ROBOTIC ASSEMBLY OF PHOTOVOLTAIC ARRAYS CHANDLER CALKINS, GLEN FINDLEY, TYLER GRONER, HOLLY KEIR, GRANT LUCKE, DAVID VOROUS
INTEGRATION
CONCEPT DEVELOPMENT
OBJECTIVE Design, build, and demonstrate a repeatable and automated assembly process for compiling thinfilm cells into larger photovoltaic arrays using two robotic arms.
Preliminary Vacuum End Effector
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BACKGROUND AND VALUE PROPOSITION Current solar array assembly methods are expensive, time-consuming, and error-prone. We aim to develop NASA's more efficient patented process of assembling solar arrays. • Estimated reduction from $450/Watt to $25/Watt • Large scale production • Solar array manufacturing in space
Preliminary Ink End Effector
Preliminary Spray End Effector
Suction cups without bellows prevented flexibility when lifting fragile cells Conductive Ink Pen with holding spring proved too stiff and inconsistent Single spray adhesive applicator produced inconsistent spray Mini I/O and hand I/O couldn't send signals to end effectors Communication through ethernet signals between arms
FINAL DESIGN
• 3-D prints used to hold end effectors on robotic arms: o Vacuum end effector uses hosing and vacuum pump for suction o Atomizing spray nozzle with pump and compressed air o Arduino and stepper motor work together for controlled dispensing of ink • Coding communication between both arms • Voltage stepped down from power supply for required electrical components
RESULTS • Each sub-assembly operates properly • Robotic arms can send signals to end effectors for power • Full surrogate solar array created with minor human interaction
Vacuum End Effector
Ink End Effect
Spray End Effector
Solar Grid
Cell Stack
NASA's Patented 4-Step Process
KEY REQUIREMENTS • Robotic arms completes 4 step process without operator interaction • Robotic arms complete the 4-step process within 35 minutes • Use 2-inch square solar cells to create a 4 x 4 array • Complete the assembly process twice to demonstrate repeatability Sponsors and Mentors: Brian Boogaard, Austin Bumbalough, John Carr, Jacob Friedberg, Senami Hodonu Dr. Michael Maughan, Dr. Matthew Swenson, Nagendra Tanikella
System Process Flowchart
Circuit Diagram
2023 Capstone Project