Solar Panel Dispensing Hopper for Robotic Overhead Installation
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Solution Overview
Problem
Current solar panel installation methods, including those for solar tracking systems, require significant manual labor, are time-consuming, and often necessitate daytime installation due to visibility needs, limiting installation efficiency and increasing costs.
Innovation Solution
A solar panel dispensing hopper and presentation system that facilitates automated or semi-automated overhead installation of solar panels using a robotic device, supported by an installation vehicle, which can dispense and align panels into a panel retention system from above, reducing manual labor and enabling nighttime installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual installation methods are used, then workers can install solar panels with basic tools, but installation time and labor costs increase significantly
Solution Approach 1:
The patent replaces manual mechanical installation with an automated robotic system that uses computer vision and automated manipulation to install solar panels. The robotic system performs drilling, fastening, and panel placement operations that were previously done manually, thereby increasing installation speed while maintaining ease of operation through centralized control.
Solution Approach 2:
The robotic installation system is self-sufficient, carrying its own tools, fasteners, and control systems. It autonomously navigates the installation site, identifies panel locations, and completes installation tasks without continuous human intervention, enabling high-speed installation while keeping the system relatively simple to deploy.
2Ease of operation
If daytime installation is required for visibility, then workers can see and work safely, but installation hours are limited and project timeline extends
Solution Approach 1:
The robotic system replaces human visual dependency with machine vision systems including cameras, sensors, and computer vision algorithms. These systems can operate in low-light or no-light conditions, enabling nighttime installation without compromising operational capability or safety.
Solution Approach 2:
The robotic system pre-maps the installation site using sensors and vision systems before beginning installation. This preliminary action creates a digital model that guides subsequent operations, allowing the system to work autonomously during nighttime without needing real-time visual feedback from operators.
3Loss of time
If large lights are deployed for nighttime installation, then work can continue after dark, but equipment costs and complexity increase
Solution Approach 1:
The system replaces external lighting infrastructure with integrated vision systems that include active sensors (such as LIDAR, infrared cameras) and passive imaging capabilities. These sensors actively probe the environment or capture available light, eliminating the need for large deployment lights while enabling nighttime operation.
Solution Approach 2:
The robotic platform integrates multiple functions including navigation, panel detection, drilling, fastening, and vision processing into a single system. This multi-functionality allows the same platform to operate day or night without requiring separate lighting equipment, reducing overall system complexity while extending operational hours.
4Productivity
If automated robotic systems are implemented, then installation speed and efficiency increase, but system complexity and initial costs increase
Solution Approach 1:
The robotic installation system is divided into modular functional units: a mobile platform for navigation, a manipulator arm for panel handling, a drilling and fastening system, and a vision/control system. Each module can be independently developed, tested, and replaced, managing complexity while maintaining high installation rates through coordinated operation of all modules.
Data Source
AI summary
A robotic solar panel presentation system, as part of a solar panel installation system, for facilitating installation of solar panels into a panel retention system of a panel support assembly, the solar panel presentation system comprising a solar panel dispensing hopper comprising a hopper enclosure operable to receive and support one or more solar panels, and a panel acquisition and placement system comprising at least one moveable installation arm, wherein the panel acquisition and placement system is operable to acquire and manipulate a lead solar panel into an overhead installation position relative to the panel retention system, and to facilitate placement of the lead solar panel into an installed position within the panel retention system. The presentation system can further comprise a control system associated with the solar panel dispensing hopper, and comprising one or more processors and memory operable to control and operate the panel acquisition and placement system.