The deployment of solar panel installation robots by Rosendin Electric and ULC Technologies promises to revolutionise the efficiency and safety of photovoltaic farm construction.
The deployment of newly developed solar panel installation robots by Rosendin Electric, in collaboration with robotics firm ULC Technologies, marks a significant advance in the construction of solar photovoltaic (PV) farms. Following extensive trials on actual solar job sites, these robots are reducing both labour costs and the physical demands on human workers, streamlining the assembly process for solar panels.
Traditionally, the installation of solar panels on large farms necessitated multi-person crews tasked with transporting and securing 80 to 100-pound panels onto preassembled mounting racks. Given that many large solar farms require upwards of a million panels, this manual process can be both labor-intensive and physically exhausting. Notably, workers often find themselves fatigued by the end of their shifts due to the strenuous nature of the work.
David Lincoln, Senior Vice President of Rosendin, sought to alleviate some of these challenges, particularly against a backdrop of worker shortages in remote project locations. His inspiration stemmed from observing robotic arms that efficiently moved modules between pallets at a photovoltaic module manufacturer. This led to thoughts on how a robotic arm could be mounted on a small backhoe or mini-excavator to automate the installation process.
In collaboration with Rosendin’s research and development team, Lincoln discovered that no existing solutions on the market matched his vision for an automated installation robot. The partnership with ULC brought about the development of a robotic system specifically designed for solar installation. After a year and a half of intensive testing and refinement, this solar installation robot has now been successfully operational across various Rosendin solar projects nationwide.
ULC Technologies’ Director of Research and Development, Ali Asmari, detailed the advancements that have set this robotic solution apart, stating, “This was a completely manual process before […] installers need to pick up [each] 100-lb panel onto their shoulders and put it onto the install rack.” The new system employs a treaded robotic platform equipped with an articulated arm that uses a vacuum suction attachment to lift and position solar panels accurately. Human operators still play a role in confirming the correct placement and securing the panels, along with two additional autonomous robots that function as panel carriers.
These panel carrier robots enhance efficiency by transporting stacked panels to the position of installation, significantly reducing the burden on human labour while working seamlessly alongside the installation robot. Each carrier can hold between 30 to 35 panels and can traverse uneven terrain, tipping the balance of work from manual to automated.
The integration of these technologies is yielding remarkable productivity gains. According to Asmari, field trials have demonstrated that the installation robots can achieve an install rate of one panel per minute, resulting in the possible installation of up to 600 panels in a 10-hour shift. In a comparative context, traditional crews were only managing to install between 100 to 120 panels in the same timeframe. Notably, in one trial, a mere two human operators were able to assist in the installation of 350 panels within an eight-hour shift.
Beyond efficiency and productivity, the introduction of these robots significantly enhances workplace safety. Lincoln noted that installation of heavy panel modules accounts for 25% of labour on solar photovoltaic projects, and the new system addresses the common issues of strains and sprains that have historically afflicted workers in the industry.
The robots have been designed with durability in mind, able to withstand adverse weather and traverse rugged ground conditions. Each robot operates independently, utilising a combination of GPS and Lidar technology for navigation, and is equipped with emergency shut-off mechanisms to ensure the safety of human workers in proximity.
With successful trials now underpinning wider application and return on investment on the horizon, Rosendin and ULC Technologies are actively working to refine the robot’s components for mass production. Lincoln has indicated that they are currently evaluating the drivetrain, striving for an option that balances performance with availability. He remarked, “We’re light years ahead of anything else on the market,” highlighting the transformative potential of these solar installation robots in reshaping the sector.
This technological advancement is not only set to revolutionise the solar installation process but also propels the industry towards greater efficiency and safety in renewable energy construction efforts.
