Photovoltaics (PV) is the key technology for the transition to a climate-neutral energy supply. The long-term performance and reliability of PV modules are crucial to their economic viability and sustainability. A major problem is moisture absorption in modules, which can lead to power losses, material degradation, and safety-related damage. Currently, there are no practical, non-destructive methods for the early detection of moisture damage in PV modules. Previous studies have been limited to invasive or purely laboratory-based methods that are not suitable for widespread use in the field.
The project aims to develop and validate a non-destructive measurement method for detecting and visualizing moisture in encapsulation material. To this end, a methodology will be developed that combines NIR spectroscopy with chemometric analysis.
Overall Project Objective
The goal of INSIGHT-PV is to develop non-destructive analytical and diagnostic methods for detecting and quantifying moisture in PV modules—both in the laboratory and under real operating conditions. The innovative aspect lies in the combination of state-of-the-art spectroscopic and imaging techniques with data-driven analysis methods (e.g., chemometrics and machine learning).
This is intended to identify moisture damage at an early stage, investigate its reversibility, and assess its effects on module performance and safety. In addition to materials analysis research, the focus is on the development of measurement systems. These are intended to be suitable and usable for industrial quality assurance and maintenance.
The integration of these non-destructive methods into production and operational processes enables new approaches to condition monitoring and lifetime prediction for PV modules, which is particularly essential in the context of the second life of PV modules. It represents a decisive step toward greater efficiency, safety, and sustainability in the PV sector.
Key Project Objectives
- Identification of suitable spectroscopic (e.g., NIR, UV fluorescence) and imaging-based measurement methods for moisture detection in PV modules
- Development, construction, and validation of non-destructive sensor systems for spatially resolved moisture measurement in laboratory and field environments
- Calibration and validation of the measurement methods using established reference methods
- Investigation of the correlation between moisture absorption and electrical performance or safety-related effects
- Analysis of the reversibility of moisture-related effects and evaluation of potential regeneration measures
- Involvement of industrial partners for testing and applying the methods on real PV systems and at production sites
- The project makes an important contribution to extending the service life of PV modules and reducing resource consumption and the carbon footprint per kWh generated. It also promotes innovation in the fields of sensor technology, materials analysis, and sustainable energy infrastructure (second life). INSIGHT-PV thus lays the foundation for future-oriented quality assurance, investment security, and new business models in the photovoltaic industry.
Project Consortium
- Lead: Silicon Austria Labs GmbH
- Scientific Partners / Testing Institutes: OFI Technologie & Innovation GmbH
- Industry Partners: 2ndCycle, SONNENKRAFT GmbH
Project facts
Title: Non-destructive detection of moisture ingress in PV modules and its impact on power output and module safety
Funding Agency: FFG Energy Research 2025, an initiative of the Federal Ministry for Infrastructure, Transport, Innovation, and Technology (BMIMI) and the Energy and Climate Fund
Project leader: Silicon Austria Labs GmbH
Project duration: 2026 - 2028
