Slide over, solar installers – Maximo is here to handle the heavy lifting.
Today the AES Corporation unveiled a first-of-its-kind AI-powered solar installation robot, Maximo, which works alongside human teams to accelerate project construction.
“We’re excited to share Maximo with the world today,” beamed AES chief product officer Chris Shelton. “The goal here is to supercharge the workforce that delivers clean energy.”
Maximo aims to enhance the speed, efficiency, safety, and scalability of solar installation by automating the placing and attaching of solar modules, explained Ron Rodrique, vice president of project management at AES. Utility-scale solar panels often weigh 60 pounds or more, and installers have to bend and lift heavy loads hundreds of times over the course of a single job.
“I think where Max really makes a difference is it takes away that heavy lifting, the repetitiveness wearing down on people and bodies,” suggested Rodrique.
“That’s really intense work,” added Shelton. “We have a ton of data to show if we can improve that, it’s net beneficial.”
Maximo will not take any human jobs, AES insists, noting its staffing on job sites has not changed since Maximo joined the workforce. The robot has already installed nearly 10 MW of solar and is projected to install 100 MW by . Previously, Maximo helped power Amazon operations at the Oak Ridge Solar project in Louisiana, its first utility-scale deployment.
“We call it ‘Max’, like a companion or a pet,” smiled Shelton. “It does have that feel to it, and the crews have reflected that on the sites.”
Invented and owned by energy company and developer AES, Maximo was programmed using a wide range of Amazon Web Services (AWS) tools, including AWS RoboMaker, a cloud-based simulation service that enables robotics developers to run, scale, and automate simulation.
AES expects to use Maximo to help build up to 5 GW of its solar backlog and pipeline over the next three years. That includes the 2 GW Bellefield project in Kern County, California, which is currently the largest solar-plus-storage project in the country, and has an offtake agreement with Amazon. It will begin installing at Bellefield in August.
“We are facing unprecedented increases in demand, driven in large part by the rise of AI and data centers, and innovations like these will be fundamental for accelerating our ability to bring projects online faster and with greater efficiency,” said Andrés Gluski, AES president and CEO.
AES says Maximo can install solar panels in half the time and at half the cost. It will not only accelerate project timelines but also create new high-tech jobs and provide new opportunities for the human workforce. Basically, the company hopes adding AI-powered automation will open up the field to more humans, not less.
“We are not focused on eliminating or replacing people in this equation,” confirmed Shelton. “It’s actually just the opposite- we want to bring more people into this workforce.”
“As we start to evolve this, we open up the door to different workers. It’s not necessarily that heavy strenuous job now, it’s more about controlling the unit,” noted Rodrique.
According to the IEA, by , solar annual additions are expected to triple, and the workforce will need to nearly double. There is more than 1 million MW of utility-scale solar being developed right now.
“The US solar industry is setting an impressive pace, installing about 15,000 modules per hour, weighing one million pounds,” said Shelton. “Looking ahead, this installation rate is projected to reach 50,000 modules per hour by . In response to this exponential growth, we are scaling Maximo, deploying fleets of continually improving robots to empower our teams for faster and more competitive installations.”
Maximo can perform in a broad range of climates and lighting conditions and has been validated in the field across a variety of US project sites. Deise Yumi Asami, head of renewable technology and innovation at AES, says Maximo can manage the complete installation of solar panels and learns with every installation and each module it handles.
“Maximo is like equipment,” she quipped. “A tool for our construction workforce that helps them be more productive and to keep systems going the entire time we’re on site.”
“The crews are looking at Max as their buddy, their coworker, who will help get their job done efficiently and safely,” added Rodrique.
Maximo’s AI-powered features include:
Other companies have unveiled somewhat similar autonomous solutions aimed at accelerating project construction. Last year, Terabase Energy and Sarcos Technology and Robotics Corp. introduced systems that they say will improve project timelines, quality, and safety.
Terafab’s automated field factory combines a digital twin of the project site, advanced supply chain and inventory management systems, an onsite wireless digital command center, a field-deployed automated assembly line, and installation rovers to allow for automated, 24/7 construction. Each Terafab unit is capable of installing up to 1 GW per year. In November , Terabase Energy announced the successful completion of its first commercial project built using its automation platform, which installed 17 MW of the 225 MW White Wing Ranch solar project in Arizona.
Sarcos signed an agreement with Blattner Company to refine its own autonomous mobile robotic system for utility-scale solar construction. It uses a mobile platform with an attached robotic arm to place individual panels one by one with the assistance of workers in the field.
Automated: A high-speed robotic arm performs the precise panel installation. The lower robotic arm tightens the clamps for fully automated installation.
Reliable: Maximo operates for extended shifts so projects get done faster.
Carbon-free capabilities: A mobile microgrid powers Maximo.
Reduces injury risk: Eliminates repetitive heavy lifting and bending at construction projects for PV installers.
Advanced sensors: Detects people in the working area and stops operation to prevent incidents.
Inclusive jobs: Enables more accessible high tech energy jobs by reducing strenuous physical requirements.
AI pipelines help Maximo continuously learn and improve with each panel installed.
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User-friendly: Easy-to-use interface provides effortless control for project managers.
Construction analytics: Tracks installation data.
Technology agnostic: Adaptable to any solar module, and rapidly expanding to a wide range of clamps, rails and trackers.
Computer vision: Lidar and cameras provide spatial awareness for precise placement.
Adaptable height operation: Operates on a wide range of torque tube heights.
Excelling in desert conditions, Maximo will accelerate the Bellefield solar project’s efficiency and timelines. The 2 GW solar + storage project will help power Amazon’s operations.
AES’ Cavalier solar project marks Maximo's first MW-scale deployment. The Maximo robot accelerates timelines while improving safety and and boosting construction project efficiency.
The 260 MW Oak Ridge Solar project in Louisiana was a significant milestone in Maximo's journey as its first utility-scale deployment.
The Maximo robot reduces solar installation timelines and utilizes cutting-edge technology developed by Amazon Web Services (AWS).
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The AES Corporation introduced “Maximo” today, the AI-powered robot that enhances solar installation speed, efficiency and safety. Maximo is a first-of-its-kind robotic solution that works alongside construction teams to help meet rapidly growing renewable energy demand.
Maximo is the only construction automation solution that provides the full end-to-end mechanical installation of solar modules directly in the field. The solar robot results in faster installation and creates safer working conditions, as construction teams do not need to lift heavy commercial solar panels – nor bend to place them – therefore reducing the risk of injury.
Maximo is technology agnostic to adapt to any solar module, and quickly expanding to a wide range of clamps, rails and trackers, which enables Maximo to install solar projects with single-axis trackers. Maximo tracks solar installation data, giving EPCs full visibility into their site's construction status.
Maximo works with solar construction teams to automate construction projects and install modules twice as fast as standard mechanical installation processes.
Maximo has been extensively tested and validated in a variety of conditions and job sites to ensure that it can perform in almost any weather condition, lighting condition, or terrain type.
It has successfully deployed nearly 10 megawatts of solar modules to date.
Yes, Maximo was built to sustainably operate in uncontrolled outdoor conditions.
Maximo runs on a mobile microgrid, using lithium-ion iron phosphate batteries as a power source. AC / DC inverters and phase converters supply the three-phase electric power required to run the larger components.
Maximo is equipped with a variety of controls and safety measures that allow it to work reliably in the field. The solar robot’s AI-enabled computer vision system detects any inconsistencies in the installation process and self-corrects to minimize any interruptions. The Maximo User Interface enables the operator to monitor the status of the Maximo unit, including the vision system and battery charge state.
Maximo combines a series of sensors, cameras, and advanced computer vision and artificial intelligence / neural network algorithms to identify the tracker structure, modules and other surroundings at solar construction projects, which serve as reference for the next module to be installed.
Advancements in computer vision, artificial intelligence and robotics have made it possible to automate tasks which just a few years ago would have been impossible to execute efficiently and cost-effectively. Applications of these advancements have been successful and are being increasingly adopted in other industries such as electronics, agriculture and automotives. In the solar industry, AI technology has been used to automate processes like preventative maintenance and module cleaning.
Solar panel boxes can be replenished with most skid steers or telehandlers, which easily lift a pallet of modules and load it into the module storage space through Maximo’s back panel.
Maximo is assisted by a human operator to move between rows on a solar construction site, and a skid steer driver tows the robot.
While we envision Maximo to have widespread use in every type of solar construction project that uses trackers , this system has great potential to solve problems in extreme desert conditions where working conditions are the hardest and where (in the US) installation jobs are harder to fill.
We also see a major benefit for solar module construction teams installing modules on the tallest trackers. Safety hazards surrounding working at heights lead to slower production rates. Maximo allows crews to install safely from the ground at the click of a button.
Site preparation: Staging and site preparation work are nearly identical to site prep and staging for traditional installation.
Maximo-specific preparation: Maximo is mechanically calibrated to ensure that its onboard systems are adjusted for the appropriate solar module and hardware used on the job site.
Maximo can be run by installation crews of two people. One person drives the system, and the other runs the machine and ensures everything is in place as the robot installs each row.
Maximo’s core robotics technology allows for the system to be positioned in a wide array of orientations and place each panel in the appropriate position. The system has tracks that enable it to maneuver on a variety of ground conditions, including in sandy, muddy, and bumpy environments.
Maximo works within the supply chain that exists today. We continue to work with module and tracker OEMs to integrate the latest technology as it is released. It is technology agnostic, adaptable to any solar module and quickly expanding to a wide range of clamps, rails and trackers. The Maximo team collaborates closely with tracker manufacturers to ensure seamless operations on current product offerings and to stay ahead of hardware revisions.
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