Photovoltaic connector installation pain points, take a look!

This paper analyzes the irregularities in the installation of PV connectors, in particular, the problem of crimping of PV cables with the metal core of the PV connector.1. The current market situation in the photovoltaic power generation system, photovoltaic connectors are mainly used for components, junction boxes, inverters, and their connections, most of which are installed in factories, and the quality of crimping is relatively reliable. The remaining 10% connector needs to be installed manually at the project site, mainly connecting various equipment PV cables need to be installed at both ends of the PV connector. According to years of experience in customer visits, due to the lack of training of field installers, the lack of professional crimping tools, crimping is not standardized phenomenon prevails.2. Types and characteristics of metal core metal core is the main body of the connector and the main flow path. Most of the photovoltaic connectors on the market today use a U-shaped metal core, stamped and molded from copper, also known as stamped metal core. Thanks to the stamping process, U-shaped metal cores are not only highly productive, but can also be arranged in chains, which is ideal for automated harness production. Some PV connectors use O-shaped metal cores, which are formed by drilling holes in the ends of thin copper rods, also known as machined metal cores. o-shaped metal cores can only be crimped individually and are not suitable for automated equipment.

There is also a rare type of non-crimped metal core that connects to the cable with a spring-loaded tab. Since no crimping tool is required, installation is relatively simple and convenient. However, the spring-loaded tab connection results in high contact resistance and does not guarantee long-term reliability. Some certification bodies do not recognize this type of metal core.3. The basics of crimpingCrimping is one of the basic and common connection techniques. Countless crimps occur every day. At the same time, crimping has proven to be a proven and reliable connection technology.3.1 Crimping processThe reliability of crimping depends largely on the tools and operation, which together determine whether the crimping effect meets the requirements of the standard.3.2 Crimp heightMany people know that it is not good for PV connectors to be crimped too loosely or too tightly, so how much of the crimp height should be controlled as the crimp is made? In addition, how do the two important quality indicators of pull-off force and conductivity change in the process? As the crimping height gradually decreases, the pull-off force between the cable and the metal core will gradually become larger. If the crimp height continues to decrease, the pull-off force will continue to decrease due to the gradual destruction of the structure of the copper wire.3.3 Evaluation of crimp qualityThe following evaluation methods are commonly used in the industry: Crimp height/width can be measured with a vernier caliper within the specified range. Pull-off force, the force required to pull or disconnect the copper wire from the crimp. Cross-sectional analysis, non-destructive cutting of the crimped area, analysis of width, height, compression ratio, symmetry, presence or absence of cracks and burrs. In the case of the release of new equipment or new crimping dies, in addition to the above points, it is also necessary to monitor the resistance stability of the PV connector under temperature cycling conditions.3.4 Crimping toolsPhotovoltaic connectors are mostly installed in factories by means of automated equipment, with a high crimping quality. However, for connectors installed at the project site, they can only be crimped by crimping pliers. Crimping is carried out using the original professional crimping pliers. Ordinary pliers or sharp-nosed pliers cannot be used for crimping. On the one hand, the crimping quality is low, and on the other hand, it is not recognized by PV connector manufacturers and certification bodies.3.5 Hazards of unregulated crimping Poor crimping may lead to non-compliance with specifications and standards, unstable contact resistance and sealing failure. It is a major risk point that affects the overall function and profitability of the PV power plant. PV connectors are small parts, but they can affect the operational efficiency of a PV project. Compromising on quality usually means subsequent high losses and risks that could have been avoided. Installation and crimping of PV connectors is important and the use of specialized crimping tools is recommended. Crimping training is an essential part of the process for engineering installers.

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