Software Solution for Monitoring Solar Panel Manufacturing and Assembly Lines

Upcore's development of a highly responsive monitoring and control software solution filled a major gap in the client's automation suite, allowing them to offer complete line automation capabilities. The engagement demonstrated how dedicated agile teams can accelerate delivery of complex enterprise software solutions. The client is now exploring additional analytics features that can be built on top of the monitoring data foundation established by this software solution project.

Client:

Our client is a leading manufacturer of automated equipment for solar panel assembly lines. With installations across the globe, the client provides turnkey solutions encompassing machinery, software, and controls required to set up end-to-end photovoltaic panel production. Their automation systems assemble panels from raw components like frames, glass, and solar cells using conveyor belt-driven processes. The client also supplies automated quality inspection and panel testing systems.

Challenge:

While the client had deep expertise in the machinery and hardware aspects, they lacked specialized software capabilities to fully optimize their production lines. The client needed an integrated monitoring and control software solution with the following features:

- Real-time tracking of solar panels through each assembly stage
- Ability to control equipment and conveyor belt remotely through the software solution
- Interface with RFID tags on machinery and components for identification
- Access to external databases containing assembly data
- Mechanisms to keep all workstations in sync with the latest assembly status

Since speed to market was critical, the client couldn't dedicate resources to build this complex software solution in-house. They required dedicated engineering teams to design and develop the software solution using agile methods within tight timelines.

Upcore's Approach:

Upcore Technologies was engaged to rapidly build the end-to-end monitoring and control software solution using a distributed agile methodology. Our team of 6 developers and testers collaborated with the client's engineers at their headquarters to gather requirements and iterate the software solution.

After grasping the intricate assembly line environment, Upcore devised a . NET-based software solution with the following capabilities:

- Dynamic console screens provide operators complete visibility into the assembly process
- Real-time tracking of solar panel status as it traverses workstations
- Ability to control equipment and conveyor belt with on-screen commands
- Alert system to flag anomalies like machinery failures requiring intervention
- Authentication using Microsoft Identity Server for database access
- Mechanisms to keep all stations updated with the latest assembly data
- Secure connectivity between internal equipment and external systems

To overcome ambiguities in the external database provided, our team worked closely with the vendor's engineers to fix documentation. We also implemented robust error handling to make the software solution resilient.

The collaborative agile approach enabled us to deliver a high-quality software solution matching the client's specifications within a 4-month timeframe.

Solution Architecture:

The monitoring and control software solution was built using a .NET framework and followed best practices for modular, maintainable code:

Frontend
- Windows Forms for responsive UI design
- Real-time charting with LiveCharts library

Backend
- RESTful APIs with MediatR for equipment integration
- Entity Framework for database access
- Continuous integration with TeamCity

Database
- MS SQL Server for transactional data
- Redis for equipment statuses cache

Third-Party Integrations
- Microsoft Identity Server for auth
- Swagger for API documentation
- Subversion for source control

The software solution was hosted on private cloud infrastructure due to compliance considerations, with extensive monitoring and alerting built-in.

Results

The deployment of Upcore's monitoring and control software solution and RFID library resulted in the following impacts:

- Reduced the time to get assembly lines operational by 3.5 weeks
- Decreased machinery downtime by 30% through preventive alerts
- Increased output by 20% through workflow optimization
- Achieved ROI in less than 8 months with faster production velocity
- Savings of $200,000 annually by eliminating manual inventory processes
- Enabled seamless integration with upstream manufacturing stages

The client was able to start fulfilling their significant order backlog once the software solution was in place. Their CTO commented:

"Upcore's expertise and agile execution were invaluable in rapidly developing the complex software solution we needed to fully optimize our solar panel assembly lines. We can now deliver projects faster than ever before."

By delivering a tailored software solution aligning closely with their environment, Upcore enabled the client to realize the maximum potential of their production facilities.

Technologies Used:

MSSQL, MediatR, Swagger, SVN, Microsoft IdentityServer, C#