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Future ID of PV Solar Panel: Through RFID

CoE RFID Lab, IaITo InFoTECh PVT. LTD.

RFID (Radio Frequency Identification) is an excellent real-time tracing tool that improves the management of supply chain by enhancing its productivity, accountability and inventory management not only in shop floor but also in large scale on/off grid power plants. Highly reliable industrial RFID provides 100% process traceability even through harsh environment condition. Thus, the unique capabilities of RFID qualified to be an integral part of the solar module for its long service & support life cycle.

he world is more and more concerned with fossil fuel exhaustion and environmental problems caused by conventional power generation, renewable resources are becoming a focal point of the environmental movement, both politically and economically. In such circumstance the photovoltaic (PV) technology is going to play a key role. India receives solar energy equivalent to over 5000 trillion kWh/year, which is far more than the total energy consumption of the country. The National Solar Mission (Nov. 2009) guideline by Govt. of India, the domestic market for PV manufacturing industry has shown an exponential growth projection. Even Govt. is trying to regulate RFID tagging (to store its manufacturing specification details) for each of its panel enabling its traceability and identification as per ISO 9000 clause 7.5.3. Historically PV manufacturer use the barcode system. Conceptually, bar coding and RFID are quite similar; both are intended to provide rapid and reliable item identification-and-tracking capabilities but they are different in many ways. Bar code Vs RFID technologies are NOT mutually exclusive, nor will one replaces the other. They are both enabling technologies with different physical attributes. The superiority of RFID over Barcode conceive it as a best in-shape technology to give better tracing tool to improve the ability of supply chain by enhancing its productivity, accountability and item level visibility of PV Panels for long life. What is RFID RFID enables wireless data capture and transaction processing. RFID is an automatic identification method which relies
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tABLe 1.0: RfiD vS. BARcODe cApABiLity MAtRix Sheet ADvAntAge Of uSing RfiD OveR BAR cODe Parameters Line of sight to track PV Solar Panel Reading multiple tags Cope with dirty & harsh environment Extra memory for storing other data for PV Solar Panel Read & write capacity Possibility of automatic tracking Electronics ID Cloning / Product Authenticity DiSADvAntAge Of uSing RfiD OveR BAR cODe Parameters Commercial New Technology Challenge Factor Availability Technology Provider Bar Code Low Low High High RFID High High Low Low Bar Code X X X X X X X RFID X

on storing and retrieving remote data on/ from devices called as Transponders or RFID Tags. Radio Frequency Identification (RFID) is the technology that has revolutionized the way identification and tracking of items is carried out. Data is stored on a chip called RFID tag which can be attached to the PV cell and module which can be read by wireless devices called RFID readers. RFID system comprises of three components: RF ID transponder or RF ID tag RFID Writer/Reader RFID Handheld How RFID Technology Works The antenna emits radio signals to activate the UHF passive tags (without battery) and to read and write data to it. The reader emits radio waves, depending upon its power output and the radio frequency used. When an RFID UHF passive tag passes through the electromag-

netic zone, it detects the readers activation signal. The reader decodes the data encoded in the tags integrated circuit (silicon chip) and the data is passed to the host computer for processing.

Figure 1: Typical RFID system components

Different RFID Technology Matrix Currently, there are several technologies/ frequencies used in RFID as above given in comparative matrix in table 2.0. Looking after the derivative parameters (like passive, maintenance free & lowest cost) UHF
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tABLe 2.0: DiffeRent RfiD technOLOgy cOMpARAtive MAtRix tABLe Technology /Ability Application Multiple Tag Read Tag Power Standards Tag Form Factor Maintenance Read Range Units Cost Labels HF Technology (13.56 MHz) Access Control, Laundry Library Management Slow(2-5 tags/Sec) Power Less ISO 15693,14443 A/B Small Not Required Very Low(10 Cm) Low( $) UHF Technology (860-960 MHz) Active Technology (2.45 GHz/433MHz)

Tagging, SCM, Inventory Management, Health Health Care, RTLS Care, Aviation, Retail, Transportation Faster(20 to 100 tags/Sec) Power Less EPC C1G1/C1G2/18000-6A,B,C Small Not Required Good Range(2-4M) Very Low(few cents) Faster(10-20 tags/Sec) Battery Power No such standards Big Required High Range(20 M) Very High(few $)

EPC Gen2 is recommended for use in Solar Power Plants for tracking and operation management. RFID technology promises to improve a broad range of processes in logistics and WIP in manufacturing of PV industry. RFID allows better monitoring of the PV manufacturing processes with expedient raw material flow and more effective planning and control. It helps in monitoring where and when a part is located throughout its flow shop in its production process. The key features that separate RFID technology from its competing partners such as optical barcodes are non-line-of-sight tag reading. The PV manufacturing industry is very much automated and it undergoes several

Figure 2: PV Solar Module (Cr-Si) Manufacturing. Process

ADvAntAge AnD DiSADvAntAge Of inteRnAL & exteRnAL tAgging Tagging Internal Tagging External tagging

Certification of the Module

Since RFID tags consist of a silicon IC and will be Here RFID tags are placed in back of the panel placed inside the module .So by internal tagging from outside. So tagging usually doesnt need any certification is mandatory. recertification. Will be low Will be higher enough to read the panel mounted at some height like steel structure, street light.

Tag Read Range

Tag life

Good, Usually the tagging will be done during the lamination process and data feed inside the tag will be after module get tested using flasher. So if in different process (high temperature) get damaged replacing the tag will be not possible.

Very Good Tagging get at the place of flasher testing using Sun simulator. Even if the tag is found damaged in the process it can be replaced easily.

Physical Abuse 25 years of Warranty of panels Maintenance Cost

Not Possible

Possible

In due course of the PV panel warranty, if the tag get In due course of the PV panel warranty, if the tag get damaged it cant replaced. As whole module need to damaged it can easily be replaced with a new one get replaced. with different unique ID. Not Required Not Required

Higher than external tag, since the tag has to Lower than internal tag, only UL level of adhesive are withstand high temperature. used for long life.

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Figure 2: PV RFID Tracker Tags.

processes to get a finished product. RFID tags will be in the form of adhesive labels (lifespan of 10,000 times write) which can be read/write with the RFID reader/writer station. RFID tags can be embedded in solar panels during PV manufacturing processes in two ways. Case 1 (embedding the tags inside PV): RFID tag is embedded in solar panel during the lamination process. PV characteristics (like Electrical, mechanical, Environmental, Certification etc) are written inside the tag after flasher system. Case2 (embedding the tags outside PV): RFID tag is attached to the solar panel externally after the flasher process externally. RFID PV Tracker Tags: RFID PV tracker tag is specifically designed for PV solar module tracking which contains a unique identity for each panel. All its performance data (electrical parameter, IV curve data, and its certification, cell and module manufacturer along with its date) is stored in the secure tag memory. It is capable of withstanding harsh environmental conditions like temperature, humidity, UV ray & rain etc. It is available in different form factor which will be suitable for various PV modules of diverse sizes. It can be tagged externally (junction box, back plate) after quality control. RFID UHF HandHeld Reader (PDA Based terminal is a rugged dual technology comes with embedded RFID middleware and windows CE 5.0 for easy integration. The RFID_HH_PDA has a software can read all the data in remote site of the on/off line of PV Power Plans. Software RFID Tracker Software is been designed and developed with open source framework and architecture. The software has
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a strong data compression, optimization & filtration algorithm which extracts all the relevant data from a data set of each module once it is being flashed inside the sun simulator. An operator can write all the data inside the RFID tags secure memory and can stick the label on the back of PV panel.

RFID System architecture & process flow in the solar PV manufacturing plant.

designed algorithm which carries all the Module information including IV curve graph as stated by MNRE guidelines (Sample tag data has also been attached for your reference) stage 3: The RFID PV tags (which will be in sticker form) will be ripped off. stage 4: Then the tags will be stuck on the backside of the PV Module. stage 5: Particular Modules as per order requirement can be tracked through RFID Hand-Held Readers in warehouse, which will also be connected with central database. stage 6: The module will be dispatched to client location for installation. Benefit for PV panel manufacturing using RFID Item-level visibility across manufacturing and distribution operations can help to track Location & quantity of the parts at each stage and the arising bottlenecks can be detected &resolved immediately. Reducing payouts for recalled or returned product. Reducing lost product and sales from shipping errors. Fast identification of the low efficient panel to be replaced/ relocated. Better preventive measurement & maintenance. Pilferage of the solar panels can be controlled. Keeping the PV panel authenticity from grey market and increase the country manufacturing facility.

stage 1: The RFID Writer Station will be installed near Sun Simulator and it will retrieve data directly from the Sun Simulator and process it for further writing process to the RFID PV tags. stage 2: The retrieved data will be burned to the RFID PV Tracker tags with specially

Conclusion The above details very much indicate how RFID technology can facilitate the entire PV solar panel manufacturer and to come out with completely enabling its traceability and identification.
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