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Physics-Informed Predictive Maintenance for PV Inverters

Predict. Extend. Optimize.

Physics-grounded RUL estimation and predictive maintenance for utility-scale photovoltaic inverters.

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The Challenge

Inverters are the bottleneck of PV plant reliability

They cause 70% of O&M events and 36% of energy losses, with a useful life of 10-15 years vs. the 25-30 years of the modules they serve.

Late Detection

Faults found post-failure

High O&M Cost

€ thousands per unplanned outage

Reactive Maintenance

Replace-after-failure cycle

No RUL Visibility

Operators fly blind on remaining life

36%

Energy losses linked to inverter faults

70%

Of all PV plant O&M events

10-15 yrs

Inverter life vs 25-30 yrs of modules

180 d

Lead time on key spare parts

The Solution

Physics-Informed AI That Knows Your Inverters

InverterAI fuses Coffin-Manson, Arrhenius and PINN models with SCADA data to deliver auditable RUL predictions you can act on.

PINN-based RUL

Physics-Informed Neural Networks forecast remaining useful life of IGBT modules, capacitors and cooling systems with confidence intervals spanning 1 to 20 years.

1-20 yrs
Forecast Horizon

Coffin-Manson Fatigue Model

Quantifies IGBT thermal cycling fatigue using Coffin-Manson kinetics and rainflow cycle counting to predict solder and bond-wire degradation.

α=4-6
Fatigue Exponent

Arrhenius Capacitor Aging

Models electrolytic capacitor degradation with Arrhenius kinetics — every 10°C rise halves remaining life. Tracks ESR drift and capacitance decay continuously.

10°C → 2×
Aging Acceleration

Virtual Tj Sensing

Estimates IGBT junction temperature without direct sensors using a Foster/Cauer thermal network constrained by physics — the most critical and unmeasurable variable.

Foster/Cauer
Thermal Network

Physics-Aware Risk Scoring

PINN-driven risk score (0-100) with admin override capability, SHAP + Integrated Gradients attribution, and full audit trail per inverter.

0-100
Risk Score

Role-Based Dashboards

Three purpose-built dashboards — Operator (fleet semaphore), Engineer (RUL trends and scenarios), and Auditor (compliance and traceability) — each surfacing the right metrics.

3
Operator / Engineer / Auditor
Platform Features

Built for Solar Asset Operators at Scale

A robust platform designed to integrate seamlessly with multi-OEM SCADA environments while providing the flexibility to grow with your solar fleet

Operator/Engineer/Auditor Dashboards

Three role-specific dashboards — fleet semaphore for operators, RUL trends and what-if scenarios for engineers, and compliance traceability for auditors.

Multi-OEM SCADA + NSRDB Weather

Connect with Huawei, Sungrow, SMA, TMEIC and Power Electronics SCADA. NREL NSRDB weather integration for physics-aware feature engineering.

IEC 61724 / IEC 62093 Reports

Generate IEC-compliant performance and inverter health reports automatically. Export in PDF and Excel for regulatory submissions and internal audits.

Pre-failure THD & Tj Alarms

Configurable thresholds for THD > 4.9%, ΔR_th rise and ESR drift — the EPRI-validated early-warning indicators for inverter pre-failure.

Enterprise Security

AES-256 encryption and SOC 2 Type II compliance with role-based access control and SHA-256 cryptographic audit trails.

On-Prem, Private Cloud or SaaS

Deploy on-premises, in your private cloud, or use our secure SaaS platform. Hybrid options available for multi-site operators.

How It Works

From SCADA to Maintenance Decision in Seconds

01

SCADA Ingestion

Multi-OEM telemetry: Huawei, Sungrow, SMA, TMEIC, Power Electronics

02

Physics-Aware Features

Tj estimation, ΔTj rainflow, ESR drift, NSRDB weather

03

Hybrid Ensemble + PINN

Gradient Boosting + RF + physics regularizers

04

Maintenance Work Orders

RCM/CMMS-ready actions per role

< 5 min
Inference Latency
180 mo
Nominal Life Modeled
1-20 yrs
Forecasts
100%
Audit Trails
Why InverterAI

Built Different. Performs Better.

Detection Lead Time
Reactive O&M:Post-failure
InverterAI:
Up to 30 days ahead
RUL Horizon
Reactive O&M:None
InverterAI:
1-20 years
Drift Monitoring
Reactive O&M:Manual recalibration
InverterAI:
Auto, continuous
Pre-failure Indicators
Reactive O&M:Vibration only
InverterAI:
THD > 4.9%, ΔR_th, ESR drift
Confidence Intervals
Reactive O&M:None
InverterAI:
Bayesian + bootstrap
Explainability
Reactive O&M:Black box
InverterAI:
SHAP + Integrated Gradients
Audit Trail
Reactive O&M:Paper logs
InverterAI:
SHA-256 cryptographic

See the difference yourself. Request a demo

Who We Serve

Built for the entire PV inverter value chain

From OEM design floors to multi-GW O&M control rooms, InverterAI delivers physics-grounded inverter intelligence to every stakeholder.

Inverter Manufacturers

Validate designs, model lifetime and protect warranty margins before silicon ships

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PV Energy Generators

Extend inverter life, recover lost MWh and cut unplanned downtime across the fleet

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Asset Management & O&M

Unified KPIs, bankable reports and predictive dispatch for multi-client portfolios

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Operating in a different segment? Contact our team

Ready to Extend the Life of Your Solar Fleet?

Join leading solar operators using InverterAI to predict, extend and optimize their inverter assets.

20%
Inverter Life Extension
35%
O&M Cost Reduction
70%
Downtime Reduction