Soiling on photovoltaic (PV) modules is an ongoing issue that reduces energy yield and necessitates frequent cleaning, especially in dusty regions. Hydrophobic anti-soiling coatings (ASCs) have emerged as a promising solution to reduce dust adhesion and cleaning frequency. However, their long-term durability under real-world cleaning practices remains a concern. To address this, a study was carried out at NCPRE by Pavan Fuke, a PhD scholar, and Sandeep Kumar, a project staff member, under the guidance of Prof. Sudhanshu Mallick, Prof. Narendra Shiradkar, and Prof. Anil Kottantharayil. The research employed a controlled laboratory abrasion test (described above) replicating realistic dew-dust-dry-clean (DDDC) runs. The four cleaning loads (300 gf, 600 gf, 900 gf, and 1010 gf) were carefully selected based on a separate outdoor experiment conducted at IIT Bombay, which measured the actual forces applied during manual PV module cleaning. Results revealed that coating degradation does not follow a simple linear relation with load. Moderate loads (600-900 gf) caused the fastest coating failure due to direct bristle-to-surface contact. In contrast, the lowest load (300 gf) applied insufficient force for strong abrasion, and the highest load (1010 gf) bent the brush bristles, preventing their sharp tips from directly scratching the surface. These effects allowed both extreme loads to preserve the coating longer. Importantly, the durability tests were performed by considering complete cleaning of soiled glass coupons. For this, the number of cleaning cycles per run was adjusted depending on load: four cycles for 300 gf, three for 600 gf, two for 900 gf, and one for 1010 gf. As shown in the figure below, coatings subjected to 900 gf failed after ~57 DDDC runs, while those under 300 gf and 1010 gf survived nearly twice as long. These insights highlight the importance of optimising cleaning practices to balance dust removal efficiency with coating preservation. The findings suggest that extreme loads, either low or high, can enhance coating durability compared to moderate loads, providing valuable guidance for cleaning strategies in utility-scale PV plants. The manuscript has been accepted for publication in Solar Energy, a reputed journal in the PV field with an impact factor of 6.6.
Effect of abrasion cycles under varying loads (300 gf, 600 gf, 900 gf, 1010 gf; black, red, blue, green) on the contact angle of the hydrophobic coating during DDDC runs to achieve the complete cleaning of the soiled glass coupon. Coloured vertical lines mark failure points, and the light sky-blue zone indicates the hydrophilic transition (WCA < 90°).