WO2023079377A1

WO2023079377A1 - Movable system for assembling support frames for arrays of photovoltaic panels and for installing said support frames on a receiving structure

Info

Publication number: WO2023079377A1
Application number: PCT/IB2022/057998
Authority: WO
Inventors: Francesco Lolli
Original assignee: Enel Green Power Spa
Priority date: 2021-11-04
Filing date: 2022-08-26
Publication date: 2023-05-11
Also published as: IT202100028058A1

Abstract

A movable system (100) for assembling support frames (1) of arrays of photovoltaic panels (2) and for installing said support frames (1) onto a receiving structure (5) arranged on an installation ground.

Description

"Movable system for assembling support frames for arrays of photovoltaic panels and for installing said support frames on a receiving structure"

DESCRIPTION

[0001] The present invention relates to the technical sector of photovoltaic systems and more in particular it relates to a movable system for assembling support frames for arrays of photovoltaic panels and for installing said support frames on a receiving structure.

[0002] As it is known, currently, the procedures for assembling and installing photovoltaic systems are significantly time-consuming and expensive. In particular, the procedures for assembling the sections of the photovoltaic systems responsible for generating electricity, also called generation sections, are particularly long and expensive.

[0003] A generation section of a photovoltaic system generally comprises a receiving structure which is stably installed in a fixed position on an installation ground and further comprises a plurality of arrays of photovoltaic panels which are mounted onto the receiving structure. The arrays of photovoltaic panels may be installed on the receiving structure in a fixed or movable manner. In the latter case, it is possible, by means of appropriate actuators, to track the position of the sun to optimize the efficiency of the generation of electricity.

[0004] The receiving structure generally comprises one or more arrays, for example linear arrays, of support poles which are to be driven into the ground. These poles have a length generally from 3 m to 5 m and, to be driven into the ground, special machines called pole drivers are used, by means of which the poles are actually hammered into the installation ground.

[0005] After the installation of the support poles, the following installation steps are generally performed:

-Mounting pole heads on the support poles;

- Mounting a saddle on each pole head;

-Mounting possible actuators which allow the saddles to rotate about a generally horizontal rotation axis;

- Mounting the support frames of the arrays of photovoltaic panels on the saddles;

-Fixing the photovoltaic panels onto the support frames. [0006] The support frames generally comprise a main arm, also called torque tube, and a plurality of secondary arms which are fixed transversely to the main arm and which are equipped with coupling profiles to slidably insert each photovoltaic panel between two consecutive secondary arms. [0007] The support frames of the photovoltaic panels may be assembled on the ground and then lifted with the aid of cranes or telescopic forklifts to be fixed onto the saddles. Due to the suspended loads, these activities are particularly risky. Alternatively, the support frames may be assembled directly at a height, by first fixing the main arm onto the saddles and then fixing the secondary arms onto the main arm. These activities are particularly laborious because the fixing of the secondary arms must be carried out at a height and the assembly precision required by the circumstances must be maintained.

[0008] As it may be easily deduced, all the assembly and installation activities described above require many manhours and a sequence of monotonous and repetitive manual operations. The activity cost is particularly high. Furthermore, since very often large photovoltaic systems are installed in desert areas, the operators in charge of the installation are forced to work for several days in hostile environmental and climatic conditions.

[0009] Furthermore, such repetitive activity proceeds in a discontinuous manner which is not optimal, including inactive steps of mere movement, during which the staff and the equipment reach a site of interest, and steps of activity, in which the installation of the frames onto the saddles is actually achieved.

[0010] The object of the present invention is to provide a movable system which allows to solve, or at least partially reduce, the drawbacks described above with reference to the prior art.

[0011] This and other objects are achieved by means of a movable system for assembling and installing the support frames of the arrays of photovoltaic panels as defined in claim 1 in the most general form thereof, and in the claims dependent thereon in some particular embodiments.

[0012] The invention will become more apparent from the following detailed description of the embodiments thereof, given by way of non-limiting examples, with reference to the accompanying drawings, in which:

- Figure 1 shows a diagrammatic plan view of a possible exemplary and non-limiting embodiment of a support frame of a two-dimensional array of photovoltaic panels;

- Figure 2 shows a diagrammatic plan view of the support frame of Figure 1 onto which the array of photovoltaic panels is fixed;

- Figure 3 shows a side view of an upper end portion of a support pole on which a pole head, a saddle and an actuator are mounted;

- Figure 4 shows a perspective three-dimensional view of an exemplary and non-limiting embodiment of a movable system for assembling and installing support frames of arrays of photovoltaic panels, in which the movable system comprises a top cover and a side cover;

- Figure 5 shows a perspective three-dimensional view of the movable system of Figure 4 from which the upper cover and the side cover have been removed.

[0013] Equal or similar elements are indicated by the same reference numerals in the accompanying drawings.

[0014] Figures 1 and 2 diagrammatically show a nonlimiting embodiment of a support frame 1 of an array of photovoltaic panels 2.

[0015] The support frame 1 comprises a main arm 3, also called torque tube, and a plurality of secondary arms 4 mechanically coupled to the main arm 1 and which are transverse, for example perpendicular, to a main longitudinal extension direction L-L of the main arm 3. The main arm 3 and the plurality of secondary arms 4 are preferably made of metal material, for example of iron or aluminum .

[0016] The secondary arms 4 are fixed onto the main arm 3 by means of mechanical coupling elements known per se and not shown in the Figures, such as, for example, bolts and/or pins and/or fixing plates and/or fixing brackets. Said mechanical coupling elements are preferably reversible mechanical coupling means.

[0017] For the purposes of the present description, the main arm 3 and the secondary arms 4 are generally components of the support frame 1 which are intended to be fixed together to assemble the support frame 1. [0018] As shown in Figure 2, after fixing the secondary arms 4 onto the main arm 3, a support frame 1 is defined onto which an array of photovoltaic panels 2 may be fixed. In the particular example shown in the Figures, without thereby introducing any limitation, the array of photovoltaic panels 2 is a two-dimensional array consisting of ten photovoltaic panels 2 arranged on two rows of five photovoltaic panels 2. It is clear that this is a mere example, since the number of photovoltaic panels 2 inside an array may be other than ten and, for example, be less than 10 or more than ten. Furthermore, the array of photovoltaic panels 2 may alternatively be a linear array, i.e., an array consisting of a single row of photovoltaic panels 2.

[0019] Figure 3 shows a side view of a support pole 5, to which a pole head 6, a saddle 7 and an actuator 8 are mechanically coupled. The actuator 8 is configured to be electronically controlled to rotate the saddle 7 about a rotation axis, for example a horizontal rotation axis. In an embodiment variant, the actuator 8 is not provided and, in this case, the arrays of photovoltaic panels 2 are fixed during the operation of the photovoltaic system and, therefore, may not rotate. In the installation operations, the pole head 6, the saddle 7 and the possible actuator 8 are mechanically coupled to the support pole 5 after driving the support pole 5 into the installation ground.

[0020] A plurality of support poles 5, for example aligned along a given alignment direction, constitutes a receiving structure onto which a plurality of arrays of photovoltaic panels 2 may be fixed. For this reason, in the present description, the same reference numeral 5 will be used to designate the receiving structure.

[0021] Preferably, an array of photovoltaic panels 2 is fixed to a plurality of saddles 7, for example, to two or more saddles 7. For this purpose, for example, the main arm 3 of the support frame 1 of an array of photovoltaic panels 2 is fixed to two or more saddles 7, for example to two or to three saddles 7 adjacent two by two.

[0022] Figure 4 diagrammatically shows a non-limiting embodiment of a movable system 100 for assembling and installing a plurality of support frames 1 of arrays of photovoltaic panels 2 on a receiving structure 5 installed on an installation ground. As already explained, the receiving structure 5 comprises a plurality of support poles 5, onto each of which a pole head 6, which preferably supports a saddle 7 which more preferably may be rotated by means of an actuator 8, is conveniently fixed. Hereafter, for simplicity, the movable system 100 for assembling and installing a plurality of support frames 1 of arrays of photovoltaic panels 2 will also be more briefly referred to as the movable system 100 or the movable assembling and installing system 100.

[0023] In accordance with an embodiment, the movable system 100 is a self-propelled system, i.e., it is equipped with an own motorization thereof, which allows the system 100 to move on the installation ground. In accordance with an embodiment, the movable system 100 is adapted and configured to move with respect to the receiving structure 5 along a working direction W, preferably astride the receiving structure 5. For example, if the receiving structure 5 extends along an own extension axis thereof, the working direction W is a direction coincident or parallel to the aforesaid extension axis.

[0024] In accordance with an advantageous embodiment, the movable system 100 comprises an upper cover 101. Preferably, the upper cover 101 comprises at least one photovoltaic module 102 adapted to supply at least part of the electricity required for the operation of the movable system 100. Preferably, the upper cover 101 comprises a plurality of photovoltaic modules 102. The movable system 100 preferably comprises at least one battery, not shown in the Figures, for storing, at least in part, the electrical power produced by the photovoltaic module 102.

[0025] The upper cover 101, as in the example shown in Figure 4, is preferably a cover with a triangular vault having the shape of a double-pitched roof. Thereby, a protection from atmospheric precipitations is advantageously obtained. Furthermore, it is possible to provide for the installation of photovoltaic modules 102 on both pitches of the upper cover 101 so as to ensure that during the operation of the movable system 100 there are always photovoltaic modules 102 which are facing south.

[0026] In alternative embodiments, the upper cover 101 may be a curved cover which is convex towards the outside or a planar cover, preferably inclined with respect to a horizontal plane.

[0027] In accordance with a particularly advantageous embodiment, the movable assembling and installing system 100 comprises a side cover 103. Advantageously, at least one portion of the side cover 103 is retractable. For example, the side cover 103 comprises a plurality of flexible retractable flanges, so as to be capable of laterally opening the movable system 100 along one or more side portions thereof. An automated control system may be provided comprising one or more actuators which may be controlled to retract and expand the flexible flanges, for example, by winding them up and unwinding them from a roller, respectively to open and close the movable system 100 laterally along one or more side portions thereof.

[0028] The movable system 100 is configured to assemble support frames 1 of arrays of photovoltaic panels 2 and to install the assembled support frames 1 on the receiving structure 5 arranged on the installation ground. As already described, the movable system 100 is further adapted and configured to translate with respect to the receiving structure 5 along a feeding direction W.

[0029] The system 100 comprises an upper frame 10 comprising a first plurality of crosspieces 11 rigidly fixed to one another. The crosspieces 11 are preferably metal crosspieces, for example steel or aluminum sections, which have end portions connected to one another in a reversible or irreversible manner. For example, the crosspieces are welded, two by two, to one another or are mechanically coupled to one another preferably by means of the use of brackets and/or joints and/or pins etc. Preferably, the upper frame 11 has a rectangular plan.

[0030] The movable system 100 further comprises a plurality of support uprights 20 having an upper end portion 21a rigidly fixed to the upper frame 10. The support uprights 20 project from the upper frame 10 towards the installation ground to space the upper frame 10 apart from the installation ground.

[0031] The support uprights 20 are for example metal uprights, for example steel or aluminum sections, which have end portions connected to the crosspieces 11 in a reversible or irreversible manner. The support uprights 20 have, for example, without thereby introducing any limitation, a height of from 3 meters to 6 meters.

[0032] The movable system 100 comprises a plurality of wheels 30 each fixed to a respective support upright 20 at a lower end portion 21b of the support upright 20 opposite to the upper end portion 21a. In accordance with a preferred embodiment, the plurality of wheels 30 comprises at least two steering wheels 30. The plurality of wheels 30 allows the system 100 to be movable, in particular with respect to the receiving structure 5. The provision of steering wheels 30 advantageously allows to rotate the movable system 100 with respect to the receiving structure 5, for example to ensure a desired alignment between the movable system 100 and the receiving structure 5. Furthermore, the provision of steering wheels 30 advantageously allows to reverse the feeding direction W once the end of a first linear array of poles 5 is reached and before starting the installation of support frames 1 on a subsequent linear array of support poles, for example adjacent and parallel to the first array of poles.

[0033] According to an embodiment, the movable system 100 is configured to be capable of proceeding and operating both by travelling forward in a direction having a feeding direction W, and in a direction having a feeding direction -W, opposite to said feeding direction W, and to be capable of selectively alternating such feeding direction configurations W, -W.

[0034] In accordance with an advantageous embodiment, in the movable system 100 at least one wheel of the plurality of wheels 30 is a motorized wheel, for example, an electric motor wheel. In accordance with a non-limiting example, it is possible to provide that all the wheels 30 are motorized wheels.

[0035] In accordance with an embodiment, in the movable system 100 at least one wheel of the plurality of wheels 30 is a braking wheel. In accordance with a non-limiting example, it is possible to provide that all the wheels 30 are braking wheels.

[0036] In accordance with an advantageous embodiment, the wheels 30 are equipped with suspensions. Thereby, the movable system 100 may easily move even on irregular surfaces. In a manner per se known, the suspensions may each include a spring and a damper.

[0037] The movable system 100 further comprises a plurality of robotic arms 40, 41 constrained to the upper frame 10 so as to be moved with respect to the upper frame 10 along or parallel to the feeding direction W. The robotic arms 40, 41 project from the upper frame 10 towards the installation ground. The robotic arms 40, 41 carry one or more tools, which, for example, may be fixed or interchangeable. The tools comprise, for example, gripping tools, such as, for example, gripping pliers, and/or one or more assembly tools, such as, for example, screwing devices or welding devices. The robotic arms 40, 41 are configured and/or articulated so as to be capable of moving the tools in the space, for example with a three-degree- of-freedom or six-degree-of-freedom movement.

[0038] The movable system 100 comprises an assembly section Al, or assembly station Al, where at least one first robotic arm 40 is arranged, being configured and/or controlled to assemble at least one support frame 1 from components 3, 4 of said support frame 1. In other words, in the assembly section Al, the assembly of the support frames 1 occurs, in particular, for each support frame 1, the mechanical coupling of the secondary arms 4 to the main arm 3.

[0039] The movable system 100 further comprises an installation section A3, or installation station A3, where at least one second robotic arm 41 is arranged, being configured and/or controlled to fix to the receiving structure 5 the support frame 1 assembled in the assembly section Al. The installation section A3 along the feeding direction W is placed downstream with respect to the assembly section Al. In other words, in the installation station A3, the fixing of the support frames 1 to the poles of the receiving structure 5 occurs. By virtue of the joint provision of an assembly section Al and an installation section A3 it is possible to advantageously carry out the following operations in parallel: assembling a support frame 1 and installing a previously assembled support frame 1 on the receiving structure 5.

[0040] During the assembly and installation operations it is possible to provide that the movable system 100 is kept stationary with respect to the receiving structure 5, to then be moved after completing the installation of a support frame 1 on the receiving structure 5 and then be stopped again once the movable system 100 has been positioned so that the installation section A3 is arranged at a portion of the receiving structure 5 on which the subsequent support frame 1 is to be installed. However, in a different embodiment it is possible to provide that the movable system 100 moves continuously or almost continuously, at a low speed, as desired and compatible with the assembly and installation operations. In this context, the term "continuous" means a motion in the space produced by the movable system 100 whereby at least one portion thereof (for example, the support uprights 20) moves according to the feeding direction with a feeding speed V_a other than zero at all times during the planned operating steps.

[0041] In accordance with an embodiment, it is possible to provide that one or more of the preferred additional operations listed below are carried out in the installation station A3:

- Fixing the heads of the poles 6 onto the support poles 5;

-Fixing the saddles 7 onto the heads of the poles 7;

-Fixing the possible actuators 8;

- Fixing the photovoltaic panels 2 onto the support frames 1.

[0042] In accordance with a particularly advantageous embodiment, the movable system 100 comprises an exchange section A2, or exchange station A2, interposed between the assembly section Al and the installation section A3 and where the at least one second robotic arm 41 collects the support frame 1 assembled in the assembly section Al. This may occur according to different operating modes. For example, it is possible to provide that, after the assembly, the support frame 1 lies on the installation ground or on a fixed or movable platform, and is collected by the second robotic arm 41. A fixed platform is, for example, a deck while a movable platform is, for example, a transport carriage. Alternatively, it is possible to provide a direct passage of the assembled support frame 1 from the first robotic arm 40 to the second robotic arm 41 or an indirect passage, for example by means of a third robotic arm arranged in the exchange section A2.

[0043] In accordance with an advantageous embodiment, the second robotic arm 41, once the assembled support frame 1 has been collected from the exchange section A2, is configured and/or controlled to move towards the installation station A3 translating in the opposite direction to the feeding direction W, so as to have a portion thereof vertically aligned with a reference point of the ground during the forward travel of the movable system 100. In order for this to occur, the movable system 100 preferably comprises at least one crosspiece 13 which is slidable in a controlled manner with respect to the upper frame 10 and which supports the second robotic arm 41. For example, the aforesaid sliding crosspiece 13 is adapted and configured to slide on a track defined on two crosspieces 11 opposite to each other of the upper frame 10. The controlled sliding may occur, for example, by means of at least one motor, for example an electric motor or a hydraulic, pneumatic or hydropneumatic piston.

[0044] In accordance with an advantageous embodiment, the movable system 100 comprises a second plurality of crosspieces 12, 13 which are slidably constrained in a controllable manner to the first plurality of crosspieces 11. The second plurality of crosspieces 12,13 comprises a first sliding crosspiece 12 and a second sliding crosspiece 13 onto which the first robotic arm 40 and the second robotic arm 41 are respectively fixed. With regard to the controlled sliding of the second plurality of crosspieces

12, 13, reference should be made to what has already been described in the previous paragraph.

[0045] In accordance with a particularly advantageous embodiment, the first robotic arm 40 and the second robotic arm 41 are constrained to the respective sliding crosspiece 12, 13 in order to slide in a controlled manner along a main longitudinal extension direction of the respective sliding crosspiece 12, 13, for example by virtue of a sliding track fixed to the sliding crosspiece 12, 13 or integrated or defined therein. Also in this case, the controlled sliding may be obtained by using one or more motors of the type described above.

[0046] In accordance with an advantageous embodiment, the first sliding crosspiece 12 and the second sliding crosspiece 13 are configured to reversibly slide with respect to the first plurality of crosspieces 11 along the feeding direction W.

[0047] In accordance with a particularly advantageous embodiment, the movable system 100 further comprises at least one storage warehouse for the components 3, 4 which, as a whole, are used to assemble a support frame 1. The storage warehouse is arranged in the assembly section 1 and is fixed to at least one of the support uprights 20. In such embodiment, the first robotic arm 40 is configured and/or controlled to collect said components from the storage warehouse.

[0048] In accordance with a further embodiment, which may be provided jointly or alternatively to the embodiment described in the preceding paragraph, the movable system 100 comprises at least one carriage which is movable with respect to the upper frame 10 and to the support uprights 20, adapted and configured to support said components 3, 4 during the assembling operations in the assembly station Al. For example, the aforesaid carriage is a motorized carriage, equipped with wheels or tracks.

[0049] The movable system 100 further comprises an electronic control system, adapted and configured to control the movement of the movable system 100 on the installation ground and to control the parts of the movable system 100 which require, for the operation thereof, to be electronically controlled, such as, for example: the robotic arms 40, 41, the sliding crosspieces 12, 13. The electronic control system may comprise, for example, at least one data processing unit, at least one storage unit for storing data or computer programs, sensors, for example position sensors, optical sensors, speed sensors, distance sensors etc., for example, useful for the automatic positioning and the automatic movement of the movable system 100 with respect to the receiving structure 5. [0050] On the basis of what has been described above, it is thus possible to understand how a movable assembling and installing system 100 of the type described above allows fully achieving the purposes mentioned above with reference to the background art. [0051] Without prejudice to the principle of the invention, the embodiments and the manufacturing details may be broadly varied with respect to the above description merely given by way of a non-limiting example, without departing from the scope of the invention as defined in the appended claims.

Claims

1. A movable system (100) for assembling support frames (1) of arrays of photovoltaic panels (2) and for installing said support frames (1) onto a receiving structure (5) arranged on an installation ground, wherein the movable system (100) is adapted and configured to translate with respect to the receiving structure (5) along a feeding direction (W), the movable system (100) comprising:

- an upper frame (10) comprising a first plurality of crosspieces (11) rigidly fixed to one another;

- a plurality of support uprights (20) having an upper end portion (21a) rigidly fixed to the upper frame (10), wherein the support uprights (20) project from the upper frame (10) towards the installation ground in order to space the upper frame (10) apart from the installation ground;

- a plurality of wheels (30) each fixed to a respective support upright (20) at a lower end portion (21b) of the support upright (20) opposite to said upper end portion (21a), wherein said plurality of wheels (30) preferably comprises at least two steering wheels (30);

- a plurality of robotic arms (40,41) constrained to the upper frame (10) so as to be moved with respect to the upper frame (10) along or parallel to the feeding direction (W), said robotic arms (40,41) projecting from the upper frame (10) towards the installation ground; wherein the movable system (100) further comprises:

- an assembly section (Al) where a first robotic arm (40) is arranged, being configured and/or controlled to assemble at least one support frame (1) from components (3,4) of the support frame (1);

- an installation section (A3) where a second robotic arm (41) is arranged, being configured and/or controlled to fix to the receiving structure (5) said support frame (1) assembled in the assembly section (Al), wherein the installation section (A3) along the feeding direction (W) is placed downstream with respect to the assembly section (Al).

2. A movable system (100) according to claim 1, comprising an exchange section (A2) interposed between the assembly section (Al) and the installation section (A3) and wherein the second robotic arm (41) collects said support frame (1) assembled in the assembly section (Al).

3. A movable system (100) according to claim 2, wherein the second robotic arm (41), once the assembled support frame (1) has been collected from the exchange section (A2), is configured and/or controlled to move towards the installation station (A3) translating in the opposite direction to the feeding direction (W), so as to have a portion thereof vertically aligned with a reference point of the ground during the forward travel of the movable system (100).

4. A movable system (100) according to any one of the preceding claims, comprising a second plurality of crosspieces (12, 13) slidably constrained to the first plurality of crosspieces (11), wherein the second plurality of crosspieces (12,13) comprises a first sliding crosspiece (12) and a second sliding crosspiece (13) to which the first robotic arm (40) and the second robotic arm (41) are fixed, respectively.

5. A movable system (100) according to claim 4, wherein the first robotic arm (40) and the second robotic arm (41) are constrained to the respective sliding crosspiece (12, 13) to slide along a main longitudinal extension direction of said respective sliding crosspiece (12, 13).

6. A movable system (100) according to claim 4 or 5, wherein the first sliding crosspiece (12) and the second sliding crosspiece (13) are configured to slide with respect to the first plurality of crosspieces (11) along said feeding direction (W).

7. A movable system (100) according to any one of the preceding claims, comprising an upper cover (101) fixed to the support frame (10) and at least one photovoltaic module (102) installed onto said upper cover (101) to provide the movable system (100) with at least part of the electricity needed for the operation thereof.

8. A movable system (100) according to claim 7, wherein said upper cover (101) is shaped like a double-pitched roof.

9. A movable system (100) according to any one of the preceding claims, comprising a side cover (103) having at least one retractable portion.

10. A movable system (100) according to claim 9, wherein the retractable portion comprises a plurality of flexible bands.

11. A movable system (100) according to any one of the preceding claims, wherein at least one wheel of said plurality of wheels (30) is a motorized wheel.

12. A movable system (100) according to any one of the preceding claims, wherein at least one wheel of said plurality of wheels (30) is a braking wheel.

13. A movable system (100) according to any one of the preceding claims, wherein said wheels (30) are equipped with suspensions.

14. A movable system (100) according to any one of the preceding claims, comprising at least one storage warehouse for said components (3,4) arranged in the assembly section (Al) and fixed to at least one of the support uprights (20), and wherein the first robotic arm (40) is configured and/or controlled to collect said components (3,4) from the storage warehouse.

15. A movable system (100) according to any one of the preceding claims, comprising at least one carriage which is movable with respect to the upper frame (10) and to said support uprights (20), adapted and configured to support said components (3,4) during the assembly in the assembly station (Al).