ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕

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Table of Contents
1. Abstract
2. Introduction
3. Customer Requirements
4. Design Selection and Analysis
4.1. Design Selection
4.2. CAD Designs and Main Components
4.3. Additional Features and Components
5. Material Selection and Analysis
6. Manufacturing Processes
7. Machine Timing and Calculation
8. Cost Analysis
9. Risk Assessment
10. Contribution Table
11. References

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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1. Abstract
This report gives an overview of a new and improved design for a solar panel
robot cleaning system. In regions such as the Middle East, there is an issue of
dust accumulation on solar panels, which reduces the efficiency of the panel
itself and causes energy loss. This turns out to be expensive for companies
using solar panels. Hence to eliminate this issue, robots have been
implemented in this industry to clean the panels, reducing manual labour costs,
and increasing the efficiency of the solar panel. However, these robots do have
issues with their drive system, etc.
The clients had approached the university since their robots were facing issues
in their drive system and hence asked the students to suggest ideas or develop
a new robot for the company. This report contains important information
regarding the new design for a cleaning robot such as costs, materials, and
necessary pictures. The report also elaborates on the CAD designs and the
additional features that can be used for the robot.

2. Introduction
Photovoltaic modules (PV), most referred to as solar panels are energy
systems that transform sunlight into electricity. Nowadays there is a need to
obtain a sustainable method of generating energy due to factors such as global
warming and increasing population. Hence solar panels are the most frequently
used system to store and convert light to electricity. Due to its efficiency and
low costs, it is widely used to generate electricity in homes, buildings,
streetlights, and even electric vehicles. Semiconductors such as silicon are
used to make solar panels more efficient. Solar panels can be altered and
catered to different sizes depending on their usage and preferably what the
customer requires [1].

Setting up solar panels is the easy part, but maintenance is the main problem
to tackle. Various factors come into play while cleaning and maintaining solar
panels. In the Middle Eastern and African regions, layers of sand accumulate
on the solar panels since these usually are operated in the desert region.
Accumulation of sand on the solar panel reduces its efficiency, causing energy
losses and eventually wasting time. Some studies show that the daily losses
caused by the accumulation of dirt are around 6%, and the weekly losses are
around 40% without cleaning. The yearly power loss due to accumulation with
weekly cleaning is around 10% [2].

To tackle the issue of dust and impurity collection on solar panels, cleaning
robots are used on solar panels. Cleaning robots implement two types of
cleaning techniques: a dry-cleaning system and a water-based cleaning
system. A dry-cleaning system would be less efficient compared to a wet
cleaning system since the panels wouldn’t be 100% dust-free. However, in a
wet cleaning system, since water is involved, the dust would be completely
removed. These robots come in different shapes and sizes, catering to different
sizes of solar panels. Each robot would have its own functions and are
completely different from each other.

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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3. Customer Requirements
The customer needed an improved drive mechanism, due to issues such as a
faulty chain, chain slack, and damaged sprockets. However, there was an
option to redesign the entire system and provide a new and better solution.
Now to design and improve the system there is a list of data that needs to be
followed and is mentioned below:

Expected Performance [3]

x Robots must be able to move in two directions.
x The robot should be able to function independently.
x Should be able to return to its charging base.
x Solar panels should not face any damage, while the robot traverses
across it.
x Must only include a dry-cleaning system.
x Should be able to clean the panel in 2 passes (i.e., remove any
contaminant in only 2 passes)

Power [3]
x Can be battery-powered or solar-powered.

Physical Features [3]

x Can only have a maximum weight of 40kg.
x Can be used in any kind of environmental conditions.
x Must be able to fit on solar panels of different dimensions.
x The wheels of the robot must exceed diameters more than 150 mm.

Environmental factors [3]

x Should have the capability to withstand harsh temperatures ranging
from -20ιC to +75ιC.
x Should be operable at wind speeds of 40km/h.
x Should withstand headwinds up to 210km/h without any damage.
x Should be waterproof, corrosive proof, and dustproof.

Safety Functions [3]

x Must include an emergency stop system.
x Should be able to detect any internal faults.

4. Design Selection and analysis

4.1. Design Selection

Each Member of the team began by designing different versions of the
robot. Different drive systems were implemented. The best design was
chosen using a Pugh Matrix containing certain key selection factors. The
design for each team member is given below:

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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¾ Design 1:

Fig 1. Design 1

¾ Design 2:

Fig 2. Design 2

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¾ Design 3:

Fig 3. Design 3

¾ Design 4:

Fig 4. Design 4

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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¾ Design 5:

Fig 5. Design 5
After these designs were put forward, the team had to collectively choose an optimal
design and add additions or make changes to it. A Pugh matrix was used to choose
the design since it listed out various key factors and is quite useful in decision-making.
Table 1: Pugh Matrix for design selection
WƵŐŚDĂƚƌŝdžͲϭ ĞƐŝŐŶϭ ĞƐŝŐŶϮ ĞƐŝŐŶϯ ĞƐŝŐŶϰ ĞƐŝŐŶϱ
ŽŵƉĂƌŝƐŽŶ tĞŝŐŚƚĂŐĞ ^ĐŽƌĞ tĞŝŐŚƚ ^ĐŽƌĞ tĞŝŐŚƚ ^ĐŽƌĞ tĞŝŐŚƚ ^ĐŽƌĞ tĞŝŐŚƚ ^ĐŽƌĞ tĞŝŐŚƚ
ƌŝƚĞƌŝĂ ͬϭϬ ͬϭϬ ͬϭϬ ͬϭϬ ͬϭϬ

&ĞĂƐŝďŝůŝƚLJ ϭϱ ϳ ϭϬϱ ϳ ϭϬϱ ϴ ϭϮϬ ϵ ϭϯϱ ϱ ϳϱ

DĂŶƵĨĂĐƚƵƌĂďŝůŝƚLJ Ϯϱ ϴ ϮϬϬ ϴ ϮϬϬ ϲ ϭϱϬ ϴ ϮϬϬ ϲ ϭϱϬ
ĞƐŝŐŶƐƉĞĐƚ ϭϬ ϱ ϱϬ ϳ ϳϬ ϰ ϰϬ ϳ ϳϬ ϴ ϴϬ
ƌŝǀĞ^LJƐƚĞŵ ϯϬ ϴ ϮϰϬ ϴ ϮϰϬ ϴ ϮϰϬ ϴ ϮϰϬ ϴ ϮϰϬ
DĂŝŶƚĞŶĂŶĐĞ ϭϱ ϱ ϳϱ ϲ ϵϬ ϱ ϳϱ ϳ͘ϱ ϭϭϮ͘ϱ ϲ ϵϬ
>ŝĨĞƐƉĂŶ ϱ ϲ ϯϬ ϱ͘ϱ Ϯϳ͘ϱ ϱ Ϯϱ ϳ ϯϱ ϲ͘ϱ ϯϮ͘ϱ
dŽƚĂů^ĐŽƌĞ ϭϬϬ ϳϬϬ ϳϯϮ͘ϱ ϲϱϬ ϳϵϮ͘ϱ ϲϲϳ͘ϱ
ZĂŶŬ ϯ Ϯ ϱ ϭ ϰ

According to Table 1, design 4 has the highest score amongst all the other designs.
Hence the team decided to work on this design and add improvements.
However, before selecting the design, the team needed to find an appropriate drive
mechanism that could replace the chain drive mechanism present in the current
cleaning robot. There are 4 main types of drive mechanisms: gear drive, chain drive,
belt drive, and rope drive mechanism.
Hence to select amongst these 4 drive systems, another Pugh matrix has been used.
Each team member researched the drive systems and provided points in the matrix.

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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Table 2: Pugh Matrix for Drive Mechanism Selection

WƵŐŚDĂƚƌŝdžͲϮ 'ĞĂƌƌŝǀĞ ŚĂŝŶƌŝǀĞ ĞůƚƌŝǀĞ ZŽƉĞƌŝǀĞ
ŽŵƉĂƌŝƐŽŶ tĞŝŐŚƚĂŐĞ ^ĐŽƌĞ tĞŝŐŚƚ ^ĐŽƌĞ tĞŝŐŚƚ ^ĐŽƌĞ tĞŝŐŚƚ ^ĐŽƌĞ tĞŝŐŚƚ
ƌŝƚĞƌŝĂ ͬϭϬ ͬϭϬ ͬϭϬ ͬϭϬ
ĞŶƚƌĞŝƐƚĂŶĐĞ ϭϬ Ϯ ϮϬ ϳ ϳϬ ϱ ϱϬ ϴ ϴϬ
^ƉĞĞĚZĂƚŝŽ ϱ ϳ ϯϱ ϲ͘ϱ ϯϮ͘ϱ ϰ ϮϬ ϭ ϱ
tŽƌŬŝŶŐ ϭϱ ϴ ϭϮϬ ϰ ϲϬ ϳ ϭϬϱ ϴ ϭϮϬ
ŽŶĚŝƚŝŽŶƐ
ŽƐƚƐ ϯϬ Ϯ ϲϬ ϳ͘ϱ ϮϮϱ ϲ ϭϴϬ ϯ ϵϬ
DĂŝŶƚĞŶĂŶĐĞ Ϯϱ ϱ ϭϮϱ Ϯ ϱϬ ϳ ϭϳϱ ϳ͘ϱ ϭϴϳ͘ϱ
>ŝĨĞƐƉĂŶ ϭϱ ϵ ϭϯϱ ϴ ϭϮϬ ϲ ϵϬ ϲ ϵϬ
dŽƚĂů^ĐŽƌĞ ϭϬϬ ϰϵϱ ϱϱϳ͘ϱ ϲϮϬ ϱϳϮ͘ϱ
ZĂŶŬ ϰ ϯ ϭ Ϯ

From Table 2, the belt drive mechanism has the highest number of points. The team
decided to use this mechanism in the new design of the solar panel cleaning robot.
4.2. CAD Designs and Main Components
To design the cleaning robot, Fusion360 is used. Different parts were
designed separately and combined in the end.
Given below are some of the main components of the system.

DŽƚŽƌ^ƉƌŽĐŬĞƚ

ƌƵƐŚ
^ƉƌŽĐŬĞƚ

tŚĞĞů^ƉƌŽĐŬĞƚ
Fig 6. Drive System of the robot

Fig 7. Blueprint of the drive system

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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Fig 8. Front Frame of the drive assembly

Fig 9. Blueprint of the front frame

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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Fig 10. Top Frame of the drive assembly

Fig 11. Blueprint of the top frame

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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Fig 12. Assembly of the drive mechanism

Fig 13. Blueprint of the Complete assembly of the drive mechanism

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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Fig 16. Rotating Brush

Fig 17. Blueprint of the brush

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&ŝŶĂůĞƐŝŐŶĨŽƌƚŚĞƐŽůĂƌ
ƉĂŶĞůĐůĞĂŶŝŶŐƌŽďŽƚ

ZŽƚĂƚŝŶŐ
ƌƵƐŚĞƐ
>ŽǁĞƌƌŝǀĞƚƌĂŝŶ
ƐLJƐƚĞŵ hƉƉĞƌƌŝǀĞƚƌĂŝŶ
ƐLJƐƚĞŵ

Fig 18. Final Design for Solar Panel Cleaning Robot

Fig 19. Front view of the robot

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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Fig 20. Side View of the robot

Fig 21. Top View of the robot

As seen in Fig 6. the drive mechanism consists of a brush, motor, wheel, and support
sprockets. These are connected to each other using a two teethed timing belt. The
support sprockets are used to maintain tension in the drive. The wheels of system are
connected to the wheel sprocket and is fastened using a bolt on the other end.
Moreover, the timing belt joining the two wheels would have ridges, ensuring an
increase in surface area and smooth traversal on the solar panel. This entire drive
mechanism is mounted in the lower assembly of the robot as in seen in Fig 12.
Fig 12. shows the entire assembly of the powertrain of the robot. This would be the
upper and lower powertrains of the system. This mainly consists of 3 frames along
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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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with a top frame which is fastened together using M8 screws. The drive mechanism
would be mounted within this enclosure to protect it from rain, dust, corrosion, and
wind. These two parts are very important since they move the robot.
There are three rotating brushes in the system. The brush length could vary depending
on the solar panel size and customer requirements. Each brush has a shaft that is
connected, ensuring that there is a tight fit as seen in Fig 16.
Fig 18. shows the final design of the solar panel cleaning robot. As seen in Fig 18. it
includes all the parts starting from the drive mechanism up until the brushes.
4.3. Additional Features and Components

Fig 22. Body Cover for the robot

Fig 23. Solar Panel Cleaning Robot with the Body Cover
Fig 22. depicts a body cover for the robot while it’s not in use. This could be used for
covering the brushes while in storage. However, this part cannot be used on the robot
while it’s on the solar panel since it would act as a dead weight and could damage the
solar panel.

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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5. Material Selection and Analysis

Aluminium is the most suitable when it comes to the manufacturing of the dry
solar panel cleaning machine for many reasons, but first, consider the other
potential materials that could work.
Brass, like aluminium, is a nonferrous metal, which means it doesn’t contain iron
allowing them to be more resistant to rusting [4]. Brass is an alloy of mainly copper
and zinc, increasing the zinc contents improves strength and ductility which is the
ability to undergo tensile force without breaking [5]. However, the increase in zinc
concentration makes the alloy more susceptible to dezincification, which is a
different kind of corrosion where the zinc in the metal is dissolved away [6]. Also,
Brass is more likely to lose its goldish shiny hue, due to oxidation of the metal,
unlike aluminium which uses oxygen as a protective layer, which means brass
requires frequent polishing and increasing maintenance costs [7] .
When considering steel, there are mild steel and stainless steel, both of which are
made up of iron and carbon, but mild steel has a lower concentration of carbon.
Stainless steel also contains chromium, which makes it both harder and more
corrosion-resistant than mild steel which does have chromium. Mild steel is more
ductile and weldable than stainless steel [8]. For the case of manufacturing a solar
panel cleaning machine, the weight and malleability of the metal is of great
importance, so mild steel is better than stainless steel, it is also cheaper due to the
lack of concentration of other metals and complete lack of chromium [9]. However,
aluminium is lighter in weight, easy to weld and machine and much better at
resisting corrosion, so being outdoors in different environments aluminium is
superior. Mild steel is cheaper than aluminium and stainless steel is more
expensive than aluminium, but due to the low maintenance costs, aluminium is
overall the better option.
Aluminium is efficient when it comes to machining, as it is more forgiving if
complications occur during construction process in terms of cost of wastage and
replacements, it also allows for a larger variety of machining methods [10]. Thus,
aluminium due to its formability, lighter weight, and lower costs per quantity than
titanium, is more suitable for this specific application, as strength and ability to
resist higher impact forces is not as important.
Finally, for this particular application, aluminium 6061 and 5052 alloys have
been considered, but 6061 is ideal due to its higher resistance to stress,
good formability and weldability, and the ability to be heat treated, which is
the heating then immediate cooling of the metal to attain the specific desired
properties of the metal [11].
Now regarding the brushes, the materials that the team were deciding on were
nylon and polypropylene but in the end, the team decided that nylon would be the
more suitable material for this specific brush in the robot for the reasons as follows.
Nylon is much better than polypropylene as it can be used in various weather
conditions such as hot and dry or wet and cold such as in Middle East and Europe.
Nylon is also much more malleable than polypropylene and is a low friction material
[12] meaning it prevents contamination, reduce noise and minimises maintenance
requirements which makes it more sustainable as its less energy consuming [13].
But no material is perfect, and Nylon also has its disadvantages such as it is more
expensive, and it is a weaker material as compared to polypropylene [12]. So,

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
'ƌŽƵƉϯ

after considering all the factors our team decided that we will be using Nylon
as the material for the brushes in the solar panel cleaning robot.
6. Manufacturing Processes
There are various manufacturing processes involved in designing and
manufacturing the robot. The most common practices involved are milling, drilling,
and turning. Each process is briefly explained below:

1. Milling [15]:
This machine has a multi-point cutter which cuts into the workpiece as its fed
in the rotating cutter.
x Can be used to machine flat surfaces and create bends at 90 degrees.
x Can be used to create keyholes and machine holes.
2. Drilling [15]:
This machine process is mainly used to create holes of specific dimensions on
a workpiece.
3. Turning [16]:
A revolving component is mounted on a lathe. This rotates at high speed, so
cuts are made to the machine part.

Some other processes used to manufacture would be welding of metal frames,

soldering and 3D Printing.

Table 3: List of components and respective manufacturing process

Component Manufacturing Process Involved
Front Frames Milling and Drilling
Middle Frames Milling and Drilling
Back Frames Milling and Drilling
Top Frames Milling, Drilling, and Welding
Sprockets (optional) Turning and Drilling
Wheels Turning and Drilling
Brush shafts Turning and Drilling

These parts need to be mass-produced in order to keep costs to a minimum, this

will overall reduce the manufacturing and production costs. Along with
manufacturing, there will be additional designing and painting to make the robot
have an aesthetic look depending upon the customer's preferences.

To manufacture these parts, it would take a certain amount of time. The next page
shows the various machine timing of some parts of the machine.
Machine timing is an important criterion when it comes to manufacturing since it
gives an estimate of the time it would take to manufacture a certain number of
pieces.

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
'ƌŽƵƉϯ

7. Machine Timing and Calculations

The calculations for the machine timing for some parts of the machine have
been mentioned below, the formula for each variable is also specified:

Formulas have been adapted from [17]:

గൈ஽ൈௌ
1. Cutting Speed(V) =
ଵ଴଴଴
௏ൈଵ଴଴଴
2. Spindle Speed(S) =
గൈ஽
3. Feed(F) = ܵ ൈ ݂ ൈ ܰ
ி
4. Feed per Tooth(f) = ௌൈே
ଵ଴଴଴ൈௌ
5. RPM(N) =
గൈ஽
6. Total Travel = ‫ ݄ܿܽ݋ݎ݌݌ܣݎ݁ݐݐݑܥ‬൅ ܱ‫ ݈݁ݒܽݎܶݎ݁ݒ‬൅ ‫ ݁ܿ݁݅݌݇ݎ݋ݓ݂݋݄ݐ݃݊݁ܮ‬൅
‫ݎ݁ݐ݁݉ܽ݅݀ݎ݁ݐݐݑܥ‬
்ൈ௡௖
7. Machine Time (t) = ி

Front Frames (748.66 x 371.15 mm)

ଵ଴଴଴ൈଽ଴
¾ RPM(N) = = 573 revs/min
గൈହ଴
¾ Feed(F) = ͳͷ ൈ ͲǤͶͷ͸ ൈ ͷ͹͵= 3919 mm/min
¾ Total Travel = 5 + 5 + 371.15 + 50 = 431.15 mm
ସଷଵǤଵହൈଵ
¾ Machine Time (t) = ൌ ͲǤͳͳ݉݅݊
ଷଽଵଽ
¾ Total Travel = 5 + 5 + 748.66 + 50 = 808.66 mm
଻ସ଼Ǥ଺଺ൈଵ
¾ Machine Time (t) = ଷଽଵଽ ൌ ͲǤʹͳ݉݅݊
¾ Total Machine time = 0.21 + 0.11 = 0.32 min

Angled Frames (131.38 mm)

ଵ଴଴଴ൈଽ଴
¾ RPM(N) = = 573 revs/min
గൈହ଴
¾ Feed(F) = ͳͷ ൈ ͲǤͶͷ͸ ൈ ͷ͹͵= 3919 mm/min
¾ Total Travel = 5 + 5 + 131.38 + 50 = 191.38 mm
ଵଽଵǤଷ଼ൈଵ
¾ Machine Time (t) = ൌ ͲǤͲͶͺͺ݉݅݊
ଷଽଵଽ
¾ Total Travel = 5 + 5 + 4370 + 50 = 4430 mm
ସଷ଻଴ൈଵ
¾ Machine Time (t) = ൌ ͳǤͳ͵Ͳ݉݅݊
ଷଽଵଽ
¾ Total Machine time = 0.0488 + 1.130 = 1.1788 min

Top Frames
ଵ଴଴଴ൈଽ଴
¾ RPM(N) = = 573 revs/min
గൈହ଴
¾ Feed(F) = ͳͷ ൈ ͲǤͶͷ͸ ൈ ͷ͹͵= 3919 mm/min
¾ Total Travel = 5 + 5 + 526.85 + 50 = 586.85 mm
ହ଼଺Ǥ଼ହൈଵ
¾ Machine Time (t) = ൌ ͲǤͳͶͻ݉݅݊
ଷଽଵଽ
¾ Total Travel = 5 + 5 + 4370 + 50 = 4430 mm
ସଷ଻଴ൈଵ
¾ Machine Time (t) = ଷଽଵଽ ൌ ͳǤͳ͵Ͳ݉݅݊
¾ Total Machine time = 0.149 + 1.130 = 1.2797 min

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8. Cost analysis
The estimated costs required to manufacture the robot is given below.
Table 4: Component lists and Costs
Material/Pro Purpose Supplier Cost per Weight/Am
duct Kg/Piece ount of
product

Aluminium Body LOSTRONAUT – amazon.com $60.56 12 inch x

6061, / Link: - 12 inch x
Frame https://www.amazon.ae/dp/B089ZVW3F8?ref_=cm_
Aluminium sw_r_apin_dp_T3XW2ST2QM7JAAAXWN6V&lang
0.25 inch
Sheets uage=en-AE

Aluminium Sprockets  Jihnhua Haoqiang Chain Co., Ltd. – Alibaba.com $2.00- 10-299
Alloy Link: - $5.00 sold for
https://www.alibaba.com/product-detail/Factory-
Wholesale-Custom-Industrial-Alloy-
 $5.00 and
Chain_1600900845129.html?spm=a2700.galleryoffe 300 and
rlist.p_offer.d_title.c1cd7b4aQCZVar&s=p above are
sold for
$2.00
Polymer Bearings Mcmaster.com $40.00 10 pieces
Lubricant Link: -
and Steel, https://www.mcmaster.com/catalog/129/13
Permanentl 87/2349K729
y
Lubricated
Ball
Bearing, 20
mm Shaft
Diameter
Stainless Screws Mcmaster.com $0.79 32 pieces
Steel and Link: -
Passivated, https://www.mcmaster.com/products/screw
Metric 18-8 s/rounded-head-screws~/system-of-
Stainless measurement~metric/thread-
Steel Pan size~m8/length~25-mm/
Head
Phillips
Screws
Nylon Brushes KARNAVATI INDUSTRIAL BRUSH $1.20 - 3 pieces
MANUFACTURING CO link:- $5.99
https://www.tradeindia.com/products/nylon-
roller-brush-c717106.html
Black Screws Mcmaster.com $4.07 4-5
corrosion- Link: - pieces
resistant

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 ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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coated https://www.mcmaster.com/catalog/129/35
steel, 30/91310A155
High-
Strength
Class 10.9
Steel Hex
Head
Screw, M20
x 2.5 mm
Thread, 30
mm Long

Cost Estimation for all this is summarized below:

x $60.56 for aluminium sheet
x $5.00 for sprockets
x $400.00 for bearings
x $25.28 for pan head Phillips screws
x $20.35 for hex head screws
x $17.97 for nylon brushes
This brings it to a total of $529.15 for building one solar panel cleaning robot. This is
well under budget.

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ĞƐŝŐŶĂŶĚDĂŶƵĨĂĐƚƵƌĞͲϮ͗/W'ƌŽƵƉZĞƉŽƌƚ͕
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9. Risk assessment

The Potential risks that could occur/take place during the installation and usage of
the cleaning robot are as follows:

Potential Who/What is Severity Precautionary Action to be

Hazards at risk? Measures taken
Mechanical User/Customer Only switch on the Press the
Hazards: High- robot once on the emergency
speed rotating solar panel. stop button if
parts such as HIGH Frequently check for the robot is
brushes. Loose loose fittings. near the user.
fittings and Tighten the
fastenings. loose fittings.
Electrical Robot, Solar Monthly maintenance Replace the
Hazards: Short- Panel, and to check the electrical circuitry in the
circuiting of User HIGH systems of the robot robot. Tighten
components and any loose
loose wiring. wiring.
Battery Hazard: Robot, Solar Weekly maintenance Replace
Overheating of Panel, and to check the battery of battery if
battery. Battery User
HIGH the robot required.
explosion.
Falling Hazard: Robot and Ultrasonic sensors Check if the
The robot may User need to be added sensors are
fall off from the onto the solar panel. faulty. Replace
solar panel due Use of good quality of sensors if
to faulty sensors. LOW rubbers on the wheels needed.
Slippage due to of the robot Change the
low traction timing belt if
needed.
Maintenance Maintenance Staff must be trained Switch off the
Hazard: personnel and for maintenance and robot before
Personnel may user repair. any repair or
MEDIUM
be exposed to maintenance.
moving parts and
circuitry
Environmental Robot Body of the robot If any corrosion
Hazard: Climate must be made with occurs, replace
factors such as
MEDIUM materials with the the specific
rain and wind can ability to withstand body part.
harm the robot. such factors

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