Solar PV Brackets are the core load-bearing structure of a photovoltaic (PV) system. They play a crucial role in fixing PV modules, optimizing installation angles, and ensuring system safety. Adaptable to various installation scenarios including rooftops, ground-mounted units, and underwater installations, they are essential supporting products for improving the power generation efficiency and lifespan of PV systems.
Product Overview
· Product Types: Rooftop Brackets / Ground-mounted Brackets / Aluminum Alloy Tracks / Steel Structure Brackets, etc.
· Application Scenarios: Residential/Commercial Rooftops, Industrial and Commercial Power Stations, Ground-mounted Power Stations, Carport Systems, etc.
· Structural Characteristics: Corrosion Resistant, Lightweight, Structurally Stable
The PV brackets utilize high-strength aluminum alloy (AL6005-T5) and stainless steel fittings (SUS304), featuring lightweight construction, high corrosion resistance, and structural stability. Suitable for large-scale commercial and industrial PV projects, they are ideal for large-scale installations.
Products Advantages
Lightweight: The aluminum alloy construction reduces weight, facilitating transportation and hoisting.
High Strength: The structure complies with standards such as AS/NZS1170 and JIS C8955 2017, ensuring reliable wind and earthquake resistance.
Corrosion Resistance: Multi-layer surface treatment and stainless steel fittings ensure long-term rust-free operation in harsh environments such as coastal areas and saline-alkali lands.
Flexible and Adjustable: Angle and spacing can be freely set according to project requirements, compatible with various photovoltaic module sizes.
Rapid Installation: Modular pre-assembly and a standardized bolt system improve on-site construction efficiency by over 30%.
Ease of installation is one of the product's core advantages. The modular design and highly standardized components eliminate the need for on-site welding. Rapid assembly via bolts allows a single person to complete 30-50㎡ of module installation per day, significantly reducing construction costs. Supporting multi-angle adjustment (0-60°), the optimal installation angle can be precisely set according to different latitudes to maximize solar radiation reception, improving power generation efficiency by 5%-10% compared to fixed-angle brackets.
Production Process Flow of Solar PV Brackets
1. Raw Material Selection and Pre-treatment
The core raw materials are mainly aluminum alloy profiles and hot-dip galvanized steel, with stainless steel used in some scenarios. All materials must meet the strength and corrosion resistance standards for photovoltaic installation.
Before raw materials are put into storage, their material composition and dimensional tolerances must be tested. For steel, the galvanized layer thickness must be confirmed, and for aluminum alloys, the basic condition of the oxide film must be checked.
Raw materials are cut according to the bracket design dimensions using sawing, shearing, or laser cutting processes to ensure smooth, burr-free cuts.
2. Structural Forming and Precision Machining
Aluminum Alloy Brackets: The basic profiles are manufactured using extrusion molding, followed by drilling, tapping, and bending to pre-drill installation holes and splicing structures.
Steel Brackets: Formed using stamping, bending, and welding processes. After welding, weld slag must be removed, and weld strength checked to avoid stress concentration in the structure.
Key processes require control of dimensional accuracy. Hole position deviations and bending angles must conform to the design drawings to ensure smooth on-site splicing.
3. Surface Treatment
Aluminum Alloy Brackets: Mainstream use anodizing to form a uniform oxide film and improve weather resistance; some high-end products undergo additional electrophoresis or powder coating.
Steel Brackets: First, pickling and phosphating for degreasing and rust removal, followed by hot-dip galvanizing. The zinc coating thickness must be ≥85μm. In extreme environments, passivation or powder coating processes can be added.
After surface treatment, adhesion and corrosion resistance must be tested to ensure suitability for long-term outdoor use.
4. Assembly and Component Integration
Assemble components according to bracket type (roof bracket, ground bracket, tracking bracket), including beams, columns, braces, clamps, connectors, etc.
Use standard fasteners (bolts, nuts, spring washers, etc.) during assembly to ensure secure connections. Some critical parts require anti-loosening treatment.
Tracking brackets require additional installation of drive motors and control modules, and debugging of mechanical transmission accuracy and angle adjustment functions.
5. Finished Product Inspection and Shipment
Appearance Inspection: Check for scratches, oxidation defects, weld cracks, etc. on the surface. Verify the dimensions of key installation areas. Performance Testing: Load tests (wind load, snow load), weathering tests, and vibration tests are conducted to verify structural stability.
Before shipment, product labels and installation instructions are checked, and products are packaged in batches to ensure no deformation or surface damage occurs during transportation.
Packaging and Logistics
Packaging Method: Cartons, pallets, customizable options available
Packaging Quantity: Per carton/per pallet
Shipping Method: Sea freight, land freight
Damage Prevention Measures: Scratch-resistant film, PE bags, and other protective measures.
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