Recently, Simulation World China 2026 was held in Ningbo, Zhejiang. With the theme “Reinventing Engineering Innovation,” the conference brought together experts from the renewable energy, automotive, high-tech, and other industries. Liu Ji, a liaison engineer from the Photovoltaic Technology Center of Tongwei Co., Ltd., was invited to attend the conference and deliver a keynote speech, providing a comprehensive presentation of Tongwei’s latest achievements in structural simulation of large-format photovoltaic modules and AI-enabled R&D.

As large-format, high-power modules have become mainstream in the market, the wind-exposed area and self-weight of PV modules have increased significantly, while extreme loads have grown exponentially. As a result, module frames face far greater torsional resistance challenges, while mounting structures and installation reliability are subjected to much more demanding requirements than before. At the same time, encapsulation technologies such as dual-glass and frameless designs have altered the stiffness distribution of modules. Traditional physical testing is limited by long testing cycles, high costs, and “black-box” validation. General-purpose finite element analysis (FEA) software also faces challenges such as complex modeling, experience-dependent meshing, and non-standardized workflows, constraining the efficiency of R&D iterations.

Liu Ji, Liaison Engineer at the Photovoltaic Technology Center of Tongwei Co., Ltd., Delivers a Keynote Speech

In his keynote speech, titled “Ansys-Based Rapid Simulation and AI Analysis Platform for Solar Module Loads,” Liu Ji stated that Tongwei has developed a “Rapid Simulation and AI Analysis Platform for Photovoltaic Module Loads.” Centered on standardization, modularization, and automation, the platform is designed to upgrade simulation from an “expert tool” into a “design tool” accessible to all.

The platform features four core capabilities. First, it enables “building-block-style” parametric modeling by breaking down components such as aluminum frames, glass, solar cells, and mounting structures into a standardized component library. These components can then be quickly assembled through parameter-driven modeling, eliminating the need for repetitive drawing. Second, it provides fully automated pre-processing, completing geometry repair, meshing, contact definition, and load and solver parameter configuration with a single click, thereby eliminating variations arising from individual experience. Third, it establishes databases for material parameters and simulation results, standardizing mechanical properties and enabling historical simulation cases to be traced and reused. Fourth, it introduces AI-based safety and load assessment. By training models on extensive simulation data and incorporating regional wind and snow load standards, the platform can output safety factors and risk levels within seconds, enabling proactive risk prevention.

At the Forum

The platform has delivered significant results: the simulation cycle for conventional modules has been shortened by more than 50%; AI-based multi-condition assessment is more than 10 times faster, reducing the overall assessment cycle by more than 60%. With simple training, conventional structural R&D personnel can independently complete routine simulations, substantially reducing reliance on expert experience.

Tongwei developed the platform with the aim of moving simulation forward to the solution design stage, replacing individual experience with standardized processes and one-off calculations with accumulated data assets. It provides structural and mechanical support for diverse technology routes, including TOPCon, HJT, TBC, and perovskite tandem technologies. It also provides a quantitative basis for matching modules and mounting structures across different environments, including areas with wind and sand, coastal regions, and regions with ice and snow. Ultimately, the platform is designed to support reductions in the levelized cost of electricity (LCOE) and safety throughout the entire life cycle.

As a leading enterprise in photovoltaic technology innovation, Tongwei continues to promote the integration of simulation digitalization and AI-driven R&D, guided by its global innovation and R&D centers. In the future, Tongwei will further deepen the integration of its simulation platform with outdoor validation and closed-loop mass-production processes, accelerate the development and iteration of large-format, highly reliable modules, and contribute Tongwei solutions to the global energy transition.