Robotic arm cooperating with an off-road capable base vehicle
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solar module installation processes face challenges such as pausing work at night, requiring repetitive training due to non-uniform solar tracker and crew changes, human complacency leading to errors, and interference from weather and bad conditions.
Innovation Solution
An autonomous solar module installation platform comprising an off-road capable base vehicle and a robotic arm that communicates and cooperates to align with solar trackers, using computer vision and suction cups to pick up and install solar modules, with a system of cooperating carrier robots and a fastening robot for secure installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human workers perform solar module installation, then installation can be performed with simple equipment, but work must pause at night and human error increases over time
Solution Approach 1:
The robotic arm performs solar module installation autonomously without continuous human intervention. The system self-manages the installation process including positioning, gripping, and placing modules on trackers, enabling continuous operation from day to night while eliminating human error in the repetitive installation tasks
Solution Approach 2:
The patent replaces human workers with an automated robotic system that uses computer vision for detection and a robotic arm with suction cup grippers for mechanical manipulation. This substitution enables uninterrupted operation and consistent precision throughout the installation process
2Ease of operation
If human crews are used for installation, then training can be performed for each solar farm, but repetitive tasks lead to complacence and errors
Solution Approach 1:
The robotic arm is designed with universal adaptability to work across different solar farm configurations. The system can adjust to various tracker types and module orientations through programmable control, maintaining consistent installation quality without requiring retraining as would be needed for human crews
Solution Approach 2:
The system incorporates computer vision and sensors that provide real-time feedback on module position, tracker alignment, and installation status. This feedback loop ensures consistent precision across different solar farm environments without relying on human attention or skill variation
3Productivity
If traditional installation methods are used, then equipment complexity is low, but weather and bad conditions interfere with work
Solution Approach 1:
The robotic arm autonomously manages its own operation including navigation to trackers, gripping of modules, and precise positioning. This self-service capability allows continuous installation through adverse weather conditions that would prevent human workers from operating safely or effectively
Solution Approach 2:
The patent replaces vulnerable human-operated simple equipment with a robust robotic system featuring protected electronics, sealed components, and automated control. This substitution enables installation continuity in conditions such as rain, wind, or darkness where human work would be interrupted
4Productivity
If manual solar module handling is used, then equipment cost is low, but labor costs and training requirements are high
Solution Approach 1:
The patent replaces manual labor with an automated robotic arm equipped with computer vision and suction cup grippers. This substitution increases installation speed through continuous automated operation while the modular robotic design helps manage system complexity and cost
5Reliability
If human workers install solar modules, then safety risks are manageable with training, but safety incidents can occur due to complacence
Solution Approach 1:
The robotic arm performs all installation tasks autonomously, eliminating human exposure to safety risks associated with working at heights, handling heavy modules, or operating in adverse weather. This autonomous operation maintains safety while preserving installation efficiency through continuous automated work
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 continuous solar module installation day and night, reduces labor costs, improves productivity and safety, and adapts to varying terrain and tracker types, minimizing human error and weather interference.
Implementation Method 1
The suction cup tool includes a set of suction cups and an actuator designed to create a vacuum, where each suction cup has its own vacuum
Implementation Method 2
The air nozzle is designed to blow off debris on a surface of the solar panel
Data Source
AI summary
An advanced system of cooperating solar module carrier robots for installing solar panels is provided. The system includes a computer vision system designed to route the cooperating solar module carrier robots to the solar tracker. The system also includes a robotic arm with a suction cup tool designed to pick up and hold a solar panel. The suction cup tool can include a set of suction cups, an actuator designed to create a vacuum in each suction cup of the set of suction cups. The suction cup tool also has an air nozzle designed to below off debris on a surface of the solar panel.