Pre-Assembled Solar Panel Blocks for Faster Leak-Safe Installation
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Solution Overview
Problem
The deployment of solar panels is slow, complicated, and expensive due to labor-intensive processes that face technical problems such as leaks and structural issues, leading to high costs and low efficiency in solar system installation and inspection.
Innovation Solution
The introduction of 'Finished MultiSensor Units' (FMUs), which are pre-assembled blocks of solar panels and structural components that can be installed as a whole, reducing onsite labor through off-site assembly and enabling automated design and installation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solar panels are installed using traditional labor-intensive processes, then installation can be performed with simple equipment, but installation speed is slow and labor costs are high
Solution Approach 1:
The patent applies preliminary action by pre-assembling complete solar panel units with all structural components, electrical connections, and mounting hardware fabricated off-site before delivery to the installation location. This allows the actual installation process to simply involve placing pre-configured modules rather than performing complex assembly operations on-site, thereby increasing installation speed without requiring overly complex installation equipment.
Solution Approach 2:
The patent segments the solar power system into modular units, each comprising a complete functional assembly of solar panels, structural supports, electrical components, and mounting hardware. This segmentation allows parallel fabrication of multiple modules in controlled manufacturing environments and simplifies on-site installation to a matter of positioning and connecting standardized modules, thus improving productivity while managing complexity through standardization.
2Reliability
If traditional installation methods are used, then equipment requirements are simple, but installation quality control is difficult and structural issues such as leaks occur
Solution Approach 1:
The patent implements preliminary action by performing all quality-critical operations—structural assembly, electrical wiring, sealing, and testing—during off-site manufacturing before the units are shipped to the installation location. This ensures that quality control measures can be applied in controlled factory environments with proper equipment and procedures, eliminating many quality issues that would otherwise occur during rushed on-site installation, while the actual installation process remains relatively simple.
3Ease of manufacture
If labor-intensive installation processes are used, then equipment costs are low, but overall installation costs are high due to labor expenses
Solution Approach 1:
The patent merges multiple separate manufacturing operations into integrated unit fabrication, where solar panels, structural components, electrical systems, and mounting hardware are assembled into complete functional units in a coordinated manufacturing process. This integration allows for economies of scale and more efficient resource utilization during manufacturing, reducing the labor and time required for on-site installation while the resulting modular units can be deployed using simple equipment.
Data Source
AI summary
A new system of solar construction, technology and methods for making off structure constructed panel blocks are disclosed.