As large-scale photovoltaic (PV) systems continue to expand across industrial rooftops, efficient and safe inspection has become a critical challenge. Traditional manual inspection methods are often time-consuming, risky, and unable to detect hidden defects.
To address these challenges, Tintec deployed an advanced inspection solution combining the VineVolt tethered long-endurance drone system with high-precision thermal imaging technology, significantly improving inspection efficiency, accuracy, and safety.
Project Background & Challenges
Dalingshan Aoda Aluminum Co., Ltd. installed a large photovoltaic power generation system on the rooftop of its factory as part of its green manufacturing initiative. However, daily inspection and maintenance faced several major challenges:
- Low Efficiency – The large rooftop area and high number of solar panels make manual inspections slow and labor-intensive
- Safety Risks – Rooftop environments involve high-altitude operations and potential electrical hazards
- Missed Defects – Issues such as hotspots, diode failures, and micro-cracks are difficult to detect with the naked eye
- Downtime Loss – Traditional inspection requires partial shutdown, reducing power generation revenue
Solution Overview
To solve these problems, Tintec provided a fully integrated drone inspection solution:
- Drone Platform – Autel Robotics EVO MAX 4T for stable flight and precise positioning
- Tethered System – VineVolt system providing continuous power for long-endurance operation
- Payload – High-resolution thermal imaging camera for accurate temperature measurement
Key Technologies
- Continuous Power Supply – Enables uninterrupted 24-hour operation without battery limitations
- RTK Positioning – Provides centimeter-level accuracy for precise fault localization
- Real-Time Monitoring – Operators can detect and mark abnormal hotspots instantly
Operation Workflow
- Planning – Generate high-resolution orthophotos and define automated inspection routes
- Deployment – Install the tethered ground system and connect to industrial power supply
- Inspection – The drone performs automated flight while collecting thermal and visual data
- Data Collection – Simultaneous recording of thermal images, videos, and GPS positioning data
Results & Performance
- Inspection time reduced from 2–3 days to just 3 hours
- Over 800% improvement in efficiency
- 27 suspected fault points identified:
- 19 hotspots
- 5 overheated junction boxes
- 3 abnormal string connections
Value & Benefits
- Safer Operations – Fully contactless with no high-altitude risk
- No Downtime – Inspection completed without shutting down the system
- Cost Savings – Early fault detection prevents major losses and potential fire risks
- Data-Driven Reports – Includes thermal images, fault maps, and precise location data
Customer Feedback
“Tintec’s tethered drone solution exceeded our expectations. We completed a full inspection in record time, and the reports clearly guide our maintenance team on where to act. This technology has significantly improved our efficiency, safety, and cost-effectiveness.”
Conclusion
Tintec’s tethered drone inspection solution sets a new benchmark for industrial PV maintenance. It is an ideal solution for large-scale solar plants and industrial rooftop installations seeking higher efficiency, accuracy, and safety.
Looking for a reliable drone inspection solution?
Contact us today or explore our tethered drone systems to learn more.
