Engineering Case Studies | SolarOne PV Automation Projects

USA PV Junction Box Assembly Line Overseas Commissioning

Reaching Stable Output on the First Production Day

Production capacity: 9,000 pcs/day achieved on the first production day after installation
Customer benefit: Fast production start-up with reduced operator dependency

Challenge: The customer needed rapid overseas ramp-up, but operators had limited experience with the full automated line. The line needed to stabilize feeding, riveting, electrical testing and unloading quickly after installation.

SolarOne solution: Engineers tuned the feeding sequence, fixture positioning, riveting parameters and testing station logic on site. Operator training focused on fault recovery, material preparation and daily maintenance routines.

Result: The production line reached 9,000 pcs/day on the first production day, giving the customer a faster path from installation to stable manufacturing.

India Connector Automation Line Balancing

Improving Throughput After Commissioning

Production capacity: 14,000 pcs/day after commissioning and line balancing
Customer benefit: Higher daily output with more stable process control

Challenge: Mixed component tolerances created unstable feeding and inconsistent hourly output. The customer needed more predictable production without adding more manual stations.

SolarOne solution: The team optimized bowl feeder tracks, servo insertion profiles, station timing and fault detection. Process adjustments focused on repeatability instead of only increasing machine speed.

Result: After commissioning and line balancing, the line reached 14,000 pcs/day and improved shift-level output stability.

China CCD Inspection FAT Validation

Reducing Defects with CCD Inspection and Factory Validation

Production capacity: Full-line FAT, fixture validation and inspection tuning before shipment
Customer benefit: Lower overseas commissioning risk and faster customer acceptance

Challenge: Manual checks were not reliable enough for missing parts, position deviations and polarity issues at automated production speed.

SolarOne solution: SolarOne integrated CCD inspection points before final unloading and connected NG handling to PLC logic. The line was validated through FAT with product samples before shipment.

Result: The customer gained stronger traceability, reduced manual inspection pressure and improved confidence before overseas installation.

Vietnam Process Upgrade Output Stability

Stabilizing Output Without Replacing the Full Line

Production capacity: 11,000 pcs/day after process upgrade and fixture tuning
Customer benefit: Improved output stability while protecting existing equipment investment

Challenge: The customer wanted higher stability from an existing production setup, but replacing the whole line would increase cost and downtime.

SolarOne solution: Engineers reviewed transfer accuracy, fixture wear, testing reliability and station timing. The upgrade focused on fixture tuning, positioning control and process integration.

Result: The line reached 11,000 pcs/day after upgrade work, with more stable transfer, positioning and electrical testing.

Malaysia Line Expansion Multi-Shift Production

Supporting Multi-Shift Manufacturing Line Expansion

Production capacity: 13,000 pcs/day supported for multi-shift production
Customer benefit: Scalable capacity with quality and cycle-time targets met

Challenge: The customer needed to expand production capacity while keeping quality stable across longer operating hours and multiple shifts.

SolarOne solution: SolarOne configured the line with maintainable station layouts, robust fixtures and practical operator access for daily inspection and recovery.

Result: The expansion supported 13,000 pcs/day and helped the customer scale production with controlled quality risk.

Türkiye Cable Handling Packaging Automation

Reducing Manual Handling in Cable and Packaging Processes

Production capacity: 8,500 pcs/day validated during acceptance testing
Customer benefit: Reduced manual handling and more predictable takt time

Challenge: Manual cable handling and packaging steps made takt time less predictable and increased operator workload.

SolarOne solution: The engineering team optimized material presentation, transfer rhythm and packaging flow around the customer's product structure and factory layout.

Result: The line validated 8,500 pcs/day during acceptance testing and reduced dependence on manual handling.

Real Automation Problems. Engineered Production Results.