Efficient Serial Number Tracking for Digital Twin Technology in Solar Plants

The digital twin for solar is an essential tool in modern solar farm management, providing a virtual replica of your solar assets with comprehensive, real-time data. The digital twin platform for solar enables effective monitoring, management, and optimization of solar panels and photovoltaic systems. A key component in developing this digital twin is the accurate recording of the serial numbers of each panel. This blog discusses two primary methods to incorporate this data into a digital twin: manual scanning and drone scanning.

FutrOS platform is a core component of the digital twin for solar power plants, providing a wealth of digital data on your solar site. A key aspect of building an effective digital twin is incorporating the serial numbers of each solar panel. This blog explores two methods to efficiently track and integrate serial numbers into your digital twin platform for solar.

Purpose of Serial Numbers in Solar Digital Twin

Each solar panel, often referred to as a photovoltaic module, comes with a unique serial number that distinguishes it from others. This identification system ensures error-free tracking of panels, especially when they are moved or replaced.

Incorporating serial numbers into the digital twin data management system has several advantages:

• Warranty Management: Serial numbers are crucial for validating warranty claims. When filing a claim, the serial numbers on the faulty panels must match the digital records.
• Defect Tracking: Serial number tracking in solar farms helps identify defective panel batches. If multiple consecutive serial numbers show the same issue, it could indicate a manufacturing defect.
• Efficient Solar Panel Management: Serial numbers simplify the management of large solar sites by providing precise tracking and monitoring of each panel’s performance.

Collect all or focus on specific

Serial numbers play a crucial role in the digital twin in photovoltaic systems. They not only help maintain accurate records for operational purposes but also assist in warranty management. If a claim needs to be made, the serial numbers stored in the digital twin software must match those on the malfunctioning panels. This facilitates a streamlined warranty process and eliminates discrepancies.

Moreover, integrating serial numbers into the solar farm digital twin integration enables the identification of problematic panel batches. If a series of consecutive serial numbers show similar defects, it can be flagged as a potential manufacturing issue. This capability of the solar panel monitoring with digital twin helps in proactive maintenance and quality assurance.

With a geolocated digital twin for solar, all serial numbers and associated data are linked to their specific locations within the solar farm, making it easy to pinpoint and address issues. This is particularly useful for large-scale Solar PV plants with digital twin technology, where managing thousands of panels manually would be cumbersome.

Incorporating this information into a digital twin model offers a comprehensive view of the entire solar farm, aiding in predictive maintenance and real-time monitoring. Such digital twin solutions are vital for improving the overall efficiency and longevity of solar power plants.

Methods of Collection

There are two primary methods for collecting serial numbers for your digital twin of a solar plant: manual scanning and drone scanning.

1. Manual scanning

The best practices to implement sorting on serial numbers entail physical scanning of barcodes for each module. What is more important, targeted scanning is done manually only, but, in general, it also can be rather efficient for bulk scanning. Here are a few advantages:

First of all, an efficient Bluetooth barcode scanner can easily pair with a smartphone or a tablet, and operate as a keyboard for entering the code of a barcode.

 It is perfectly possible to have a simple Excel structure for the database and an even better Application for Field can facilitate the input of records and minimize errors.

Secondly, the task is quite basic, so even Studentjohn or any worker who just arranged another temporary job can accomplish it; at that, the task is rather easily parallelizable. Scanning in larger sites can be manageable when the sites are divided into blocks.

 The last type of scanning is manual scanning; this type of scanning is flexible and can be made under most environmental conditions. It is easy to deal with a mistake because the code may be rescanned or manually input if it has been partially erased.

Pro tip: It is suggested that new sites introduce the manual scanning method into the QC process in construction or commissioning for less effort.

2. Drone scanning

Recently, large numbers of guns’ serial numbers have been collected by drone-based scanning techniques. The process is fairly straightforward: a drone covers the modules and takes pictures or records a video or barcodes are sensed in the photographed images. However, the following are demerits of this method:

First of all, the imager’s resolution must be very high to gather adequate barcodes for scanning with no problems. This requirement is to restrain the flight altitude and speed to relatively low levels, which tremendously elongates the time that is required for the flight.

Secondly, the skilled operational manned/unmanned aircraft pilots and barcode detection technology are costly. Pilots flying the drones can be as much as ten times more expensive than non-specialist personnel while drone flights may be up to ten times faster than manual scanning. However, the cost of processing and analysis generally is higher and when one looks at the level of cost per scanned module, the cost is relatively higher.

Last but not least, drone-based scanning is relatively rigid. This approach is not suitable for all types of modules and depends on the weather conditions. As for labels, many modules have serial number stickers on the back, which is why objects cannot be scanned using drones. This issue is expected to increase due to the rising popularity of frameless bifacial modules. Moreover, correction processes are difficult, particularly in the areas of mistakes that have been made. If a barcode picture is blurry, or the sticker has been faded, then it cannot be registered.

However, manual scanning is not always the better option as it is also colored with the following limitations. It must be prepared in advance to be worked out to the smallest detail. The paper-based approach can be a good match if your modules have barcodes with stickers on the front side and you require scanning all of the serial numbers at once.

Comparison of different parameters between drone & manual scanning

3. Digital Twin

Serial number tracking is not at all straightforward, no matter which method is used to collect them. Storing this data requires a systematic approach, which a geolocated digital twin for solar can provide. By integrating the serial numbers of each panel into the digital twin platform for solar, it becomes possible to manage this information more effectively. This process, known as digital twin data management, is essential for maintaining accurate records and tracking the performance of individual panels within the digital twin of a solar plant.

For selective scanning, the digital twin in photovoltaic systems and its corresponding field application help avoid time-consuming and unproductive searching for the desired module. The solar module digital twin application allows users to more effectively pinpoint the necessary modules for scanning. It also records the modules that have been scanned, saving the serial numbers to the cloud, which is crucial for efficient digital twin software operation. This process makes it impossible for a user to lose data, ensuring the integrity and accuracy of the information stored.

When performing bulk scanning, the barcodes can be stored in the corresponding sections within the solar farm digital twin integration, organized in the most systematic way possible. This organization prevents data from being lost and ensures that serial numbers are always associated with their respective modules. Such digital twin technology enables the identification of problematic batches of panels, facilitating warranty claims and proactive maintenance for solar panel monitoring with digital twin solutions.

In the case of failures, having a digital twin for solar power plants with all serial numbers integrated is crucial for warranty claims or replacements. Whether entering all serial numbers in advance or gathering them as needed, a well-implemented solar digital twin software combined with a field application will efficiently address the issue. The choice between manual or mechanical scanning of defective modules can be determined based on the number of defective modules and the available personnel, guided by the appropriate digital twin model.

Utilizing different types of digital twins, such as performance twins, operational twins, and predictive twins, can enhance the management of solar PV plants. The digital twin meaning encompasses the virtual representation of physical assets that provides real-time data and analytics, supporting decision-making and optimizing operations. The versatility of digital twin solutions allows for various digital twin uses in monitoring, maintenance, and asset management.

In conclusion, digital twin technology for solar plants plays a vital role in efficient serial number tracking and management, improving operational efficiency and ensuring the longevity of Solar PV Plants with Digital Twin capabilities.

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