Flexible Gripper Array for Curved Solar Panel Placement
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Solution Overview
Problem
Current manufacturing processes for complex curved surfaces, such as solar panels, face challenges in handling and placing flexible solar cell arrays on convex surfaces without causing damage due to stress from bending, torsion, or deformation, and existing solutions are either costly, labor-intensive, or result in non-uniform arrays and increased risk of solar cell failure.
Innovation Solution
A pick-flat, place-curved (PFPC) assembly tool system that uses a flexible array of gripper heads with suction and heat-enabled capabilities to precisely transfer and align pre-assembled solar cell arrays from a flat surface to a doubly curved substrate, accommodating necessary expansion and contraction through variable inter-row connectors and dynamic vacuum modulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If mechanical actuation is used to create convex curvature, then the tool can conform to convex surfaces, but mechanical actuation and gravity oppose each other leading to deviations from intended curvature
Solution Approach 1:
The patent applies partial action by using only gravity-induced conformality without active mechanical actuation. The flexible gripper array allows the tool surface to passively conform to the convex mold surface under its own weight, eliminating the conflict between mechanical actuation and gravity while achieving sufficient curvature matching for solar cell placement.
2Adaptability or versatility
If active mechanical actuation is used to achieve convex surface conformity, then the tool can adapt to curved surfaces, but the system becomes more expensive to implement
Solution Approach 1:
The flexible gripper array serves itself by using its own weight and flexibility to conform to the convex surface. No external actuation system is needed - the material properties of the flexible grippers (elasticity and gravity) automatically provide the surface adaptation, eliminating complex and expensive mechanical actuation systems.
Solution Approach 2:
The patent replaces active mechanical actuation systems with passive material properties. Instead of using motors, actuators, or complex mechanical systems to achieve surface conformity, the invention relies on the inherent flexibility and gravitational behavior of the gripper array material to adapt to curved surfaces.
3Productivity
If solar cells are handled in conventional processes, then manufacturing can proceed, but stress from bending, torsion, or deformation causes damage and fracture
Solution Approach 1:
The patent uses a flexible gripper array composed of thin, compliant elements that can bend and deform without transmitting harmful stresses to the solar cells. The flexibility of the gripper material allows it to conform to curved surfaces while maintaining gentle contact with the delicate solar cells, preventing fracture during handling and placement.
Solution Approach 2:
The gripper array is designed to be dynamically flexible rather than rigid, allowing it to adapt its shape to match the convex surface contours. This dynamic flexibility enables the system to handle solar cells on curved surfaces without imposing rigid constraints that would cause stress, torsion, or deformation damage.
4Manufacturing precision
If precision alignment is required during placement, then solar cell positioning accuracy improves, but maintaining alignment during subsequent operations becomes difficult
Solution Approach 1:
The patent performs preliminary alignment by using the flexible gripper array to precisely position and hold solar cells in their correct locations on the convex surface before release. The grippers maintain this pre-established alignment throughout subsequent operations such as soldering and lamination, ensuring that precision placement is preserved during later manufacturing steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable, precise, and damage-free handling and placement of solar cell arrays on curved surfaces, reducing the risk of solar cell failure and allowing for mass production of doubly curved solar panels suitable for vehicular applications at lower costs.
Implementation Method 1
a flexible array of gripper heads with suction
Implementation Method 2
heat-enabled capabilities
Data Source
AI summary
A pick-and-place assembly tool, system and method comprising a flexible array of gripper heads is adapted to pick a sheet of flexible material or a pre-assembled array of flexibly coupled elements from a flat surface and place it on a convex, doubly curved surface. Gripping action may be provided by a suction force. When picking the pre-assembled array of elements, the array of gripper heads may conform to the flat surface. The assembly tool may then be moved above and aligned to the compound curved placing surface. When lowered onto the receiving surface, the assembly tool passively may precisely conform to the convex surface. Distortion of the material or array may be controlled by flexible couplers disposed between the gripper heads. Heating elements disposed on some or all of the gripper heads may be used to tack the workpiece in place to maintain registration during subsequent processing, e.g., lamination.