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Customized metal stamping connecting terminals for photovoltaic field

Customized metal stamping connecting terminals for photovoltaic field

2024-06-04

² What is metal photovoltaic stamping terminal?

       With the development of science and technology in recent years and the increasing demand for new energy, the market application prospects of customized metal stamping photovoltaic connection terminals are becoming more and more extensive. Dongguan Fortuna Metals Co., Ltd. can design, process and manufacture metal stamped photovoltaic connection terminals according to customer drawings, which is also a type of photovoltaic connector. Through customized design, connection terminals can meet specific needs in different scenarios, such as connecting different types of wires and adapting to different installation environments. Especially in practical applications, photovoltaic connection terminals can be used to connect wires, saving time and energy while ensuring the stability and reliability of the connection and reducing electrical failures caused by poor connections.

² Type of photovoltaic stamping terminal

      1. Crimp pin terminal: It is a terminal made of copper, stainless steel, aluminum and other materials through die stamping technology to crimp the wires to connect them. The connection is tight, the on-resistance is small, and the contact is reliable.

      2. Crown spring pressure terminal: It is mainly composed of three parts: shell, pressure spring and conductive sheet. The wires and components are connected together through pressure, making the various components, wires and cables fixed and connected stably.

      3.Current terminal block: The main function of the current terminal block is to connect the wiring harness of power supply, equipment and external interface. It is used to transmit electric energy and signals. It is suitable for the connection between commonly used moving parts and the motherboard, and between the PCB board and the PCB board. High current photovoltaic power connection. Among them, there are many types of terminals, such as direct plug-in type and plug-in type, which can reduce production costs and improve production efficiency.

      4.  PCB board welding terminals: suitable for connecting PCB terminals or PCB connectors to circuit boards in photovoltaic systems; providing mechanical support for the fixed assembly of electronic components such as integrated circuits, and realizing wiring and electrical connections between components. Electrical insulation.


 

Crimping pin terminal

 Optimized structure female connector

               

Signal pin terminal

     

           Cotact terminal


² The materials used for metal stamping photovoltaic connection terminals:


Conductor material: mainly silver, copper or copper alloy, stainless steel, aluminum and other due to its excellent electrical conductivity, low resistance, high conductivity and easy processing and molding. Although silver has excellent electrical properties, it is expensive; aluminum has relatively poor electrical conductivity, and there is little demand from customers to choose this material. In order to ensure the conductivity of the product to the greatest extent and also reduce the cost, partial silver plating or gold plating is generally used to maximize the benefits of the product.

Metal stamped photovoltaic connection terminals play a key role in photovoltaic systems and are mainly used to connect and transmit electrical energy. They ensure the normal operation of photovoltaic systems by providing a stable power supply. In addition, precision terminals also have excellent electrical conductivity, corrosion resistance, accuracy and stability, allowing them to maintain reliable power transmission under various environmental conditions.

² Processing methods of metal photovoltaic connection terminals

1.Stamping processing


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Blanking: Also known as preliminary processing, it is to punch and shape the plate to remove excess edge material to achieve the set shape. In order to stabilize product quality and improve production efficiency, automatic manipulators are now used to complete the unloading and product placement actions.

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Drilling: According to the design requirements of the connection terminal, the punching operation is performed on the stamped plate to facilitate subsequent assembly and connection.

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Electroplating: According to the customer's product needs and performance, the required electroplating layer is selected, and full electroplating or partial electroplating can be used. The choice of plating materials includes silver plating, matte tin plating, silver plating, gold plating, nickel plating, etc.;

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Press riveting, tapping, and welding: Press riveting is to install rivets to the 

fixed parts of the stamping parts; tapping is processed using multi-axis or

uniaxial methods according to product needs; welding is used to connect 

different parts to ensure that the connection terminals stability and reliability.

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Bending: According to the product design and functional requirements, the stamping parts are bent to form the required shape and structure.

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Bending: According to the product design and functional requirements, the stamping parts are bent to form the required shape and structure.



    2.Product Assembly


Assembly is to combine the stamped components according to the design requirements and process flow to form a complete photovoltaic connection terminal. During the assembly process, various sub-components or parts are assembled mainly in accordance with product design and performance requirements, as well as process flow and design requirements, to ensure the stability and reliability of the connection terminals. During the assembly process, crimping pliers, welding equipment or automatic assembly machines will be used to ensure assembly quality and efficiency; after assembly is completed, a comprehensive inspection of the connecting terminals is required, including appearance quality, dimensional accuracy, functional structure, etc. Ensure products meet design requirements and quality standards.

To sum up, the processing methods of hardware photovoltaic connection terminals mainly include hardware stamping processing and assembly. Metal stamping processing is to process metal sheets into the required shape and structure through stamping, drilling, riveting, tapping, welding and other process steps; assembly is to process each stamped component according to the design requirements and process flow Combined to form a complete photovoltaic connection terminal. During the processing process, attention needs to be paid to selecting appropriate components, correct assembly sequence, using appropriate tools and equipment, and checking assembly quality to ensure product stability and reliability.


            

   The video of  automatic selecting and inspecting machine


               

Automated equipment full inspection of the product process

       ² Product design to manufacturing, stamping processing, inspection and packaging flow chart


       Step 1:  Purchasing materials according to customer drawings and product requirements; cutting and sorting metal plates according to design requirements to ensure that the size and surface quality of the plates meet the requirements of subsequent stamping processing. Choose materials with high electrical conductivity, corrosion resistance and good mechanical strength, such as copper, copper alloy, stainless steel, etc. Fully consider the cost, processability and environmental adaptability of materials to meet the long-term stable operation needs of photovoltaic energy storage systems.

       Step2: According to the shape and size requirements of photovoltaic connection terminals, corresponding stamping molds are designed and manufactured. The design of the mold needs to fully consider the strength and deformation properties of the material, as well as the stress distribution and deformation during the stamping process, to ensure that the stamped terminals have accurate shapes and reliable quality. According to the specific needs of the photovoltaic energy storage system, the size, shape, connection method and other parameters of the connection terminals are customized. Consider the current, voltage, power and other parameters of the system to ensure that the connection terminals can meet the performance requirements of the system. Customized design and manufacturing are carried out according to customers' special needs, such as special materials, special processing methods, etc.

        Step3: Stamping processing is a key link in the manufacturing of connection terminals, and processing accuracy and surface quality should be strictly controlled. During the stamping process, it is necessary to control the embossing depth and suppress the lateral twist of the lead to ensure the accuracy and stability of the terminal shape. Design and implement an appropriate correction stage to suppress the deviation of the lead frame lead position during stamping processing and improve product qualification rate.

        Step4: Deburr the stamped photovoltaic connection terminals to remove possible burrs and sharp edges on the surface, clean them, remove dirt and grease on the surface of the terminals, and ensure the surface quality of the terminals.

        Step5: According to the requirements of the product, surface treatment is performed on the photovoltaic connection terminals, such as galvanizing, silver plating, nickel plating or partial gold plating, etc., to improve the corrosion resistance and aesthetics of the terminals;

       Step6: Inspection and packaging. Conduct quality inspection on the stamped photovoltaic connection terminals to check whether their size, appearance and function meet the requirements. Fortuna has introduced multiple CCD automatic full inspection machines and automated assembly equipment to meet customers' various packaging needs.

        In short, Fortuna pays attention to many details when manufacturing customized metal stamping connection terminals to ensure its performance, reliability and safety. By selecting appropriate materials, optimizing structural design, strictly controlling processing accuracy and surface quality, conducting rigorous reliability testing, and meeting environmental protection and sustainability requirements, high-quality, high-performance customized connection terminals can be manufactured for Provide a strong guarantee for the stable operation of photovoltaic energy storage systems.

² Quality inspection of photovoltaic terminals

       Fortuna can meet the high-standard quality inspection requirements of photovoltaic terminals. It not only uses professional quality inspectors but also introduces various advanced inspection equipment to conduct strict reliability tests on customized connection terminals, including electrical performance and mechanical performance. and environmental adaptability testing. Testing should cover performance under different conditions of temperature, humidity, vibration and shock to ensure that the connection terminals can work stably and reliably under various environmental conditions. Fortuna mainly controls product quality through the following aspects and pursues 0 PPM products.

BEST QUALITY

Our professional quality personnel use optical plane inspection equipment and visual inspection equipment to check whether the surface of stamping parts is smooth and whether there are obvious scratches, deformations, cracks and other defects, and whether the terminal crimping is neat and whether there is exposed or oxidized copper wire, etc. According to the situation, verify whether the dimensions of the stamping parts meet the design requirements, including key dimensions such as length, width, thickness, etc., to ensure the accuracy and quality of the photovoltaic connection terminals. For photovoltaic terminals, dimensional inspection also includes whether the crimp size meets the standard and matches the size of the wire used;



                 

                 

According to the usage requirements of photovoltaic terminals, conduct corresponding performance tests, such as strength, toughness, hardness, electrical performance, salt spray test, etc.

Tensile testing : used to test the tensile strength of terminals to ensure that they can maintain stable connection performance in various environments.

Insertion and extraction force test: A fully automatic insertion and extraction force testing machine is used to test the insertion and extraction force of the USB interface of the terminal connector to evaluate the insertion and extraction force and stability of its terminals.

Corrosion resistance testing: Especially for photovoltaic terminals used outdoors, corrosion tests should be carried out to simulate marine or industrial corrosion environments, and the terminals should be tested for salt spray resistance to evaluate their corrosion resistance; our products can meet 96H salt spray Testing requirements to ensure there are no problems with the product.

BEST QUALITY


BEST QUALITY

Strength testing: Ensure that metal stamping parts or photovoltaic terminals are not easily deformed or damaged when subjected to external force.

Toughness testing: Evaluates a material’s ability to resist breaking when subjected to shock or vibration.

Hardness testing: Measuring the hardness of a material to ensure it meets the requirements of a specific application.

Electrical performance testing (for photovoltaic terminals): including contact resistance, insulation resistance, withstand voltage testing, etc. to ensure that the electrical connection of the terminal is stable and reliable.

These steps and testing requirements together form the framework for quality inspection of metal stamped photovoltaic terminals, aiming to ensure that the quality and performance of the product comply with industry standards and customer requirements.

               

² Fortuna’s advantages

Fortuna has extremely rich experience and excellent design capabilities in the manufacturing of photovoltaic terminals, mainly from the following aspects:


Technical advantages:

Advanced metal stamping technology and sophisticated testing equipment are used to ensure the accuracy and quality of photovoltaic connection terminals and meet the needs of use in various complex environments.


Material advantages:

Using high-quality materials, such as high-temperature-resistant, oxidation-resistant and corrosion-resistant copper and aluminum materials, to ensure the long-term reliability and stability of photovoltaic connectors, Fortuna is able to improve the material's durability by relying on its superb stamping technology. Utilization rate to reduce costs and increase efficiency for customers.



Design advantages: 

We can modify and design drawings according to customer requirements to make product assembly simpler and faster. We can also develop and study the functional structure of products according to customer requirements.



Production advantages:

By introducing advanced production equipment and processes, we can improve production efficiency and product quality, reduce production costs, and provide customers with more competitive prices.


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In summary, Fortuna's advantages in manufacturing photovoltaic connection terminals are mainly reflected in technology, materials, design, safety and production. These advantages will help improve the overall performance and reliability of photovoltaic systems and meet customer needs.

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