Production solution for metal components in the photovoltaic industry

In the manufacturing and system integration of photovoltaic products, metal springs and wire forming components are common elements that ensure reliable electrical connections, stable structures, and durability. The photovoltaic industry has set clear requirements for the production of these components: they need to be made of materials that are durable enough to withstand outdoor environments, meet the supply stability required for large-scale installations, and be able to flexibly adjust with product technology iterations.

1. Production plan for photovoltaic connection system components

The electrical connection between photovoltaic panels, as well as the internal conduction and fixation of junction boxes, rely on a series of components molded from metal wires. These components are typically required to serve outdoors for extended periods, and thus have corresponding requirements for contact reliability, mechanical elasticity, and environmental resistance.

Solution:

Integrated molded connection terminal: Utilizing a five-axis or higher-axis CNC wire bending machine, multiple servo axes can coordinate their movements according to a preset program, completing the bending and winding of metal wires in a single process, forming a connection terminal that combines elastic contact and mechanical locking functions, which helps reduce subsequent welding or assembly processes.

Stable production of standard spring components: For standard springs used for cushioning and clamping inside junction boxes, a CNC spring coiling machine is employed for production. The equipment manages wire feeding, rotating, and forming steps through a digital system, ensuring consistency in production pace and product specifications.

Rapid adaptation to design updates: The adoption of a camless spring machine. When component designs change, the motion programs of each forming arm are adjusted through software to adapt to the new shape, providing production-side response support for product iteration at the OEM level.

II. Production Plan for Photovoltaic Support System Components

Photovoltaic (PV) support systems need to withstand loads such as wind and snow. In some designs, elastic components are used to achieve buffering, adjustment, or locking functions. These components must possess mechanical properties that meet the design expectations.

Solution:

Variable diameter and pitch spring forming: For buffer or pressure springs used in brackets, a CNC spring coiling machine can achieve changes in the spring's outer diameter and pitch through program control, processing conical or mid-convex springs that meet design requirements.

Bending of non-standard shock-absorbing gaskets: For non-standard metal shock-absorbing gaskets, multi-axis CNC equipment is used. By programming and controlling multiple bending steps, wire or strip materials can be shaped into complex planar shapes required by the design.

Adapt to high-intensity wire processing: For materials commonly used in stent systems, such as stainless steel, the equipment features adjustable wire feeding force and forming speed to support the processing of materials with different characteristics.

III. Production Plan for Auxiliary Wire Components of Photovoltaic Systems

The wiring, fixing, and grounding systems of photovoltaic power stations require the use of various customized wire formings, such as cable fixing buckles and grounding clamps. There are many varieties of such products, but the quantity for a single batch may be limited.

Solution:

Rapid changeover production of irregular parts: Use a CNC universal spring machine or camless spring machine. By writing separate processing programs for clamps and locks of different shapes, different programs can be called during production to switch products, which is suitable for production organizations with multiple varieties and small to medium batches.

Maintain batch assembly compatibility: Control the dimensions of the molded equipment to support stable production of products within the same batch specification, thereby facilitating compatibility with standard components such as cables and brackets during on-site installation.