AI and Robotics for the Reuse of Used PV Modules

The rapid expansion of photovoltaic systems is a key factor in the energy transition, but it also presents new challenges. One such challenge is knowing how to deal with the millions of PV modules that will reach the end of their service life in the coming years.
Currently, disused modules are typically recycled without first checking whether they can be reused. Until now, there have been no automated processes in place to make objective decisions. This is precisely where the new research project comes in, asking the question, “Watts OK? - Can the module be reused, or should it be recycled?”

With the official launch, the ‘WattsOK?’ research project is taking up its work and focusing 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 to the systematic reuse of photovoltaic modules – and in doing so, we are leveraging the strength of AIT to translate research into industrial solutions,’ explains Andreas Kugi, Scientific Director of the AIT Austrian Institute of Technology (AIT).

Coordinated by the AIT , the research project addresses the growing volume of used PV modules and lays the technological foundation 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 demonstrates how applied research can contribute to more efficient use of resources in line with the principles of the circular economy,” adds her colleague Laurin Ginner. Both scientists conduct research at AIT in the field of high-performance optical inspection and image processing.

Smart decision-making process
At the heart of the project lies an intelligent, automated process that determines whether used PV modules can be reused or need to be recycled. This process includes:

• AI-supported optical inspection procedures to check surface quality
• precise electrical measurements to check functionality.

The process is complemented by the robot-assisted replacement of connectors, which is an initial refurbishment step that makes the modules usable again.
A central role in this process is played by a database that links inspection data, measured values and product specifications. Not only does this database serve as the basis for the AI algorithms, it also ensures transparency and traceability of decisions.
“With our system, we are the first in the field of automated, economically viable testing of PV modules that is also suitable for larger quantities. WattsOK? uses the data from these tests. We, and therefore our customers, benefit from the results of the research project. It is a great example of how research and commercial use can be efficiently combined for the benefit of everyone involved,” says Simon Prüller, CEO and co-founder of 2nd Cycle.

Success story: From a pilot project in EDIH AI5Production to a funded FFG project
The research project that has now been launched was preceded by a successful pilot project within the framework of the European Digital Innovation Hub (EDIH) AI5Production. As part of the ‘Test Before Invest’ initiative, initial innovative approaches to automated optical inspection of used PV modules were tested and validated in close cooperation between the AIT Centre for Vision, Automation & Control and the Lower Austrian green tech start-up 2nd Cycle FlexCo. 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 exemplifies how a low-threshold entry into digitalisation via the EDIH can become a fully-fledged, funded research project.

AI5Production – Digital booster for industry
AI5Production supports Austrian companies in their digital transformation with a focus on artificial intelligence, Industry 5.0, cybersecurity and digital production. With access to state-of-the-art infrastructure, consulting and test environments, the hub is the central point of contact for innovative developments. 

Project partners
AIT Austrian Institute of Technology  – Coordination, high-performance surface inspection, AI decision-making processes, reuse strategies
2nd Cycle FlexCo  – Multi-sensor reuse/Recycling Line
PROFACTOR GmbH  – Robotics
TÜV AUSTRIA HOLDING AG  – Development of scalable data structure and data fusion, AI decision-making processes
Montanuniversität Leoben, Lehrstuhl für Abfallverwertungstechnik und Abfallwirtschaft  – Life cycle assessment
METRAN Rohstoff-Aufbereitungsgesellschaft m.b.H.  – Recycling-strategies

The ‘WattsOK?’ project is funded by the Federal Ministry for Innovation, Mobility and Infrastructure (BMIMI) as part of the national RTI call for proposals on circular economy and production technology. It is administered by the Austrian Research Promotion Agency (FFG).