Hailstorm Impact on Photovoltaic Modules: Damage Mechanisms, Testing Standards, and Diagnostic Techniques

This study examines the effects of hailstorms on photovoltaic (PV) modules, focussing on damage mechanisms, testing standards, numerical simulations, damage detection techniques, and mitigation strategies. A comprehensive review of the recent literature (2017–2025), experimental results, and case studies is complemented by advanced simulation methods such as finite element analysis (FEA) and smoothed particle hydrodynamics (SPH). The research emphasises the crucial role of protective glass thickness, cell type, number of busbars, and quality of lamination in improving hail resistance. While international standards such as IEC 61215 specify test protocols, actual hail events often exceed these conditions, leading to glass breakage, micro-cracks, and electrical faults. Numerical simulations confirm that thicker glass and optimised module designs significantly reduce damage and power loss. Detection methods, including visual inspection, thermal imaging, electroluminescence, and AI-driven imaging, enable rapid identification of both visible and hidden damage. The study also addresses the financial risks associated with hail damage and emphasises the importance of insurance and preventative measures. Recommendations include the use of certified, robust modules, protective covers, optimised installation angles, and regular inspections to mitigate the effects of hail. Future research should develop lightweight, impact-resistant materials, improve simulation modelling to better reflect real-world hail conditions, and improve AI-based damage detection in conjunction with drone inspections. This integrated approach aims to improve the durability and reliability of PV modules in hail-prone regions and support the sustainable use of solar energy amidst increasing climatic challenges.