Solar panels are long-term investments and are built to last for decades. However, sometimes invisible, tiny fractures, also known as microcracks, develop, which can significantly impact the amount of electricity the panel generates. This can degrade the panel’s performance and shorten its lifespan. So, the early detection of microcracks is important. Today, advanced technologies and AI (Artificial Intelligence) tools are making it possible to detect these microcracks early. This article explains the hidden microcracks in solar panel, their impact on solar panel performance, and a step-by-step process for how AI detects microcracks in solar panels early.
What Are Microcracks in Solar Panels?
Microcracks are the tiny cracks in the solar panel and are usually not visible to the naked eye. They develop within the silicon cells of a solar panel. A solar panel consists of multiple silicon wafers. When the sunlight falls on the silicon wafers, electricity is produced. And the microcracks on the wafers disrupt the electrical pathway, which leads to a reduction in the output power.
The microcracks are caused due to:
1. Sudden change in temperature
2. Mechanical pressure due to heavy loads or improper handling
3. During transportation
4. Sharp impacts from hailstones or falling branches
The damaged cell due to the microcracks reduces the electricity production capacity of solar panels. These cracks create areas that heat up more than others and also cause the panels to wear out faster.
The professionals use advanced imaging tools to detect microcracks. They are:
1. Electroluminescence (EL) Testing: This uses electric current to make cracks visible on the screen.
2. Infrared Thermography: Heat maps of the panel can identify panel areas that are affected due to microcracks.
How Microcracks Affect Solar Panel Performance?
1. Lowers output Power:
Microcracks interrupt the electrical pathway within a solar cell, reducing its electricity production capacity. As the crack grows, the power drop can spread across the panel. A small 5% crack can result in 15% power loss.
2. Creates Hotspots:
The microcracks create hotspots, the section of the panel that heats up faster than others. These hotspots reduce the overall efficiency of the solar panel, damage the protective layer, and damage the panel’s internal infrastructure.
3. Degrades Performance:
The microcracks speed up the degradation process. It causes frequent inverter faults and degrades the performance of the solar panel.
4. Wasted Energy Investment:
A solar system is a long-term investment. But the microcracks present in the solar cell reduce the total amount of output power and also lead to reduced returns and longer payback periods.
How AI Detects Microcracks in Solar Panel Early?
A step-by-step process on how AI detects microcracks in solar panels is discussed below.
1. Scanning of Solar Panel:
The first step in detecting microcracks in a solar panel is capturing panel images by using specialized equipment. Advanced imaging technology, such as Electroluminescence (EL) Imaging and Infrared Thermography (IR), is used to scan the solar panels. These tools can capture internal cell structure by sending a small electrical current through the panel in low light, causing it to glow. When the light glows, microcracks appear as dark lines or spots.
2. Image Processing:
In the next step, the scanned images are processed to remove unwanted noise, shadows, or low contrast. Here, the brightness of the image is adjusted, shadows are filtered out, and the fine details are enlarged such that small cracks don’t get missed.
3. Pattern Recognition:
Once the scanned image is processed thoroughly, the AI-powered tool scans the panel’s cell structure and categorizes its key features into various categories to recognize the patterns. The key features include surface textures, cell boundaries, etc.
4. Defects Classification
In the next step, the AI tool analyzes and compares the defects, such as shapes, dark spots, and broken lines, with a database of known defect types. According to the compared data, the defects are classified into various categories, such as hairline cracks, edge cracks, finger interruptions, and severe cell breakage.
5. Reporting
Based on the size, depth, and position of the defects, the detected cracks are assigned a score. A full report is generated, which represents the number of affected cells, crack, length, and its pattern, type of cracks, estimated energy loss, and the score of the cracks. This report helps the engineers and the repairing team identify whether it is a low-level crack or high-score panels. The low-level cracks are advised to be monitored, and the high-scoring panels are marked for replacement or repair.
Technology Used in Microcrack Detection in Solar Panels
Advanced tools and systems used in the detection of microcracks in solar panels are explained below.
1. Electroluminescence (EL) Testing
This testing is done to identify the microcracks, broken fingers, and dead spots in cells. In this process, an electric current is passed through the panel, which makes the silicon cells glow.
2. Infrared (IR) Thermography
This technology is used to detect the cracks and hotspots caused by broken pathways. It uses thermal cameras to detect temperature differences across the panel surface.
3. High-Resolution Visual Scanning
This advanced technology is used to find out discoloration, scratches, and physical signs of surface stress. It takes zoomed-in photos of the panel surface under controlled lighting.
4. Smart Image Analysis Software
This software can detect unnatural cell textures and pattern disruptions. For accurate crack identification, it processes the scanned images and compares them with reference datasets.
Why Early Detection of Microcracks Matters?
1. The microcracks in the solar panel lead to a reduction in output power. So, the early detection of microcracks prevents damage from spreading and keeps the panel producing at its best.
2. Early detection of microcracks protects against hotspots and overheating.
3. This allows the solar panel users to perform timely repairs and selective panel replacement, which increases the lifespan of the system.
4. Early detection can limit the damage to a few panels. This saves money on maintenance and repairs.
5. Early detection of microcracks supports warranty claims.
Case Studies
1. Case Study 1: Solar Farm (Maricopa County, Arizona)
The solar farm’s size is 80MW. After running continuously for 4 years, the technician noticed a 12% drop in energy output despite clear skies. So, the engineers performed infrared thermal imaging and EL (electroluminescence) testing and identified early-stage microcracks near the cell edges. They also concluded that heat cycles in dry areas can cause invisible cracks.
After the detection, the cracked panels were isolated and repaired, and thus the energy output level returned to the expected value.
Reference: https://www.edf-re.com/projects/
2. Case Study 2: Rooftop Solar Panel (Trenton, New Jersey)
The residential rooftop’s size is 10 kW. After noticing a sudden drop in energy production level, the solar technicians went to detect microcracks by using advanced technology. They used handheld EL imaging technology and uploaded the scanned images into a smart diagnostic platform. Thus, they detected microcracks in two panels. They also predicted future loss if cracks spread further. So, they replaced the two damaged panels, and the power production returned to normal values.
Conclusion
Microcracks are small, but their effects can be big. These serious hidden issues can reduce energy output to long-term system damage. But nowadays it is now possible to detect the microcracks by modern inspection tools and advanced image analysis. These technologies are available for rooftop solar panels, commercial plants, and remote solar sites. So, if you are a homeowner or owner of a large utility farm, early detection can protect your solar investment. It’s no longer a luxury. It’s a must for modern solar care.
FAQS
- What are hotspots in solar panels?
The section of the panel that heats up faster than others is known as a hotspot in solar panels.
2. What is Electroluminescence (EL) Testing?
Electroluminescence (EL) testing is done to identify the microcracks, broken fingers, and dead spots in cells. In this process, an electric current is passed through the panel, which makes the silicon cells glow.
3. What is High-Resolution Visual Scanning?
High-Resolution Visual Scanning is an advanced technology used to find discoloration, scratches, and physical signs of surface stress. It takes zoomed-in photos of the panel surface under controlled lighting.
4. What Are Microcracks in Solar Panels?
Microcracks are the tiny cracks in the solar panel and are usually not visible to the naked eye. They develop within the silicon cells of a solar panel.
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