A machine for solar panel pickup & placement over fixed or tracking type structures

Abstract

A system for installing multiple variants of solar panels on multiple types of structures including fixed and sun tracking type System may include a robotic arm and an end of arm tooling performing multiple functions to place solar panels on panel Support structures. The system can be installed on an autonomous or semi- autonomous self-powered machine using genset or battery capable of autonomously or semi- autonomously moving in solar farm using positioning devices and sensors to accurately pick and place panels on the structures. The Machine houses all other systems on its structural frame to work as an independent complete Machine. The machine can place panels on one side or both sides while traversing through narrow gaps of fixed or sun tracking structures. The machine can be operated via a control system or a handheld pendant.

Description

[0001] TITLE : A MACHINE FOR SOLAR PANEL PICKUP & PLACEMENT OVER FIXED OR TRACKING TYPE STRUCTURES

[0002] FIELD OF INVENTION:

[0003] This invention relates to the field of Installing Solar Panels in Solar farms. More specifically the invention relates to an Automatic machine for picking and placement of solar panels from solar panel skids to panel placement structures. The same invention can also be used for picking and placement of panels from panel placement structure to solar panel skids.

[0004] PRIOR ART: BACKGROUND OF THE INVENTION:

[0005] Solar panel installation and dismantling on solar farms involve lot of challenges like large workforce availability, workforce training because of multiple variants of panels, structures and installation methodologies, constant workforce attrition, worker fatigue due to repetitive work, risk of worker injuries, Pausing the work at night and at unfeasible weather conditions, fluctuating productivity, errors due to worker negligence. Productivity using workforce is not sufficient to meet the global demands for renewable energy. Workforce sheltering and providing facilities in remote locations is expensive and challenging.

[0006] SUMMARY OF THE INVENTION:

[0007] The Machine uses a Track chain system to help it travel through the terrain conditions where rocky, sandy, or Marshy conditions are encountered. The Track chain systems can spread the load over a bigger area than Wheeled systems whereby better suited for the intended application.

[0008] The drive system consists of servo motors to be able to move accurate distances which is critical when placing panels at constant distances from each other.

[0009] Rotary Encoders are installed on the sprocket of track chain system to compensate for any backlash errors which further improves the travel accuracy of the Machine. Distance measuring sensors are placed on sides of machine to measure the distance between machine and tables constantly while travelling between the tables. This way the machine can adjust itself towards the center of the gap between tables to avoid any collision arising due to drift in table placements or machine movement due to backlash. A Robot / Articulated arm is placed on the Machine with a panel gripping mechanism to be able to pick and place panels from the Shipping pallets on to the fixed or tiltable table of solar farm.

[0010] The Robot eliminates the manual labor work which reduces the number of workers needed to work in such harsh environmental conditions. It also reduces the risk of injuries and worker fatigue.

[0011] A robot can perform these tasks at a faster rate without taking any breaks and can work all three shifts whereby improving the rate of panel placements and helping in completing projects faster and as per plans.

[0012] A vacuum based suction system with multiple suction pads is used on robot arm to help in gripping the solar panels without damaging the panels.

[0013] A Camera is used on Robot arm to be able to identify the features of table to be able to place the panel in right position on the table.

[0014] BRIEF DESCRIPTION OF THE DRAWINGS:

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[0016]

[0017]

[0018] Fig 1-4: Detailed illustration of an example configuration for a system for installing solar panels according to an embodiment of present disclosure. Fig 5: Detailed illustration of an example configuration for a system with Panel Placement Structure for installing solar panels according to an embodiment of present disclosure.

[0019] Fig 6: Perspective view of an example End of Arm Tooling configuration holding a single solar panel in accordance with an embodiment of present disclosure.

[0020] Fig 7: Alternate view of an example End of Arm Tooling configuration holding a single solar panel using pneumatic / hydraulic / electric gripper in accordance with an embodiment of present disclosure.

[0021] Fig 8: side view of panel support structure with end of arm tooling showing structure scanning position in accordance with an embodiment of present disclosure.

[0022] Fig 9: Top view of panel support structure with end of arm tooling showing structure scanning position in accordance with an embodiment of present disclosure

[0023] Fig 10: Front view indicating the distance measurement system in accordance with an embodiment of present disclosure.

[0024] Fig 11: Perspective view indicating the travel measurement system in accordance with an embodiment of present disclosure.

[0025] Fig 12: Perspective view indicating the travel measurement system with wheeled system in accordance with an embodiment of present disclosure.

[0026] Fig 13: Perspective view indicating the Autonomous travel system in accordance with an embodiment of present disclosure. Fig 14a : Perspective view indicating the Machine Structure in accordance with an embodiment of present disclosure.

[0027] Fig 14b: Perspective view indicating the Machine Structure in accordance with an embodiment of present disclosure.

[0028] Fig 14c: Perspective view indicating the Machine Structure in accordance with an embodiment of present disclosure.

[0029] Fig 14d : Back view indicating the Machine Structure in accordance with an embodiment of present disclosure.

[0030] Fig 14e: Front view indicating the Machine Structure in accordance with an embodiment of present disclosure.

[0031] Fig 15: schematic view indicating the chilled air distribution system in accordance with an embodiment of present disclosure.

[0032] Fig 16: schematic view indicating the vacuum and compressed air distribution system in accordance with an embodiment of present disclosure.

[0033] Fig 17: schematic view indicating the Electrical Power distribution system in accordance with an embodiment of present disclosure.

[0034] Fig 18: Front view of Panel Holder system in accordance with an embodiment of present disclosure

[0035] DETAILED DESCRIPTION OF THE INVENTION: Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying figures.

[0036] Figure 1,2, 3, 4, 5 show various views of the system in accordance with an embodiment of the present disclosure. Machine Structure 300 can be as shown in figure 14a, 14b, 14c, 14d, 14e is arranged in a way that it can allow mounting of many other systems and components safely on it. It can be made strong enough so that the system can perform all required functions as disclosed here. The Machine structure 300 can be made with steel and a combination of various other materials bolted or welded or joined to each other by other joining processes and methods.

[0037] The system consists of a 6 axis Robotic arm 100 or a Gantry System 102 which can handle the weight of individual solar panel 201 and End of arm tooling 150 and moving the individual solar panel 201 from Solar panel skid 200 on the machine to the panel placement position on Panel placement Structure 900. This Robotic Arm or the gantry system can be mounted for example on the back side of the system as shown in figures 1, 2, 3, 4, 5. The Robotic Arm 100 can be mounted on a structural table known as a robotic pedestal 105 which helps in keeping the Robotic Arm at correct height on the system to be able to reach required positions. Robot Arm Controller 101 is required to communicate and control the Robotic arm with Main Control system 1000. This Robotic controller 102 is mounted on the Mechanical structure in a weather sealed structural box to prevent it from Dust and Rain. Most of the Electronics, Electrical, Controls, Sensor related hardware can be contained on the system in a similar way to protect them from environmental factors. Most of these structural boxes (not shown here) are equipped with rubber seals and locking systems like mechanical or electronic but not limited to. Most of the Electronics, electrical, controls, sensors related hardware need to be maintained below a certain operating temperature since the system can operate in solar farms 1115 where ambient temperatures can reach up to 60 degrees centigrade cooling may be needed.

[0038] An Air-conditioning system 750 is mounted on the Mechanical structural frame 300 in a weather protection box (as shown in figure 3) allowing it to have convectional heat exchange over its condenser coils. Ducts (not shown) can be installed from the Air conditioning system 750 to various components needing air conditioning as shown in figure 15.

[0039] A vacuum generation 550 and an Air compression system 950 can be used in case the solar panels 201 needs to be picked up using vacuum system. Figure 16 shows a basic air distribution schematic that can be used to achieve the task.

[0040] To power this system a power system 800 consisting of a Genset 801 or a Battery pack 802 can be used. A Power distribution system 850 consisting of Inverter, SMPS and a stabilizer can be used to convert the Electrical power from 3 phase AC into Single phase Ac and DC Power supply or A DC Power supply into # phase AC supply and Single-phase AC supply. Figure 17 shows the schematic of power distribution system 850.

[0041] A Fuel System 450 consisting of a fuel tank and an Exhaust system 500 consisting of an exhaust Silencer will be needed in case a Genset 801 is used to power the system. Figure 1,2, 3, 4 shows possible mounting location of all these items within the Mechanical structural frame 300 of the system.

[0042] Forklift operator can pick up Solar panel skid 200 and place it over the System (As shown in figure 1,2, 3, 4). The solar panel skid 200 needs to be secured so that it does not move while the system is in motion. Figure 18 shows an example way of doing this. Linear actuators 251 like but not limited to Electrical, Mechanical, Pneumatic or hydraulic can be installed on all four sides of the solar panel skid 200 and when actuated they can lock the solar panel skid 200 on the system.

[0043] Solar panel 201 needs to be picked up at correct position so that while placing on the panel placement structure 900 no error from pickup causes wrong placement. To avoid such errors actual position of the panel 201 can be sensed using linear variable differential transducer (LVDT) mounted on linear actuator 252 which can clamp the solar panel using but not limited to electrical, pneumatic, hydraulic or any linear mechanism. The sensors can provide the distance of panel from both sides of the Panel. The main control system 1000 can compute the center of panel by adding Panel length to the distance shown by both sensors and then dividing the value by 2. Since panels are resting on Solar panel skid and skid height is fixed the height of panel center can be computed by main control system 1000 by adding skid height to half of panel height. These two values along with the distance of panel 201 from End of Arm Tooling 150 given by Structure scanning device 154 which can be but not limited to 3D camera or a laser profiler can perfectly locate the panel 201 on the system. These coordinates can be shared by Main control system 1000 to Robotic Controller 101 so that Robotic Arm 100 or a gantry System 102 can pickup the panel perfectly from the system.

[0044] All standard panel sizes and Panel support structure 900 dimensions can be stored on the Main control system 1000 so that the compatibility of the system extends to all variants. More variants can be added to the system even at a future date. Operator can select panel type and Panel support structure type on the HMI screen of Main control system 1000 to indicate the system which configuration needs to be used. Figure 6. shows a perspective view of an end of arm tooling 150 along with a solar panel 201 in accordance with an embodiment of the present disclosure. The end of arm tooling 150 can grip individual solar panel 201 from solar panel skid 200 and move to the panel placement structure 900 for placement.

[0045] The end of arm tooling 150 may include a structural frame 151 and one or more panel attachment devices 153 connected to the structural frame 151. Panel attachment devices 153 include but not limited to suction cups, pneumatic grippers, hydraulic grippers, electrical grippers or mechanical grippers etc. which can grip and release either surface of panel or edges of the individual solar panel 201 during its movement from pickup position in solar panel skid 200 to its drop position on panel placement structure 900 using end of arm tooling 150.

[0046] The end of arm tooling 150 is connected to the robotic arm 100 by a robotic arm connection 152 which can be but not limited to a mechanical coupling, pneumatic coupling, hydraulic coupling, electrical coupling etc. structural frame 151 provides required strength and stability to end of arm tooling 150 and provides required connection points for other devices that connect on to it as disclosed herein.

[0047] Panel attachment devices 153 are arranged in a configuration that can grip smaller size as well as bigger size panels. Additionally various mounting positions can be provided on structural frame 151 (not shown here) to accommodate oversized or undersized panels. Panel attachment devices like vacuum pads 153a are installed on a plane which mates with the individual solar panel 201 when pushed into the solar panel skid 200 by the robotic arm 100. This causes air to escape out of the vacuum pads 153a (panel attachment device 153) and grips the individual solar panel 201. Additionally, the vacuum generator or Vacuum system 550 can also be installed into the system which helps in gripping faster, more reliably and with better gripping force.

[0048] To release the individual solar panel 201 from the vacuum gripper (panel attachment device) a jet of compressed air is supplied into the vacuum pads 153a via an ejector (not shown here) taking supply from pneumatic supply manifold 157 which in turn could be connected to compressed air system 950 having an air compressor 951 installed on to the system.

[0049] Figure 7. shows an example alternate arrangement to pickup individual solar panel 201 using end of tooling 150 housing gripper (panel attachment device 153) working on Pneumatics, Hydraulics, mechanical or electrical actuator 153c. This gripper (panel attachment device 153) can have at least one movable jaw and the gripper (panel attachment device 153) be coupled to structural frame 151.

[0050] With the help of panel detection sensors 158 like but not limited to ultrasonic, laser, proximity or limit switch type sensors the Main control system 1000 can get positional feedback of individual panel 201 when the robotic arm 100 pushes the end of arm tooling 150 into the solar panel skid 200. Once the signal is received indicating the correct pickup position is reached the main control system 1000 activates the grippers (panel attachment device 153) the movable jaw 153b of the actuator (pneumatic, hydraulic, mechanical, electrical etc.) 153c grips the edges of the panels so that the robotic arm can move it to its dropping position on panel placement structure 900.

[0051] A combination of vacuum pads 153a and Grippers (pneumatic, hydraulic, mechanical, electrical etc.) as explained in Figure 6. And Figure 7. Can be used together to further increase the reliability of the panel movement process between solar panel skid 200 and dropping position on panel placement structure 900.

[0052] Figure 8. shows an example side view of Panel placement structure 900 with end of arm tooling 150 placed over the panel mount Perlin 901 and scanning for hole position on Panel mount Perlin 901 using a single or multiple structure scanning devices 154 like but not limited to 2D / 3D Camera or 2D / 3D Laser Line scanner / Laser profiler / photodetector / or any other optical imaging or light sensing device coupled with if needed Perlin distance measuring system 159 mounted on structural frame 151 of end of arm tooling 150. The structure scanning device 154 can be configured to provide orientation of End of arm tooling with respect to panel mount Perlin and distance between the structure scanning device and any feature like but not limited to hole, slot, intersection of Perlin and rafter (not shown here) or any other feature on panel support structure 900. Positional data from structure scanning device 154 can be used to move the robotic arm 100 or a gantry system 102 to place the individual solar panel 201 supported in end of arm tooling 150 on to panel support structure correctly.

[0053] The structure scanning device 154 can also use a 3d imaging cameras (stereo lithic) coupled with Al models to compute the distance between current position of End of arm tooling 150 and the refence feature on the panel mount Perlin 901. These features can be but not limited to holes, slots, intersection of various members or features on the panel mount Perlin 901 or Panel support structure 900.

[0054] Ambient light control 155 can be used in case of using Imaging devices (2D / 3D Camera) or reflection measurement devices (Laser profiler / 2D / 3D Line scanner) to sense the position of hole or any other feature on Panel mount Perlin 901 or panel placement structure 900 under harsh light conditions this can be achieved by as shown in Figure 6 by connecting light blocking material over the structure scanning device 154. This can reduce the amount of light falling on Galvanized Iron Perlin members which can help in a better sensing.

[0055] Figure 9 shows the top view of panel placement structure 900 with end of arm tooling 150. Perlin distance measurement system 159 using distance measuring sensors like but not limited to Laser / ultrasonic sensors can be used to place the structure scanning device 154 at a fixed distance above panel mount Perlin 901.

[0056] The system may further include a Junction box 156 mounted on the End of arm tooling 150. This junction box 156 may include a controller configured to take input from structure scanning device 154, panel detection sensor 158, Perlin distance measurement sensor 159 and computes the End of arm tooling 150 offset with respect to the feature being scanned on the panel mount Perlin 901. This offset information can be shared to Robotic arm controller 101 mounted on the system and this in turn will move the robotic arm 100 or Gantry system 102 to reach the placement position. Junction box 156 may also include a power supply or a power controller for controlling the power supply to various components.

[0057] Figure 10. refers to the distance measuring system 700 that can be used to keep the vehicle moving along the panel placement structure 900. This can help in keeping the robotic arm 100 in scanning range of Panel mount Perlin 901. This can also help prevent any collisions between the system and panel mount structure 900. A distance measurement sensor like but not limited to laser type, ultrasonic type etc. can be mounted on sides of the system pointed towards any beam on panel placement structure 900. The sensor 700 provides distance data between the system and the panel placement structure 900, The system can be programmed to keep the distance between both within a set range. If the distance increases or reduces the Main control system 1000 can change the speed of drive motor 401 accordingly to turn the vehicle in opposite direction to adjust the distance. The same sensor 700 is installed on all four sides of the vehicle to monitor the distance with respect to any potential obstruction along the travel path. The system can be programmed to trigger a warning buzzer or stop completely depending on the distance between vehicle and potential collision object.

[0058] Figure 11. refers to travel measurement system 650. The vehicle needs to stop at equal distances along the length of panel placement structure 900 to limit the travel of robotic arm and related cycle time issues. The vehicle movement system 350 can use a rotary encoder 651 installed on the follower side like follower socket in case of track chain system 351 or follower wheel in case of wheeled system 352 or like get rotational feedback of the vehicle which can be translated into linear travel by the Main control system 1000 using basic mathematical formulae. The main control system 1000 can send stop command to the vehicle movement system when the required travel distance is attained. The rotary encoders 651 can be installed on both sides of the vehicle for better positional control of the vehicle.

[0059] Vehicle drive system 400 can consist of motors 401 like but not limited to electrical, hydraulic, pneumatic etc. coupled to a vehicle movement system 350 like track chain 351 or wheeled system 352 (as shown in figure 12) either directly (as shown in figure 11, 12) or through powertrain mechanisms like but not limited to chain and sprocket, belt and pulley, Gear arrangement. The vehicle moves along a straight line when both motors 401 are rotating at the same speed. Vehicle can turn in any direction by controlling the individual speed of each motor 401 via the main control system 1000. The backlash in track and chain system 351 or additional backlash arising due to indirect coupling between drive motor 401 and movement system 350 using chain drives or belt drives or gear drives may cause incorrect travel position. These errors can be compensated based on Rotary encoder 651 or any similar devices.

[0060] Figure 13. refers to an example of Autonomous movement system 1100 for such a system. It can consist of GPS receiver 1112 mounted within the system connected to the Main control system capable of identifying its current position. A Map file 1119 containing the GPS coordinates of the solar farm 1115 and its boundary positions 1116 along with RFID tag values for each panel placement structure 900 is uploaded onto the Main Controller 1001 like but not limited to Industrial PC 1001a. The main controller 1001 can then compute the panel placement travel path 1117 which will be the approximate center between two panel placement structures 900 and Structure to Structure travel path 1118 which can be a preset fixed distance from the panel placement structure 900. Operator can specify which rows of panel placement structure to be placed with solar panels 201 in what order. Based on the selections main controller 1001 can compute the travel paths 1117 & 1118. The Main control system 1000 sends signals to movement system 350 which in turn controls the drive system 400 to steer the vehicle. The Main control system 1000 takes constant feedback from Travel measurement system 650 and distance measurement system 700 to keep the vehicle moving along the computed path and prevent collisions. The main control system keeps reading RFID Tags 1110 placed on panel placement structure 900 along the computed travel path 1118 for a more accurate positioning in the solar farm 1115. Once the vehicle arrives at required panel placement travel path it makes a 90 degree turn via the speed control of drive motors 401. Once inside the Panel placement travel path 1117 the main control system takes continuous feedback from distance measurement system 700 and travel measurement system 650 to keep the machine along the path and stop at panel placement position along the Panel Placement Travel Path 1117. Alternatively, a Handheld drive pendant 405 can be used by the machine operator to steer the vehicle till the panel placement travel path 1117. Once at this position the main control system takes continuous feedback from distance measurement system 700 and travel measurement system 650 to keep the machine along the path and stop at panel placement position along the Panel Placement Travel Path 1117 making the system Semi-Autonomous 1101.

[0061] Alternatively, the system can be pulled by a Tugger vehicle like but not limited to a tractor to move the vehicle at every individual panel placement position. While the vehicle is being tugged the Distance measurement system 700 can give out a buzzer when computed distance is the required stop position so that the tugger operator can stop the tugger. Once at the stop position the system can pace panels as described earlier in this document. This makes it a Tugger vehicle movement system 1102.

[0062] The novelty of the invention lies in many aspects :

[0063] In one aspect a system for placing single or multiple variants of solar panels on to various types of panel placement structures in Fixed and Sun tracking configuration by picking up individually each panel or multiple panels at a time from a fixed pickup location or locations connected to the system. Further capable of placing solar panels on any side or both sides of the system one after other or simultaneously.

[0064] In another aspect the invention further comprising and end of arm tooling mounted on a robotic arm, or a gantry system connected to the system and consisting of a frame and a plurality of gripping devices like but not limited to vacuum grippers, mechanical mechanisms, pneumatic grippers, electrical grippers, hydraulic grippers etc. and sensors to move solar panels from the pickup position on the machine to placement position on the panel placement structure.

[0065] In another aspect the invention further comprising of single or multiple scanning, sensing or imaging devices mounted on end of arm tooling capable of identifying features of Panel placement structures (fixed or sun tracking) and assisting Robotic arm or Gantry on the placement position of solar panels.

[0066] In another aspect the invention further comprising of an autonomously, semi autonomously driven or tugged using tugger vehicles like but not limited to tractors,

[0067] In another aspect the invention further comprising vehicle consisting of Track chain or wheeled system.

[0068] In another aspect the invention further comprising an internally mounted distance measuring system using devices like but not limited to encoders coupled with additional GPS receiver or RFID scanners to determine its exact position on solar farm.

[0069] In another aspect the invention further comprising a power generation system like a Genset but not limited to mounted within the system to power one or all its systems electrically.

[0070] In another aspect the invention further comprising a power storage system like a battery system but not limited to mounted within the system to power one or all its systems electrically.

[0071] In another aspect the invention further comprising devices mounted on one or all sides of the system like Sensors or scanners but not limited to help in collision avoidance or keeping the system travelling along the panel placement structure.

[0072] In another aspect the invention further comprising a panel skid holding system within the system using a holding system consisting of but not limited to electrical, Pneumatic, hydraulic actuators to prevent the panel from moving during movement of the system.

[0073] In another aspect the invention further comprising a panel alignment system using a holding system consisting of but not limited to electrical, Pneumatic, hydraulic actuators to assist the robotic arm pick up the panel using end of arm tooling at its current position on the system.

[0074] In another aspect the invention further comprising of drive systems like but not limited to Electrical motors, Hydraulic motors, Pneumatic motors to move the system on solar farm.

[0075] In another aspect the invention further comprising an electrical power conversion system into AC 3 phase or AC Single phase or DC power to power one or all its electrical devices.

[0076] Some of the embodiment have been disclosed and illustrated but these are the limiting factors. All other variations and modification which are possible are also within the scope of the invention.

Claims

W E CLAI M :1 . An autonomous or a sem i-autonomous solar panel installation system for solar panel installation onto fixed or sun tracking solar panel support structure comprising of : a. a robotic arm mounted on the system , and b. a plurality of tooling systems mounted on the remote free end of robotic arm and said adapted for mounting the solar panels onto one or both sides of solar panel support structure.

2. The autonomous or a semi-autonomous solar panel installation system is configured to be operable with power source.

3. The autonomous or a semi-autonomous solar panel installation system is configured to adapted its drive with associated GPS sensor mounted therein.

4. The autonomous or a semi-autonomous solar panel installation system is operable to transverse safely without collision through gaps in panel support structure with associated GPS sensor mounted therein and in cooperation with a drive control means which has software and electronic hardware.The autonomous or a semi-autonomous solar panel installation system having a panel skid means mounted therein, for holding onto panels and which means are generally electronic, pneumatic or hydraulic actuator.

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