Comau labored with EDP to check this heavy-duty robotic for photo voltaic panel set up. Supply: Comau
Whereas insurance policies round various power sources might shift, general power demand remains to be resulting in rising curiosity in automation. Final yr, Comau S.p.A. partnered with world power firm EDP SA to advance automation for photo voltaic panel set up.
“Our relationship with EDP goes again a number of years,” famous Nicole Clement, chief business-unit chief for superior automation options at Comau. “They approached us with their ache level, which is that they’ve to put in loads of photo voltaic panel fields within the close to future. The set up frequency has to triple within the subsequent three years to fulfill European expectations, and EDP wanted an answer that was very versatile.”
Lisbon, Portugal-based EDP claimed that 98% of its power comes from renewable sources, and it has put in photo voltaic capability of greater than 4GW. The firm has pledged to be “100% inexperienced” by 2030, and it has greater than 13,000 staff worldwide.
That world scale led EDP to hunt a companion that additionally has a global presence, and Comau is in 12 nations, stated Clement.
“It wanted somebody near prospects who can join rapidly within the subject,” she advised The Robotic Report. “EDP advised us that it checked out different options, however Comau’s expertise, dimension, flexibility, service, and monetary energy made us their first alternative.”
Comau, EDP progress from testing to scaling
In 2023, Comau unveiled its Hyperflex cell manufacturing unit, which makes use of robots, lifting tools, and different proprietary applied sciences developed in-house. The system is designed to assemble photo voltaic blades, which may measure 48 sq. m (516.6 sq. ft.), immediately within the subject.
Hyperflex can enhance charge of modules put in per hour by as much as 30%, convey new vegetation to market as much as 25% sooner, and save a mean of 35% per panel, claimed Comau. It could possibly additionally accommodate totally different trackers and panels to fulfill the various wants of power suppliers, the Turin, Italy-based firm stated.
“On this joint industrial innovation venture, EDP could be very revolutionary and has seen that they can’t roll out methods in gradual movement,” Clement stated. “Our answer was a ‘manufacturing unit in a truck’ that was adaptable and may get to market rapidly.”
The businesses went from a pilot in 2022 to a large-scale check in October 2024. The AutoPV venture in Spain demonstrated Comau’s computerized meeting station and a rover to move and place photovoltaic buildings. Over the following month, set up took half the time of purely handbook processes, stated Clement.
Comau developed with EDP a “manufacturing unit in a truck” together with robotic arms and cell robots. Supply: Comau
Hyperflex posed design challenges
For its transportable manufacturing unit to work, Comau needed to account for various situations and area limitations. A robotic arm with a 300 kg (661.3 lb.) capability picks up the photo voltaic panel and makes positive it’s mounted on a tracker system. Two operators then safe the panel, after which the rover strikes it into the sphere.
“Comau could be very dedicated to renewable power and going open air. It’s not like a warehouse flooring,” added Clement. “We have now one other venture in shipbuilding with out of doors welding. Our robots can function in harsh situations. For instance, Spain has had loads of rain not too long ago, which is totally different than our operations in Australia. We needed to modify our sensors to beat rain, mud, sand, and dust. We’ve additionally completed loads of work on the floor of the robotic and grippers.”
The autonomous rover wanted a small turning radius and needed to soak up shocks touring over uneven floor.
“From an ergonomic perspective, we had to consider bringing tractors to work in tight areas,” she recalled. “We needed to overcome logistics challenges and developed a compact tractor with a companion. The manufacturing unit in a field was not what we initially considered, however EDP wanted to extend productiveness. The way in which to a subject may be blocked, so we wanted all the pieces to be on there.”
EDP seems forward to fewer operators
Whereas Hyperflex requires fewer operators than standard photo voltaic panel set up, the operators nonetheless want some coaching. As a part of Comau’s upkeep and repair bundle, the firm trains operators the right way to information the tractor system so the rover can assemble the panels.
“We additionally provide coaching and enterprise modeling for the installers to know the ROI [return on investment],” stated Clement. “The first cause EDP wished automation is to not have fewer folks now however as a result of it sees in 5 to 10 years even fewer out there. Jobs with heavy lifting pose ergonomic constraints, and never lots of people will wish to do them.”
Along with workforce challenges, robots provide tangible advantages in improved security and effectivity for current crews, she stated.
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Area robots simply beginning to understand their potential
Area robots typically depend on rental or robotics-as-a-service (RaaS) fashions as a result of that’s what number of corporations handle their tools.
“We’re nonetheless in discussions in regards to the enterprise mannequin and who’s utilizing this machine,” acknowledged Clement. “Photo voltaic panel installers aren’t essentially capital-equipped, so that they’re trying extra at a rental mannequin.”
“Step one was that EDP needed to endorse Hyperflex to the installer neighborhood and specify it to them,” she added. “We’re discussing a number of choices on how installers will deploy and use it.”
Comau is in discussions with EDP and different organizations to deploy the system in Australia, and it’s trying on the U.S., Europe, and Africa. The corporate is seeing the market change into extra aggressive, not from different robotics suppliers, however from photo voltaic engineering companies.
“There’s additionally curiosity from power suppliers,” Clement famous. She stated that Comau expects photovoltaic panel set up will expertise a ten% compound annual development charge (CAGR) between 2022 and 2030.
May a rugged cell manipulator be helpful for different industries, akin to building, shipbuilding, and infrastructure/utilities?
“We have now some initiatives occurring with each Hyperflex and MR4Weld, in addition to with the College of Torino, nevertheless it’s nonetheless early days,” replied Clement. “We’re considering of the right way to work with totally different supplies onsite and offering security and suppleness for operators. Our answer for scalable, movable, and repeatable functions open air is all a part of our price proposition transferring ahead.”
Editor’s be aware: Mike Oitzman contributed to this text.