Automatic solar module cleaner

Abstract

The present invention relates to a solar module cleaner that used to clean the surface of the solar module. This solar module cleaner comprises a mainframe having 4 support profile pipe, 2 gearbox assembly, 2 brush, 1 brush connector assembly, 4 drive wheel assembly, 4 support drive, 2 gearbox & electronic control box mounting plate, 1 swappable battery box mounting plate, 2 electronic control box, 1 swappable battery box, 4 proximity sensors, 1 centre support wheel mounting plate, 2 centre support wheel drive assembly, 2 centre support wheel, 1 PV module.

Description

Automatic solar module cleaner

[0001] This application is related to Indian Patent application No. IN202421097190 filed on 9thDec, 2024 and is incorporated herein in its entirety.

[0002] The present invention relates to an automatic solar module cleaner used to clean the surface of the solar panel. More particularly, the present invention provides waterless cleaning of solar panel and said system powered by only one motor.

[0003] The increasing challenges of global climate change and the demand for sustainable energy sources have highlighted the importance of renewable energy technologies. Among these, solar power has emerged as a leading solution, offering the potential to meet the world’s growing energy needs by harnessing the abundant energy from the sun. As the cost of solar energy continues to decrease and conventional fuel prices rise, the solar energy industry is experiencing substantial growth.

[0004] Solar panels, typically made from high-quality glass, are central to solar power generation. However, the efficiency of these panels can be significantly impacted by the accumulation of dirt, dust, and debris on their surfaces. Cleanliness is crucial to ensuring the panels can absorb maximum sunlight and generate optimal energy. As such, regular cleaning is essential for maintaining solar panel performance.

[0005] Traditional methods of cleaning solar panels are often labor-intensive, water-consuming, and costly. These methods also tend to be inefficient and environmentally unsustainable, especially in regions where water is a scarce resource. Consequently, there is a pressing need for a more efficient, cost-effective, and eco-friendly solution for cleaning solar panels.

[0006] The present invention addresses these challenges by providing anAutomatic Solar module Cleaner, which utilizes awaterless cleaning mechanism. This device effectively removes dirt and debris from solar panels using rotating brushes powered by asingle motor. Thegearboxtransmits all the power to the wheel drive and support drive wheel, ensuring efficient operation with minimal energy consumption. Additionally, the system features acustom photovoltaic (PV) modulethat charges a battery, thereby eliminating the need for external power sources and making the device self-sufficient. This split frame design allows Automatic solar module cleaner to glide even on two tilted mounting structure. The system feature power drive at centre support wheel by additional pipe to prevent tilting of the automatic solar module cleaner.

[0007] This innovative design allows for an efficient, sustainable, and cost-effective solution for cleaning solar panels. By addressing the inefficiencies of traditional cleaning methods, the Automatic Solar module cleaner helps maintain the efficiency and performance of solar panels while reducing water and energy consumption. It represents a significant advancement in the solar energy sector, contributing to the broader goals of sustainability and energy independence.Summary of the Invention

[0008] The present invention is Automatic solar module cleaner for cleaning / dust removing process from solar panel. It provides waterless cleaning of solar panel. This solar module cleaner comprises a mainframe having support pipe, gearbox assembly, brush, brush connector assembly, drive wheel, support wheel, Gearbox and electronic control box mounting plate, electronic control box, center support wheel, center support wheel mounting plate, Centre support wheel power drive assembly, proximity sensors, proximity sensors mounting plate, and solar module on top of the mainframe.

[0009] The present invention also introduces the following key features:

[0010] Waterless Cleaning: The cleaning process does not require water, significantly reducing water consumption and making the device more environmentally friendly, especially in areas where water is scarce.

[0011] Single Motor Operation: The system is powered by a single motor, simplifying the design and improving energy efficiency.

[0012] Gearbox for Power Transmission: A gearbox transmits power from the motor to the wheel drive and support drive wheel, optimizing the power transfer and improving the overall efficiency of the cleaning system.

[0013] Custom PV Module for Battery Charging: The cleaner uses a custom-designed PV module to charge its battery, removing the need for an external power supply and making the system energy-independent.

[0014] Innovative Support Profile Pipe Design: The cleaner features a newly invented profile shape for the support pipe, enhancing the structural integrity and providing better stability and durability.

[0015] Application-Controlled System: The device can be operated and controlled via a dedicated application, allowing users to monitor and manage the cleaning process remotely, making it user-friendly and customizable.

[0016] The main objective of the present invention is to design automatic solar module cleaner to remove dust from surface of solar panel.

[0017] Another objective of the present invention is to provide waterless cleaning of solar panel.

[0018] Yet another objective of the present invention is that system powered by only one motor.

[0019] Yet another objective of the present invention is to use gearbox for transmission of all power to the wheel drive.

[0020] Yet another objective of the present invention is to uses custom PV module to charge battery to eliminate power dependency.

[0021] Yet another objective of the present invention is to use of power drive at centre support wheel to prevent tilting of the automatic solar module cleaner.

[0022] Yet another objective of the present invention is to use split frame design to allow glide on two tilted mounting structure.

[0023] shows an isometric view of the solar module cleaner configured on the top surface of a solar module arrayNotationRepresents100Solar module cleaner on solar module101Mainframe of solar module cleaner102Top surface of the solar module

[0024] shows an isometric view of the solar module cleaner with all assemble partsNotationRepresents201Support profile pipe202a and 202bGear box203a and 203bDrive wheels204Support drive wheel205PV module206Brush207Electronic control box 1208Electronic control box 2209Swappable battery box210Proximity sensors

[0025] shows a top view of the mainframe of the solar module cleanerNotationRepresents301Gearbox & electronic control box mounting plate302Swappable battery box mounting plate303Centre support wheel mounting plate304Electronic mounting plate305a and 305bCentre support mounting plate

[0026] shows a bottom view of the mainframe of the solar module cleanerNotationRepresents401Centre support wheel drive assembly402Centre support wheel403PV module mounting plate404Proximity sensors mounting plates

[0027] shows a detailed view of the gear box assemblyNotationRepresents501Main gear502a & 502bDriven spur gear503a & 503bDriven bevel gear504Idler gear505Drive shaft506a&506bDriven shaft507a&507bBevel driven shaft

[0028] shows a detailed view of the brush connector assemblyNotationRepresents601Brush shaft602Bearing housing603Support plate

[0029] shows a cleaning brushNotationRepresents701Cleaning brush rod702Bristles

[0030] shows a detailed view of the bristles of the cleaning brush

[0031] shows a cross-section view of the support profile pipe

[0032] Various aspects of the present invention will be described in detail in connection with the accompanying drawings, in order to provide a better understanding of the present invention.

[0033] The present invention relates to a solar module cleaner that used to clean the surface of the solar module. This solar module cleaner comprises a mainframe having 4 support profile pipe, 2 gearbox assembly, 2 brush, 1 brush connector assembly, 4 drive wheel assembly, 4 support drive, 2 gearbox & electronic control box mounting plate, 1 swappable battery box mounting plate, 2 electronic control box, 1 swappable battery box, 4 proximity sensors, 1 centre support wheel mounting plate, 2 centre support wheel drive assembly, 2 centre support wheel, and 1 PV module.

[0034] The Gear box assembly is located at the end of the 2-support pipe on the gearbox & electronic control box mounting plate. The brush is connected at gear box assembly by shaft and both brush is connected by brush connector assembly. The 4-drive wheel is connected to the both gear box assembly for traverse movement of the solar module cleaner. The 4-support wheel is attached to the perpendicular to the both gearbox assembly for secure movement of the solar module cleaner on the solar module array.

[0035] The solar module cleaner includes 2 gearbox assembly for a traverse movement of the solar module cleaner over the solar module array. The solar module cleaner includes 2 gear box assembly to provide power and torque to the drive wheel, support drive wheel and brush synchronously for the cleaning of the solar modules.

[0036] The solar module cleaner further includes brush connector assembly to connect 2 or more brushes for 2 or more vertically or horizontally setup of the solar module array. This provides the solution to the length adjustment as, different solar module manufacturer made different length of the solar module and further more solar EPC (Engineering, Procurement and Construction) is installing their setup into 2 or more vertically or horizontally solar modules.

[0037] The present invention relates to a solar module cleaner (100). The solar module cleaner (100) is configured to traverse along the top of the solar module (102) to clean the dirt and debris accumulated on the surface of the solar module (101), the mechanism of which is illustrated in the following embodiments.

[0038] Main embodiment of the present invention is an Automatic solar module cleaner (101) for waterless cleaning of solar panel comprises of:

[0039] Gearbox assembly (202a and 202b) located with motor mounting assembly, and at the left and right side of the solar module cleaner (101);

[0040] Brushes (206) are placed between gearboxes (202a and 202b);

[0041] Support profile pipe (201) is connected via gearbox and electronic control box mounting plates (301) to give full support to the mainframe solar module cleaner (101);

[0042] Drive wheels (203a and 203b) for movement of solar module cleaner (101) only on the border frame of the solar module array;

[0043] Customized Photovoltaic (PV) module (205) is mounted on the PV module mounting plates (403);

[0044] Proximity sensors (210) are located on the proximity sensors mounting plates (404) which is located on the support profile pipe (201);

[0045] Support drive wheel (204) is located at the perpendicular to the gearbox assembly (202a and 202b) which is used to lock the solar module cleaner on the top surface of the solar module;

[0046] Swappable battery box (209);

[0047] Gearboxes and electronic control box mounting plate (301) holds the gearbox, electronic control box (207 and 208) and motor mounting assembly;

[0048] Swappable battery box mounting plate (302);

[0049] Electronic mounting plate (304);

[0050] Center support wheel (402) is located at the mid of the solar module cleaner (101) to give support to the whole mainframe;

[0051] Center support mounting plate (305a and 305b) for movement of the center support wheel (204) for 10 mm along with the axis of center support pipe;

[0052] Centre support wheel drive assembly (401) allows centre support wheel (402) to get drive from gearbox assembly;

[0053] Main gear (501) is attached on the drive shaft (505);

[0054] Main gear (501) transfers the rotation via idler gear (503) to the driven spur gear (502a and 502b) and driven bevel gear (503a and 503b);

[0055] Drive wheel (203a and 203b) is attached to the driven shaft (506a & 506b);

[0056] Brush connector assembly is mount on the Centre support wheel mounting plate (303); and

[0057] Cleaning brush (206);

[0058] wherein said cleaner (101) is configured to traverse along the top of the solar module (102) to clean the dirt and debris accumulated on the surface of the solar module and said cleaner (101) is powered by a single motor.

[0059] Another embodiment of the present invention is said PV module (205) is used to charge the battery that supply power to the main motor that rotates the main drive shaft (505).

[0060] Another embodiment of the present invention is said solar module cleaner (101) is moves on the solar module array and reach at one of the ends of the docket station, the proximity sensors (210) sense the side plate of the docket station that gives signal to the electronic control box (207 and 208) which change the rotation of the main electric motor that reverse the rotation of the drive wheel and change the direction of the solar module cleaner (101).

[0061] Another embodiment of the present invention is said driven spur gear (502a and 502b) is mounted on the driven shaft (506a and 506b) and driven bevel gear (503a and 503b) is mounted on bevel driven shaft (507a and 507b).

[0062] Another embodiment of the present invention is said idler gear (504) is used to transfer the rotation with speed reduction and to increase torque to the driven gear.

[0063] Another embodiment of the present invention is said Brush connector assembly comprises of brush connector shaft (601), bearing housing (602), and support plate (603).

[0064] Another embodiment of the present invention is said cleaning brush (206) comprises of six series of bristles (702) in spiral shape, in combination of soft and hard bristles on the cleaning brush rod (701).

[0065] illustrates an isometric view (100) of a solar module cleaner configured on the top of the solar module surface (102).shows an isometric view of mainframe of solar module cleaner (101).

[0066] Referring toand 2, the solar module cleaner is configured to move on the top surface of the solar module (102) to clean the dust and debris accumulated on the surface of the solar module (101). The placement of the drive wheels (203a and 203b) is design such as solar module cleaner (101) only move on the border frame of the solar module array.

[0067] is an isometric view of the solar module cleaner (101). It is open mainframe as the purpose to reduce weight of the solar module cleaner (101). In theat the right side, there is gearbox 1 (202a) located with motor mounting assembly, and at the left side of the solar module cleaner (101) there is another gearbox assembly (202b). The 2 brushes (206) are placed between those 2 gearboxes (202a and 202b). The Support profile pipe (201) is connected via gearbox mounting plates to give full support to the mainframe solar module cleaner 101. The profile of the support pipe is unique and the detailed drawing of the support profile pipe is shown in the

[0068] Customized Photovoltaic (PV) module (205) is mounted on the PV module mounting plates (403). The PV module (205) is used to charge the battery that supply power to the main motor that rotates the main drive shaft (505). The PV module (205) capacity can be varied according to the length of the solar module cleaner (101).

[0069] At the rightmost and leftmost side of the solar module cleaner (101), there is electronic control box 1 and 2 is placed.

[0070] The proximity sensors (210) are located on the proximity sensors mounting plates (404) which is located on the support profile pipe (201). At the Both end of the solar module array, there is docket station which contain side plates. When solar module cleaner (101) is moves on the solar module array and reach at one of the ends of the docket station the proximity sensors (210) sense the side plate of the docket station that gives signal to the electronic control box which change the rotation of the main electric motor that reverse the rotation of the drive wheel and change the direction of the solar module cleaner (101).

[0071] The support drive wheel (204) is located at the perpendicular to the gearbox assembly (202a and 202b) which is used to lock the solar module cleaner on the top surface of the solar module. The distance between the solar module and the support drive wheel (204) which is located at the opposite side of the motor mounting assembly is kept in such way it can moves freely even if there is misalignment of up to 10 mm of solar modules in the solar module array.

[0072] shows a top view of the mainframe of the solar module cleaner (101). The Gearboxes and electronic control box mounting plate (301). This plate (301) holds the gearbox and motor mounting assembly.

[0073] The electronic control box 1 and 2 (207 & 208) is mounting on the both; gearbox and electronic control box mounting plate (3010 which is mount on the both end of the support pipe (201).

[0074] Center support wheel (402) is located at the mid of the solar module cleaner to give support to the whole mainframe. It contributes the whole load of the mainframe to the center support wheel (402). It is also set in such way that it only moves on the border frame of the solar module array. It is located on the centre support mounting plate (305a & 305b) which is located on the support profile pipe (201). Centre support mounting plate (305a & 305b) is designing such way that it allows movement of the centre support wheel (402) for 10 mm along with the axis of center support pipe. This allows position of the center wheel to be moves on center of the 2 solar module’s border frames with slight misalignment. With the help of centre support wheel drive assembly (401) it allows centre support wheel (402) to get drive from gearbox assembly. With the help of pipe that connect both gearbox’s drive wheel and centre support wheel: it transfers power from drive wheel to centre support wheel.

[0075] shows brush connector which connect two brushes. This brush connector keeps the 2 brushes in the align in such way that their one end connects to the gear box assembly via shaft (601). Brush connector is mount on the Centre support wheel mounting plate (303). The customized PV module (205) is mount on the PV module mounting plates (403). The Centre support wheel mounting plate (303) design in such way that it allows the brush connector to move 10 mm align in the direction of the support profile pipe (201). This gives advantage even if Solar EPC uses different solar module manufacturer. The proximity sensors (210) are attached to the proximity sensors mounting plates (404). The proximity sensors mounting plates (404) is attached to the support profile pipe (201).

[0076] shows drive shaft (505) is at the center of the gearbox assembly. Main gear (501) is attached on the drive shaft (505). Drive shaft (505) is connected to the motor shaft which rotates the drive shaft in clockwise and anticlockwise direction, control via electronic control box. The main gear (501) transfers the rotation via idler gear (503) to the driven spur gear (502a & 502b) & driven bevel gear (503a & 503b). The driven spur gear (502a & 502b) is mounted on the driven shaft (506a&506b) & driven bevel gear (503a & 503b) is mounted on bevel driven shaft (507a & 507b). The purpose of the idler gear (504) is to transfer the rotation with speed reduction and to increase torque to the driven gear. Idler gear (504) is design as a step gear with one larger pitch circle diameter gear followed by small pitch circle diameter gear. Spacer is use to lock the gearbox cover into fix position.

[0077] The material for the drive, driven and idler gear is selected as Nylon which can be varied as set from the hard plastic. The material used in drive; driven and idler shaft is stainless steel for this gearbox assembly which can be varied as a hard strength metals. Drive wheel (203a & 203b) is attached to the driven shaft (505a & 505b). Drive shaft (505) transmits the rotation received via drive shaft by driven shaft (505a & 505b) and key mechanism. The gearbox is working on the speed reduction mechanism. One bevel gear is mount on driven shaft (506a & 506b) and another one is mount on the bevel driven shaft (507a & 507b). While drive shaft (505) rotates it will rotate idler shaft (504) & driven shaft (506a & 506b). The driven bevel gear (503a & 503b) mounting on driven shaft (506a & 506b) will rotate as driven shaft (506a & 506b) gets rotates & that bevel gear mechanism will transfer that rotation to bevel driven shaft (507a & 507b). On bevel driven shaft (507a & 507b) there is support drive wheel (204). By getting power in drive wheel (203a & 203b) & support drive wheel (204), Automatic solar module cleaner (101) will glide even 2 solar modules having 35 mm of offset in north to south direction.

[0078] shows detailed view of the brush connector assembly. It comprises brush connector shaft (601), bearing housing (602), and support plate (603). It helps to connect 2 brush (206) align parallel to the support profile pipe (201). This brush connector assembly transmits the rotation received by drive shaft from motor via 1 brush to another brush. The brush connector shaft (601) is connected to the both brush end. Brush connector assembly is attached to the brush connector mounting plate. Centre support wheel mounting plate (303) has slots so brush connector assembly can move freely up to 10 mm in both directions align to the support profile pipe (201).

[0079] The cleaning brush (206) comprises of series of bristles (702) in spiral shape on the cleaning brush rod (701). The material of cleaning brush rod (701) is nylon for this product which can be selected as any high strength plastic material to reduce all over weight of the cleaning brush (206). The material used for bristles is PBT (Polybutylene terephthalate). The PBT is used in bristles because of it does not absorb water and create no scratches on the top surface of the solar module (102). The cleaning brush (206) comprises of 6 series of bristles in spiral shape, in combination of soft and hard bristles.

[0080] shows detailed view of the bristles (702) of the cleaning brush (206). On the cleaning brush rod (701), there is hole of 5 mm diameter is in the spiral shape. The distance between 2 hole is 8 mm. The bristles material is Hard / Soft PBT.

[0081] shows a cross-section view of the support profile pipe (201). The shape of the profile pipe is selected like “I” section because “I” section has high load-bearing capacity with low pipe thickness. This reduces the weight of the support profile pipe (201) and all-over solar module cleaner.

Claims

An Automatic solar module cleaner (101) for waterless cleaning of solar panel comprises of:a) Gearbox assembly (202a and 202b) located with motor mounting assembly, and at the left and right side of the solar module cleaner (101);b) Brushes (206) are placed between gearboxes (202a and 202b);c) Support profile pipe (201) is connected via gearbox and electronic control box mounting plates (301) to give full support to the mainframe solar module cleaner (101);d) Drive wheels (203a and 203b) for movement of solar module cleaner (101) only on the border frame of the solar module array;e) Customized Photovoltaic (PV) module (205) is mounted on the PV module mounting plates (403);f) Proximity sensors (210) are located on the proximity sensors mounting plates (404) which is located on the support profile pipe (201);g) Support drive wheel (204) is located at the perpendicular to the gearbox assembly (202a and 202b) which is used to lock the solar module cleaner on the top surface of the solar module;h) Swappable battery box (209);i) Gearboxes and electronic control box mounting plate (301) holds the gearbox, electronic control box (207 and 208) and motor mounting assembly;j) Swappable battery box mounting plate (302);k) Electronic mounting plate (304);l) Center support wheel (402) is located at the mid of the solar module cleaner (101) to give support to the whole mainframe;m) Center support mounting plate (305a and 305b) for movement of the center support wheel (204) for 10 mm along with the axis of center support pipe;n) Centre support wheel drive assembly (401) allows centre support wheel (402) to get drive from gearbox assembly;o) Main gear (501) is attached on the drive shaft (505);p) Main gear (501) transfers the rotation via idler gear (503) to the driven spur gear (502a and 502b) and driven bevel gear (503a and 503b);q) Drive wheel (203a and 203b) is attached to the driven shaft (506a & 506b);r) Brush connector assembly is mount on the Centre support wheel mounting plate (303); ands) Cleaning brush (206);wherein said cleaner (101) is configured to traverse along the top of the solar module (102) to clean the dirt and debris accumulated on the surface of the solar module and said cleaner (101) is powered by a single motor.The Automatic solar module cleaner (101) as claimed in claim 1, wherein said PV module (205) is used to charge the battery that supply power to the main motor that rotates the main drive shaft (505).The Automatic solar module cleaner (101) as claimed in claim 1, wherein said solar module cleaner (101) is moves on the solar module array and reach at one of the ends of the docket station, the proximity sensors (210) sense the side plate of the docket station that gives signal to the electronic control box (207 and 208) which change the rotation of the main electric motor that reverse the rotation of the drive wheel and change the direction of the solar module cleaner (101).The Automatic solar module cleaner (101) as claimed in claim 1, wherein said driven spur gear (502a and 502b) is mounted on the driven shaft (506a and 506b) and driven bevel gear (503a and 503b) is mounted on bevel driven shaft (507a and 507b).The Automatic solar module cleaner (101) as claimed in claim 1, wherein said idler gear (504) is used to transfer the rotation with speed reduction and to increase torque to the driven gear.The Automatic solar module cleaner (101) as claimed in claim 1, wherein said Brush connector assembly comprises of brush connector shaft (601), bearing housing (602), and support plate (603).The Automatic solar module cleaner (101) as claimed in claim 1, wherein said cleaning brush (206) comprises of six series of bristles (702) in spiral shape, in combination of soft and hard bristles on the cleaning brush rod (701).

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