Rosendin Electric contracted with ULC Technologies to design robots for solar module movement and installation.
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Rosendin Electric tested solar module installation with robots it contracted ULC to build. Source: ULC Technologies
Construction of photovoltaic cells requires heavy lifting, precise assembly, and repetitive placement at scale, making it a good use case for robotics. ULC Technologies LLC last week said Rosendin Electric Inc. has contracted it to design and develop a robotic system for solar module installation.
ULC said its systems have already undertaken field trials on real-world solar construction sites. They work with skilled trade workers to accelerate construction timeframes, increase worker safety, and support the expansion of renewable energy production, claimed the Hauppauge, N.Y.-based company.
“The solution we designed and developed consists of three separate autonomous systems, a Panel Setting Robot and two Panel Carrier Robots, working collaboratively with human operators to install solar PV panels at mid- to large-scale solar facilities,” explained Ali Asmari, director of research and development project management at ULC Technologies.
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ULC designs rugged systems for fast rollout
“The Panel Setting Robot is a construction-grade tracked robotic platform with an integrated robotic arm to perform semi-autonomous installation of solar panels in collaboration with human operators,” Asmari said. “Once the robot positions the panel, field operators can guide it into position and complete the installation with fastening hardware and electrical connections.”
The two Panel Carrier Robots carry pallets of solar panels between the loading area and the Panel Setting Robot’s installation location. This ensures a continuous feed of panels and eliminating downtime.
The robots were designed to withstand exposure to high temperatures while navigating a range of construction site terrain including deep mud, uneven surfaces, and more. ULC said this upfront work enabled it to rapidly move from the conceptualization phase of the project to field trials in just 18 months.
Founded in 2001, ULC Technologies designs, develops, and deploys robots, artificial intelligence processes, and inspection systems for the energy, utility, renewables, and industrial sectors. The company said its technologies help companies cause less disruption to the public, reduce greenhouse gas emissions, improve worker safety, and minimize costs.
ULC has developed multiple robots to carry and install photovoltaic modules. Source: ULC Technologies
Rosendin runs field tests of solar installation robots
Traditional installation methods require extensive manual labor, noted ULC Technologies. Large solar farms can have up to 1 million panels that need to be installed and, with each panel weighing 80 to 100 lb. (36.2 to 45.3 kg), this is strenuous work.
In addition, the remote nature of solar sites makes it challenging for contractors to find enough skilled labor to meet the demand, said the company.
Established in 1919, Rosendin is employee-owned and one of the largest electrical contractors in the U.S., employing over 8,000 people, with $3 billion in revenue. The San Jose, Calif.-based company said its customers “lead some of the most complex construction projects in history and rely on us for our knowledge, our ability to scale, and our dedication to quality.”
The companies extensively tested ULC’s robots at utility-scale solar construction sites, resulting in a robotic system capable of production rates of under one minute per panel. In a 10-hour shift, ULC estimated that its robots and a two-person crew could install 600 panels.
“Working with Rosendin’s use case, we designed and developed a solution that will revolutionize solar panel installation at large-scale sites,” said Steve Green, vice president of business development for location and inspection at SPX Technologies, the parent company of ULC. “Extensive field testing proved how the robots relieve heavy lifting from workers, supplementing their expertise with a supportive tool that helps protect workers while allowing them to be more productive.”
Charlotte, N.C.-based SPX Technologies said it is a leader in the heating, ventilation, and air conditioning (HVAC) and the detection and measurement markets. The company, which acquired ULC in 2020, has about 3,100 employees in 15 countries.
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