Robotic Solar Module Assembly With Clinched Terrain-Following Posts
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Solution Overview
Problem
The installation of solar panels on open areas is hindered by the need for secure anchoring against external loading forces like wind, which increases costs due to the requirement of separate beam and post structures.
Innovation Solution
The development of autonomous systems and methods for planning and executing the installation of solar modules using robots and mobile platforms that can autonomously position and assemble solar modules on various terrains without the need for additional tools or fasteners, utilizing sensors and clinching mechanisms to create stable connections with posts that can contour to the terrain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate beam and post structures are used to secure solar panels against wind loading, then the reliability of solar panel anchoring is improved, but the device complexity and installation cost increase
Solution Approach 1:
The patent combines the beam and post structures into an integrated L-shaped support structure. The vertical post is directly coupled to the horizontal beam, eliminating the need for separate anchoring components and reducing overall structural complexity while maintaining wind loading resistance
Solution Approach 2:
The L-shaped support structure serves multiple functions simultaneously: it provides vertical support, horizontal positioning, and wind load resistance all in one component. This multi-functional design reduces the number of parts needed and simplifies the overall assembly
2Strength
If separate beam and post structures are used to secure solar panels, then the anchoring strength is improved, but the installation time and productivity decrease
Solution Approach 1:
By merging the beam and post into a single L-shaped structure, the installation process is simplified from multiple assembly steps to a single placement operation, significantly increasing installation speed while preserving anchoring strength
Solution Approach 2:
The L-shaped support structure is pre-assembled as an integrated unit before deployment. This preliminary preparation eliminates on-site assembly steps, allowing for rapid installation while ensuring structural integrity
3Reliability
If additional fasteners and tools are used to assemble solar modules, then the connection reliability is improved, but the ease of manufacture and installation deteriorate
Solution Approach 1:
The solar module is designed with an integrated L-shaped support structure that is coupled directly to the module frame. This integration eliminates the need for separate fasteners and connection hardware, simplifying both manufacturing and installation while maintaining connection reliability
Solution Approach 2:
The L-shaped support structure is designed to be self-coupling to the solar module frame through direct attachment. The structure serves itself by providing both support and connection functionality without requiring external fastening components
Data Source
AI summary
In an aspect, the present disclosure describes a method comprising using at least one robot to fully autonomously position and assemble at least one solar module and its supporting structure at a sensed geolocation without aid from a user.