AI & robotics check used PV modules

AI & robotics check used PV modules

Based on the test results, the system makes informed decisions about reuse or recycling with the aim of maximizing the service life of the modules and at the same time increasing resource efficiency and sustainability in the photovoltaic sector. The project builds on a successful pilot project as part of EDIH AI5Production and is being implemented by AIT (Austrian Institute of Technology) in cooperation with several industrial partners.

The rapid expansion of photovoltaic systems is a central key to the energy transition - but also brings with it new challenges. One of them: How do you deal with millions of PV modules that will reach the end of their life in the coming years?

Currently, used modules are usually recycled directly without first checking whether they are still usable. To date, there has been a lack of automated processes for an objective decision. This is exactly where the new research project comes in and asks the question: “Watts OK? – can the module be reused or should it be recycled?”

With the official starting signal, the research project “WattsOK?” its work and relies on the reuse of PV modules with the help of robotics and artificial intelligence. The aim is to develop an automated decision-making process that determines the optimal recycling route for used PV modules: reuse or recycling.  "With WattsOK?, we are developing an AI-based approach for the systematic reuse of photovoltaic modules - and in doing so we are leveraging AIT's strength in transferring research into industrial solutions," explains Andreas Kugi, Scientific Director of the AIT Austrian Institute of Technology (AIT).

The research project coordinated by AIT addresses the growing amount of used PV modules and lays the technological basis for their systematic reuse. “With WattsOK? we are creating a data-driven, automated solution to a real problem in the PV sector,” explains Nicole Brosch, head of the project. “At the same time, it also shows how applied research can contribute to better use of resources in the spirit of the circular economy,” adds her colleague Laurin Ginner. Both scientists conduct research at AIT in the area of ​​high-performance optical inspection and image processing.

Smart decision-making process: What does WattsOK do?

At the heart of the project is an intelligent, automated decision-making process that determines which used PV modules deserve a second life and which actually need to be recycled.

It includes

• KI-gestützte optische Inspektionsverfahren zur Prüfung der Oberflächenqualität, sowie
• präzise elektrische Messungen zur Prüfung der Funktionalität.

This process is supplemented by a robot-assisted replacement of connectors - a first refurbishment step that makes the modules usable again.
A central role is played by a database that links inspection data, measured values ​​and product specifications. This database not only serves as the basis for the AI ​​algorithms, but also ensures transparency and traceability of decisions.
"With our system, we are first movers in the area of ​​automated, economically sensible testing of PV modules that is also suitable for larger quantities. WattsOK? uses the data from the tests. We - and therefore our customers - benefit from the results of the research project. The project is a great example of how research and commercial use can be efficiently combined - to the benefit of everyone involved," says Simon Prüller, CEO and co-founder of 2nd Cycle.

From pilot project to funded FFG project

The research project that has now started was preceded by a successful pilot project as part of the European Digital Innovation Hub (EDIH) AI5Production. In close collaboration between the AIT Center for Vision, Automation & Control and the Lower Austrian green tech startup 2nd Cycle FlexCo, the first innovative approaches to the automated optical inspection of used PV modules were tested and validated as part of the “Test Before Invest” initiative. This preliminary project served as a feasibility study and laid the technological foundation for the scalable solution that has now been launched. WattsOK? builds directly on these findings and shows an example of how a low-threshold start to digitalization via the EDIH can become a fully-fledged, funded research project.

Digital booster for industry

AI5Production supports Austrian companies in digital transformation with a focus on artificial intelligence, Industry 5.0, cybersecurity and digital production. With access to state-of-the-art infrastructure, advice and test environments, the hub is the central contact point for innovative developments. Now it's time to move on to the next round.

The project partners

• AIT Austrian Institute of Technology: Koordination, hoch-performante Oberflächeninspektion, KI-Entscheidungsprozesse, Reuse-Strategien
• 2nd Cycle FlexCo: Multi-Sensor Reuse/Recycling Line
• Profactor: Robotik
• TÜV Austria Holding: Aufbau skalierbarer Datenstruktur und Datenfusion, KI-Entscheidungsprozesse
• Montanuniversität Leoben (Lehrstuhl für Abfallverwertungstechnik und Abfallwirtschaft): Life Cycle Assessment
• Metran Rohstoff-Aufbereitung: Recycling-Strategien

The “WattsOK?” project is funded by the Federal Ministry for Innovation, Mobility and Infrastructure (BMIMI) as part of the national RTI call for circular economy and production technology. Processing is carried out by the Austrian Research Promotion Agency (FFG). (gw)