Back Ground
5B
Australia-wide
5B changes the energy sector with prefabricated solar technologies, focusing on delivering clean energy faster and safer. Their Maverick system redefines how solar farms function. The engineering team needed a way to verify the structural limits of these modules.
They contacted Giant Inflatables Industrial for a specialised inflatable load testing bag. The goal was to create a tool that could assist in rigorous compression testing for their commercial solar arrays.
Challenge
Testing solar panels demands precision. Applying weight unevenly causes inaccurate results. Standard weights often damage the delicate photovoltaic surface. 5B required a method to apply even pressure across the whole module.
- The tool had to fit a custom test rig.
- It needed to handle repeated high-pressure cycles.
Design and Fabrication
Giant Inflatables Industrial used drop-stitch matrix web construction. This material features thousands of threads connecting the top and bottom fabric layers.
- It ensures the inflatable load testing bag stays flat when filled.
- It prevents bulging and ensures uniform contact with the panel.
- This specific size matches the 5B module dimensions perfectly.
The inflatable construction allows for high compression without losing shape, creating the controlled environment 5B needed for precise calculations.
Results
The project met every requirement for the 5B testing facility. Rhett Evans, Head of Performance and Reliability, noted the system was highly successful.
- His team tested hundreds of modules.
- The inflatable load-testing bag maintained stable pressure, providing accurate data.
- Monitoring equipment showed the solar panel holding loads over 266 kilograms.
- 5B commissioned a second unit for larger modules.
The inflatable load testing bag provided the accuracy 5B needed to validate their products with confidence.
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