Electric Motor Applications in Solar Panel Cleaning Robots

1. Component Composition

The solar panel cleaning robot is an intelligent, autonomous robot designed for the periodic cleaning needs of large-scale outdoor photovoltaic power stations. The main components of the robot include:

• Drive System: Consists of drive wheels, reduction motors, and transmission gears, responsible for running along the solar panel paths in straight or curved routes.
• Cleaning System: The core is the electric roller brush mechanism, with motors driving high-efficiency rotating brushes to clean the solar panel surface evenly.
• Lifting Adjustment Mechanism: The electric lifting support system adapts to panels of varying heights, tilt angles, and edge locations.
• Navigation and Obstacle Avoidance System: Includes high-precision encoders, infrared sensors, cameras, etc., working with control motors to dynamically plan paths and avoid obstacles.
• Power System: Typically consists of lithium batteries, solar charging systems, and power management units.
• Main Control System: Includes MCU/PLC control board, wireless communication modules, motion control cards, etc., responsible for coordinating the logic of various subsystems.

2. Working Principle

When the device receives a start command, the main control system sends path planning information to the drive motor, adjusting the speed via PWM signals for stable movement. The roller brush system is activated simultaneously, with the brush motor driving high-speed rotation to clean the panel surface, removing dust and contaminants.

During operation, the navigation system monitors the position, tilt angle, and edge distance in real-time, using micro stepper or servo motors to precisely adjust the brush head angle or position. If an obstacle (such as snow or raised structures) is detected, the obstacle avoidance system instructs the motors to turn or brake, avoiding dangerous areas.

After cleaning is complete, the robot will automatically return to the charging station and recharge via a charging motor or wireless power supply module. The system reports its operational status to the cloud via BLE or Wi-Fi.

3. Role of Motors in the System

The motor system in the solar cleaning robot must meet multiple requirements including high performance output, low energy consumption, resistance to extreme weather conditions, and intelligent control. The specific roles of each type of motor in the system are as follows:

• Drive Motor: Usually a high-torque DC reduction motor or brushless hub motor, designed to handle slopes (10°~30°), wind resistance, and dust. It is paired with a planetary gearbox to achieve high torque output, typically with a rated torque of 1-2Nm or higher. It includes a Hall sensor for speed measurement and closed-loop control to enhance path accuracy and anti-slip capabilities.
• Cleaning Brush Motor: Requires high speed and constant torque, typically a brushless DC motor with a speed range of 300-1500rpm. The motor should support long hours of continuous operation (>3 hours) and feature low noise and good heat dissipation.
• Position Adjustment Motors (Stepper or Servo Motors): Used for adjusting the height of the cleaning module, controlling the brush head angle, and performing precise position control tasks like end position limit zeroing. Stepper motors with encoders are commonly used for closed-loop precision control, while servo motors with feedback are used for more complex path control.
• Lifting and Suspension Motors: Small power DC reduction motors are used in the lifting mechanism, ensuring stable operation without affecting the cleaning angle. These motors are paired with overcurrent protection and soft limit mechanisms to prevent structural damage.
• Power Management and Auxiliary Motors: Small power motors used for switching contact points and controlling battery compartment positions. These motors work with relays and the MCU to perform actions like power on/off and wireless connections.

4. Customized Motor Solutions

Considering that photovoltaic panel cleaning robots often operate in complex environments such as high altitudes, large temperature differences, strong winds and sand, and unattended sites, extremely high demands are placed on the reliability and intelligent control capabilities of their motor systems. To address these challenges, we offer a comprehensive customized solution for such robots:

For the walking drive system, we recommend the high-protection GPG-WD series hub brushless motors. Their integrated design effectively reduces wiring complexity and waterproofing risks. With an IP67-rated sealed structure, they can operate directly in dusty and rainy conditions. These motors support both PWM and CAN communication control, feature multi-speed regulation and braking functions, and deliver stable torque output, making them ideal for shuttling on multi-terrain rails and between solar panels.

For the roller brush drive, we offer the GPG-BL70 high-speed brushless DC motor. This model supports a wide voltage input range (18–48V) and can reach speeds of up to 1500 rpm. It is equipped with dual ball bearings and a heat-dissipating turbine design, enabling continuous operation for over 3 hours without thermal degradation. It is widely compatible with both single and dual brush systems, as well as modular, multi-section configurations.

For lifting and adjustment mechanisms, we recommend the GPG-MI42 closed-loop stepper motor or the GPG-SV60 servo system. These options offer fast response times and strong position-holding capabilities, with support for path fine-tuning, auto-reset, and power-off position retention—effectively enhancing cleaning efficiency and coverage.

In addition, the complete system includes intelligent motor drivers with built-in protections such as stall detection, temperature control, and undervoltage alarms. This ensures 24/7, low-failure, and energy-efficient operation even in fully unattended environments. We also offer optional lightweight, integrated control board solutions tailored to customer needs, enabling rapid development and easy maintenance.