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Solar Mounting Structure Equipment Series
Solar Steel Frame Roll Forming Machine（Closed frame)
Solar Steel Frame Roll Forming Machine（Closed frame)
Solar Steel Frame Roll Forming Machine（Closed frame)
Solar Steel Frame Roll Forming Machine（Closed frame)
Solar Steel Frame Roll Forming Machine（Closed frame)
Solar Steel Frame Roll Forming Machine（Closed frame)
Solar Steel Frame Roll Forming Machine（Closed frame)

Solar Steel Frame Roll Forming Machine（Closed frame)

The Solar Steel Frame Roll Forming Machine (Closed Frame) is used to produce high-strength closed-frame photovoltaic module frame profiles. The closed-frame structure offers superior bending resistance and stability, meeting the strength and durability requirements of large-scale photovoltaic power plants.

Solar Steel Frame Roll Forming Machine (Closed-Frame Design) — Featuring 45° die-cutting, automatic corner connector insertion and riveting, in-line inspection, and automatic stacking. A professional-grade, fully automated intelligent production line delivering high-strength, closed-profile sections via a one-stop process from steel coil to finished product.

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Equipment Introduction

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I. Equipment Introduction

The Solar Steel Frame Roll Forming Machine (Closed-Frame Type) is a fully automated cold-roll forming system designed specifically for producing closed-profile steel frames for photovoltaic (PV) modules. Compared to open-profile frames, closed-profile frames offer superior torsional rigidity. Utilizing a cold-roll forming process that requires no heating or surface treatment, the equipment is energy-efficient and environmentally friendly. It processes steel coil stock through a continuous cold-roll forming line, executing a complete workflow—including uncoiling, guided feeding, servo punching, roll forming, hydraulic cutting, lateral transfer, double-head 45° die-cutting, conveying, automatic corner connector insertion (riveting), online inspection with automatic rejection, and automatic stacking—to directly produce finished closed-profile steel frames ready for PV module assembly.
The entire line features PLC-based automation, ensuring continuous, fully automated operation from uncoiling to finished product stacking. Integrating core functions such as servo punching, double-head 45° die-cutting, automatic corner connector riveting, online inspection/rejection, and automatic stacking, the system transforms raw materials into finished frames ready for assembly without the need for intermediate handling or manual intervention. Requiring only 1–2 operators for monitoring, this equipment is a key asset for PV frame manufacturers seeking to upgrade to automated and intelligent production.
The equipment is compatible with various materials—including galvanized steel, Al-Zn coated steel, and Zn-Al-Mg coated steel—and supports material thicknesses ranging from 0.8 mm to 2.5 mm. It can produce closed-profile steel frames in multiple specifications to meet the diverse assembly requirements of PV modules. Given that the elastic modulus of steel is three times that of aluminum alloy, a steel frame offers three times the rigidity of an aluminum frame for the same cross-sectional profile; this effectively minimizes module deformation under various loads and enhances the module's overall strength and rigidity.


II. Core Advantages and Selling Points

(1) Closed-profile structure with torsional strength far exceeding open-profile frames
Closed-profile PV module frames offer superior torsional strength compared to open-profile alternatives. The closed cross-section design creates a sealed, load-bearing structure that distributes forces—such as wind loads, snow loads, and thermal expansion/contraction—more evenly, making the frame resistant to twisting and deformation. Steel offers significantly higher mechanical strength than aluminum alloy while also providing superior toughness. Steel frames feature a yield strength of ≥450 MPa and an elastic modulus three times that of aluminum frames, delivering double the strength of traditional aluminum counterparts.

(2) Lateral shift + dual-head 45° die-cutting: Precision end-cutting in a single process
Following the hydraulic cut-off stage, the equipment incorporates lateral shifting and dual-head 45° die-cutting processes—critical steps for ensuring end-face precision in closed steel frame production:
Lateral shift: The cut frame automatically shifts laterally to the 45° die-cutting station, enabling high-speed transition between process stages.
Dual-head 45° die-cutting: Precision 45° die-cutting is performed simultaneously on both ends, shaping both ends in a single operation.
The 45° die-cutting creates the mitered end-cuts essential for precise corner assembly of PV module frames.
Compared to traditional secondary processing, this in-line die-cutting method eliminates the need for standalone corner-cutting equipment, secondary clamping, and intermediate material handling.
It delivers high angular precision and smooth, burr-free cuts, ensuring a perfect fit during frame assembly.

(3) Servo-driven punching: Precision and efficiency
A high-precision servo system is employed for accurate material feeding and punching, enabling the precise formation of mounting holes and various other hole patterns. Hole position deviation is controlled within ±0.2 mm, ensuring accuracy in subsequent assembly steps.

(4) Hydraulic cut-off (servo tracking): Continuous in-line cutting without stopping the line
Utilizing a hydraulic cut-off system combined with servo tracking technology, the equipment automatically tracks the frame's movement speed and performs fixed-length cutting synchronously while the frame is moving at high speed. This eliminates the need to slow down or stop the line, ensuring high cutting precision, smooth cut surfaces, and length dimensions that strictly adhere to drawing tolerances in a single pass.

(5) Automatic Corner Key Insertion & Riveting: Secure and Reliable Connections
The equipment integrates automatic corner key insertion and riveting at the end of the production line; formed and die-cut frames travel via conveyor directly to the insertion station. Corner keys are automatically fed, positioned, and precisely pushed into the enclosed mounting cavities at the frame ends. Automatic riveting follows immediately, securely bonding the corner key to the frame body. The entire process is fully automated, requiring no manual intervention, thereby eliminating the need for separate insertion stations, additional equipment investment, and dedicated operators.

(6) In-line Inspection & Automatic Rejection: Real-time Quality Monitoring
Equipped with an in-line inspection system, the machine automatically monitors key dimensions, 45° die-cut angles, riveting quality, and surface appearance for every finished frame in real time. The system identifies and automatically rejects non-conforming units, preventing them from mixing with qualified products. Eliminating the need for manual spot checks ensures that output meets standards, prevents defective products from leaving the line, and significantly reduces quality control costs and risks.

(7) Automatic Palletizing: Neat Output of Finished Products
Equipped with a fully automatic palletizer, finished frames are conveyed to the palletizing station. They are stacked neatly and systematically according to preset programs. Manual sorting and stacking are unnecessary, drastically reducing labor intensity and enabling a seamless transition from production to warehousing.

(8) Advantages of Steel Frames: An Industry Trend
Cost reduction of approximately 40%: Replacing aluminum with materials like Zinc-Aluminum-Magnesium coated steel significantly lowers overall costs.
Strength double that of aluminum frames: Steel frames offer a yield strength of ≥450 MPa and an elastic modulus up to three times that of aluminum frames.
Thermal expansion coefficient matched to glass: Effectively reduces the risk of micro-cracks in modules caused by temperature fluctuations.
High efficiency and eco-friendliness: Production carbon emissions are far lower than those of aluminum frames, and steel offers a high recycling rate.
Industry standard leadership: The China Iron and Steel Association (CISA) is spearheading the development of relevant industry group standards.

(9) Intelligent Control: Simple Operation
Features fully automated PLC control and a touchscreen HMI for intuitive, convenient parameter settings. The entire line—from material feeding to palletizing—is automated, requiring only 1–2 personnel for monitoring. Automatic fault diagnosis and alarming facilitate rapid troubleshooting and maintenance.


III. Technical Specifications

Item Parameter
Applicable materials: Galvanized sheet, Al-Zn coated sheet, Zn-Al-Mg coated sheet, etc.
Material thickness: 0.55–0.8 mm (customizable)
Production line speed: 0–30 m/min
Punching method: Servo punching
Punching accuracy ≤±0.2 mm
Cutting method: Hydraulic cutting (servo tracking); continuous online cutting without stopping the line
45° die-cutting Synchronous dual-head operation; completed online
Corner connector assembly: Fully automatic online assembly
Riveting method: Fully automatic online riveting
Inspection method: Online inspection; automatic rejection of non-conforming products
Stacking method: Fully automatic stacking
Control system: Fully automatic PLC control
Operators: 1–2 persons
Equipment footprint: Approx. 45 m (L) × 7.5 m (W)


IV. Production Process

Uncoiling → Guided Feeding → Servo Punching → Roll Forming → Hydraulic Cutting (Servo Tracking) → Lateral Transfer → Dual-Head 45° Die-Cutting → Conveying → Automatic Corner Connector Installation (Riveting) → Conveying (In-line Inspection & Automatic Rejection) → Automatic Palletizing

Process Description
Uncoiling: A hydraulic uncoiler supports the steel coil and ensures stable material feeding.
Guided Feeding: Automatic material guiding and alignment ensure the steel strip enters the next station smoothly.
Servo Punching: The servo system provides precise positioning to punch mounting holes and various other hole patterns.
Roll Forming: Multi-stage progressive cold-roll forming gradually shapes the steel strip into a closed steel frame profile.
Hydraulic Cutting (Servo Tracking): Servo-tracking synchronous cutting allows for precise length cutting without stopping the production line.
Lateral Transfer: After cutting, the frame is automatically transferred laterally to the 45° die-cutting station.
Dual-Head 45° Die-Cutting: Simultaneous precision 45° miter die-cutting at both ends.
Conveying: Automatic transport to the corner connector installation station.
Automatic Corner Connector Installation (Riveting): Automatic feeding, insertion, and pressing of corner connectors, followed by automatic riveting.
Conveying (In-line Inspection & Automatic Rejection): Automatic inspection of critical dimensions and riveting quality; defective products are automatically rejected.
Automatic Palletizing: Finished products are automatically stacked and discharged neatly.


V. Application Areas

Closed-profile steel frames produced by the cold-roll forming machine are widely used in the following sectors:
Photovoltaic (PV) Module Manufacturing: Framing for various single-glass and double-glass PV modules; their high strength and low cost make them an ideal alternative to traditional aluminum frames.
Ground-Mounted PV Power Plants: Large-scale ground-mounted installations; steel frames withstand higher wind and snow loads, making them suitable for harsh environments such as deserts, Gobi regions, and tidal flats.
Commercial and Industrial Distributed PV: Rooftop distributed PV projects; the high strength and low self-weight of steel frames reduce the load on the roof structure.
Bifacial PV Modules: The closed-profile design minimizes rear-side shading, fully unlocking the power generation potential of bifacial modules.
BIPV (Building-Integrated Photovoltaics): The thermal expansion coefficient of the steel frame matches that of the glass, reducing the risk of micro-cracks and ensuring tighter integration with the building structure.


VI. Service & Support

Solution Design: Personalized equipment selection and production line layout based on customer product drawings, capacity requirements, and target markets.
Custom Manufacturing: Support for non-standard customization, with full control over the entire process—from roll design to complete line manufacturing.
Installation & Commissioning: On-site installation, commissioning, and operator training provided by engineers to ensure rapid production startup.
After-Sales Support: Long-term technical consultation and spare parts supply; engineers hold valid visas and are available for on-site service worldwide at any time.
Continuous Optimization: Equipment modification and capacity upgrade services available to adapt to changing production needs.


VII. Why Choose Us

Nearly 20 years of manufacturing experience: Proven technology, refined processes, and reliable quality
Specialized expertise in closed-profile steel frames: Deep understanding of the technical intricacies of the forming process
End-to-end integrated capabilities: One-stop delivery covering material feeding, punching, forming, cutting, 45° die-cutting, corner connector installation, riveting, inspection, and palletizing
Core dual-head 45° die-cutting technology: Synchronous, in-line precision 45° end-cutting eliminates the need for separate corner-cutting equipment and processing steps
In-line inspection and automatic rejection: Real-time monitoring and automatic rejection ensure that every finished product meets quality standards
Direct manufacturer: No middlemen, offering excellent value for money
Global service network: Engineers hold valid visas and provide rapid response

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Double-head uncoiling and feeding → Hydraulic punching → Multi-stage cold roll forming → Straightening → Flying cut-to-length → Conveying → Automatic corner connector insertion → Automatic riveting → In-line self-inspection → Automatic palletizing. The entire line utilizes fully automatic PLC control, ensuring a continuous, automated process from uncoiling to the palletizing of finished products.

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About
Wuxi Yanwu Xinhui Technology Co., Ltd.

Established in 2012, Wuxi Yanwu Machinery Co., Ltd., is a professional manufacturer specializing in the R&D, design, manufacturing, and servicing of cold roll forming equipment. The company is dedicated to providing global customers with integrated solutions for automated cold roll forming production lines.

Our main products include cable tray forming machines, racking forming machines, C/Z purlin machines, solar mounting bracket forming machines, floor deck machines, door frame machines, automotive profile equipment, and cut-to-length/slitting lines.

These products are widely used in the construction, electrical power, logistics and warehousing, automotive manufacturing, new energy, and infrastructure sectors.

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News
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