Case Overview
A renewable-energy equipment manufacturer producing PV modules and wind-generator systems found field failures in PV busbar assemblies. Inconsistent conductivity and coating adhesion in a previous supplier’s stamped busbars increased series resistance and hot-spot temperatures in module strings. Generator winding wire also lacked resistance documentation for coil-design validation.
DZX qualified with stamped copper busbar strip having verified conductivity and surface condition, plus winding wire with documented resistance per meter, restoring module consistency and confidence in generator coil design.
This case summarizes the application requirements, materials supplied by DZX and delivery value. For case-specific technical data, please contact our engineering team.
| Item | Details |
|---|---|
| Client Profile | Renewable-energy equipment manufacturer (PV modules and wind systems) |
| Project Scale | High-volume module strings and generator coils |
| Application | PV busbars and interconnection ribbon; wind-generator winding wire |
| Materials Supplied | Copper strip, copper alloys and winding wire |
| Supply Forms | Strip, flat wire and wire |
| Lead Time | Qualification batches: 2 weeks; production: 3-4 weeks |
| Project Country | Spain |
| Project Year | 2024 |
Our Solution
The manufacturer’s quality system flagged three material issues:
- Conductivity variation: inconsistent PV busbar conductivity increased series resistance and hot-spot temperature, reducing module output.
- Coating adhesion: inconsistent surfaces caused soldering and coating-adhesion failures on interconnection ribbon.
- Unverified winding wire: wind-generator wire lacked resistance documentation, forcing coil-design revalidation.
DZX made electrical properties part of the delivery specifications:
Copper busbar strip was supplied with verified conductivity and controlled surfaces for stamping, soldering and plating. Flat wire and winding wire included resistance-per-meter documentation for generator coil design. Every batch included chemistry, conductivity and dimensional reports for incoming inspection.
| Material | Representative Grades | Key Properties | Available Forms |
|---|---|---|---|
| Copper and Copper Alloys | C1100, C12200 | Conductivity and busbar service | Strip and flat wire |
| Winding wire | To drawing | Wind-generator coils | Wire and flat wire |
| Tinned copper | To drawing | Interconnection ribbon | Strip |
View Copper and Copper Alloys → | View Copper-Nickel Alloys →
PV busbar strip
Wind-power and electrical connections
Conductive busbars
Technical Specifications
Key technical parameters agreed before production. Contact us for grade-specific datasheets and tolerance-verification reports.
| Parameter | Agreed Specification | Verification Method |
|---|---|---|
| Busbar strip thickness | To drawing (e.g. 0.2 mm ± 0.01 mm) | Coil-by-coil micrometer measurement |
| Conductivity | By grade (e.g. ≥ 98% IACS) | Batch conductivity testing |
| Surface condition | Clean and ready for plating | Visual + cleanliness inspection |
| Winding-wire resistance | To drawing, ±2% Ω/m | Batch resistance testing |
| Stamping consistency | Flat, with burr-free edges | Batch dimensional report |
Each supplied batch includes a quality inspection certificate with chemical analysis, meeting the applicable standard for each grade.
| Material | Applicable Standards |
|---|---|
| Copper | ASTM B152, B187 |
| Winding wire | IEC 60317 (where applicable) |
| Quality System | Quality inspection certificate including chemistry and conductivity reports |
Delivery and Quality Support
- Fast delivery: Sample and production lead times follow the project schedule; standard grades and sizes can be dispatched promptly from stock.
- Quality traceability: Every batch includes material certificates and inspection reports, with full heat and batch traceability.
- Technical support: Responsive support covers pre-sale material selection, drawing review and post-sale processing advice.
- Ongoing service: Regular follow-up after delivery tracks performance and addresses feedback promptly.
Customer Feedback
- Module performance restored: verified conductivity eliminated PV-string hot-spot temperature differences
- Reliable interconnection ribbon: controlled surfaces stabilized soldering and coating adhesion
- Confident coil design: documented winding-wire resistance per meter
- Auditable batches: chemistry, conductivity and dimensional reports for each batch
- Ready for volume supply: stable production delivery in 3-4 weeks
- One new-energy package: busbar, winding-wire and interconnection materials from one manufacturer
Our Capabilities
Jiangsu DZX Technology Co., Ltd. (Changzhou DLX Alloy) was founded in 2016. Its core team has worked in the field since 2002, with 24 years of precision-alloy R&D and production experience, operating a self-owned 12,000-square-meter modern factory with an ISO9001 system covering three inspection stages. Annual alloy output exceeds 1,200 tonnes, serving 1500+ business customers worldwide. The company operates integrated melting, drawing, annealing and precision-machining workshops, supporting volume customization of strip, wire, tube and bar. Every batch includes a chemical analysis report (MTC) for full delivery-quality traceability.
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