faces), and return away from the ground vehicle / module vehicle. As described, replenishment can be, for example, automatic, remote-controlled, or manually operated.

[0046] 15-34 provide detailed views of example structures of systems for installing solar panels, according to embodiments of the present disclosure.

[0047] The embodiments of the present invention have been described above using functional components that illustrate the implementation of specific functions and relationships thereof. The boundaries of these functional components have been arbitrarily defined herein for the convenience of description. Alternative boundaries may be defined as long as the specific functions and relationships thereof are appropriately implemented.

[0048] It will be apparent to those skilled in the art that various modifications and variations can be made in the solar panel installation system of the present invention without departing from the spirit and scope of the present invention. Accordingly, it is intended that the present invention cover the modifications and variations of the present invention provided they come within the scope of the appended claims and their equivalents. It should be understood that the terms or terminology used herein are for the purpose of description and not limitation, and should be interpreted by those skilled in the art in a teaching and guidance light.

[0049] The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. [Explanation of symbols]

[0050] 100 Arm Assembly Tools, Robot Arms 102 frames 102-A Truss 104 Mounting Device 106 Linear guide assembly 108 Linearly movable fastener 108-A Engagement member 108-B Proximity Sensor 110 Force torque transducer, force torque actuator 112 Junction box, controller 120 solar panels 602 Clamp Assembly 604 Installation structure, torque tube 606 Laura 608 Spring Mechanism 610 Receptor Channel 802 Optical Sensor 802-A, 802-B position 804 Orientation Assembly 903 Assembly Mobile Robot 905 Storage Container 907 Ground Vehicle 908 Upper part 909 Lower part 911 Second Robot Arm 1005 Module Vehicle

Claims

1. A system for installing solar panels, comprising: an arm assembly tool end including a frame and a plurality of mounting devices coupled to the frame; a linear guide assembly coupled to the arm assembly tool end; Equipped with The linear guide assembly a linearly movable fastener including an engagement member configured to engage a clamp assembly slidably coupled to the installation structure; a force-torque transducer configured to move the fastener along the installation structure; a controller configured to control the force torque transducer and the plurality of attachment devices; Including, the system.

2. The system of claim 1 , further comprising an optical sensor configured to sense an orientation of the solar panel relative to the mounting structure.

3. 3. The system of claim 1, wherein the mounting structure includes a torque tube having an octagonal cross section, and the clamping assembly is configured to slide along a side of the torque tube.

4. The system of claim 1 , further comprising an orienting assembly configured to tilt the arm assembly tool end relative to the installation structure.

5. An optical sensor configured to sense an orientation of the solar panel relative to the mounting structure; and an orienting assembly configured to tilt the arm assembly tool end relative to the mounting structure; The system of claim 1 , wherein the controller is configured to control the orienting assembly to enable leveling of the solar panel relative to the mounting structure based on input from the optical sensor.

6. 6. The system of claim 1, wherein the controller is configured to actuate the force-torque transducer to enable the engagement member to engage or disengage the clamp assembly during operation.

7. 7. The system of claim 1, wherein the controller is further configured to activate or deactivate the plurality of mounting devices to couple or decouple the solar panel to the frame during operation.

8. 8. The system of claim 1, further comprising an assembly mobile robot coupled to the arm assembly tool end and configured to position the arm assembly tool end relative to the installation structure.

9. 9. The system of claim 8, wherein the assembly mobile robot is further configured to position the arm assembly tool end relative to a stack of solar panels to enable the arm assembly tool end to obtain a solar panel in the stack of solar panels during operation.

10. 10. The system of claim 8 or 9, wherein the assembly mobile robot is operatively coupled to the force torque transducer.

11. The system of claim 1 , wherein the linear guide assembly further comprises a proximity sensor configured to sense a distance between a side of the solar panel and the engagement member.

12. The system of claim 1 , wherein the linear guide assembly further includes rollers to enable movement of the engagement member along the installation structure.

13. 10. The system of claim 8, wherein the assembly mobile robot comprises an autonomous ground vehicle having the arm assembly tool mounted thereon.

14. 14. The system of claim 13, wherein the assembly mobile robot further comprises at least one modular vehicle configured to store the solar panels prior to installation.

15. 15. The system of claim 8, 13, and 14, wherein the assembly mobile robot includes at least one modular vehicle configured to store the solar panels prior to installation, and wherein the at least one modular vehicle is autonomously driven.

16. 16. The system of claim 15, wherein the assembly mobile robot comprises a ground vehicle having the arm assembly tool mounted thereon.

17. 17. The system of claim 1, further comprising a control system, said control system receiving operational instructions from the neural network.

18. A system for installing solar panels, comprising: an arm assembly tool end including a frame and a plurality of mounting devices coupled to the frame; a linear guide assembly coupled to the arm assembly tool end; Including, The linear guide assembly a linearly movable fastener including an engagement member configured to engage a clamp assembly slidably coupled to the installation structure; a force-torque transducer configured to move the fastener along the installation structure; a controller configured to control the force torque transducer and the plurality of attachment devices; an optical sensor configured to sense an orientation of the solar panel relative to the mounting structure; an orienting assembly configured to tilt the arm assembly tool end relative to the installation structure; Including, the mounting structure includes a torque tube having an octagonal cross section, and the clamp assembly is configured to slide along a side of the torque tube; The controller controlling the orienting assembly to enable leveling of the solar panel relative to the mounting structure based on input from the optical sensor; In operation, actuating the force-torque transducer to enable the engagement member to engage or disengage the clamp assembly; activating or deactivating the plurality of mounting devices to couple or release the solar panels to or from the frame during operation; The system is configured as follows:

19. The linear guide assembly a proximity sensor configured to sense a distance between a side of the solar panel and the engagement member; rollers that allow movement of the engagement member along the mounting structure; 20. The system of claim 18, further comprising:

20. an assembly mobile robot coupled to the arm assembly tool end and configured to position the arm assembly tool end relative to the installation structure; the assembly mobile robot is further configured to position the arm assembly tool end relative to a stack of solar panels to enable the arm assembly tool end to obtain a solar panel in the stack of solar panels during operation; 20. The system of claim 18 or 19, wherein the assembly mobile robot is operatively coupled to the force torque transducer.

21. 21. The system of claim 20, wherein the assembly mobile robot comprises an autonomous ground vehicle having the arm assembly tool mounted thereon.

22. 22. The system of claim 21, wherein the assembly mobile robot further comprises at least one modular vehicle configured to store the solar panels prior to installation.

23. 21. The system of claim 20, wherein the assembly mobile robot includes at least one modular vehicle configured to store the solar panels prior to installation, and wherein the at least one modular vehicle is autonomous.

24. 24. The system of claim 23, wherein the assembly mobile robot includes a ground vehicle having the arm assembly tool mounted thereon.

25. 21. The system of claim 20, further comprising a control system, the control system receiving operational instructions from the neural network.

26. 1. A method for installing solar panels, comprising: engaging an arm assembly tool end with the solar panel, the arm assembly tool end including a frame and a plurality of mounting devices coupled to the frame; placing the solar panel against a mounting structure having a clamp assembly slidably coupled thereto; engaging a linear guide assembly coupled to the arm assembly tool end with the clamp assembly, the linear guide assembly including the linearly movable fastener including an engagement member configured to engage the clamp assembly and a force-torque transducer configured to move the linearly movable fastener along the installation structure; actuating the force-torque transducer to move the clamp assembly along the mounting structure to engage a side of the solar panel, thereby securing the solar panel to the mounting structure; A method comprising:

27. 27. The method of claim 26, further comprising leveling the solar panel relative to the mounting structure.

28. 28. The method of claim 26 or 27, wherein the mounting structure includes a torque tube having an octagonal cross section, and the step of positioning the solar panel includes positioning the solar panel against a side of the torque tube.

29. 29. The method of any one of claims 26 to 28, wherein the step of engaging the arm assembly tool end comprises: positioning the frame relative to the solar panel; and removably coupling the solar panel to the frame using the plurality of mounting devices.

30. 30. The method of any one of claims 26 to 29, wherein the step of engaging the linear guide assembly includes the steps of sensing a position of the clamping assembly along the installation structure and actuating the force-torque transducer to position the linear guide assembly to allow engagement between the engagement member and the clamping assembly.

31. 31. The method of any one of claims 26 to 30, wherein the arm assembly tool is mounted to an autonomous ground vehicle, the method further comprising driving the autonomous ground vehicle relative to the installation structure.

32. 31. The method of any one of claims 26 to 30, wherein the arm assembly tool is mounted to a non-driven ground vehicle, the method further comprising moving the non-driven ground vehicle relative to the installation structure together with the autonomous ground vehicle.

33. 33. The method of claim 31 or 32, wherein an assembly mobile robot comprises the autonomous ground vehicle having the arm assembly tool attached thereto.

34. 34. The method of any one of claims 26 to 33, further comprising operating a control system of the arm assembly tool based on operation commands received by the control system from a neural network.

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