Comau labored with EDP to check this heavy-duty robotic for photo voltaic panel set up. Supply: Comau
Whereas insurance policies round different vitality sources could shift, total vitality demand remains to be resulting in rising curiosity in automation. Final 12 months, Comau S.p.A. partnered with international vitality 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 numerous 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 vitality 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 international scale led EDP to hunt a companion that additionally has a world presence, and Comau is in 12 international locations, mentioned Clement.
“It wanted somebody near clients who can join rapidly within the subject,” she instructed The Robotic Report. “EDP instructed us that it checked out different options, however Comau’s expertise, measurement, flexibility, service, and monetary energy made us their first alternative.”
Comau, EDP progress from testing to scaling
In 2023, Comau unveiled its Hyperflex cellular manufacturing facility, which makes use of robots, lifting gear, 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% quicker, and save a median of 35% per panel, claimed Comau. It might additionally accommodate totally different trackers and panels to fulfill the various wants of vitality suppliers, the Turin, Italy-based firm mentioned.
“On this joint industrial innovation undertaking, EDP could be very revolutionary and has seen that they can not roll out programs in sluggish movement,” Clement mentioned. “Our answer was a ‘manufacturing facility 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 undertaking in Spain demonstrated Comau’s automated meeting station and a rover to move and place photovoltaic constructions. Over the subsequent month, set up took half the time of purely handbook processes, mentioned Clement.
Comau developed with EDP a “manufacturing facility in a truck” together with robotic arms and cellular robots. Supply: Comau
Hyperflex posed design challenges
For its transportable manufacturing facility to work, Comau needed to account for diverse circumstances and area limitations. A robotic arm with a 300 kg (661.3 lb.) capability picks up the photo voltaic panel and makes certain 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 vitality and going outside. It’s not like a warehouse flooring,” added Clement. “We’ve one other undertaking in shipbuilding with out of doors welding. Our robots can function in harsh circumstances. For instance, Spain has had numerous rain lately, 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 carried out numerous 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 facility 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 every thing to be on there.”
EDP appears forward to fewer operators
Whereas Hyperflex requires fewer operators than typical photo voltaic panel set up, the operators nonetheless want some coaching. As a part of Comau’s upkeep and repair package deal, the firm trains operators information the tractor system so the rover can assemble the panels.
“We additionally supply coaching and enterprise modeling for the installers to grasp the ROI [return on investment],” mentioned Clement. “The first purpose EDP needed automation is to not have fewer individuals now however as a result of it sees in 5 to 10 years even fewer obtainable. Jobs with heavy lifting pose ergonomic constraints, and never lots of people will need to do them.”
Along with workforce challenges, robots supply tangible advantages in improved security and effectivity for current crews, she mentioned.
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Discipline robots simply beginning to notice their potential
Discipline robots typically depend on rental or robotics-as-a-service (RaaS) fashions as a result of that’s what number of firms handle their gear.
“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 group 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 develop into extra aggressive, not from different robotics suppliers, however from photo voltaic engineering companies.
“There’s additionally curiosity from vitality suppliers,” Clement famous. She mentioned that Comau expects photovoltaic panel set up will expertise a ten% compound annual development charge (CAGR) between 2022 and 2030.
Might a rugged cellular manipulator be helpful for different industries, resembling development, shipbuilding, and infrastructure/utilities?
“We’ve some tasks happening with each Hyperflex and MR4Weld, in addition to with the College of Torino, however it’s nonetheless early days,” replied Clement. “We’re considering of work with totally different supplies onsite and offering security and suppleness for operators. Our answer for scalable, movable, and repeatable functions outside is all a part of our worth proposition shifting ahead.”
Editor’s word: Mike Oitzman contributed to this text.
