OF INSTALLING SOLAR MODULES

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The subject patent application claims priority to and all the benefits of U.S. Provisional Patent Application No. 61/492,674 filed June 2, 2011; U.S. Provisional Patent Application No. 61/492,694 filed June 2, 2011; U.S. Provisional Patent Application No. 61/524,688 filed August 17, 2011; and U.S. Provisional Patent Application No. 61/524,661 filed August 17, 2011, each of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present invention includes a mobile assembly system for assembling a rail on a solar module for supporting the solar module on a racking system of a solar module installation site. The present invention also includes a method of installing solar modules on the racking system of the solar module installation site with the use of the mobile assembly system.

2. Description of the Related Art

[0003] Solar module installation sites include a plurality of solar module assemblies for converting the energy of sunlight into electricity. The solar module assemblies include one or more solar modules and one or more rails mechanically fastened to the solar modules. The solar module installation site includes a racking system that extends upwardly from a substrate, such as the ground, a building, etc. The rails of the solar module assemblies engage the racking system to support the solar modules on the racking system.

[0004] The assembly of solar module installation sites is labor intensive and time consuming. The solar module assemblies include framing, typically formed of metal, having mechanical hardware, such as fasteners and clamps, that extend around one or more solar modules to mechanically fasten the solar modules to the rail. The rail is mounted to the framing to support the metal framing and the solar modules on the racking system. During assembly, the solar modules and the metal framing are rested on saw horses and workers manipulate the metal framing and the solar module to mount the metal framing on the solar module.

[0005] The material for the metal framing adds cost to the solar module assembly and also consumes space that could otherwise be used to absorb additional sunlight with the solar module. In addition, the assembly of the metal framing to the solar module adds labor costs because the process of mounting the metal framing to the solar module is cumbersome and time consuming. In addition, the process of mounting the metal framing to the solar module requires handling of the fragile solar module, which increases the risk of damaging the solar module. Further, the mechanical hardware of the metal framing can be accidentally over-tightened by workers, which results in breakage of the solar module. In addition, the solar modules are subject to theft because the mechanical hardware merely has to be loosened to release the solar modules. Accordingly, there remains an opportunity to improve the process of installing solar modules to solar module installation sites.

SUMMARY OF THE INVENTION AND ADVANTAGES

[0006] The present invention includes a mobile assembly system for assembling a rail on a solar module for supporting the solar module on a racking system of a solar module installation site. The mobile assembly system comprises a table transported to the solar module installation site and configured to support the solar module and/or the rail during assembly of the rail to the solar module. A robot is fixed to the table to apply adhesive to the rail and/or the solar module on the table adjacent the solar module installation site to adhere the rail to the solar module. A portable enclosure is transported to the installation site to house the table and the robot adjacent the solar module installation site.

[0007] The mobile assembly system advantageously allows for easy and efficient assembly of solar module assemblies at the solar module installation site. Since the robot is fixed to the table, the table and robot are moved together as a unit and are therefore self-leveling. In other words, since the robot maintains position relative to the table, the robot maintains its calibration relative to the table when the table and robot are transported to the solar module installation site. As such, the robot advantageously does not need to be calibrated relative to the table when the table and the robot are transported to the solar module installation site. Also, the portable enclosure houses the table and the robot so that the assembly process is protected from the elements, e.g., sun, wind, rain, to prevent, among other things, the contamination of the adhesive when applied to the rail and/or solar module.

[0008] The present invention also includes a method of installing solar modules on a racking system of a solar module installation site with the use of a mobile assembly system adjacent the solar module installation site. The method comprises transporting the mobile assembly system to be adjacent the solar module installation site. The method further comprises loading at least one of a solar module and a rail onto the mobile assembly system and adhering the rail to the solar module. The rail is configured to support the solar module on the racking system. The method also comprises moving the adhered solar module and rail from the mobile assembly system adjacent the solar module installation site to the racking system of the solar module installation site for assembly with the racking system.

[0009] The method advantageously reduces the time and cost of assembly of the solar module assemblies. Since the mobile assembly system is transported to be adjacent the solar module installation site, the solar module assemblies can be assembled adjacent the solar module installation site. This eliminates the costs associated with shipping assembled solar module assemblies and minimizes the risk of damaging the solar module assemblies during transportation.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0011] Figure 1A is a cut-away perspective view of a mobile assembly system;

[0012] Figure IB is a perspective view of a portion of another embodiment of the mobile assembly system;

[0013] Figure 2 is a cut-away perspective view of yet another embodiment of the mobile assembly system;

[0014] Figure 3 is a perspective view of a portion of the mobile assembly system with components in a stowed position;

[0015] Figure 4 is a perspective view of a portion of the mobile assembly system with components in an extended position;

[0016] Figure 5 is a perspective view of a portion of the mobile assembly system with a plurality of solar modules loaded onto a table of the mobile assembly system;

[0017] Figure 6 is a perspective view of a portion of the mobile assembly system with a robot applying adhesive to the plurality of solar modules;

[0018] Figure 7A is a perspective view of a portion of the mobile assembly system with the robot applying adhesive between spacers on one of the solar modules;

[0019] Figure 7B is a perspective view of a portion of the mobile assembly system with the robot applying adhesive between spacers on another of the solar modules;

[0020] Figure 8 is a perspective view of a portion of the mobile assembly system with the robot placing rails on adhesive;

[0021] Figure 9 is a perspective view of the mobile assembly system including dispensing heads disposed over the solar modules;

[0022] Figure 10 is a perspective view of a solar module assembly being installed on a racking system of a solar module installation site with a lifting device.

DETAILED DESCRIPTION OF THE INVENTION

[0023] Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a partially assembled solar module installation site 10 is shown in Figures 1-2. The solar module installation site 10 includes a racking system 12 for supporting a plurality of solar modules 14. The solar modules 14, also referred to in industry as photovoltaic cells, convert sunlight into electricity. The solar module installation site 10 typically includes various components such as inverters, batteries, wiring, etc., which are not shown in the Figures for the sake of drawing clarity. The solar module installation site 10 can, for example, be a solar field, e.g., for large-scale commercial energy production, a roof top of building, a side of a building, etc.

[0024] The solar modules 14 are typically 1.0- 1.7m wide and 0.6- 1.1m tall and are typically mounted to the racking system 12 in a landscape orientation. It should be appreciated that the solar modules 14 can be of any size and can be mounted to the racking system in any orientation without departing from the nature of the present invention. The solar modules 14 can be of any type without departing from the nature of the present invention. Merely for the same of example, the solar modules 14 can be, but are not limited to, glass-glass thin film cell modules 14, glass- glass polycrystalline modules 14, glass-backsheet polycrystalline modules 14, or glass-backsheet monocrystalline modules 14. As one example, the solar module 14 can be the type described and shown in U.S. Patent Application Publication No. 2012/0080065 to Krajewski et al. filed September 30, 2010 and published April 5, 2012, which is incorporated herein by reference.

[0025] With continued reference to Figures 1-2, a solar module assembly 16, e.g., an array, includes the solar module 14 and a rail 18 configured to support the solar module 14 on the racking system 12. The solar module assembly 16 can include a plurality of solar modules 14, i.e., typically referred to in industry as a multi-module panel. The solar module assemblies 16 shown in the Figures include two rails 18 and five solar modules 14; however, the solar module assembly 16 can include any number of rails 18, i.e., one or more rails 18, and any number of solar modules 14, i.e., one or more solar modules 14. When the solar module assembly 16 includes a plurality of solar modules 14, each of the solar modules 14 of the assembly 16 are physically connected to each other via the rail 18 and are also typically electrically connected to each other. Although the figures show the solar modules 14 positioned in columns, the solar modules 14 can alternatively be arranged in a matrix of solar modules 14 arranged in columns and rows, e.g., 2 by 2, 3 by 3, etc.

[0026] In one embodiment (not shown), the solar module assembly 16 includes a single solar module 14 and at least one rail 14 mounted to the solar module 14. For example, a plurality of rails 14 can be mounted to the single solar module 14 with each of the rails being short relative to the solar module 14, i.e., only extending along small portion of the solar module 14. In such an embodiment, the rails 14 can be referred to in industry as "pads" and the assembly of the pads to the solar module 14 can be referred to as "pad bonding." [0027] The rail 18 is typically engaged with the racking system 12 to support the assembly 16 on the racking system 12 and can be engaged with the racking system 12 in any suitable fashion without departing from the nature of the present invention. The rail 18 can be formed of any type of material such as, for example, galvanized steel, aluminum, etc.

[0028] Typically, the rail 18 is connected to the solar modules 14 only with an adhesive 20, i.e., the solar module assembly 16 is frameless. The rail 18 is adhesively secured to the solar modules 14. The attachment of the rails 18 to the solar modules 14 is typically free of any type of mechanical hardware such as fasteners and clamps that clamp the rail 18 onto the solar module 14, i.e., the rails 18 typically are not mechanically fastened to the solar modules 14. As such, the material and assembly costs associated with such mechanical hardware or fasteners are eliminated and the handling of the fragile solar modules 14 by workers associated with assembling mechanical hardware or fasteners is eliminated. In addition, damage to the solar modules 14 caused by over-tightening of the mechanical hardware is eliminated. Also, the adhesive 20 is a theft deterrent because it is relatively difficult to break the adhesive 20 between the rail 18 and the solar module 14 without proper tools.

[0029] The adhesive 20 can be any type of adhesive 20. For example the adhesive 20 can be silicone 21 such that the assembly of the rails 18 to the modules 14 is further defined as silicone panelization. The silicone 21 advantageously has excellent adhesion to glass and metals. The silicone 21 is also flexible so as to absorb mismatches caused by differences coefficient of thermal expansion of different material and to reduce stress on the solar module 14. The silicone 21 can also withstand wind load and snow load and adequately resists deterioration.

[0030] The silicone 21 can be any type of silicone. Typically, the silicone 21 is room- temperature vulcanizing silicone (RTV). The silicone 21 can be, for example, a 1-part silicone or a 2-part silicone, as set forth further below. Specifically, the silicone 21 can be, but is not limited to, that which is available under the tradenames PV-8301 Fast Cure Sealant, PV-8303 Ultra Fast Cure Sealant, or PV-8030 Adhesive from Dow Corning Corporation headquartered in Midland, MI, USA.

[0031] A plurality of spacers 23, e.g., tape, can be disposed between the solar module 14 and the rail 18. The spacers 23 are typically adhered to the solar module 14 and the rail 18, and the primary purpose of the spacers 23 are to prevent adhesive squeeze-out from between the solar module 14 and the rail 18 when the solar module 14 and rail 18 are assembled together. In other words, the spacers 23 have a thickness that spaces the solar module 14 from the rail 18 when the solar module 14 and the rail 18 are assembled together so that the silicone 21 is not squeezed out from between the solar module 14 and the rail 18. [0032] The spacer 23 is typically tape, however, the spacer 23 can be any type of spacer disposed between the solar module 14 and the rail 18 to provide a space that prevents the silicone 21 from squeezing out when the module 14 and rail 18 are assembled together. In an embodiment where the spacer 23 is tape, the spacer 23 can be any type of tape without departing from the nature of the present invention. The spacer 23 can be, for example, double-sided pressure- sensitive foam tape. As one example, the spacer 23 could be that commercially available from 3M located in St. Paul, Minnesota, USA, under the tradename 4991. It should be appreciated that the spacer 23 can be single-sided or double-sided and can be of any material.

[0033] The spacer 23, e.g., tape, is typically applied at multiple locations on the solar module 14 and the silicone 21 is typically applied along a line between two pieces of spacer 23, as shown for example in Figure 6. Specifically, spacers 23 are typically applied to edges of the solar module 14 and spaced apart and the line of silicone 21 is applied to the solar module 14 from one piece of spacer 23 to another spacer 23.

[0034] As set forth further below, the solar module assembly 16 can be assembled, i.e., one or more rails 18 can be assembled to one or more solar modules 14, with the use of an assembly system 22, as shown in Figures 1-9. With particular reference to Figures 1-2, the assembly system 22 can be further defined as a mobile assembly system 24 that is transported to be adjacent the solar module installation site 10 for assembling the rails 18 to the solar modules 14 adjacent the solar module installation site 10. In other words, the mobile assembly system 24 is transported to be in close disposition to the racking system 12 so that the solar module assemblies 16 can be easily moved from the mobile assembly system 24 to the racking system 12 without long haul transport such as highway trucking, rail, ship, etc. For example, when the mobile assembly system 24 is adjacent the solar module installation site 10, the solar modules 14 can be moved from the mobile assembly system 24 to the solar module installation site 10 by fork lift (not shown), hand truck (not shown), hand-carrying, etc. The mobile assembly system 24 can, for example, be transported to a common field with the racking system 12 immediately next to the racking system 12 to be adjacent the solar module installation site 10, as shown in Figures 1-2. It should be appreciated that the mobile assembly system 24 can be transported to any type of location adjacent the solar module installation site 10 without departing from the nature of the present invention. Alternatively, although not shown in the Figures, the assembly system 22 can disposed remotely from the solar module installation site 10, e.g., at a factory, such that the assembled rails 18 and solar modules 14 are assembled remotely and subsequently transported to the solar module installation site 10 via long haul transport.

[0035] With reference to Figures 3 and 4, the assembly system 22 includes a work table 26. In the case of the mobile assembly system 24, the work table 26 is transported to the solar module installation site 10, as set forth further below. The work table 26 can, for example, include a brace 35 for receiving forks of a fork lift (not shown), or other vehicle or tool, to move the work table 26.

[0036] With reference to Figures 5-9, the work table 26 is configured to support the solar module 14 and/or the rail 18 during assembly of the rail 18 to the solar module 14. Specifically, the work table 26 includes a surface 28 that supports one or more solar modules 14 in position to subsequently receive one or more rails 18. Alternatively, although not shown in the Figures, the surface 28 can support one or more rails 18 in position to subsequently receive one or more solar modules 14 thereon.

[0037] The work table 26 typically includes adjustable legs 27. Specifically, with reference to Figure 3, the adjustable legs include an outer leg 29 and an inner leg 31 telescopically received in the outer leg 29. The adjustable legs typically include gearing (not shown) coupling the outer

29 and inner 31 legs. A crank 33, for example, is connected to the gearing for adjusting the relative position of the outer 29 and inner 31 legs to adjust the height of the work table 26 and/or to level the work table 26. The work table 26 typically includes four adjustable legs 27.

[0038] With reference to Figures 3 and 4, the work table 26 typically includes a main conveyor

30 that presents the surface 28. When multiple solar modules 14 are placed on the main conveyor 30, the main conveyor 30 can spaces the solar modules 14 apart from each other a predetermined distance D. For example, the conveyor can include jigs (not shown), spacers (not shown), etc., to space the modules 14 the predetermined distance D. The predetermined distance D, for example, allows for thermal expansion of the solar modules 14. The predetermined distance D is typically about 1cm. The main conveyor 30 can, for example, include a belt 32 extending along an axis A and powered by a motor (not shown) to move the solar module assembly 16 along the axis A and off the main conveyor 30 to create space for the assembly of another solar module assembly 16.

[0039] With continued reference to Figures 3 and 4, stowable platforms 34 can be moveably coupled to the work table 26. The stowable platforms 34 can be moved to a stowed position, as shown in Figure 3, for example, for reducing the size of the mobile assembly system 24 during transportation. The stowable platforms 34 can also be extended to an extended position, as shown in Figure 4, for supporting the solar module 14 and/or the rail 18 adjacent the solar module installation site 10. The stowable platforms 34 typically include a conveyor system 36 such as, for example, a belt and/or rollers, for moveably supporting the solar module assembly

16. The conveyor system 36 of the stowable platforms 34 can be passive or can be powered.

[0040] With reference to Figure 4, typically at least one, and more typically, two axial stowable platforms 38 extend from the work table 26 along the axis A. The axial stowable platforms 38 support one or more solar modules 14, as shown in Figures 5-9. The axial stowable platforms 38 are moved along the axis A to move the axial stowable platform 34 between the stowed and extended positions.

[0041] With reference to Figures 3 and 4, the work table 26 defines cutouts 40 adjacent the conveyor for receiving the axial stowable platforms 38. The axial stowable platforms 38 are slideable relative to the work table 26 such that the axial stowable platforms 38 are slid into the cutouts 40 to the stowed position and slid out of the cutouts 40 to the extended position. However, it should be appreciated that the axial stowable platforms 38 can be moveably coupled to the work table 26 in any fashion, e.g., rotatable, pivotable, collapsible, etc., without departing from the nature of the present invention.

[0042] The conveyor system 36 and the main conveyor 30 typically work in conjunction with each other to space adjacent solar modules 14 by the predetermined distance D. For example, sensors (not shown) in the main conveyor 30 and the conveyor system 36 track the location of the solar modules 14 relative to each other. For example, the sensors track the location of a first solar module 14 when the first solar module 14 moves onto the main conveyor 30. When a second solar module 14 is loaded onto the conveyor system 36, the conveyor system 36 moves the solar module 14 relative to the first solar module 14 to space the first and second solar modules 14 apart from each other by the predetermined distance D. When the first and second solar modules 14 are spaced the predetermined distance D, the conveyor system 36 and the main conveyor 30 move in conjunction to simultaneously move the first and second solar modules 14 onto the main conveyor 30 while maintaining the predetermined distance D between the solar modules 14. These steps are then repeated for additional solar modules 14 such that the solar modules 14 are spaced from adjacent solar modules 14 by the predetermined distance D.

[0043] Typically at least one lateral stowable platform 42 extends from the work table 26 transversely to the axis A. The lateral stowable platform 42 supports a supply of rails 18 for attachment to the solar modules 14. The lateral stowable platform 42 is moved transversely to the axis A to move the lateral stowable platform 42 between the stowed and extended positions.

[0044] With reference to Figures 3 and 4, the work table 26 defines tracks 44 below the main conveyor 30 for receiving the lateral stowable platforms 34. The lateral stowable platforms 34 are slideable relative to the work table 26 such that the lateral stowable platforms 34 are slid into the tracks 44 to the stowed position and slid out of the tracks 44 to the extended position. However, it should be appreciated that the lateral stowable platforms 34 can be moveably coupled to the work table 26 in any fashion, e.g., rotatable, pivotable, collapsible, etc., without departing from the nature of the present invention. [0045] With reference to Figures 3-8, the mobile assembly system 24 includes a robot 46 fixed to the work table 26 to apply adhesive 20, e.g., silicone 21, to the rail 18 and/or the module 16. Specifically, as set forth further below, the rail 18 and/or the module 16 are disposed on the work table 26 adjacent the solar module installation site 10 and the robot 46 applies adhesive 20, e.g., silicone 21, to the rail 18 and/or the solar module 14 to adhere the rail 18 to the panel, as shown in Figure 8.

[0046] The robot 46 is typically supported by the work table 26. Specifically, with reference to Figures 3 and 4, a pedestal 48 is fixed to the work table 26 and extends upwardly from the work table 26. A base 50 of the robot 46 is fixed to the pedestal 48 such that the base 50 of the robot 46 and the work table 26 are fixed in position relative to each other. The pedestal 48 is typically cantilevered over the work table 26, as shown in Figures 3 and 4.

[0047] Since the robot 46 is fixed to the work table 26, the work table 26 and robot 46 are self- leveling. In other words, since the robot 46 maintains position relative to the work table 26, the robot 46 maintains its calibration relative to the work table 26 when the work table 26 and robot 46 are transported to the solar module installation site 10. As such, the robot 46 does not need to be calibrated relative to the work table 26 when the work table 26 and the robot 46 are transported to the solar module installation site 10.

[0048] The robot 46 includes an arm 52 that is moveable relative to the base 50 for applying adhesive 20, e.g., silicone 21, to the solar modules 14, as shown in Figures 6-7B, and for placing the rails 18 on the adhesive 20, as shown in Figure 8. With reference to Figures 5-8, the robot 46 typically includes a plurality of attachments heads 54 selectively and individually engaged by the arm 52 to perform various functions. For example, the attachment heads 54 include at least one nozzle 56 for dispensing adhesive 20, e.g., silicone 21, and at least one gripper mechanism 58 for lifting the rails 18. In the alternative to separate heads 54, the arm 52 can be configured to simultaneously include each of the attachment heads. Although not shown in the Figures, the attachment heads 54 can also include a lifting mechanism including, for example, grippers, suction cups, etc. for lifting the solar modules 14 onto the work table 26.

[0049] With continued reference to Figures 5-8, each of the attachment heads 54 typically includes a coupling plate 60 and the arm 52 typically includes a coupling mechanism 62 for selectively coupling to the coupling plates 60. The coupling plates 60 of each of the attachment heads 54 are typically identical so that the coupling mechanism 62 can interchangeably connect with any of the attachment heads 54. The coupling mechanism 62 can include an actuating system (not shown) configured to engage the coupling plate 60. The actuating system can, for example, be mechanical, hydraulic, pneumatic, magnetic, or combinations thereof. [0050] A rack 64 supports the attachment heads 54 when not engaged with the arm 52. The rack 64 is typically fixed to the work table 26 so that the rack 64 is fixed in position relative to the robot 46.

[0051] As shown in Figures 5-8, the attachment heads 54 can include two nozzles 56 with each nozzle 56 designated for dispensing different types of adhesive 20, e.g., different types of silicone 21. For example, one nozzle 56 can be used for applying a two-part adhesive to the solar modules 14. Typically, the two-part adhesive is applied to the solar modules 14 when the mobile assembly system 24 is adjacent the solar panel installation site 10. The other nozzle 56 can be used for applying a one-part adhesive to the solar modules 14. Typically, the one-part adhesive is applied to the solar modules 14 when the mobile assembly system 24 is remote from the solar panel installation site 10, e.g., at a factory. It should be appreciated that the nozzle 56, when attached to the arm 52, is in communication with a source of adhesive 20 (not shown).

[0052] The gripper mechanism 58 typically includes the gripper mechanism 58 can include fingers 66 that open and close to grasp the rail 18 and lift the rail 18 onto the solar modules 14. The gripper mechanism 58 can include an actuating system (not shown) configured to actuate the fingers 66 and the actuating system can be of any type such as, for example, mechanical, hydraulic, pneumatic, magnetic, or combinations thereof. Alternatively or in addition, the gripper mechanism 58 can include suction cups (not shown) that are connected to a vacuum source (not shown) and are configured to lift and move the rail 18 onto the solar modules 14 by suction. It should be appreciated that the gripper mechanism 58 can be of any type without departing from the nature of the present invention.

[0053] In an alternative embodiment shown in Figure 9, the mobile assembly system 24 can include one or more stationary nozzles 57 for dispensing adhesive on solar modules 14. The mobile assembly system 24 can include a beam 59 that is stationary relative to the work table 26 with the stationary nozzles 57 supported by the beam 59 above the solar modules 14. The stationary nozzles 57 are adjustable along the beam 59 to adjust the positioning of the adhesive 20 applied to the solar modules 14. In other words, the stationary nozzles 57 are adjusted to a desired position along the beam 59 before the stationary nozzles are used. The adjustment of the stationary nozzles 57 relative to the beam 59 is typically manual but alternatively is automatic. In the embodiment of Figure 9, an overhead rail applicator 61 can apply the rails 18 to the solar modules 14. The overhead rail applicator 61 can be mounted to the work table 26 or can be separate from the work table 26.

[0054] With reference to the embodiment of Figures 3-8, as set forth further below, the robot 46 is programmed to automatically adhere the rail 18 to the solar module 14. In other words, once programmed, the robot 46 can adhere the rail 18 to the solar module 14 without any additional instruction. The robot 46 can also repeatedly adhere separate pairings of rails 18 and solar modules 14 to consecutively form a plurality of solar module assemblies 16. It should be appreciated that the robot 46 includes a computer (not shown) and is connected to an electrical source (not shown).

[0055] With reference to Figuresl-2B, 5, 6, 8, and 9, the assembly system 22, can include a spacer dispenser 94, e.g., a tape dispenser. The spacer dispenser 94 can be part of the mobile assembly system 24 as shown in Figures 1 and 2. The spacer dispenser 94 automatically dispenses spacers 23 on the solar module 14 in the configuration set forth above. Specifically, for example, the spacer dispenser 94 automatically applies spacers 23 spaced from each other on edges of the solar module 14 so that the line of silicone 21 is automatically applied to the solar module 14 from one spacer 23 to another spacer 23.

[0056] The spacer dispenser 94 is typically stationary relative to the work table 26 and the solar module 14 is automatically moved relative to the spacer dispenser 94 so that the spacer dispenser 94 automatically applies the spacer 23 to predetermined locations on the solar module 14. Alternatively, the spacer dispenser 94 is moveable relative to the work table 26 so that the spacer dispenser 94 moves relative to the solar module 14 to automatically apply the spacer 23 to predetermined locations of the solar module 14.

[0057] The spacer dispenser 94 can be located at any position relative to the work table 26 without departing from the nature of the present invention. The spacer dispenser 94 is shown as being cantilevered from the work table 26 in Figures 1, 2, and 5, 6, 8, and 9 upstream of the robot 46. In other words, the conveyor 30 moves the solar module 14 by the spacer dispenser 94 before the robot 46. It should be appreciated that the spacer dispenser 94 can be attached to the work table 26, as shown in Figures 1, 2, and 5, 6, 8, and 9, or alternatively can be separately moveable relative to the work table 26. The spacer dispenser 94 can also be located at any location relative to the work table 26 and the robot 46 without departing from the nature of the present invention.

[0058] The spacer dispenser 94 is, for example, the type commercially available from Tapeler Tape Machines Inc. located in Ashland, Massachusetts, USA under the tradename Model 1501 Tape Application System. However, it should be appreciated that the spacer dispenser 94 can be of any type without departing from the nature of the present invention. The spacer dispenser 94 is only shown in Figures 1, 2, and 5, 6, and 9 and are not shown in the other drawings merely for the sake of simplicity of the other drawings. It should be appreciated that the spacer dispenser 94 can be included in any of the drawings including the assembly system 22.

[0059] With reference to Figures 1-2, the mobile assembly system 24 includes a portable enclosure 68 transported to the installation site 10 to house the work table 26 and the robot 46 adjacent the solar module installation site 10. When located adjacent the solar module installation site 10, the mobile assembly system 24 assembles the solar module assemblies 16 adjacent the solar module installation site 10 so that the solar module assemblies 16 have to be moved only a relatively short distance for assembly to the solar module installation site 10. As such, high costs associated with transporting assembled solar module assemblies 16 from a manufacturing plant to the solar module installation site 10 are eliminated. Also, assembly adjacent the solar module installation site 10 reduces the risk of damaging the solar module assembly 16 during transportation to the solar module installation site 10.

[0060] With reference to Figures 1A and IB, the portable enclosure 68 can be further defined as a trailer 70 that supports the work table 26 and the robot 46. One embodiment of the trailer 70 is shown in Figure 1A and another embodiment of the trailer 70 is shown in Figure IB. The trailer 70 is moved, for example by a semi-truck (not shown), to be adjacent the solar module installation site 10. The trailer 70 is typically loaded with the solar modules 14, rails 18, and adhesive 20 so that the trailer 70 can be transported to be adjacent the solar module installation site 10 as a self-contained unit that outputs solar module assemblies 16. Alternatively, solar modules 14, rails 18, and/or adhesive 20 is loaded onto the trailer 70 adjacent the solar module installation site 10.

[0061] The trailer 70 has at least one door 72 and the work table 26 and the robot 46 are typically arranged in the trailer 70 such that the solar module assemblies 16 are moved along the work table 26 toward the door 72 during assembly. When assembled, the solar module assemblies 16 are removed from the trailer 70 through the doors 72. The doors 72 are shown on the back of the trailer 70 in Figure 1. The work table 26 is typically fixed to a floor 74 of the trailer 70. Alternatively, the work table 26 can be moveably supported by the floor 74 of the trailer 70 such that the work table 26 can be appropriately arranged in the trailer 70 after the trailer 70 is transported to the solar module installation site 10.

[0062] With reference to Figure IB, the trailer 70 can include one or more sides 73 that fold down to create working platforms that can support workers, equipment, components of solar module assemblies 16, and/or assembled solar module assemblies 16. Specifically, the sides 73 can be moved between a lowered position, as shown in Figure IB, and a raised position (not shown). In the lowered position, the sides 73 typically extend horizontally and expose openings 75 that communicate with an interior of the trailer 70. In the raised position, the sides 73 cover the openings 75 to protect the interior of the trailer 70, for example, when the trailer 70 is not in use or is being transported. The sides 73 are typically connected to the rest of the trailer 70 with one or more hinges (not numbered). [0063] With reference to Figure 2, the portable enclosure 68 can be further defined as a temporary enclosure 76 configured to be erected adjacent the solar module installation site 10. The temporary enclosure 76 typically includes a frame 78 and a covering 80 disposed over the frame 78. The frame 78 is typically collapsible for transportation. The covering 80 can be, for example, fabric, plastic, or other types of materials that are easily minimized in size for transportation. Since the work table 26 supports the robot 46 to be self-leveling, as set forth above, the work table 26 can be placed directly on the ground underneath the porwork table 26 disclosure. Alternatively, the portable enclosure 68 can include a floor (not shown) for supporting the work table 26.

[0064] The mobile assembly system 24 can include a removeable drying table 82 configured to be disposed adjacent the work table 26 for receiving the solar module 14 and rail 18 after assembly of the solar module 14 and rail 18. The removeable drying table 82 can be separable from the work table 26 during transportation to accommodate for packaging constraints. The removeable drying table 82 can include casters (not shown) to aid in moving the removeable drying table 82 relative to the work table 26. The removeable drying table 82 can be collapsible, e.g., accordion-like, to reduce size during transportation. The removeable drying table 82 can also include height adjustment features.

[0065] The mobile assembly system 24 can also include a cage (not shown) for enclosing the work table 26 and the robot 46. The cage 84 can include, for example, rods that support acrylic glass. The cage can also be removeable to access the work table 26 and robot 46.

[0066] Figures 1-10 also show a method of installing solar modules 14 on the racking system 12 of the solar module installation site 10. For example, the method includes installing a solar module assembly 16 including a plurality of solar modules 14 and a rail 18 onto the racking system 12 of the solar module installation site 10. However, it should be appreciated that the method can include the assembly one or more rails 18 to one or more solar modules 14. The method can include the use of the mobile assembly system 24 adjacent the solar module installation site 10. In such an embodiment, as set forth further below, the step of transporting the mobile assembly system 24 to be adjacent the solar module installation site 10 is performed before the solar modules 14 and the rails 18 are adhered together and the solar modules 14 and the rails 18 are adhered adjacent the solar module installation site 10, i.e., on-site assembly. Alternatively, the method can include the use of the assembly system 22 remotely from the solar module installation site 10 such that the solar module assemblies 16 are transported to the solar module installation site 10 subsequent to assembly.

[0067] With reference to Figure 5, the method includes loading at least one of the solar module

14 and/or the rail 18 onto the assembly system 22, e.g., the mobile assembly system 24. Typically, the solar module 14 is loaded onto the work table 26 before the rail 18 is loaded onto the work table 26, as shown in Figure 5. Alternatively, the rail 18 is loaded onto the work table 26 before the solar module 14.

[0068] With continued reference to Figure 5, loading includes loading a plurality of solar modules 14 onto the work table 26. Specifically, the method includes loading a first solar module 14 on the mobile assembly system 24 and loading a second solar module 14 on the mobile assembly system 24 adjacent the solar module 14, which are both subsequently adhered to at least one rail 18, as set forth further below. As set forth above, any number of solar modules 14, i.e., one or more, can be loaded onto the work table 26 without departing from the nature of the present invention.

[0069] Whether one or more solar modules 14 are loaded onto the work table 26 at once, the solar module 14 can be loaded onto the work table 26 manually. In other words, the solar module 14 can be loaded onto the work table 26 by hand. Alternatively, loading the solar modules 14 onto the work table 26 is automated with the use of the robot 46. For example, the solar module 14 can be automatically loaded onto the work table 26 with the lifting mechanism (not shown) of the robot 46, as set forth above.

[0070] Whether the solar modules 14 are loaded onto the work table 26 manually or automatically, when a plurality of solar modules 14 are loaded onto the work table 26, the method includes automatically spacing each of the plurality of solar modules 14 the predetermined distance D apart from each other prior to moving the solar modules 14 and/or the rails 18 to adhere the solar modules 14 and the rail 18 together. For example, the solar modules 14 can be operatively engaged with jigs (not shown) and/or spacers (not shown) of the work table 26, as set forth above, to space the solar modules 14 apart by the predetermined distance D. Alternatively, the solar modules 14 can be spaced from each other by the predetermined distance D by moving the conveyor system 36 and the main conveyor 30 relative to each other, as set forth above, to move adjacent solar panels 14 relative to each other to be spaced by the predetermined distance D.

[0071] With reference to Figures 6-9, the method includes adhering at least one rail 18 to at least one solar module 14 on the assembly system 22, such as the mobile assembly system 24. Typically, the method includes connecting the rail 18 to the solar module 14 only with adhesive 20 and free of any type of mechanical hardware or fasteners. In other words, the rail 18 and solar module 14 are connected to each other with only adhesive 20 to form a unit that is held together free of mechanical hardware.

[0072] Adhering the rail 18 to the solar module 14 includes applying adhesive 20, e.g., silicone

21, on at least one of the solar module 14 and/or the rail 18 and moving the solar module 14 and the rail 18 toward each other with the adhesive 20 disposed therebetween. For example, as shown in Figures 6-7B, the adhesive 20 is applied to the solar modules 14 on the work table 26 and, as shown in Figure 8, the rails 18 are moved toward the solar modules 14 and the adhesive 20 to contact the rails 18 with the adhesive 20.

[0073] As set forth above, any number of rails 18 can be adhered to any number of solar modules 14. In the embodiment shown in Figures 6-8, two rails 18 are adhered to five solar modules 14. Specifically, the two rails 18 are adhered to each of the five solar modules 14. However, for example, in such an embodiment it should be appreciated that the two rails 18 can be selectively adhered to any number of the five solar modules 14 such that, when adhered, two rails 18 and the five solar modules 14 are attached together as a unit.

[0074] With reference to Figures 6-7B, the method includes automatically applying adhesive 20, e.g., silicone 21, to the solar modules 14 and/or the rail 18 with the assembly system 22, such as the mobile assembly system 24, e.g., the adhesive 20 is applied with use of the robot 46 through the nozzle 56. For example, the robot 46 operates to apply the adhesive 20, e.g., silicone 21, to the solar modules 14 without human direction during the application of the adhesive 20 to the solar modules 14. The method includes automatically moving the robot 46 along at least one of the solar module 14 and the rail 18 while dispensing adhesive 20, e.g., silicone 21, onto at least one of the module 16 and the rail 18. The automatic application of adhesive 20 reduces the amount of handling of the solar modules 14 by workers thereby minimizing the risk of damage to the solar modules 14. As set forth above, the robot 46 is programmed and the program instructs the robot 46 to dispense the adhesive 20 at specified locations along the solar module 14.

[0075] With reference to Figure 6, a plurality of solar modules 14 can be loaded onto the work table 26. Once each of the plurality of solar modules 14 are arranged on the work table 26, the robot 46 automatically moves along the plurality of solar modules 14 and applies adhesive 20, e.g., silicone 21, to the solar modules 14. Specifically, the method applying adhesive 20 to the plurality of solar modules 14 without applying adhesive 20 along the predetermined distance D between solar modules 14. More specifically, the method includes applying a spacer 23 to edges of the plurality of solar modules 14 and applying a line of silicone 21 across the solar module 14 from one spacer 23 to another spacer 23, typically without applying silicon 21 to the spacer 23. For example, the robot 46 can be programmed to refrain from dispensing adhesive 20, e.g., silicone 21, when the nozzle 56 is disposed along the predetermined distance D between the solar modules 14 and when the nozzle 56 is along the spacer 23. In other words, the method includes automatically moving the robot 46 along the plurality of solar modules 14 while dispensing adhesive 20, e.g., silicone 21, from the nozzle 56 only when the nozzle 56 is disposed over exposed solar modules 14.

[0076] Figures 7 A and 7B show an alternative to Figure 6. Specifically, as shown in Figure 7 A, a single solar module 14 is loaded onto the work table 26 and, before another solar module 14 is loaded onto the table, the robot 46 automatically moves along the single solar module 14 and applies adhesive 20, e.g., silicone 21, to the single solar module 14. More specifically, spacers 23 are applied to edges of the solar module 14 before or after the solar module 14 is loaded onto the work table 26. The spacers 23 are typically automatically applied to the solar module 14. After the spacers 23 are applied, the method includes applying a line of silicone 21 across the solar module 14 from one piece of table 23 to another spacer 23, typically without applying silicone 21 to the spacer 23, as shown in Figure 7A. As set forth above, the robot 46 can be programmed to refrain from dispensing adhesive 20, e.g., silicone 21, when the nozzle 56 is disposed along the predetermined distance D between the solar modules 14 and when the nozzle 56 is along the spacer 23. After the silicone 21 is applied to the solar module 14, the conveyor system 36 and/or the main conveyor 30 move the single solar module 14 and a second solar module 14 is loaded onto the work table 26, as shown in Figure 7B. The steps above for applying adhesive, i.e., silicone 21 and spacer 23, are repeated for the second solar module 14. These steps are then repeated for each additional solar module 14 loaded onto the work table 26.

[0077] Applying adhesive 20 to the plurality of solar modules 14 typically includes applying a continuous line of adhesive 20, e.g., silicone 21, across each solar module 14 for each rail 18. In other words, the continuous line of adhesive 20 extends uninterrupted from one end to another with each rail 18 in contact with a single line of adhesive 20, as shown in Figures 8 and 9. The single line of adhesive 20, e.g., silicone 21, can extend between edges of the solar module 14 or, as shown in Figures 8 and 9, can extend from one spacer 23 to another spacer 23. The adhesive 20 can alternatively be intermittently applied to the solar module 14 in discontinuous segments, i.e., with breaks between each segment

[0078] With reference to Figure 8, as set forth above, the method includes moving the solar module 14 and/or the rail 18 with the assembly system 22, such as the mobile assembly system 24, to adhere the solar module 14 to the rail 18. For example, the method includes moving the rail 18 toward the solar modules 14 and/or moving the solar modules 14 toward the rail 18 until the adhesive 20 is in contact with the solar modules 14 and the rail 18 to adhere the rail 18 to the solar modules 14. In Figure 8, the adhesive 20 has already been applied to the plurality of solar modules 14 and, with the work table 26 and solar modules 14 remaining stationary, the robot 46 moves the rails 18 toward the solar modules 14 and the adhesive 20 to contact the rails 18 with the adhesive 20. [0079] After assembly, the solar module assemblies 16 are moved to the drying table 82, as shown in Figure 7A and 7B, so that the adhesive 20 can at least partially cure before further movement. Specifically, the method typically includes activating the belt 32 of the work table 26 to move the solar module assembly 16 along the axis A and onto the drying table 82.

[0080] The method includes moving the solar module assembly 16, i.e., the solar modules 14 and the rail 18, from the drying table 82 to a holding unit 86. The holding unit 86 can be, for example, a pallet as shown in Figures 7A, 7B, and 9, on which several solar module assemblies 16 are stacked. The solar module assembly 16 can be moved from the drying table 82 to the holding unit 86 automatically, e.g., with the robot 46, or manually. Typically spacers 88, such as pieces of foam as shown in Figures 7A, 7B, and 9, are spaced between the solar module assemblies 16.

[0081] As set forth above, assembly system 22 can be further defined as a mobile assembly system 24 and the method includes assembling the components of the solar module assembly 16, i.e., the solar module 14, the rail 18, and the adhesive 20, adjacent the solar module installation site 10. Specifically, the method includes transporting the mobile assembly system 24 to be adjacent the solar module installation site 10.

[0082] As shown in Figure 1, for example, transporting the mobile assembly system 24 can be accomplished by hauling the mobile assembly system 24 to the solar module installation site 10 on the trailer 70. In such an embodiment, the steps described above, including loading at least one of the solar module 14 and the rail 18 onto the mobile assembly system 24 and adhering the rail 18 to the solar module 14, are performed on the trailer 70.

[0083] During transportation on the trailer 70, the method typically includes stowing the stowable platforms 34 in a stowed position to reduce the size of the mobile assembly system 24 during transportation. When at the solar module installation site 10, the method includes extending the stowable platforms 34 from the stowed position, shown in Figure 3, to the extended position, shown in Figure 4, for supporting the solar module 14 and/or the rail 18. When the lateral stowable platform 42 is in the extended position, rails 18 are loaded on the lateral stowable platform 42, as shown in Figure 5. The method also includes placing solar modules 14, e.g., in a stack, adjacent the work table 26 for being loaded onto the trailer 70.

[0084] During transportation on the trailer 70, the drying table 82 is typically collapsed and not properly aligned along the axis A. The method includes extending the drying table 82 and moving the drying table 82 to be adjacent the work table 26 along the axis A for receipt of newly assembled solar module assemblies 16.

[0085] As set forth above, in the alternative to the trailer 70, the portable enclosure 68 can be further defined as the temporary enclosure 76, as shown in Figure 2. In such an embodiment, the method includes erecting the temporary enclosure 76 adjacent the solar module installation site 10 and extending the drying table 82 and moving the drying table 82 to be adjacent the work table 26 along the axis A for receipt of newly assembled solar module assemblies 16. In the embodiment where the mobile assembly system 24 includes the temporary enclosure 76, the mobile assembly system 24 can be transported to the solar module installation site 10 in a trailer 70 similar to that shown in Figure 1. In such an embodiment, the method includes unloading the mobile assembly system 24 from the trailer 70 and positioning the mobile assembly system 24 adjacent the solar module installation site 10.

[0086] When performed in the temporary enclosure 76, the method includes moving the stowable platforms 34 from the stowed position, shown in Figure 3, to the extended position, shown in Figure 4. When the lateral stowable platform 42 is in the extended position, rails 18 are loaded on the lateral stowable platform 42, as shown in Figure 5. The method also includes placing solar modules 14, e.g., in a stack, adjacent the work table 26 for being loaded onto the trailer 70.

[0087] The method includes moving the solar module assembly 16, i.e., the solar module 14 and the rail 18, from the mobile assembly system 24 adjacent the solar module installation site 10 to the racking system 12 of the solar module installation site 10 for assembly with the racking system 12. Specifically, the method includes moving the module 16 and the rail 18 from the mobile assembly system 24 to a holding unit 86 for holding until the adhesive 20, e.g., silicone 21, is at least partially cured. Typically, after the adhesive 20, e.g., silicone 21, is completely cured, the holding unit 86 is moved to the solar module installation site 10. For example, the holding unit 86 and plurality of solar module assemblies 16 can be moved to the solar module installation site 10 with a fork lift (not shown), hand truck (not shown), etc. Alternatively, solar module assemblies 16 can be moved from the mobile assembly system 24 to the solar module installation site 10 by hand, i.e., carried by one or more people. However, it should be appreciated that the holding unit 86 and plurality of solar module assemblies 16 can be transported to the solar module installation site 10 in any suitable fashion without departing from the nature of the present invention.

[0088] In the embodiment shown in Figure IB with the one or more sides 73 that fold down, the method includes moving the mobile assembly system 24 along the racking system 12 while assembling solar module assemblies 16. Specifically, the method can include lowering the one or more sides 73 from the raised position to the lowered position. The method can further include producing solar module assemblies 16 at various positions along the racking system 12.

In other words, the method includes producing a desired number of solar module assemblies 16 on the mobile assembly system 24 at a first location along the racking system 12 and subsequently moving the mobile assembly system 24 to a second location and producing a desired number of solar module assemblies 16 at the second location. Likewise, the mobile assembly system 24 can be moved to any number of locations along the racking system 12. Such a method reduces the transportation distance from the mobile assembly system 24 to the area of the racking system 12 on which each solar module assembly 16 is to be mounted.

[0089] Once transported to the solar module installation site 10, the method includes engaging the rail 18 with the racking system 12 to support the module 14 on the racking system 12. Specifically, the method includes lifting the solar modules 14 and rail 18, i.e., the solar module assembly 16, onto the racking system 12 with a lifting device after the rail 18 is adhered to the solar modules 14. With reference to Figure 10, the lifting device can be a crane 90 and/ora pulley system 92. It should be appreciated that the lifting device can be any type of suitable device without departing from the nature of the present invention. Alternatively, the solar module assembly 16 can be manually lifted onto the racking system 12.

[0090] As shown in Figure 10, the racking system 12 typically includes beams 96 that support the solar module assembly 16. Typically, the rail 18 is mechanically fastened to the beams 96. A shoe 98 can be hung from the from the beams 96 to support the solar module assembly 16 in a proper position relative the beams 96 such that the solar module assembly 16 can be fastened to the beams 96 in the proper position.

[0091] Specifically, the shoe 98 includes a body 100 that hangs from the beams 96 and is slideable along the beams 96. The shoe 98 also includes a ledge 102 that is rotatable relative to the body 100. The ledge 102 is placed in an upright position relative to the body 100, as shown in Figure 10. A solar module assembly 16 is then rested on the ledge 102 and the beams 96 and the solar module assembly 16 is fastened to the beams 96. The ledge 102 is then moved to a lowered position (not shown) by rotating the ledge 102 toward the ground in Figure 10. When in the lowered position, the shoe 98 is free from the solar module assembly 16 is free to slide along the beams to another position to fasten another solar module assembly 16 to the beams 96.

[0092] The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.