Robotic Solar Panel Array Assembly for Fast Field Installation
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Solution Overview
Problem
Existing methods for assembling and installing arrays of photovoltaic solar panels in outdoor fields are complex and costly, lacking in flexibility and efficiency.
Innovation Solution
A method and system involving a transportable station where robots assemble photovoltaic solar panels and support frameworks, which are then transported to the installation site using a motorized carriage for final assembly on pre-prepared support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot is used to assemble photovoltaic solar panels directly in the outdoor field, then automation and installation speed are improved, but system complexity and cost increase
Solution Approach 1:
The installation process is divided into two distinct phases: assembly phase (in the assembly area) and transportation phase (to the installation site). The robot performs only the assembly operation in a controlled area, then the completed array is transported as a single unit to the final installation location. This segmentation allows automation without requiring the robot to traverse the entire installation field.
Solution Approach 2:
A transportation mechanism serves as an intermediary between the assembly area and the installation site. This mediator transfers the completed photovoltaic array from the robot's working area to the final mounting location, decoupling the automation system from the terrain challenges of the installation field.
2Adaptability or versatility
If a robot moves along the installation field to position panels, then installation flexibility is improved, but accuracy decreases due to ground irregularities
Solution Approach 1:
The photovoltaic array is completely assembled in a predetermined assembly area with controlled conditions and precise positioning infrastructure before transportation. This preliminary assembly ensures high precision without the robot needing to navigate irregular terrain during the positioning-critical assembly operations.
Solution Approach 2:
Instead of assembling panels directly at the final installation location (traditional approach), the invention inverts the sequence by first assembling the complete array in a controlled area and then transporting it to the installation site. This reversal allows precision assembly in a controlled environment while still achieving field installation flexibility.
3Device complexity
If manual assembly is used in the field, then system cost is reduced, but installation time increases
Solution Approach 1:
The invention creates a mobile assembly station that can be transported to different field locations, copying the benefits of automated assembly to multiple sites without requiring permanent infrastructure. This allows rapid deployment of automated assembly capability across different installation projects.
Solution Approach 2:
The assembly system is designed to be mobile rather than fixed, allowing the automated assembly station to be transported to different locations. This dynamic capability enables automated assembly benefits to be applied flexibly across various installation sites while maintaining system simplicity.
Data Source
AI summary
A method for assembling and installing arrays (1) of photovoltaic solar panels (P) in an outdoor field, includes a first step of assembling an array (1) of photovoltaic solar panels, which is carried out with the aid of at least one robot (R) in a transportable station (S1), located adjacent to the installation field (F). In a second step the assembled array (1) of photovoltaic solar panels is transported from the station (S1) to the site of installation of the array (1) of photovoltaic solar panels with the aid of a motorized carriage (V) controlled by an operator external to the carriage. Finally, the method includes a third step of assembling the array (1) of photovoltaic solar panels thus transported, wherein the array (1) of photovoltaic solar panels is mounted on support structures (5) previously prepared in the installation field (F).