The challenge
EagleNXT evaluated whether drone-based 100% IR inspection could replace conventional manual methods across four solar sites ranging from 12.5 MW to 74 MW. Each site used a different legacy inspection method — clamp testing with 20% IV curve tracing, Voc/Isc testing at combiner box level, 100% handheld IR scanning, and full IV curve tracing — making this a uniquely comprehensive comparison.
The sites
The solution
Each site received a 100% infrared drone inspection. RGB and thermal datasets were combined with automated defect detection, geo-located anomaly mapping, and manual QC classification. Final reports were delivered within 5 business days of data collection.
The results
Across all four sites, drone inspection was 97% more efficient than manual methods. The drone inspection rate was 10 minutes per MW — compared to days per site with ground crews. Cost savings ranged from $1,074 to $1,717 per MW, averaging $1,254/MW.
Crucially, when manual inspection crews revisited to validate drone findings, they confirmed results with 99% accuracy — but the manual validation alone took 2 days per site versus 2 hours with the drone.
EagleNXT comparative study — four utility-scale solar sites totaling 137.5 MW across Mississippi, Connecticut, Georgia, and California.
Results cited are from third-party field studies and may not represent AXION-operated missions. Savings, timelines, and accuracy figures depend on site conditions, equipment, and methodology.
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