Method and systems for fastening solar panels

Abstract

A method includes positioning a crossbeam so as to obliquely traverse a beam to form an attachment joint. The method includes positioning, using the solar positioning system, a solar attachment device at the attachment joint. The method includes attaching an attachment member of the crossbeam to the beam at the attachment joint to form a support frame. The method includes positioning a solar panel adjacent to the crossbeam such that a fastening side of the solar panel is touching a fastening flange of the crossbeam. The method includes positioning a solar fastening device adjacent to the fastening flange of the crossbeam such that the solar fastening device is opposite the solar panel. The method includes fastening the fastening side of the solar panel to the fastening flange using at least one fastener.

Description

METHODS AND SYSTEMS FOR FASTENING SOLAR PANELSBACKGROUND

[0001] Solar panels convert solar energy into electrical energy to power residential homes and commercial properties. The need for solar panels is increasing as more individuals and companies move to reduce reliance on fossil fuels for electrical energy as solar panels produce electrical energy and reduce reliance on fossil fuels. However, solar panels can be expensive and cost prohibitive. There is a need for improvement in the manufacturing and assembling of solar panel systems that improve efficiency and reduce costs.SUMMARY

[0002] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0003] In some aspects, the techniques described herein relate to a method for fastening solar panels. The method may include positioning, using a solar positioning system, a crossbeam so as to obliquely traverse a beam to form an attachment joint. The method may include positioning, using the solar positioning system, a solar attachment device at the attachment joint. The method may include attaching, using the solar attachment device, an attachment member of the crossbeam to the beam at the attachment joint to form a support frame. The method may include positioning, using the solar positioning system, a solar panel adjacent to the crossbeam such that a fastening side of the solar panel is touching a fastening flange of the crossbeam. The method may include positioning, using the solar positioning system, a solar fastening device adjacent to the fastening flange of the crossbeam such that the solar fastening device is opposite the solar panel. The method may include fastening, using the solar fastening device, the fastening side of the solar panel to the fastening flange using at least one fastener.

[0004] In some aspects, the techniques described herein relate to a system for fastening solar panels. The system includes a solar panel having a fastening side, a beamconfigured to form an attachment joint, a crossbeam configured to attach to the beam to form the attachment joint, a support member, a fastening flange, at least one fastener configured to fasten the solar panel to the fastening flange of the crossbeam, a solar connection system, a solar fastening device configured to install the at least one fastener, and a solar positioning system. The crossbeam includes an attachment member. The solar connection system includes a solar attachment device configured to attach the crossbeam and the beam. The solar positioning system is configured to position the crossbeam so as to obliquely traverse the beam to form an attachment joint. The solar positioning system is configured to position the solar attachment device at the attachment joint. The solar positioning system is configured to position the solar panel to attach to the crossbeam. The solar positioning system is configured to position the solar fastening device to install the at least one fastener. The solar attachment device is configured to attach the attachment member of the crossbeam to the beam at the attachment joint to form a support frame. The solar fastening device is configured to fasten the fastening side of the solar panel to the fastening flange using the at least one fastener.

[0005] Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.BRIEF DESCRIPTION OF DRAWINGS

[0006] Specific embodiments of the disclosed technology will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency.

[0007] FIG. 1 illustrates a solar assembly system in accordance with one or more embodiments.

[0008] FIG. 2 shows an exploded view of a solar panel system in accordance with one or more embodiments.

[0009] FIG. 3 shows a portion of a back view of a solar panel system in accordance with one or more embodiments.

[0010] FIG. 4 shows a sectional view of an attachment joint and a fastening location of a solar panel system in accordance with one or more embodiments.

[0011] FIG. 5 shows one or more fasteners in accordance with one or more embodiments.

[0012] FIG. 6 shows a solar fastening device used in relation to the solar panel system in accordance with one or more embodiments.

[0013] FIG. 7A shows a robotic arm used in relation to a solar panel system in accordance with one or more embodiments.

[0014] FIG. 7B shows suction sups on a robotic arm used in relation to a solar panel system in accordance with one or more embodiments.

[0015] FIG. 8 shows a sectional view of an attachment joint in accordance with one or more embodiments.

[0016] FIG. 9 shows an attachment tool used in relation to a solar panel system in accordance with one or more embodiments.

[0017] FIG. 10 shows a sectional view of an attachment joint in accordance with one or more embodiments.

[0018] FIG. 11 depicts a flowchart in accordance with one or more embodiments.DETAILED DESCRIPTION

[0019] In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to a person having ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

[0020] Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before,” “after,” “single,” and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompassmore than one element and succeed (or precede) the second element in an ordering of elements.

[0021] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0022] Terms such as “approximately,” “substantially,” etc., mean that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

[0023] It is to be understood that one or more of the processes shown in the flowchart may be omitted, repeated, and / or performed in a different order than the order shown. Accordingly, the scope disclosed herein should not be considered limited to the specific arrangement of processes shown in the flowchart.

[0024] Although multiple dependent claims are not introduced, it would be apparent to a person having ordinary skill that the subject matter of the dependent claims of one or more embodiments may be combined with other dependent claims.

[0025] In the following description of FIGs. 1-11, any component described with regard to a figure, in various embodiments disclosed herein, may be equivalent to one or more like-named components described with regard to any other figure. For brevity, descriptions of these components will not be repeated with regard to each figure. Thus, each and every embodiment of the components of each figure is incorporated by reference and assumed to be optionally present within every other figure having one or more like-named components. Additionally, in accordance with various embodiments disclosed herein, any description of the components of a figure is to be interpreted as an optional embodiment which may be implemented in addition to, in conjunction with, or in place of the embodiments described with regard to a corresponding like-named component in any other figure.

[0026] Disclosed herein are methods and systems for fastening solar panels that may include a robotic arm for automatically fastening solar panels. Solar panels are configured for converting solar energy into electrical energy. The system includes one or more solar panels and a support frame having one or more beams and one ormore crossbeams. Each beam and crossbeam are attached together to form the support frame for attaching the solar panels. Each crossbeam includes one or more fastening flanges for fastening the solar panels. The system includes one or more fasteners for fastening the solar panels at one or more fastening locations. The method includes positioning the solar panels adjacent to the fastening flanges and fastening the solar panel to the crossbeam via the fastening flange.

[0027] The solar panels and support frame may be well suited for automated assembly due to the modularity, versatility and ease of assembly of the solar panels and support frame. The automated assembly may utilize a robotic arm. Accordingly, the automated assembly of solar panels and support frame may reduce time, cost, and manual effort required to assemble the solar panels and support frame.

[0028] FIG. 1 shows a solar environment including a system for fastening solar panels (10) (hereafter “solar assembly system (10)”) and a sun (165) in accordance with one or more embodiments. The solar assembly system (10) includes a solar panel system (20). The solar panel system (20) includes a solar panel (100) and a support frame (210) as described in relation to FIG. 2. In some embodiments, the solar panel system (20) includes at least one additional solar panel (101). Each solar panel (100, 101) includes a collection side (110). The collection side (110) is operatively configured to receive light such as solar radiation from the sun (165).

[0029] In FIG. 1, the solar radiation is depicted as a plurality of rays (167) for simplicity. The collection side (110) includes a plurality of photovoltaic (“PV”) cells. Each PV cell receives at least a portion of solar radiation during the time that the solar panel system (20) receives solar radiation from the sun (165) (e.g., daylight hours). Each PV cell may be constructed from a semiconductor material. The semiconductor material may include any material suitable for absorbing light and transfer negatively charged particles such as electrons and thereby leaving positively charged holes. The energy from absorbing light such as sunlight excites the electrons causing the electrons to flow from their present position thereby leaving the charged holes. The flow of electrons creates an electric current (112) (e.g., a direct current (“DC”)).

[0030] In some embodiments, the solar panel (100) is configured to extract the electric current (112) from each PV cell through conductor contacts operatively connected to each PV cell and a solar collection system (115). The solar collection system (115)may include solar collection hardware and / or software for the generation, collection, and distribution of solar electrical energy. For example, solar collection hardware may include cables, wires, electrical connectors, inverters, computer systems, and storage components such as batteries. In some embodiments, the solar collection system (115) may be operatively connected to a distribution grid that distributes electrical energy to a load, such as a residential house or commercial property configured to use the electric current (112). The inverters may be configured to convert the electric current (112) from DC flowing from the PV cells to alternating current (“AC”) for distribution through the distribution grid.

[0031] In some embodiments, the solar assembly system (10) includes a solar control system (120) and a solar connection system (130). The solar control system (120) is configured to control assembly of the solar panel system (20). The solar control system (120) includes solar control system hardware and / or software for controlling operation of assembling the solar panel system (20). For example, the solar control system hardware may include one or more sensors for monitoring the assembly of the solar panel system (20). The sensors are operatively connected to the various equipment of the solar panel system (20). The solar control system (120) may be a computer system for managing various process and operations of the solar assembly system (10). The computer system may include solar assembly system specific software configured to control operations of the solar assembly system (10). The solar control system (120) may include a user device. The user device may include a user interface (e.g., graphic user interface). The solar control system (120) is operatively connected to the solar panel system (20) and the solar connection system (130).

[0032] Continuing with solar connection systems, the solar connection system (130) is operatively connected to the solar control system (120). The solar connection system (130) is configured to communicate instructions with the solar control system (120) wirelessly and / or through cables. The solar connection system (130) is configured to attach various components to form the support frame (210), such as beams and crossbeams. The solar connection system (130) is configured to connect the solar panels (100, 101) to the support frame (210). The solar connection system (130) includes one or more solar connection devices and one or more fasteners configured for connecting various components of the solar panel system (20) such as fastening,using one or more fasteners, solar panels (100, 101) to support frames and attaching various components of the support frame (210) together such as beams and crossbeams using the solar connection devices. The solar connection devices may include a solar fastening device (600) and / or a solar attachment device (150). The solar connection system (130) includes connection hardware for connecting various components of the solar panel system (20). For example, connection hardware may include hoses, cables, and wires configured to operatively connect various components of the solar connection system (130).

[0033] In accordance with one or more embodiments, the solar connection system (130) may include a solar positioning system (140). The solar positioning system (140) includes solar positioning system hardware and / or software for positioning various components of the solar panel system (20) for assembling. For example, the solar positioning system (140) may include a robotic arm, as described in relation to FIG. 7, that is configured to position the solar panels (100, 101), the support frame (210) and / or the solar connection devices for fastening and attaching various components of the solar panel system (20), such as beams, crossbeams, and / or solar panels.

[0034] In some embodiments, the solar panel system (20) may be disposed on or above a base surface (162) (e.g., surface of the Earth and / or roof surface). The solar panel (100) may be installed above the base surface (162) using a pile (160). The pile (160) may be constructed of a suitable material for supporting the solar panels (100, 101), such as aluminum, steel, or other metals or metal alloys . The first end of the pile (160) may be connected to the support frame (210). A second end of the pile (160) may be connected to the base surface (162). In some embodiments, the surface end may be disposed, at least partially, below the base surface (162) (e.g., buried in the earth). In some embodiments, if multiple piles are utilized, the piles may be various lengths to orient the solar panels (100, 101) at a predetermined angle relative to the base surface (162) (e.g. , surface of the earth). In some embodiments, the piles may be equal lengths to support the solar panels (100, 101) an equidistant space from the base surface (162) (e.g., roof surface).

[0035] While FIG. 1 shows various configurations of components, other configurations may be used without departing from the scope of the disclosure. For example, variouscomponents in FIG. 1 may be combined to create a single component. As another example, the functionality performed by a single component may be performed by two or more components.

[0036] FIG. 2 shows an exploded view of the solar panel system (20) in accordance with one or more embodiments. The solar panels (100, 101) are fastened to the support frame (210). The support frame (210) includes a beam (212) and a crossbeam (214). In some embodiments, the solar panels (100, 101) are configured to fasten to the crossbeam (214). In some embodiments, the support frame (210) includes at least one additional beam (213) and at least one additional crossbeam (215). The beam (212) may be arranged parallel with each additional beam (213). The crossbeam (214) may be arranged parallel with each additional crossbeam (215). The crossbeam (214) may be configured to attach to the beam (212) to form an attachment joint (250). Each additional crossbeam (215) may be arranged to obliquely traverse the beam (212) to form an additional attachment joint (251). In some embodiments, the crossbeams (214, 215) may be arranged to perpendicular traverse the beams (212, 213) to form the attachment joints (250, 251). Even though some figures may show a certain number of crossbeams, beams, and solar panels and additional crossbeams, beams, and solar panels, it is not meant to be limiting. It should be apparent to a person of ordinary skill in the art that greater or fewer numbers of crossbeams, beams, and solar panels with any number of additional crossbeams, beams, and solar panels may be included without departing from the scope of disclosure herein.

[0037] In some embodiments, the solar positioning system (140) may be configured to position the crossbeam (214) so as to obliquely traverse the beam (212) to form the attachment joint (250). In some embodiments, the solar positioning system (140) may be configured to position the solar attachment device (150) at the attachment joint (250). The solar attachment device (150) is configured to attach the attachment member (406) of the crossbeam (214) to the beam (212) at the attachment joint (250) to form the support frame (210). In some embodiments, the solar positioning system (140) may be configured to position the crossbeam (214) perpendicular to the beam (212) to form the attachment joint (250). The solar attachment device (150) is further configured to attach the additional crossbeam (215) and the additional beam (213) to the support frame (210) forming the additional attachment joint (251).

[0038] In some embodiments, the solar positioning system (140) is configured to position the solar panels (100, 101). The solar positioning system (140) may include a solar positioning device, not pictured. The solar positioning device may include hardware for removably connecting to one of the solar panels (100, 101). The solar positioning device may include a suction device configured to removably suction to the solar panel. In some embodiments, the solar positioning system (140) may be configured to position the solar panel (100) and the at least one additional solar panel (101) (e.g., at least two solar panels) simultaneously. In some embodiments having multiple solar panels, the solar panels (100, 101) may be arranged in a grid configuration where the solar panel (100) and each additional solar panel (101) is aligned in columns and / or rows. The solar panel (100) may be positioned adjacent to the crossbeam (214), so the solar panel is touching the crossbeam (214). The solar connection system (130) is configured to fasten the solar panel (100) to the support frame (210). In some embodiments, the solar connection system (130) may be configured to fasten the solar panel (100) and the additional solar panel (101) simultaneously.

[0039] In some embodiments, the solar panel system (20) may include a connection member (216). The connection member (216) is utilized to attach the support frame (210) to the pile (160). The connection member (216) may be attached to the pile (160) using mechanical connectors such as bolts, pins, fastening clips, and the like. In some embodiment, the connection member (216) may adjust a directional angle of the solar panels (100, 101) towards the sun (165). In some embodiments, the directional angle between the beam (212) and the pile (160) may be fixed. In other embodiments, the directional angle may be adjusted automatically or manually periodically.

[0040] In general, a solar panel system can be configured in a myriad of ways. Therefore, the solar panel system configuration as shown in FIG. 1 and FIG. 2 is not intended to be limiting with respect to the particular configuration of the solar panel system. Based upon the disclosure herein, a person of ordinary skill in the art will recognize a variety of solar panel systems that may be used in relation to different embodiments.

[0041] FIG. 3 shows a portion of a back view of the solar panel system (20) in accordance with one or more embodiments. Each solar panel (100, 101) includes a fastening side (310) opposite the collection side (110). The fastening side (310) is configured to receive one or more fasteners such as screws, bolts, rivets, fastening clips, and the like. In some embodiments, the fastening side (310) is fastened to the crossbeam (214).

[0042] Continuing with connection members, the connection member (216) may be configured to support the solar panels (100, 101) at different angles relative to the base surface ( 162) . The connection member (216) may be configured to be adjustable in respect to the angle of attachment. In some embodiments, the connection member (216) may be configured to support the solar panels (100, 101) at a predetermined angle relative to the base surface (162). The solar connection system (130) may be configured to fasten the connection member (216) to the support frame (210) with the mechanical connectors. The beam (212) is configured to receive the crossbeam (214) for attachment. The beam (212) may include an attachment flange (217) so as to provide an attachment surface for the crossbeam (214). In some embodiments, the crossbeam (214) is attached to the beam (212) via the attachment flange (217) to form the attachment joint (250).

[0043] FIG. 4 shows a sectional view of the attachment joint (250) and a fastening location (451) in accordance with one or more embodiments. Each crossbeam (214, 215) includes an attachment member (406), a support member (403), and a fastening flange (402). The attachment member (406), the support member (403), and the fastening flange (402) may be integrally connected to form each crossbeam (214, 215). In some embodiments, the attachment member (406), the support member (403), and the fastening flange (402) may be substantially perpendicular to each other to support the solar panels (100, 101). Each solar panel (100, 101) comprises one or more lateral edges (e.g., a first lateral edge (421) and / or a second lateral edge (422)). The first lateral edge (421) of the solar panel (100) may be positioned adjacent to the second lateral edge (422) of the additional solar panel (101) so that the solar panel (100) may be aligned adjacent with the additional solar panel (101). In some embodiments, the lateral edges of solar panels (100, 101) adjacent to each other may be touching. In some embodiments, the solar panels (100, 101) may be spaced witha predetermined distance between each solar panel (100, 101). The first lateral edge (421) of each solar panel (100, 101) may be aligned with the fastening flange (402). The solar panel system may include one or more fasteners (400) such as rivets, bolts, screws, self-tapping screws, fastening clips, and the like. The one or more fasteners (400) are configured to fasten the solar panel (100) to the fastening flange (402) of the crossbeam (214).

[0044] In some embodiments, one or more of the crossbeams (214, 215) may include two fastening flanges (e.g. , a fastening flange (402) and an additional fastening flange (405)) and two support members (e.g., the support member (403) and an additional support member (404)). The additional support member (404) is arranged opposite the support member (403) connected to the attachment member (406). The attachment member (406), the support member (403), and the additional support member (404) may form a u-channel in accordance with one or more embodiments. The additional fastening flange (405) may be integrally connected to the additional support member(404) and configured to receive the additional solar panel (101) to be fastened to the additional fastening flange (405).

[0045] In some embodiments, the solar positioning system (140) may be configured to position the additional solar panel (101) adjacent to the additional fastening flange(405) such that the additional solar panel (101) is touching the additional fastening flange (405). In some embodiments, the second lateral edge (422) of each additional solar panel (101) may be aligned with the additional fastening flange (405) of the additional crossbeam (215).

[0046] In some embodiments, each attachment joint (250, 251) is formed from positioning one of the crossbeams (214, 215) so as to obliquely traverse at least one of the beams (212, 213). The crossbeams (214, 215) are positioned adjacent to the attachment flange (217) of each beam (212, 213). The crossbeams (214, 215) are attached to each beam (212, 213) using an attachment connection (450) (e.g., clinching or welding) and / or using the one or more fasteners at one or more fastening locations (451).

[0047] FIG. 5 shows an example of one or more solar connection surfaces (510) (e.g., the fastening flanges (402, 405), the attachment member (406), the attachment flange (217), the fastening side (310) of the solar panels (100, 101), or combination thereof)receiving one of the fasteners (400) at various positions of fastening (positions A-D) in accordance with one or more embodiments.

[0048] In some embodiments, the one or more fasteners (400) may include a selftapping screw (500). In some embodiments, the self-tapping screw (500) may include a head (501), a head flange (502), a shaft (503) having a fastening surface (504), and a shaft tip (505). The shaft tip (505) may include drilling edges configured to drill a hole for the one or more fasteners (400) to penetrate the solar connection surface (510). The fastening surface (504) may include threads configured to induce a rotation of the fastener (400) and impose threading on the solar connection surfaces (510).

[0049] In accordance with one or more embodiments, the fastener (400) may be placed in position A. In position A, the fastener (400) is positioned adjacent to the solar connection surface (510) with the shaft tip (505) in close proximity so as to touch the solar connection surface. In position B, the fastener (400) is rotated or pushed, using the solar fastening device (600), to drill and / or displace a portion of the solar connection surfaces (510) so as to penetrate the solar connection surface (510). In position C, the fastener (400) is rotated until the head (501) and / or the head flange (502) is in close proximity to the solar connection surfaces (510) and the shaft (503) has at least partially penetrated the solar connection surfaces (510). In position D, the fastener (400) is rotated and / or pushed until the solar connection surfaces (510) are bonded together so as each solar connection surface (510) is touching, and the head (501) and / or the head flange (502) is tight against one of the solar connection surfaces (510).

[0050] FIG. 6 shows the solar fastening device (600) in accordance with one or more embodiments. The solar fastening device (600) includes a fastening tool tip (601), a fastening actuator (602), and a fastening control unit (606) having control lines (605). The fastening tool tip (601) is configured to guide each fastener (400) for installation. The fastening tool tip (601) may be operatively connected to the fastening actuator (602). The fastening tool tip (601) may include a safety mechanism (620) such as a safety bar that contacts the solar connection surface (510) and when pressed with enough force disengages a safety lock on the fastening actuator (602) allowing the fastening actuator (602) to actuate and install the fastener (400). The control lines(605) may include hoses, wires, cables, and line connectors for operating the solar fastening device (600).

[0051] In some embodiments, the fastening actuator (602) may be configured to rotate the fastener (400) (e.g. , screwing). In some embodiments, the fastening actuator (602) may be configured to pull and shear a rivet stem (e.g., riveting). In some embodiments, the fastening actuator (602) may be configured to push the fastener (400) at a force sufficient for the fastener (400) to penetrate the one or more solar connection surfaces ( 10) (e.g., nailing). In some embodiments, the fastening actuator (602) may be operatively coupled with a pneumatic system and configured to use air to actuate the fastening actuator (602) in order to install the fasteners (400). In some embodiments, the fastening actuator (602) may be configured for a hydraulic system to use hydraulic fluids to actuate the fastening actuator (602) to install the fasteners (400).

[0052] The pneumatic system may be any system known in the art that is capable of actuating an actuator using air. Based upon the disclosure provided herein, a person of ordinary skill in the art will recognize a variety of pneumatic systems that may be used in relation to different embodiments.

[0053] In some embodiments, the fastening actuator (602) is operatively connected to the fastening control unit (606). The fastening control unit (606) may be operatively connected to the solar connection system (130). In some embodiments, the solar control system (120) may be configured to communicate with the solar fastening device (600) and the fastening control unit (606) instructions on when to actuate the fastening actuator (602). The fastening control unit (606) may include fastening control hardware and / or software for communicating with the solar control system (120) and the fastening actuator (602). Fastening control hardware may include cables, wires, wireless adapters, cable ports, and electronics for communicating with the solar control system (120). In some embodiments, the wires may be configured to transmit electrical signals to / from the solar connection system (130). In some embodiments, the cables may be configured to transmit electrical power to the various components of the solar fastening device (600) from a power supply.

[0054] In some embodiments, the solar fastening device (600) includes a fastener loading unit (603), and a fastener storage unit (604). The fastener loading unit (603)may include a fastener channel configured to receive the one or more fasteners (400) from the fastener storage unit (604). The fastener loading unit (603) is configured to channel the one or more fasteners (400) to the fastening tool tip (601) and loading one of the fasteners (400) into the fastening tool tip (601). The fastener loading unit (603) may include a loading mechanism for loading the one or more fasteners (400). In some embodiments, the loading mechanisms may be coupled with the pneumatic system and configured to use air to actuate the loading mechanism.

[0055] In some embodiments, the fastener storage unit (604) may include a storage area configured to store the one or more fasteners (400). The fastener storage unit (604) is operatively connected to the fastener loading unit (603). The fastener loading unit (603) is configured to retrieve the one or more fasteners (400) from the fastener storage unit (604). The fastener storage unit (604) may include a fastener inlet for loading the one or more fasteners (400) to the fastener storage unit (604).

[0056] In some embodiments, the solar fastening device (600) may include an arm attachment end (610) having a first connection mechanism (611). The arm attachment end (610) is configured to operatively connect to the solar positioning system (140) In some embodiments, the solar positioning system (140) may be configured to position the crossbeam (214) so as to obliquely traverse the beam (212) to form the attachment joint (250). In some embodiments, the solar positioning system (140) may be configured to position the solar fastening device (600) to install the one or more fasteners (400). The solar fastening device (600) is configured to fasten the fastening side (310) of the solar panels (100, 101) to the fastening flanges (402, 405) using the one or more fasteners (400).

[0057] FIG. 7A shows a robotic arm (700) in accordance with one or more embodiments. The solar positioning system (140) may include the robotic arm (700). The robotic arm may be a portal robot / area gantry robot in one or more embodiments. The robotic arm (700) includes a positioning joint (706), an arm member (703), a robotic actuator (705), and a tool end (701). The positioning joint (706) includes several linear axes used for positioning. The solar control system (120) is configured to communicate data and instructions with the robotic arm (700). The arm member (703) is operatively connected to each other by a positioning joint (706). The positioning joint (706) may house the robotic actuator (705). The robotic actuator(705) may include motors and / or servos for actuating the arm member (703) such as moving the arm (703) member via independent movement of the linear axes. The robotic actuator (705) is operatively connected to the arm member (703). The positioning joint (706) may be configured to move the robotic arm (700) to position the solar connection devices such as the solar attachment device (150) and solar panels (100, 101) according to the instructions received from the solar control system (120). In one or more embodiments, the positioning joint (706) may be mounted to the mounting end (702) in such a way as to allow 360 degree rotation of the positioning joint (706) on the mounting end (702). Based on the disclosure provided herein, it will be apparent to a person of ordinary skill in the art that the robotic arm (700) may have any number of arm members, positioning joints and / or linear axes, and robotic actuators that may be used in relation to the different embodiments. In some embodiments, the robotic arm (700) may include amounting end (702) configured for mounting the robotic arm (700) on an operating surface such as the floor of the structure.

[0058] In some embodiments, the robotic arm (700) may be configured to position the solar panels (100,101). The tool end (701) of the robotic arm (700) may be configured to receive the solar positioning device. The robotic arm (700) and the solar positioning device may be configured to retrieve one of the solar panels (100, 101) from the stowing position. The robotic arm (700) may include suction cups (708), for example, that are configured to adhere to the solar panels (100, 101) to allow for the robotic arm (700) to position the panels. Examples of the suction cups (708) on the robotic arm are shown in FIG. 7B. In some embodiments, the solar positioning device may be configured to retrieve the solar panel ( 100) and the additional solar panel (101) simultaneously. Furthermore, the robotic arm (700) may be configured to position other components in the system, including but not limited to beams (212, 213) and the crossbeams (214, 215).

[0059] In some embodiments, the tool end (701) of the robotic arm (700) may be configured to receive the arm attachment end (610) of the solar connection devices (e.g., the solar fastening device (600) and the solar attachment device (150)). The solar fastening device (600) may include the first connection mechanism (611) configured to connect to the tool end (701) of the robotic arm (700). For example, thefirst connection mechanism (611) may include connection pins. The tool end (701) of the robotic arm (700) may include connection cavities. The connection pins may be configured to interlock with the connection cavities.

[0060] FIG. 8 shows a sectional view of the attachment joint (250) in accordance with one or more embodiments. The beam (212) and the crossbeam (214) may be attached using a clinching connection (800). The clinching connection (800) may be formed using the solar attachment device (150). For example, the clinching connection (800) may be formed by pressing the beams (212, 213) and the crossbeams (214, 215) together into a molded tool tip having a mold cavity. Each crossbeam (212, 214) may be pressed and molded at the attachment joint (250) into the beams (212, 213) so that the molded crossbeam (212, 214) may interlock with the molded beam to form the clinching connection (800).

[0061] FIG. 9 shows the solar attachment device (150) in accordance with one or more embodiments. In some embodiments, the solar attachment device (150) includes a solar clinching device (900). The solar clinching device (900) is configured to form the clinching connection (800) with the solar connection surfaces (510). The solar clinching device (900) may include a first attachment tip (901), a tool member (903), and a second attachment tip (902). The first attachment tip (901) is operatively connected to the tool member (903). The first attachment tip (901) may include the molded tool tip configured to clinch the solar connection surfaces (e.g., the beam (212) and / or the crossbeam (214)) so the solar connection surfaces (510) interlock as shown in FIG. 8. The first attachment tip (901) having the molded cavity is configured to receive, at least partially, the second attachment tip (902). The second attachment tip (902) may be a mold plunger that presses on the solar connection surfaces (510) forcing the solar connection surfaces (510) into the mold cavity of the first attachment tip (901). The first attachment tip (901) may be integral with the tool member (903). The tool member (903) may be any suitable shape for connecting the first attachment tip (901) and the attachment tool actuator (904) that allows the solar connection surfaces (510) to be place between the first attachment tip (901) and the second attachment tip (902).

[0062] In some embodiments, the solar clinching device (900) includes an attachment tool actuator (904). The attachment tool actuator (904) is operatively connected tothe tool member (903). The second attachment tip (902) is operatively connected to the attachment tool actuator (904). The attachment tool actuator (904) is configured to actuate the second attachment tip (902) to press the solar connection surfaces (510) into the molded cavity of the first attachment tip (901). The attachment tool actuator (904) may be operatively coupled with the pneumatic system and configured to use air to actuate the attachment tool actuator (904).

[0063] In some embodiments, the solar clinching device (900) may include a positioning unit (910). The positioning unit (910) may be configured to position the attachment tool actuator (904) and the second attachment tip (902) in closer proximity to the first attachment tip (901) after the solar connection surfaces ( 10) have been placed between the first attachment tip (901 ) and the second attachment tip (902) . The positioning unit (910) may further be configured to position the attachment tool actuator (904) and the second attachment tip (902) farther apart from the first attachment tip (901) to remove the solar connection surfaces (510) from between the first attachment tip (901) and the second attachment tip (902). In some embodiments, the positioning unit (910) may be configured for use with the pneumatic system and use air for positioning the attachment tool actuator (904) and the second attachment tip (902). In some embodiments, the positioning unit (910) may be configured for use with the electrical systems and use electrical power for positioning the attachment tool actuator (904) and the second attachment tip (902).

[0064] The solar clinching device (900) includes an attachment control unit (906). The attachment control unit (906) may be operatively connected to the solar connection system (130). The solar connection system (130) is configured to communicate with the attachment control unit (906) instructions on when to actuate the attachment tool actuator (904). The attachment control unit (906) may include attachment control hardware and / or software for communicating with the solar control system (120) and / or the attachment tool actuator (904). Attachment control hardware may include cables, wires, wireless adapters, and electronics for communicating with the solar control system (120) and the attachment tool actuator (904). In some embodiments, the wires may be configured to transmit electrical signals to / from the solar connection system (130). In some embodiments, the cables may be configured to transmit electrical power to the various components of the solar clinching device (900) fromthe power supply. In some embodiments, the attachment tool actuator (904) may be operatively coupled with the pneumatic system and configured to use air to actuate the attachment tool actuator (904).

[0065] In some embodiments, the solar clinching device (900) includes the arm attachment end (610). The tool end (701) of the robotic arm (700) may be configured to receive the arm attachment end (610) of the solar connection devices (e.g., the solar fastening device (600) and the solar attachment device (150) such as the solar clinching device (900)). The solar clinching device (900) may include a second connection mechanism (911) configured to connect to the tool end (701 ) of the robotic arm (700). For example, the second connection mechanism (911) may include a connection plate. The tool end (701) of the robotic arm (700) may include a connection plate cavity. The connection plate may be configured to interlock with the connection plate cavity. The robotic arm (700) may be configured to position the solar fastening device (600) and / or the solar clinching device (900) automatically.

[0066] In accordance with one or more embodiments, the solar attachment device (1 0) may include a welder such as a spot welder. The welder is configured to weld the crossbeams (214, 215) and the beams (212, 213) to form the attachment joints (250, 251).

[0067] FIG. 10 shows a sectional view of the attachment joint (250) and the fastening location (451) in accordance with one or more embodiments. The solar panel system may include one or more fastening clips (1000). Each crossbeam (214, 215) and fastening side (310) may include one or more locking holes (1010). Each fastening flange (402, 405) and fastening side (310) may be configured to receive the one or more fastening clips (1000).

[0068] The one or more fastening clips (1000) are configured to fasten the solar panel ( 100) to the fastening flange (402) of the crossbeam (214). Each fastening clip (1000) may include a locking tab ( 1011 ) configured to lock the fastening clip at the fastening location (451). The locking tab (1011) may interlock with the locking holes (1010) at the fastening location (451) to fasten the solar panel (100) to the fastening flange (402) of the crossbeam (214).

[0069] The robotic arm (700) may include a robotic hand (not shown) configured to install the fastening clip (1000). The robotic hand may include a gripper (not shown) configured to hold the fastening clip (1000) for installation. A magazine of multiple fastening clips (1000) may be included in the robotic arm (700) allowing for multiple installations. The one or more fastening clips (1000) may be installed by sliding the one or more fastening clips (1000) to encompass the fastening flange (402, 405) and the fastening side (310) of the solar panel (100, 101) at the fastening location (451) and interlocking the locking tab (1011) with the locking holes (1010).

[0070] As will be appreciated by those skilled in the art, the systems described herein may be configured to readily change between different tools (e.g., the solar fastening device (600), the robotic arm (700), and the solar clinching device (900)). As such, a docking station may be included for each tool that holds the tool while not in use. Tools may be swapped as needed with minimal time added to the process.

[0071] FIG. 11 depicts a flowchart in accordance with one or more embodiments describing a method for fastening solar panels (hereafter “solar assembly method”) (1100). In some embodiments, the solar assembly method (1100) uses the assembly system (10) as described in relation to FIGs 1-10 and accompanying description. Although the processes in the flowchart using the solar assembly method (1100) are shown in sequential order, it will be apparent to a person having ordinary skill in the art that some processes may be conducted in parallel, in a different order than shown, or may be omitted without departing from the scope of the invention.

[0072] In box ( 1102), the solar assembly method ( 1100) may include positioning, using the solar positioning system (140), the crossbeam (214) so as to obliquely traverse the beam (212) to form the attachment joint (250), in accordance with one or more embodiments. The solar positioning system (140) may position, using the robotic arm (700), the beam (212) in a predetermined orientation. The beam (212) may be positioned on a flat surface such as a floor of a structure or assembling platform. The structure may be an assembly plant for assembling solar panel systems. The crossbeam (214) is positioned, using the robotic arm (700), so as to obliquely traverse the beam (212). In some embodiments, the crossbeam (214) may be positioned perpendicular to the beam (212).

[0073] In box (1104), the solar assembly method (1100) may include positioning, using the solar positioning system (140), the solar attachment device (150) at the attachment joint (250), in accordance with one or more embodiments. The solar positioning system (140) may include the robotic arm (700). The robotic arm (700) operatively connects to the solar attachment device (150) such as the solar clinching device (900). The robotic arm (700) may pivot using the pivot junction (706) and the robotic actuator (705) so as to position the solar attachment device (150) at the attachment joint (250). In some embodiments, the solar assembly method (1100) may include automatically positioning the solar attachment device (150) such as the solar clinching device (900) using the robotic arm (700).

[0074] In accordance with one or more embodiments, the solar assembly method (1100) may include communicating, using the solar control system (120), instructions with the robotic arm (700). The solar assembly method (1100) may include pivoting, using the pivot junction (706), the robotic arm (700) to position the solar attachment device (150) according to the instructions received from the solar control system (120).

[0075] In box (1106), the solar assembly method (1100) may include attaching, using the solar attachment device (150) such as the solar clinching device (900), the attachment member (406) of the crossbeam (214) to the beam (212) at the attachment joint (250) to form a support frame (210), in accordance with one or more embodiments. The attaching the attachment member (406) of the crossbeam (214) to the beam (212) may include positioning the solar attachment device (150) to encompass opposing sides of the attachment joint (250). The solar attachment device (150) operatively presses on the attachment joint (250) so as to press together the crossbeam (214) and the beam (212). The attaching the attachment member (406) of the crossbeam (214) to the beam (212) at the attachment joint (250) may include clinching and / or welding at the attachment joint (250) the attachment member (406) to the beam (212) using the solar clinching device (900) and / or welder, respectively.

[0076] In accordance with one or more embodiments, the solar assembly method (1100) may include positioning, using the solar positioning system (140), at least one additional crossbeam (215) parallel so as to obliquely traverse at least one additional beam (213) to form at least one additional attachment joint (251). In someembodiments, the at least one additional crossbeam (215) is parallel to the crossbeam (214). In some embodiments, the at least one additional beam (213) is parallel to the beam (212). The solar assembly method (1100) may include attaching, using the solar attachment device (150), the additional crossbeam (215) and the additional beam(213) to the support frame (210) forming the additional attachment joint (251). In some embodiments, the positioning and the attaching of the additional beam (213) and the additional crossbeam (215) may include similar processes as described in relation to box (1102), box (1104), and / or box (1106) that may be used in relation to different embodiments.

[0077] In box (1108), the solar assembly method (1100) may include positioning, using the solar positioning system (140), the solar panel (100) adjacent to the crossbeam(214) such that a fastening side (310) of the solar panel ( 100) is touching the fastening flange (402) of the crossbeam (214), in accordance with one or more embodiments. The positioning of the solar panel (100) may include retrieving, using the robotic arm (700), the solar panel (100) from a stowing position. In some embodiments, the stowing position may be on a transport vehicle that transported the solar panel (100) from a solar storage facility. In some embodiments, the stowing position may be a distinct location on the flat surface of the structure where the solar panel (100) had been placed previous to assembling the solar panel system (20). In some embodiments, the solar assembly method (1100) may include automatically retrieving the solar panel (100) from the stowing position using the robotic arm (700) based on instructions from the solar control system (120). The robotic arm (700) may include the tool end (701) that is operatively connected to the solar positioning device.

[0078] In box (1110), the solar assembly method ( 1100) may include positioning, using the solar positioning system (140), the solar fastening device (600) adjacent to the fastening flange (402) of the crossbeam (214) such that the solar fastening device (600) is opposite the solar panel (100) and the fastening tool tip (601) is point toward the fastening side (310) of the solar panel (100), in accordance with one or more embodiments. In some embodiments, the solar fastening device (600) may be oriented normal to the fastening side (310) of the solar panel (100) prior to installing the one or more fasteners (400).

[0079] In box (1112), the solar assembly method (1100) may include fastening, using the solar fastening device (600), the fastening side (310) of the solar panel (100) to the fastening flange (402) using the one or more fasteners (400), in accordance with one or more embodiments. In some embodiments, the one or more fasteners (400) may include a self-tapping screw. The self-tapping screw may be rotated by the solar fastening device (600) and screwed into the fastening flange (402) and the fastening side (310) of the solar panel (100). In some embodiments, the fastening of the fastening side (310) of the solar panel (100) to the fastening flange (402) comprises self-tapping the fastening side (310) of the solar panel (100) to the fastening flange (402) using a self-tapping screw as one of the one or more fasteners (400). In some embodiments, the fastening of the fastening side (310) of the solar panel (100) to the fastening flange (402) may include pre-drilling fastening holes into the fastening flange (402) and the fastening side (310) using the robotic arm (700). The one or more fasteners (400) may include a rivet or a fastening clip. The solar fastening device (600) may insert the rivet into the pre-drilled holes and operatively rivet the fastening flange (402) and fastening side (310) together.

[0080] In box (1114), the solar assembly method ( 1100) may include positioning, using the solar positioning system (140), the additional solar panel (101) adjacent to an additional fastening flange (405) of the crossbeam (214) such that the fastening side (310) of the additional solar panel (101) is touching the additional fastening flange (405), in accordance with one or more embodiments. The positioning of the additional solar panel (101) to the additional fastening flange (405) may include similar processes as described in relation to box (1108) and / or box (1110) that may be used in relation to different embodiments. In some embodiments, the solar assembly method (1100) may include positioning, using the solar positioning system (140), of the solar panel (100) and the at least one additional solar panel (101) (e.g., at least two solar panels) may include positioning the solar panels (100, 101) simultaneously. Each solar panel (100, 101) may be positioned adjacent to one of the two fastening flanges (e.g., the fastening flange (402) and the additional fastening flange (405)) of the crossbeam (214).

[0081] In box (1116), the solar assembly method (1100) may include fastening, using the solar fastening device (600), the additional solar panel (101) to the additionalfastening flange (405) using the one or more fasteners (400), in accordance with one or more embodiments. The fastening of the additional solar panel (101) to the additional fastening flange (405) may include similar processes as described in relation to box (1112) that may be used in relation to different embodiments.

[0082] Embodiments of the present disclosure may provide at least one of the following advantages. The methods and systems disclosed herein may provide improvements in assembling solar panel systems and reducing costs allowing more entities to purchase solar panel systems thereby reducing carbon emissions from the use of fossil fuels for power generation. The methods and systems disclosed herein may provide increased automation in assembling solar power systems and thereby reduce solar assembly worker related injuries.

[0083] Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.

Claims

CLAIMSWhat is claimed:

1. A method for fastening solar panels, the method comprising: positioning, using a solar positioning system, a crossbeam so as to obliquely traverse a beam to form an attachment joint; positioning, using the solar positioning system, a solar attachment device at the attachment joint; attaching, using the solar attachment device, an attachment member of the crossbeam to the beam at the attachment joint to form a support frame; positioning, using the solar positioning system, a solar panel adjacent to the crossbeam such that a fastening side of the solar panel is touching a fastening flange of the crossbeam; positioning, using the solar positioning system, a solar fastening device adjacent to the fastening flange of the crossbeam such that the solar fastening device is opposite the solar panel; and fastening, using the solar fastening device, the fastening side of the solar panel to the fastening flange using at least one fastener.

2. The method of claim 1, wherein attaching the attachment member of the crossbeam to the beam at the attachment joint further comprises clinching the attachment member to the beam using a solar clinching device as the solar attachment device.

3. The method of claim 1 or 2, wherein fastening the fastening side of the solar panel to the fastening flange comprises self-tapping the fastening side of the solar panel to the fastening flange using a self-tapping screw as the at least one fastener.

4. The method of any one of claims 1-3, wherein positioning the crossbeam comprises positioning, using the solar positioning system, the crossbeam perpendicular to the beam.

5. The method of any one of claims 1-4, further comprising automatically positioning the solar attachment device using a robotic arm.

6. The method of claim 5, further comprising: communicating, using a solar control system, instructions with the robotic arm; andpivoting, using at least one pivot junction, the robotic arm to position the solar attachment device according to the instructions received from the solar control system.

7. The method of any one of claims 1-6, further comprising automatically retrieving the solar panel from a stowing position using a robotic arm.

8. The method of any one of claims 1-7, further comprising: positioning, using the solar positioning system, at least one additional solar panel adjacent to an additional fastening flange of the crossbeam such that the fastening side of the at least one additional solar panel is touching the additional fastening flange; and fastening, using the solar fastening device, the at least one additional solar panel to the additional fastening flange using the at least one fastener.

9. The method of any one of claims 1-8, further comprising: positioning, using the solar positioning system, at least one additional crossbeam parallel so as to obliquely traverse at least one additional beam to form at least one additional attachment joint, wherein the at least one additional crossbeam is parallel to the crossbeam, wherein the at least one additional beam is parallel to the beam; and attaching, using the solar attachment device, the at least one additional crossbeam and the at least one additional beam to the support frame forming at least one additional attachment joint.

10. A method for fastening solar panels, the method comprising: positioning, using a solar positioning system, a crossbeam having two fastening flanges so as to obliquely traverse a beam to form an attachment joint; positioning, using the solar positioning system, a solar attachment device at the attachment joint; attaching, using the solar attachment device, an attachment member of the crossbeam to the beam at the attachment joint; positioning, using the solar positioning system, at least two solar panels simultaneously, each solar panel having a fastening side, each solar panel being positionedadjacent to one of the two fastening flanges of the crossbeam such that each solar panel is touching one of the two fastening flanges; positioning, using the solar positioning system, a solar fastening device adjacent to one of the two fastening flanges opposite one of the at least two solar panels; and fastening, using the solar fastening device, each solar panel to one of the two fastening flanges using a plurality of fasteners.

11. A system for fastening solar panels, the system comprises: a solar panel having a fastening side, a beam configured to form an attachment joint, a crossbeam configured to attach to the beam to form the attachment joint, wherein the crossbeam comprises an attachment member, a support member, and a fastening flange, at least one fastener configured to fasten the solar panel to the fastening flange of the crossbeam, a solar connection system comprises a solar attachment device configured to attach the crossbeam and the beam, a solar fastening device configured to install the at least one fastener, and a solar positioning system; the solar positioning system is configured to position the crossbeam so as to obliquely traverse the beam to form an attachment joint, position the solar attachment device at the attachment joint, position the solar panel to attach to the crossbeam, position the solar fastening device to install the at least one fastener; the solar attachment device is configured to attach the attachment member of the crossbeam to the beam at the attachment joint to form a support frame; and the solar fastening device is configured to fasten the fastening side of the solar panel to the fastening flange using the at least one fastener.

12. The system of claim 11, wherein the solar attachment device comprises a solar clinching device configured to clinch the attachment member to the beam.

13. The system of claim 11 or 12, wherein the at least one fastener comprises at least one selftapping screw configured to self-tap to fasten the solar panel to the fastening flange.

14. The system of any one of claims 11-13, wherein the solar positioning system is configured to position the crossbeam perpendicular to the beam.

15. The system of any one of claims 11-14, further comprising a robotic arm having a tool end configured to receive an arm attachment end of the solar attachment device, wherein the robotic arm is configured to position the solar attachment device automatically.

16. The system of claim 15, further comprising a solar control system configured to communicate instructions with the robotic arm comprising at least one pivot junction configured to pivot the robotic arm to position the solar attachment device according to the instructions received.

17. The system of any one of claims 11-16, further comprising a robotic arm having a tool end configured to receive a solar positioning device, wherein the robotic arm is configured to retrieve the solar panel from a stowing position automatically.

18. The system of any one of claims 11-17, further comprising: at least one additional solar panel configured to fasten to the crossbeam comprising an additional support member configured to support the solar panel, and an additional fastening flange configured to fasten to the solar panel; wherein the solar positioning system is further configured to position the at least one additional solar panel adjacent to the additional fastening flange such that the at least one additional solar panel is touching the additional fastening flange and the solar attachment device is further configured to fasten the at least one additional solar panel to the additional fastening flange using at least one fastener.

19. The system of claim 18, wherein the solar positioning system is configured to position the solar panel and the at least one additional solar panel simultaneously.

20. The system of any one of claims 11-19, further comprising: at least one additional beam configured to attach to at least one additional crossbeam, wherein the solar positioning system is further configured to position the at least one additional crossbeam parallel so as to obliquely traverse the at least one additional beam to form at least one additional attachment joint, wherein the atleast one additional crossbeam is parallel to the crossbeam and the at least one additional beam is parallel to the beam, wherein the solar attachment device is further configured to attach the at least one additional crossbeam and the at least one additional beam to the support frame forming at least one additional attachment joint.

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