CASE STUDY: Detecting Busbar Corrosion & Delamination

2024

Client Challenge

A solar farm operator required a detailed inspection after noticing irregular performance across certain strings. They needed:

• High-resolution imaging to confirm whether panel degradation was linked to busbar corrosion or other issues.

• A full record of affected panels to support warranty claims.

• Insight into whether these faults were isolated or following a wider pattern.

Our Approach & Findings

Our Approach:
Futurewise Aerial deployed ultra high-resolution drone imaging across the site, capturing every panel at cell-level clarity. Our proprietary processing system enabled us to: – Detect water ingress at scale. – Extract and verify serial numbers up to 8x faster than manual methods. – Map the location and distribution of faults across the entire layout.

Analysis revealed:
– Multiple panels showing clear signs of water ingress.
– Faults were not evenly distributed across the site.
– Instead, faults formed a regular linear pattern down the site.

Our Approach

Futurewise Aerial conducted a full-site inspection using ultra high-resolution drone imagery. Our proprietary processing identified defects at cell-level detail and allowed us to:

• Detect and classify busbar corrosion and delamination.

• Record precise panel positions and serial numbers.

• Map fault clusters and distribution across the solar farm.

Findings

• Clear evidence of busbar corrosion in multiple strings.

• Several modules displayed delamination, visible as detachment within the encapsulant layer.

• The faults were clustered in certain areas, suggesting a potential link to batch quality or installation handling rather than random wear.