Strength Tester for Lead-End of Photovoltaic Modules
Category：Battery Testing Equipment
Introduction
The Strength Tester for Lead-End of Photovoltaic Modules is designed to evaluate the mechanical integrity and tensile strength of PV module connectors and leads. It ensures the durability and reliability of electrical connections under standardized loading conditions, supporting quality control, R&D, and compliance verification for photovoltaic modules.
Application
(1) Mechanical testing of MC4, H4, and custom PV module connectors
(2) Lead-end tensile strength verification for 72-cell and large-format modules
(3) Evaluation of junction box durability under repeated thermal cycling
(4) R&D testing for module design optimization
(5) QC inspection in manufacturing lines to ensure IEC 61215-2 compliance
(6) Failure analysis for IV curve correlation and connector degradation studies
Standards
(1) IEC 61215-2:2016 – Test Requirements for Electrical and Mechanical Components of Terrestrial PV Modules
(2) CE Certification (Conformité Européenne)
Parameters
| Parameter | Specification |
|---|---|
| Test Area | 2,000 mm × 1,000 mm (customizable) |
| Force Range | 0–5,000 N (5 kN capacity) |
| Force Resolution | 0.1 N (10 gf) |
| Speed Accuracy | ±1% of setpoint |
| Power Supply | 220V AC, 50/60Hz (single-phase) |
| Dimensions | 2,200 mm (W) × 1,200 mm (D) × 1,800 mm (H) |
| Weight | 250 kg (net) |
Features
(1) Motorized Tensile Stage: Adjustable 0–500 mm/min with real-time force-displacement graphing
(2) Dynamic Force Feedback: 0.1 N resolution load cell with peak force memory
(3) Self-Calibrating System: Auto-linearity and tare checks before each test
(4) Quick-Change Fixtures: Compatible with MC4, H4, and custom PV connectors
(5) User-Centric Interface: 7” touchscreen HMI with preloaded IEC 61215-2 test sequences
(6) Durable Construction: Rust-resistant 304 stainless steel frame with epoxy coating
(7) Automated Testing: Programmable load profiles simulating long-term mechanical stress
(8) Safety Systems: Emergency shutoff and overload protection at 5 kN
Accessories
(1) Testing Kit: 10x PV connector fixtures (MC4/H4 compatible), 5x calibration grade load cells (10 N–5,000 N)
(2) Software Suite: License key for TensileTest Pro (Windows/Linux), 1-year free access to cloud-based fatigue analysis tools
(3) Calibration & Safety: NIST-traceable force gauge, insulated gloves (Class 0, 3 pairs)
(4) Maintenance Kit: Spare drive belts and bearings, machine cleaning solution (non-corrosive)
(5) Documentation: Multilingual quick-start guide (printed + digital), IEC/UL/ISO compliance certificates
Maintenance Information
(1) Inspect load cells, clamps, and drive belts regularly for wear or damage.
(2) Clean fixtures and frame surfaces with non-corrosive cleaning solutions.
(3) Verify calibration of force measurement system periodically.
(4) Lubricate moving parts according to scheduled maintenance.
(5) Store in a dry environment to maintain precision and prolong service life.
FAQ
1. What is a Strength Tester for Lead-End of Photovoltaic Modules?
This machine is designed to measure the mechanical strength and adhesion of the electrical lead wires (or ribbons) at the junction box of photovoltaic (PV) modules, ensuring reliable electrical connections.
2. How does the lead-end strength test work?
The tester grips the lead wire or ribbon and applies a tensile force at a controlled speed and angle until failure occurs. The maximum force and elongation are recorded to evaluate the adhesion and mechanical robustness of the lead connection.
3. What types of PV modules can be tested?
It can test monocrystalline, polycrystalline, and thin-film PV modules with different lead wire sizes, materials, and junction box designs.
4. What parameters are measured during testing?
The tester measures tensile strength (N), elongation at break (mm), mode of failure (lead breakage or junction detachment), and compliance with electrical safety requirements.
5. Why is lead-end strength testing important?
Testing ensures that the electrical connections of PV modules can withstand handling, transportation, installation, and environmental stresses without failure. It helps manufacturers guarantee product reliability, electrical safety, and compliance with IEC standards.
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