Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated photovoltaic solar film installation device that is capable of applying a layer of protective photovoltaic solar film over a user-specified area in an automated manner, thereby eliminating chances of inconsistent in application.

BACKGROUND OF THE INVENTION

[0002] PV (photovoltaic) solar film converts sunlight directly into electricity, providing a clean and renewable source of energy. This helps reduce reliance on fossil fuels and lowers greenhouse gas emissions, contributing to environmental sustainability. Solar film installations typically have a long lifespan (often 20-25 years or more) with minimal maintenance requirements. This long-term reliability makes it a solid investment for homeowners, businesses, and governments looking to stabilize energy costs over time.

[0003] Installation of solar films often involved manual processes such as cutting and adhering thin-film solar cells directly onto substrate. Achieving precise alignment and uniform adhesion of solar films was challenging, affecting the overall efficiency and durability of installations. With the development of roll-to-roll manufacturing techniques, solar films could be mass-produced in continuous rolls, similar to how newspapers are printed. Early materials used in roll-to-roll manufacturing sometimes had lower efficiency or durability compared to traditional silicon-based solar cells. Modern PV solar film installation techniques include advancements such as adhesive application systems, automated cutting tools, and specialized mounting systems. Although PV solar films typically require less maintenance than traditional panels, ensuring proper installation is crucial to minimizing potential issues such as delamination or reduced efficiency over time.

[0004] US20040082097A1 relates to a thin-film solar cells and method of making. The devices comprise a low-cost, low thermal stability substrate with a semiconductor body deposited thereon by a deposition gas. The deposited body is treated with a conversion gas to provide a microcrystalline silicon body. The deposition gas and the conversion gas are subjected to a pulsed electromagnetic radiation to effectuate deposition and conversion.

[0005] US20070298590A1 discloses methods for depositing a microcrystalline silicon film layer with improved deposition rate and film quality are provided in the present invention. Also, photovoltaic (PV) cell having a microcrystalline silicon film is provided. In one embodiment, the method produces a microcrystalline silicon film on a substrate at a deposition rate greater than about 20 nm per minute, wherein the microcrystalline silicon film has a crystallized volume between about 20 percent to about 80 percent.

[0006] Conventionally, many devices are available in the market that are capable of applying a layer of solar panel over a flat surface. However, the available devices limit in ensuring consistent performance and durability standards across diverse PV film applications remains a challenge, requiring ongoing research and testing.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that needs to be capable of applying a layer of protective photovoltaic solar film over a user-specified area in an automated manner, thereby eliminating the chances of inconsistent in application.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that is capable of applying a layer of protective photovoltaic solar film over a user-specified area in an automated manner, thereby eliminating chances of inconsistent in application.

[0010] Another object of the present invention is to develop a device that is capable of facilitating precise attachment and detachment of roll of a photovoltaic solar film in an automated manner, thereby facilitates seamless application of solar films over specified portions with ease.

[0011] Yet another object of the present invention is to develop a device that is capable of cutting the solar film upon application of the solar film over the specified area, thereby facilities precise application of the solar film over the specified portion of flat surface.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to an automated photovoltaic solar film installation device that is capable of facilitating precise attachment and detachment of roll of a photovoltaic solar film in an automated manner, thereby facilitates seamless application of solar films over specified portions with ease.

[0014] According to an embodiment of the present invention, an automated photovoltaic solar film installation device, comprises of a body developed to be positioned on a ground surface, an artificial intelligence-based imaging unit mounted on the body to generate 3-dimensional map of surrounding, a touch interactive display panel arranged on the body for displaying captured images, multiple motorized omnidirectional wheels arranged underneath body for moving body, an inverted L-shaped telescopically operated rod attached with the body to extend/ retract for positioning a cuboidal member in contact with the user-specified portion, a motorized roller configured with member via a L-shaped supporting bar, a pair of telescopic clippers arranged on the body for gripping end-portions of the film, a pair of robotic grippers installed on the body to grip a roll of the photovoltaic solar film from a chamber configured on the body and attach over a pair of clutches configured on edge of the supporting member. plurality of grooves are fabricated on each of the wheels and arranged with an extendable pole, each integrated with a suction cup that are actuated by the microcontroller to extend and acquire a grip over the surface while climbing vertical surfaces, a motorized ball and socket configured in between the body and rod for providing multi-axis rotational motion to the rod, plurality of grooves fabricated on each of the wheels and arranged with an extendable pole, a motorized slider configured in between base of the body and wheels for translating the wheels along the slider, a motorized cutting unit installed on the body via a link rod for cutting the film.

[0015] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of an automated photovoltaic solar film installation device.

DETAILED DESCRIPTION OF THE INVENTION

[0017] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0018] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0019] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0020] The present invention relates to an automated photovoltaic solar film installation device that is capable of cutting solar film upon application of the solar film over the specified area, thereby facilitating precise application of the solar film over the specified portion of flat surface.

[0021] Referring to Figure 1, an isometric view of an automated photovoltaic solar film installation device is illustrated, comprising a body 101 developed to be positioned on a ground surface, an artificial intelligence-based imaging unit 102 mounted on the body 101, a touch interactive display panel 103 arranged on the body 101, multiple motorized omnidirectional wheels 104 arranged underneath body 101, an inverted L-shaped telescopically operated rod 105 attached with the body 101 to extend/ retract for positioning a cuboidal member 106 in contact with the user-specified portion.

[0022] Figure 1 further illustrates a motorized roller 107 configured with member via a L-shaped supporting bar 108, a pair of telescopic clippers 109 arranged on the body 101, a pair of robotic grippers 110 installed on the body 101, a chamber 111 configured on the body 101, wheels 104 integrated with a suction cup 112, and a motorized cutting unit 114 installed on the body 101 via a link 113.

[0023] The device disclosed herein comprises of a body 101 developed to be positioned on a ground surface. The body 101 is constructed from sturdy and robust material which includes, but is not limited to stainless steel, aluminum, and high-grade engineered plastics like polycarbonate or reinforced nylon. These materials offer strength and rigidity to the body 101 making it resistant to mechanical stress and pressure. The surface of the body 101 is coated with material like Teflon or other low-friction coatings to improve wear resistance and reduce friction.

[0024] Vibration-dampening materials are integrated into the body 101 to minimize noise and shaking of the body 101 during operations, thereby enhancing user comfort and machine longevity. An artificial intelligence-based imaging unit 102 is configured on the body 101 for capturing and processing multiple images of the surroundings. The imaging unit 102 consists of multiple high-resolution cameras for capturing multiple images from different angles and perspectives and providing comprehensive coverage in vicinity to the body 101. The imaging unit 102 captures multiple images of the surroundings from various angles simultaneously. Before analysis, the captured image goes through pre-processing steps to enhance image quality which includes adjusting brightness and contrast and removing any distortions. The processed images are then sent to the processor linked with the imaging unit 102.

[0025] The processor processes the captured images of the surroundings by means of an artificial intelligence protocol encrypted within the microcontroller for generating a 3-dimensional map of the surrounding. The microcontroller uses artificial intelligence protocol like Convolution Neural Network (CNN) for detecting distinctive patterns or characteristics in the image. Once potential features are detected, the microcontroller localizes them by identifying their positions within the image. This involves finding their coordinates or regions of interest where these features are located. The microcontroller also uses techniques like object recognition, edge detection, and shape analysis to accurately generate a 3-dimensional map of the surroundings.

[0026] The generated 3D map is then displayed on a touch interactive display panel 103 mounted on the body 101. The touch interactive display panel 103 as mentioned herein is typically an LCD (Liquid Crystal Display) screen that presents output in a visible form. The screen is equipped with touch-sensitive technology, allowing the user to interact directly with the display using their fingers. A touch controller IC (Integrated Circuit) is responsible for processing the analog signals generated when the user selects a portion of flat surface, where the user desires to install photovoltaic solar films. The touch controller is typically connected to the microcontroller through various interfaces which may include but are not limited to SPI (Serial Peripheral Interface) or I2C (Inter-Integrated Circuit).

[0027] Based on selected portion, an inbuilt microcontroller associated with the device actuates multiple motorized omnidirectional wheels 104 arranged underneath the body 101 for maneuvering the body 101 in proximity to the user-selected portion of surface. The wheels 104 herein are a circular object that revolves on an axle to enable the body 101 to move easily over the ground surface. The hub motor is an electric motor that is integrated into the hub
of the wheels 104. The hub motor is comprising of a series of permanent magnets and electromagnetic coils. When the motor is activated, a magnetic field is set up
in the coil and when the magnetic field of the coil interacts with the magnetic
field of the permanent magnets, a magnetic torque is generated causing the
stator of the motor to turn and that provides the rotation motion to the wheels 104
for maneuvering the body 101.

[0028] Plurality of grooves are fabricated on each of the wheels 104 and arranged with an extendable pole, each integrated with a suction cup 112 that are actuated by the microcontroller to extend and acquire a grip over the surface while climbing vertical surfaces. The suction cup 112 is used herein are consist of a circular disc which are made of a flexible material mostly rubber with a rounded edge. When the center of the suction cup 112 is pressed against the surface. The volume of the space between the suction cup 112 and the surface is reduced, that creates a negative pressure by creating a partial vacuum inside the cup 112.

[0029] The pressure difference between the atmosphere on the outside of the cup 112 and the low-pressure cavity on the inside of the cup 112 keeps the cup 112 adhered to the surface. A motorized slider is configured in between base of the body 101 and wheels 104 for translating the wheels 104 along the slider and adjusting gap between the sliders in view of facilitating the body 101 to climb stairs and uneven surfaces with ease. The slider consists of a motor, and a rail unit integrated with ball bearings to allow smooth linear movement. The microcontroller actuates the slider to rotate, and the rotational motion of the motor is converted into linear motion through a pair of belts and linkages. This linear motion provides a stable track and allows the body 101 to maneuver over uneven terrain with ease.

[0030] After successful placement of the body 101 in proximity to the user-specified portion, the microcontroller actuates an inverted L-shaped hydraulically operated rod 105 attached with the body 101 and configured with a cuboidal member 106 in contact with the user-selected portion of surface. The rod 105 mentioned above basically consist of multiple cylindrical sections with one section sliding inside the other. The sections are basically made of materials that may include but are not limited to metals and lightweight alloys. The rod 105 as mentioned herein are powered by a pneumatic unit that utilizes compressed air to extend and retract the rod 105.

[0031] The air cylinder of the pneumatic unit contains a piston that moves back and forth within the cylinder. The cylinder is connected to one end of the rod 105. The piston is attached to the telescopically operated rod 105s and its movement is controlled by the flow of compressed air. To extend the rod 105 the piston activates the air valve to allow compressed air to flow into the chamber 111 behind the piston. As the pressure increases in the chamber 111, the piston pushes the rod 105 to the desired length. By controlling the flow of compressed air and the position of the piston, the rod 105 length is adjusted. A motorized ball and socket configured in between the body 101 and the rod 105 that is actuated by the microcontroller for providing multi-axis rotational motion to the inverted rod 105 for facilitating proper installation of the film over the user-specified portion of surface.

[0032] The motorized ball and socket joint consists of a ball-shaped element that fits into a socket, which provides rotational freedom in various directions. The ball is connected to a motor, typically a servo motor which provides the controlled movement. The rod 105 is attached to the socket of the motorized ball and socket joint. The microcontroller sends precise instructions to the motor of the motorized ball and socket joint. The motor responds by adjusting the ball and socket joint and rotates the ball in the desired direction, and this motion is transferred to the socket that holds the rod 105. As the ball and socket joint move, it provides the necessary angular movement to the rod 105 for positioning the member in proximity to the user-specified portion.

[0033] A motorized roller 107 is configured with the member via an L-shaped supporting bar 108, and the roller 107 is further wrapped with a photovoltaic solar film. Simultaneously, the microcontroller actuates the roller 107 to unwind for unwrapping the sheet from the roller 107. The roller 107 mentioned above is a mechanical unit designed to rotate on its axis with the help of an integrated electric motor. The cylindrical roller 107 tube serves as a surface for supporting, and unwinding the positioned film. The roller 107 is equipped with an electric motor that provides the rotational power necessary to turn the roller 107. The motor is connected to the roller 107 tube through a drive mechanism, which involves gears, belts to transfer the motor’s rotational force to the roller 107, causing it to rotate, resulting in unwrapping of the film.

[0034] During unwrapping of the film, the microcontroller actuates a pair of telescopic clippers 109 arranged on the body 101 for gripping end-portions of the film, and synchronously extend and affix the film over the surface by applying an optimum amount of force. The clippers 109 have an open side and a curved side, forming a partial circle or a half-moon shape. At the open side of the clippers 109, there is a screw mechanism which includes a threaded screw or spindle and an electric motor. As the motor rotates it causes the screw to move in or out, which in turn adjusts the width of the clippers 109 opening and eventually applies the required force to grip the film.

[0035] The curved side of the clippers 109 that grips the film is lined with non-marring materials like rubber or plastic for securely gripping the film in a secured manner and affix the film over the surface by applying an optimum amount of force. Based on the dimension of the user specified portion, the microcontroller actuates motorized cutting unit 114 comprises of a high-precision cutting tool, typically a cutting blade, installed on a sturdy body 101. The microcontroller connected with the artificial intelligence-based imaging unit 102 controls the operation of the motorized cutting unit 114. An ultrasonic sensor is installed on the member and synced with the imaging unit 102 to detect amount of the photovoltaic solar film present on the roller 107.

[0036] The ultrasonic sensor works by emitting ultrasonic waves and then measuring the time taken by these waves to bounce back after hitting the surface of roll of the solar film. The ultrasonic sensor includes two main parts viz. transmitter, and a receiver. The transmitter sends a short ultrasonic pulse towards the surface of solar film which propagates through the air at the speed of sound and reflects back as an echo to the transmitter as the pulse hits the solar film. The transmitter then detects the reflected eco from the surface of solar film and calculations is performed by the sensor based on the time interval between the sending signal and receiving echo to determine the length of solar film left in the roll.

[0037] The determined data is sent to the microcontroller in a signal form, and in case the detected amount recedes a threshold value, the microcontroller actuates a pair of robotic grippers 110 installed on the body 101 to grip a roll of the photovoltaic solar film from a chamber 111 configured on the body 101, stored with the photovoltaic solar film and attach the roll over a pair of clutches configured on edge of the supporting member. The robotic gripper typically consists of two opposing arms or fingers that mimic a human hand-gripping motion. These arms are usually made of durable materials like metal or plastic to provide strength and flexibility.

[0038] The robotic gripper design incorporates springs to securely hold the roll of solar film and position the roll over the clutches Electric motors and servo motors are used to control the robotic gripper's movement. These motors provide the necessary force and precision to manipulate and position the roll. The motors are connected to the gripper arms through an arrangement of gears and linkages, allowing for controlled positioning of the roll over the supporting member, and thereby facilitating precise attachment and removal of the photovoltaic solar film with ease. an IR (Infrared) counter is embedded within the chamber 111 for counting number of the rolls coiled with photovoltaic films are stored within the chamber 111.

[0039] The IR counter includes an IR emitter and a corresponding receiver placed opposite each other, creating a beam path. Infrared beams are emitted across the body 101 and when the container is empty, the infrared beams travel freely from the emitter to the receiver. However, when a roll coiled with photovoltaic films is present in the beam path, it interrupts the flow of infrared light. The receiver detects the interruption in light caused by the rolls coiled with photovoltaic films and this interruption is translated into an electrical signal. The electrical signal triggers a counting mechanism, decrementing the count each time a roll coiled with photovoltaic films is detected.

[0040] Based on the detected counting, when the counted number of rolls coiled with photovoltaic films recedes a threshold number, the microcontroller sends an alert notification on the computing unit of the user for notifying the user to re-fill the rolls coiled with photovoltaic films in the chamber 111. The microcontroller is wirelessly linked with the computing unit via a communication module which includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module.

[0041] In the device discussed above, there is a battery associated with the device that supplies current to all the components that need electric power to perform their functions and operation in an efficient manner. The battery utilized here is generally a dry battery which is made up of Lithium-ion material that gives the device a long-lasting as well as an efficient DC (Direct Current) current which helps every component to function properly in an efficient manner. The device is battery-operated and does not need any electrical voltage to function. Hence the presence of the battery leads to the portability of the device i.e., the user is able to place as well as move the device from one place to another as per the requirements.

[0042] The present invention works best in the following manner, where the body 101 developed to be positioned on the ground surface, the artificial intelligence-based imaging unit 102 to generate 3-dimensional map of surrounding, the touch interactive display panel 103 for displaying captured images, multiple motorized omnidirectional wheels 104 for moving body 101, the inverted L-shaped telescopically operated rod 105 to extend/ retract for positioning the cuboidal member 106 in contact with the user-specified portion, the motorized roller 107 via the L-shaped supporting bar 108, the pair of telescopic clippers 109 for gripping end-portions of the film, the pair of robotic grippers 110 to grip the roll of the photovoltaic solar film from the chamber 111 and attach over the pair of clutches configured on edge of the supporting member. Further, multiple grooves with the extendable pole, each integrated with the suction cup 112 that are actuated by the microcontroller to extend and acquire the grip over the surface while climbing vertical surfaces, the motorized ball and socket for providing multi-axis rotational motion to the rod 105, the motorized slider for translating the wheels 104 along the slider, the motorized cutting unit 114 via the link 113 and rod 105 for cutting the film.

[0043] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to individuals skilled in the art upon reference to the description of the invention. , Claims:1) An automated photovoltaic solar film installation device, comprising:

i) a body 101 developed to be positioned on a ground surface, wherein said body 101 is installed with an artificial intelligence-based imaging unit 102 for capturing multiple images in vicinity of said body 101 to generate a 3-dimensional map of said surrounding;
ii) a touch interactive display panel 103 arranged on said body 101 for displaying said captured images that are accessed by a user for selecting a portion of flat surface, where said user desires to install photovoltaic solar films, in accordance to which an inbuilt microcontroller actuates multiple motorized omnidirectional wheels 104 arranged underneath said body 101 for moving said body 101 in proximity to said user-selected portion of surface;
iii) an inverted L-shaped hydraulically operated rod 105 attached with said body 101 and configured with a cuboidal member 106, wherein said microcontroller actuates said rod 105 to extend/ retract for positioning said member in contact with said user-specified portion of surface, and a motorized roller 107 is configured with said member via a L-shaped supporting bar 108, rolled with photovoltaic solar film that is to installed over said surface;
iv) a pair of telescopic clippers 109 arranged on said body 101 for gripping end-portions of said film, wherein upon successful gripping said film, said microcontroller actuates said roller 107s to unwind said sheet from said roller 107, and synchronously said microcontroller actuates said clippers 109 to extend and affix said film over said surface by applying an optimum amount of force; and
v) an ultrasonic sensor installed on said member and synced with said imaging unit 102 to detect amount of said photovoltaic solar film present on said roller 107, wherein in case said detected amount recedes a threshold value, said microcontroller actuates a pair of robotic grippers 110 installed on said body 101 to grip a roll of said photovoltaic solar film from a chamber 111 configured on said body 101, stored with said photovoltaic solar film and attach said roll over a pair of clutches configured on edge of said supporting member, thereby facilitating precise attachment and removal of said photovoltaic solar film.

2) The device as claimed in claim 1, wherein plurality of grooves is fabricated on each of said wheels 104 and arranged with an extendable pole, each integrated with a suction cup 112 that are actuated by said microcontroller to extend and acquire a grip over said surface while climbing vertical surfaces.

3) The device as claimed in claim 1, wherein a motorized ball and socket joint configured in between said body 101 and said rod 105 that is actuated by said microcontroller for providing multi-axis rotational motion to said rod 105 for facilitating proper installation of said film over said user-specified portion of surface.

4) The device as claimed in claim 1, wherein a motorized slider is configured in between base of said body 101 and wheels 104 for translating said wheels 104 along said slider and adjusting gap between said sliders in view of facilitating said body 101 to climb stairs and uneven surfaces with ease.

5) The device as claimed in claim 1, wherein based on said dimension of said user specified portion, said microcontroller actuates a motorized cutting unit 114 installed on said body 101 via a link 113 rod 105 for cutting said film according to said detected dimension, thereby facilitating proper and precise installation of said film over said user-specified surface.

6) The device as claimed in claim 1, wherein an IR (Infrared) counter is embedded within said chamber 111 for counting number of said rolls coiled with photovoltaic films are stored within said chamber 111, and as soon as said counted number recedes a threshold number, said microcontroller sends an alert on a computing unit for notifying said user to re-fill said chamber 111.

7) The device as claimed in claim 1, wherein said microcontroller is wirelessly linked with said computing unit via a communication module which includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module.

8) The device as claimed in claim 1, wherein a battery is associated with said device for powering up electrical and electronically operated components associated with said device.