Photovoltaic Module Feeder Assembly for Automated Solar Installation
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Solution Overview
Problem
The existing methods for installing photovoltaic (PV) modules at large scales are inefficient and lack automation, leading to a need for improved systems and methods to streamline the process.
Innovation Solution
An automated feed mechanism mounted on an autonomous cart with rotatable arms and gripping pieces is used to lift and deliver PV modules to a tilted conveyor, coupled with a mobile unit and computer-implemented software for just-in-time installation scheduling, enabling efficient and parallel alignment of modules during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual installation methods are used for PV modules, then flexibility and adaptability are maintained, but productivity and installation efficiency are low
Solution Approach 1:
The system enables self-service installation through autonomous mobile units that automatically navigate to PV modules, grasp them using robotic arms with gripping pieces, and transport them to installation positions without human intervention. The automated feed mechanism and conveyor system operate autonomously to持续提升 installation productivity
Solution Approach 2:
Manual mechanical operations are replaced with an automated robotic system featuring mobile units with articulated arms and gripping mechanisms. The system substitutes human labor with programmable mechanical systems that can precisely grasp, move, and position PV modules, dramatically improving installation efficiency
2Productivity
If automated feed mechanism with rotatable arms is used, then productivity and installation speed are improved, but device complexity increases
Solution Approach 1:
The installation system is divided into modular mobile units, each with its own rotatable arms and gripping pieces. This segmentation allows the complex automation task to be broken down into manageable independent modules that can operate in parallel, improving productivity while making the overall system more manageable despite the increased automation level
Solution Approach 2:
The system employs dynamically adjustable rotatable arms with multiple articulation points that can adapt their configuration based on the position and orientation of PV modules. This dynamic capability allows the automated system to handle various module positions efficiently, maintaining high productivity while managing complexity through adaptive motion control
3Manufacturing precision
If multiple articulation points and gripping pieces are used to maintain module alignment, then manufacturing precision and alignment accuracy are improved, but device complexity increases
Solution Approach 1:
The gripping pieces at the end of each rotatable arm are specifically designed with local features optimized for grasping PV modules while maintaining alignment. The articulation points are strategically positioned to provide precise control over module orientation during transport and installation, achieving high alignment precision through localized functional design rather than uniform complexity throughout the system
Data Source
AI summary
Photovoltaic module feeder assemblies, systems and methods are provided which comprise two rotatable arms, a grabber bar, and at least two gripping pieces. Each arm has a proximal end and a distal end and a plurality of articulation points. The grabber bar is coupled to the distal end of each rotatable arm, and the gripping pieces are connected to each grabber bar. When the rotatable arms rotate to position the grabber bars in alignment with a photovoltaic module, the gripping pieces activate and grip or support the photovoltaic module. The rotatable arms maintain the short sides of the photovoltaic module in a horizontal position by utilizing one or more of the plurality of articulation points. The photovoltaic module feeder assembly may be coupled to a mobile unit having a conveyor and guide rails for moving and holding a pallet of photovoltaic modules. Disclosed methods may be controlled by software that can determine a just-in-time installation schedule.