The robotics firm ULC Technologies was commissioned by Rosendin to engineer and create a robotic solution for the installation of solar modules. The robotic systems, which have already participated in field evaluations at actual utility-scale solar construction locations, collaborate with skilled tradespeople to expedite construction timelines, enhance worker safety, and facilitate the growth of renewable energy generation.
“The solution we devised and created encompasses three distinct autonomous systems: a Panel Setting Robot and two Panel Carrier Robots, functioning in conjunction with human operators to install solar PV panels at mid- to large-scale solar installations,” stated Ali Asmari, Director of R&D Project Management at ULC Technologies. “The Panel Setting Robot is a construction-grade tracked robotic platform equipped with an integrated robotic arm to conduct semi-autonomous installation of solar panels alongside human operators. Once the robot positions the panel, field operators can direct it into place and finalize the installation with fastening hardware and electrical connections. ”
Continuous supply of panels and minimizing downtime
The two Panel Carrier Robots transport pallets of solar panels between the loading zone and the installation site of the Panel Setting Robot, ensuring a continuous supply of panels and minimizing downtime.
The solar panel installation robots were engineered to endure high-temperature exposure while maneuvering through varying construction site terrains, including deep mud and uneven surfaces. This initial work allowed ULC to swiftly progress from the project’s conceptual phase to field trials in just 18 months.
Robots undergo field testing
The robots underwent rigorous field testing at utility-scale solar construction sites, resulting in a robotic system capable of production rates of under one minute per panel. During a ten-hour shift, ULC estimates that the robots, along with a two-person crew, could install 600 panels.
Conventional installation methods necessitate substantial manual labor. Large solar farms may consist of over one million panels that require installation, and with each panel weighing between 80 to 100 pounds, this translates to physically demanding work. Furthermore, the remote nature of solar sites complicates contractors’ ability to locate sufficient skilled labor to satisfy the demand.
“Collaborating with Rosendin’s use case, we designed and developed a solution that will revolutionize the installation of solar panels at large-scale sites,” remarked Steve Green, VP of Business Development for Location and Inspection at SPX Technologies, the parent company of ULC Technologies. “Extensive field testing demonstrated how the robots alleviate the heavy lifting burden from workers, augmenting their expertise with a supportive tool that aids in protecting workers while enabling increased productivity. ”
