Robotic Solar Panel Handling for Precise Leveling on Torque Tubes
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Solution Overview
Problem
The installation of solar panels on rotatable structures poses challenges in ensuring all panels are coplanar and leveled, and the process is inefficient and costly due to the fragile and large nature of the panels.
Innovation Solution
A solar panel handling system comprising an end-of-arm assembly tool with suction cups, a linear guide assembly, and a force torque transducer, which includes a clamping tool and a controller to securely attach and position solar panels on a torque tube, facilitating efficient and reliable installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solar panels are manually installed on rotatable structures, then installation flexibility is maintained, but installation efficiency decreases and leveling precision is compromised
Solution Approach 1:
The patent replaces manual mechanical installation with an automated robotic system that uses a robotic arm equipped with specialized end-effectors. The system incorporates force torque sensors and control algorithms to automatically position and level solar panels on rotatable structures, eliminating manual labor while ensuring precise coplanarity and leveling through sensor feedback and automated adjustment mechanisms.
Solution Approach 2:
The robotic installation system performs self-positioning and self-leveling of solar panels through integrated sensors and control systems. The force torque sensors automatically detect panel orientation and position, and the control system autonomously adjusts the robotic arm to achieve precise leveling and coplanarity without requiring manual intervention, enabling the system to service itself during the installation process.
2Reliability
If traditional handling tools are used for solar panels, then equipment simplicity is maintained, but installation reliability decreases due to panel fragility
Solution Approach 1:
The patent introduces specialized end-effectors as intermediary tools between the robotic arm and solar panels. These end-effectors are designed with soft gripping mechanisms and distributed contact points that evenly distribute force across the panel surface, preventing damage to fragile panels while providing reliable handling. The intermediary tool acts as a buffer that protects the panel from direct mechanical stress.
Solution Approach 2:
The robotic handling system incorporates pneumatic or hydraulic actuation mechanisms in the end-effectors to provide controlled, compliant gripping forces. These fluid-powered systems enable smooth, damage-free contact with solar panels while maintaining secure holding during installation, offering reliable handling without excessive mechanical complexity through well-established pneumatic/hydraulic technology.
3Ease of manufacture
If manual installation processes are used, then system simplicity is maintained, but installation costs increase due to labor intensity
Solution Approach 1:
The robotic installation system performs preliminary positioning and pre-alignment of solar panels before final attachment. The force torque sensors pre-calculate the required panel orientation and position, and the robotic arm pre-positions the panel in the correct location and orientation, reducing the need for costly post-installation adjustments and minimizing overall installation time and labor costs.
Solution Approach 2:
The system incorporates real-time feedback through force torque sensors that continuously monitor panel position, orientation, and applied forces during installation. The control system uses this feedback to dynamically adjust the robotic arm's movements and gripping forces, ensuring precise installation while optimizing the automation process to reduce labor costs through intelligent, sensor-driven control.
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
The system ensures accurate leveling and coplanarity of solar panels, reducing installation costs and improving efficiency by using suction cups and a controlled clamping mechanism to securely attach panels to the installation structure.
Implementation Method 1
suction cups coupled to the frame
Data Source
AI summary
A system for installing a solar panel may include an end of arm assembly tool and a linear guide assembly coupled to the end of arm assembly tool. The end of arm assembly tool includes a frame and plurality of attachment devices, such as suction cups, coupled to the frame. The linear guide assembly includes a linearly moveable clamping tool including an engagement member configured to engage a clamp assembly slidably coupled to an installation structure, and a force torque transducer configured to move the clamping tool along the installation structure. A controller configured to control the force torque transducer and the plurality of attachment devices. The end of arm assembly tool is coupled to a robotic arm and is part of an assembly robot that includes autonomous and non-autonomous vehicles. The various components can be operated by a control system based on operation instructions received from a neural network.