Autonomous 3D Visual-Thermal Inspection for Utility-Scale Solar Farms

Abstract

Utility-scale photovoltaic (PV) inspection is dominated by aerial surveys, which are effective for identifying module-level hot cells but provide limited visibility of critical components located under the array, including connectors, cabling, fasteners and structural elements. These assets are difficult to inspect consistently at scale, and their defects are often spatially small, partially occluded and difficult to localise from isolated images. We present an automated 3D visual-thermal inspection system (Tricorder) for under-panel PV asset inspection. The approach combines LiDAR-inertial Simultaneous Localization and Mapping (SLAM) with geometrically calibrated RGB and thermal imagery and machine-learning-based object detection and segmentation. Detected assets are associated with the reconstructed 3D environment, allowing visual and thermal observations from multiple viewpoints to be spatially fused and localised. We demonstrate the approach on utility-scale PV data for MC4 connector detection and connection-state recognition, thermal anomaly identification, and detection of structural components including bolts, nuts and torque tubes. The results demonstrate a pathway from image-based inspection toward spatially grounded autonomous inspection, where defects are detected and linked to specific assets and their 3D locations within the solar farm.