Autonomous Solar Module Assembly With Integrated Ground Supports

Solution Overview

Problem

The installation of solar panels in open areas is hindered by the need for securing them to the ground to resist external loading forces, which can be costly and labor-intensive, often requiring separate beam and post structures.

Innovation Solution

The use of autonomous robots and mobile platforms to position and assemble solar modules and their supporting structures on various terrains, utilizing clip-clip interfaces and clinched joints without fasteners, allowing for efficient and rapid installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate beam and post structures are used to secure solar panels to the ground, then the solar panels become resistant to external loading forces, but the installation costs and structural complexity increase significantly

Engineering Contradiction:

Improveresistance to external loading forcesVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the beam and post structures into a single integrated ground-mounted solar support structure. The support structure includes a vertical post element and a horizontal beam element that are formed as one unified component, eliminating the need for separate structures while maintaining resistance to external loading forces from wind and other environmental factors.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated support structure serves multiple functions simultaneously: it provides vertical support through the post element, horizontal support through the beam element, and anchoring to the ground through integrated ground engagement features. This multi-functional design reduces the number of separate components needed while maintaining structural reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate beam and post structures are used to secure solar panels, then the panels can resist external forces, but the installation becomes labor-intensive and costly

Engineering Contradiction:

Improveresistance to external loading forcesVSAvoidinstallation efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges the beam and post structures into a single integrated ground-mounted solar support structure. The support structure includes a vertical post element and a horizontal beam element that are formed as one unified component, eliminating the need for separate structures while maintaining resistance to external loading forces from wind and other environmental factors.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If traditional securing methods are used, then solar panels can be installed on open areas, but additional fasteners and deep excavation are required

Engineering Contradiction:

Improvesimplicity of installationVSAvoidmaterial requirements

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent extracts and eliminates the need for separate fasteners from the assembly system. The integrated support structure incorporates ground engagement features directly into the design, allowing the structure to be secured to the ground without additional fastening components. This reduces the quantity of materials required while simplifying the installation process.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS20250239965A1Systems and methods for solar power plant assembly

Publication Date: 2025.07.24 PLANTED SOLAR INC

AI summary

In an aspect, the present disclosure describes a method comprising using at least one robot to fully autonomously position and assemble at least one solar module and its supporting structure at a sensed geolocation without aid from a user.