WIRE ROLLING

The German manufacturer of wire rolling machines, Fuhr GmbH & Co. KG, brings its latest developments in PV ribbon and CTC wire manufacturing technologies. Continuously Transposed Conductor [CTC] cable consists of several individual rectangular wires, which successively and repetitively take up every possible position along the cross-section of the cable and eventually, are all connected up in a parallel way. Hence, the production of CTC cable requires high-precision rectangular copper wires, which have to be enameled prior to the stranding process. In general, applications for CTC cables are windings in transformers, motors and generators. Apart from CTC cables, high-precision rectangular copper wires with small cross-sections are being used for high-efficient hybrid motors and wind generators. With the emergence of CTC cables and hybrid motors, required tolerances for these rectangular wires have come down to ± 0.005-0.010mm, which cannot be achieved with the traditional cold rolling technology. In the past, the low tolerances required for the enameling process were sometimes also achieved by the application of a multi-step drawing process, thus being rather costly as the drawing dies had to be replaced on a regular basis, not to mention the down time due to the change of the latter. We at Fuhr provide you with the latest wire rolling technology that enables you to manufacture rectangular copper wire the lowest tolerances by using a combination of our “Duo Rolling Mill” [WSR type] and our patented WST rolling mill, also called the “Universal Turks Head.” Photovoltaic ribbon is a hot dip-tinned conductor strip [rectangular profile with a high width/thickness ratio] that is installed in Photovoltaic [PV] or solar panels, made of pure copper [99.99%] or OFC [oxygen-free copper]. The ribbon is soldered directly onto silicon crystal to interconnect the solar cells [wafers] in a solar panel. The ribbon forwards the current generated in the solar cells to the PV bus bar, which carries the current through the solar panel. PV bus bar is also made of PV ribbon. Dimensions, tensile strengths and plating specifications vary subject to the type of solar cells and their specifications. Prior to the tinning process, the copper strip has to be soft-annealed [yield strength 50-130N/mm²], which is important to obtain a good soldering quality and ensure a long-lasting bond of the interconnect ribbon with the wafers even during extreme weather conditions and high temperature fluctuations.
With the WSR-type rolling mills, customers are enabled to produce high-precision flat copper wire as per the following specifications:
– Max. final width: 8.0mm
– Max. final thickness: 0.40mm
– Width tolerance: ±0.05mm
– Thickness tolerance: ±0.005mm
– Production speed: 300-600m/min

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