Solar Industry Digital Transformation

Digital technologies have contributed significantly to the solar engineering industry. Previously, tasks such as hand calculation for shading angles, using Excel sheets for estimates, relying on historical data for project costs, and employing non-site-specific solutions were common practice.

Below, Sophie Nguyen, Senior Technical Support Engineer at PVcase, shares her experience regarding the evolution of solar engineering and the ongoing progress of solar design tools.

Early Experiences in Solar Engineering Design

Land due diligence was once a manual process—requiring visits to state institutions to gather information for land searches, estimating project size by experience or guesswork, and using that information for project financing. Designs were initially created for flat terrain and later modified once site surveys were completed. This approach led to longer redesign times to fit terrain information, increased engineering risks for site-specific projects, and calculations performed in Excel sheets. Despite heavy manual engineering work, frequent onsite revisions often caused project delays or unexpected increases in project costs during development.

Evolution of Software Tools

Before the advent of advanced tools, most designs were created in AutoCAD or Civil 3D. Designers manually created all blocks within AutoCAD, using automation tools like Dynamic Block or copy/paste, and performed many geometrical calculations by hand before inputting them into AutoCAD.

As project requirements expanded to include considerations like terrain, drainage, and roads, Civil 3D became more widely used due to its capabilities for ground grading and other civil engineering aspects. Designers began employing 3D elements instead of just flat 2D plans. However, tasks like cut-and-fill still had to be done manually in Civil 3D, which could be challenging for those without a civil engineering background. Civil 3D was also more complex and expensive than standard AutoCAD, and there was no comprehensive single tool for solar designers.

Later, applications such as Aurora Solar and Helioscope emerged, integrating sales and design processes. Initially, these tools focused on generating PDF reports for sales design and quick quote generation, rather than engineering. Over time, features were added to allow data export to DWG or DXF files, enabling layouts generated in Aurora or Helioscope to be imported into AutoCAD. However, designers still needed to clean up and connect elements in AutoCAD before proceeding with the design.

Improvements with PVcase Tools

PVcase introduced significant automation to the engineering process. Blocks are generated automatically when executing commands, and elements are joined together rather than being separate line segments. PVcase can automatically assign each element to different layers within AutoCAD, eliminating the need for manual layer assignment.

Spacing between frames is calculated automatically based on project location, removing the need for manual calculations of sun position, coordinates, and shading geometry. This automation reduces human error and streamlines the design process. What once took a week or two can now be accomplished in a day with automation tools.

For electrical design, PVcase automates labeling and numbering, making it easier for engineers to present data to clients. The tool also generates a detailed Bill of Materials (BOM), including precise cable lengths, which electrical engineers can use to calculate wire size or voltage drops.

PVcase's 3D elements display the distance from the frame to the ground and generate quick profile cuts through frames to analyze specific segments. This provides accurate models tailored to the terrain, rather than relying on approximations.

PVcase has also introduced new tools:

• ​PVcase Prospect: Integrates site selection and design by connecting seamlessly with PVcase Ground Mount. This reduces risks, keeps projects on schedule, and increases financial accuracy.
• ​PVcase Yield: Accurately calculates energy production, aiding in project financing and site feasibility estimations. It helps identify problematic site issues and reduces future operational risks.

The Future of Digital Solar Engineering

Looking ahead, the industry will see more accurate, site-specific solutions and increasingly streamlined, automated processes for development, financing, design engineering, and project management. For example, PVcase Prospect can be used for site selection, PVcase Ground Mount and Roof Mount for design engineering, and PVcase Yield for financial decisions. Eventually, these platforms will be integrated into a single, streamlined process.