Foldable Solar Panel Assembly Deployment Mechanism
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Solution Overview
Problem
The installation of solar panels in solar farms is labor-intensive and existing robotic solutions require significant precision and are expensive, necessitating a cost-effective and efficient method for pre-assembling and transporting foldable solar panel assemblies.
Innovation Solution
A foldable solar panel assembly design featuring an elongated beam, shaft portions, drive links, and a transfer key, allowing for easy transportation and deployment by unfolding and locking panels relative to each other, with the ability to track sun movement or remain fixed, using heavy-duty lifting equipment and mounting brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solar panels are installed using traditional manual labor methods, then installation flexibility and adaptability are maintained, but installation time and labor costs increase significantly
Solution Approach 1:
The solar panel assembly is divided into modular components including multiple panels (32, 34), frames (34, 36), drive links (26, 30), and shaft portions (44) that can be independently manufactured and assembled. This segmentation enables faster deployment while maintaining structural integrity through standardized connection interfaces.
Solution Approach 2:
The assembly incorporates movable and adjustable components such as drive links that can rotate around shaft portions, allowing the structure to adapt to different installation configurations and terrain conditions. This dynamic capability enables rapid deployment without requiring complex custom fabrication for each site.
2Volume of moving object
If foldable solar panel assemblies are designed for easy transportation, then shipping costs and logistics efficiency improve, but structural stability and reliability during operation must be maintained
Solution Approach 1:
The solar panel assembly features a folded configuration where panels and frames are nested together in a compact arrangement during transportation. The drive links and frames are positioned to occupy minimal space, reducing transport volume while maintaining structural integrity through rigid connection points.
Solution Approach 2:
The assembly transitions from a compact folded state for transportation to an expanded operational state for electricity generation. The drive links and shaft portions enable controlled deployment, ensuring structural stability is maintained during the transition and in the final deployed configuration.
3Ease of manufacture
If cost-effective manufacturing methods are used, then production costs decrease, but manufacturing precision and quality control may be compromised
Solution Approach 1:
The assembly is manufactured as separate modular components using standardized processes, allowing each component to be produced independently with controlled precision requirements. This segmentation enables cost-effective manufacturing through economies of scale while maintaining overall assembly quality through standardized interfaces.
Solution Approach 2:
The drive links and shaft portions are designed with universal connection interfaces that can accommodate variations in manufacturing tolerances. This universality allows components to be assembled reliably even with moderate manufacturing precision, reducing overall production costs while maintaining functional integrity.
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
This solution reduces manual labor, lowers installation costs, and enhances the reliability and environmental durability of solar panel assemblies, enabling efficient and cost-effective manufacturing, shipping, and operation while maintaining adaptability to sun orientation.
Implementation Method 1
The first frame (34) may hold a first panel (32) of photovoltaic cells. The second frame (36) may hold a second panel (38) of photovoltaic cells.
Data Source
AI summary
Several pre-assemblies holding panels of photovoltaic cells are constructed and pre-wired in a factory. The pre-assemblies are shipped to a solar farm, where they are lifted above posts secured to the ground. By being foldable, the solar panel assemblies can provide a compact shipping arrangement. Operators can connect the solar panel assemblies to a support and then unfolded the solar panel assemblies and lock them in the unfolded position.