Spain's Matrix Renewables Deploys Automated Assembly System at U.S. PV Project

en.Wedoany.com Reported - On November 12, Spain's Matrix Renewables deployed the Terafab V2 automated construction system developed by Terabase Energy in a portion of the construction area of its 457 MW Tormes Solar PV project in Navarro County, Texas, USA, with SOLV Energy serving as the project EPC contractor. This marks the first time the system has been used at a project site to integrate robotic assembly, AI-based quality inspection, and autonomous transport vehicles, creating an automated workflow covering PV module pre-assembly, quality inspection, and on-site transport.

Terafab V2 uses a modular assembly factory installed at the construction site, shifting part of the module assembly work that would otherwise be scattered across the PV array area to a centralized production line. After PV modules and tracker structural components enter the assembly line, robots pre-install the modules onto the tracker torque tubes, and the completed module units then undergo quality inspection through an integrated inspection system. Qualified modules are then loaded by robots onto autonomous transport vehicles called Rovers and delivered to designated installation locations. The modular factory can be relocated as construction progresses, with equipment redeployment and installation taking approximately 4 hours.

The system is equipped with a Manufacturing Execution System (MES) that centrally manages assembly processes, material flow, quality inspection, and transport tasks, and interfaces with construction planning, inventory management, and logistics software. A project digital twin system is used to map the on-site construction layout, while AI tools participate in workflow optimization and coordination of automated equipment. The system supports the configuration of multiple assembly lines within the same project to accommodate production needs at different construction stages.

According to equipment performance data published by Terabase, the production cycle of a single Terafab V2 assembly unit is approximately 2 minutes, and a single production line can assemble approximately 20 MW of PV module structures per week under continuous operating conditions. The equipment is designed to support round-the-clock continuous operation, and the company claims that its automated construction approach can achieve labor productivity up to twice that of traditional on-site installation methods. However, this efficiency figure is a performance metric provided by the company, and actual output still depends on project configuration, equipment utilization, and site conditions.

Currently, Terafab V2 mainly automates the pre-assembly of modules and tracker structures, quality inspection, loading, and transport. After the transport vehicles deliver module units to predetermined locations, construction personnel are still required to install them onto the pre-positioned trackers. At this stage, the equipment is primarily compatible with First Solar Series 7 modules and Nextpower tracker systems, with plans to expand compatibility in the future. Terabase announced in March 2026 that this version had completed on-site testing and was ready for commercial delivery. The Tormes Solar deployment will be used to verify its operational efficiency, quality consistency, safety, and cost performance in large-scale PV projects.

The Tormes Solar project held its groundbreaking ceremony on May 19, 2026, with a planned DC installed capacity of 457 MW, a total investment exceeding USD 750 million, an expected approximately 450 jobs during construction, and planned entry into commercial operation in the first half of 2027. Matrix Renewables is responsible for project development and investment, while SOLV Energy serves as the EPC contractor. The equipment operation and on-site organization data generated from this automated construction validation will be used to evaluate the conditions for applying this technology in subsequent large-scale PV projects.