IP Library Granted Patent US 10,520,223
Granted Patent B2
US 10,520,223 · App. 15/356,433 · Granted Dec 31, 2019

Robotic heliostat calibration system and method

Inventors: Daniel Fukuba (Palo Alto, CA); Jos Goble (Santa Clara, CA); Salomon Trujillo (Redwood City, CA); Thomas Joseph Currier (Rochester, MN); Wasiq Bokhari (Half Moon Bay, CA)
Assignee: SolarCity Corporation
F24S40/00F24S30/452F24S50/00G01D18/004G01D18/008G05D1/0278H02S50/00H02S50/15F24S2020/16F24S2030/134F24S2050/25Y02E10/47Y10S901/01Y10S901/14
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 10,520,223
App. No.
15/356,433
Granted
Dec 31, 2019
Kind
B2
Abstract

A robotic controller for autonomous calibration and inspection of two or more solar surfaces wherein the robotic controller includes a drive system to position itself near a solar surface such that onboard sensors may be utilized to gather information about the solar surface. An onboard communication unit relays information to a central processing network, this processor combines new information with stored historical data to calibrate a solar surface and/or to determine its instantaneous health.

Claims (39)

1. A robot, comprising:

a flight system configured to maneuver the robot above ground-based obstacles and characterize an unstructured environment suitable for supporting an array of photovoltaic modules, the robot being configured to:

map terrain in the unstructured environment with a 3-D vision system;

compute safe and unsafe areas on the terrain in the unstructured environment;

identify known obstacles within the terrain in the unstructured environment, and

determine a current position, orientation and non-perpendicularity of one or more solar surfaces distributed across the terrain; and

compare the current position, orientation and non-perpendicularity of the one or more solar surfaces to a historical position, orientation and non-perpendicularity of the one or more solar surfaces to determine one or more of field installation tolerances, manufacturing errors and ground settling.

2. The robot of claim 1 , wherein the known obstacles include one or more of the following: a solar surface; a supporting structure system for the solar surface; and a supporting foundation for the supporting structure system.

3. The robot of claim 1 , wherein computing safe and unsafe areas comprises identifying optimal drive paths that lead to desired destinations in the unstructured environment.

4. The robot of claim 1 , further comprising:

an onboard position location system capable of determining the location of the robot in global coordinates.

5. The robot of claim 4 , wherein the onboard position location system comprises a triangulation system able to communicate with a multiplicity of devices calibrated in a global reference frame.

6. The robot of claim 4 , wherein the onboard position location system is a GPS device.

7. The robot of claim 1 , further comprising:

a calibration unit configured to determine calibration information for adjustable solar surfaces distributed across the unstructured environment.

8. The robot of claim 7 , wherein the calibration unit includes a perpendicularity unit to determine a perpendicularity measure of support structures supporting the adjustable solar surfaces based on orientation of the robot and orientation of the support structure relative to the orientation of the robot, wherein the status information identified for the adjustable surface comprises the orientation of the support structure relative to the robot.

9. The robot of claim 8 , wherein the perpendicularity unit comprises a software program.

10. The robot of claim 8 , wherein computing safe and unsafe areas on the terrain in the unstructured environment comprises determining safe zones where, given a known field configuration, a solar surface would not be able to shade an adjacent solar surface.

11. A method for mapping terrain in an unstructured environment suitable for supporting a field of solar surfaces, the method comprising:

maneuvering a robot having a flight control system and a 3-D vision system above ground-based obstacles to characterize the unstructured environment;

mapping terrain in the unstructured environment using the 3-D vision system;

computing safe and unsafe areas on the terrain in the unstructured environment;

identifying known obstacles within the terrain in the unstructured environment; and

determining a current position, orientation and non-perpendicularity of one or more solar surfaces distributed across the terrain; and

comparing the current position, orientation and non-perpendicularity of the one or more solar surfaces to a historical position, orientation and non-perpendicularity of the one or more solar surfaces to determine one or more of field installation tolerances, manufacturing errors and ground settling.

12. The method of claim 11 , wherein determining the current position, orientation and non-perpendicularity of the one or more solar surfaces comprises using a position location system on-board the robot to determine the current position, orientation and non-perpendicularity of the solar surfaces.

13. The method of claim 11 , further comprising determining an alignment value for one or more of the solar surfaces, the alignment value describing reorientation of the one or more solar surfaces to an optimal solar vector.

14. The method of claim 11 , wherein mapping the terrain comprises mapping a plurality of solar surfaces distributed across the unstructured environment.

15. The method of claim 14 , further comprising adjusting the orientation of one or more of the solar surfaces using the mapped terrain data.

16. A robot, comprising:

a flight system configured to maneuver the robot through the air above ground-based obstacles and characterize an unstructured environment suitable for supporting an array of photovoltaic modules, the robot being configured to:

map terrain in the unstructured environment with a 3-D vision system,

compute safe and unsafe areas on the terrain in the unstructured environment,

identify known obstacles within the terrain in the unstructured environment, and

determine a current position, orientation and non-perpendicularity of one or more solar surfaces distributed across the terrain; and

compare the current position, orientation and non-perpendicularity of the one or more solar surfaces to a historical position, orientation and non-perpendicularity of the one or more solar surfaces to determine one or more of field installation tolerances, manufacturing errors and ground settling; and

a transmitter configured to transmit the safe and unsafe areas as well as the identified obstacles to a receiver external to the robot.

17. The robot of claim 16 , wherein the receiver external to the robot comprises one or more adjustable solar surfaces distributed within the unstructured environment.

18. The robot of claim 17 , wherein the robot further comprises a natural light camera or a distance sensing system.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 6, 2021
From: SOLARCITY CORPORATION
To: TESLA, INC.
Reel/Frame 056172/0062 →
Continuity (6)
Continuation 13868036 · Apr 22, 2013
Continuation 13310520 · Dec 2, 2011
Continuation In Part 13182297 · Jul 13, 2011
Continuation In Part 13118274 · May 27, 2011
Provisional Application 61419685 · Dec 3, 2010
Related Publication 20170067668A1 · Mar 9, 2017