A new imaging approach developed by researchers offers a practical way to detect hard to spot glass cracks in photovoltaic modules during daytime inspections, potentially improving safety and performance monitoring across utility scale solar plants. The findings are published in the paper titled ‘A novel method for detecting low-energy front glass cracks in photovoltaic modules using daylight electroluminescence imaging’.
The method uses daylight electroluminescence imaging combined with controlled motion, allowing operators to identify low energy cracks that are typically invisible to conventional drone based RGB or infrared thermography surveys. These subtle fractures, while less dramatic than shattered glass, can still lead to moisture ingress, corrosion, and long term system failures.
Unlike traditional electroluminescence imaging, which captures only silicon cell emissions and requires stable conditions, the new approach relies on movement during image capture. As a camera shifts position slightly between frames, light reflecting off fractured glass changes with viewing angle. These variations are then combined during image reconstruction, making crack patterns visible alongside standard cell defect data.
The technique was validated during a drone based inspection at a university solar plant, where two modules with glass cracks were successfully detected. Notably, these defects were not visible in either infrared thermography or standard visual imagery, highlighting a key gap in current inspection practices.
Imaging performance was found to be optimal at distances between 8 m and 12 m using a 640 × 512 InGaAs camera, with detection accuracy declining beyond 15 m. The visibility of cracks also depends on lighting and viewing angles, meaning results can vary depending on field conditions.
Glass cracks in solar modules are a known risk factor in large scale installations. They can result from installation stress, environmental loading, or impacts such as hail or debris. Even minor cracks can compromise module sealing, increasing the risk of electrical faults and inverter shutdowns.
Current inspection methods are effective at identifying severe damage but often fail to detect these early stage defects at scale. By enabling simultaneous detection of internal cell issues and surface cracks in a single pass, the new method could enhance operational efficiency for solar asset owners and service providers.
However, the approach has limitations. It can only detect cracks on the illuminated side of the module, meaning rear side fractures in bifacial panels may go unnoticed unless they propagate to the front or are inspected separately. In addition, excessive camera motion can disrupt image reconstruction, reducing accuracy.
The researchers suggest that future work could explore similar motion based detection using short wave infrared imaging without electrical excitation, as well as extending the method to rear side inspections and varying light conditions.
As solar fleets continue to scale across regions such as Africa, where harsh environmental conditions can accelerate module wear, improved diagnostic tools like this could play a critical role in reducing downtime and maintaining energy yield.
Author: Bryan Groenendaal






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