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A global solar energy leader, involved in integrated solar silicon wafer and solar cell module production – the most widely applied technology in the solar energy industry.
What
The client utilized a standard OEM junction box, which increasingly failed to meet the requirements of advancing technology. To maintain leadership status and be first-to-market with an alternative solution, the client redesigned the junction box to its own specifications. The junction box, which protects the solar cells against damage when the panel is only partially illuminated by sunshine, must pass North American UL certification and European CE marking as well as environmental testing.
Craftech was selected as the supplier to research suitable materials and design the manufactured part to conform to the client’s automated assembly process.
That approach provided numerous advantages including a tool and fastener-free, snap-on design. Once the unit is built and tested the panels are assembled on the unit in less than 6 minutes.
In order to accomplish this there were many snaps and clips that needed to be incorporated into the plastic parts and they needed to be molded with a high-degree of repeatability & process capability.
“By going to the modular approach and using Craftech’s expertise in engineering and tooling design we were able to make the design successful”.
There are 10 parts to the Enclosure that include over 16 side actions and 14 molded snap features. A number of these parts are user interface and the snaps allow the clinicians so access what they need to easily and without any tools.
“In addition to unique snap design many of the parts require Craftech’s Advanced manufacturing offerings including thermal and ultrasonic insert installation, pad printing and converted part installation all of which reduced costs and streamlined procurement” Wing says.
How
Craftech collaborated with client engineers to manufacture a plastic junction box with demanding specifications. The manufactured part must withstand environmental stresses, including temperature fluctuations ranging well below and above 0 F, repelling both moisture and dust. Additionally, the selected resin must have anti-UV light strength, with a life expectancy of 25 years and meet industry safety codes and standards.
Until a merger that redirected the client’s focus, Craftech ran over 1 million assemblies over 24 months. This global leader realized approximately $500,000 over the life of the project through Craftech’s implementation of Lean Manufacturing protocols.
Result
Long before the current trend toward environmental awareness and conservation, projects such as the junction box helped position this client as one of the early leaders in the solar energy industry.