Case Study 02: CONCRETE BUSHING

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1 – INTRODUCTION

DEFINITION OF INITIAL PROBLEM

The anchoring systems for photovoltaic panels often present structural issues. Fixing with concrete counterweights often hides safety and reliability problems against the stresses of weather agents. The problems are mainly caused by anchoring bushings composed of two or more welded parts. These bushings conceal critical weaknesses that, when subjected to high tensile forces typical of bad weather, lead to deformations and breakages.

How can the safety issues of photovoltaic systems with counterweights be resolved? How can a more efficient and safe bushing be produced while simultaneously being less complex and costly?

2 – HOW WE WORK

APPROACH

To solve the safety issues related to photovoltaic systems, Pettarini intends to design and manufacture a steel anchoring bushing in a single piece, using cold forming of metal wire. Feasibility analysis is conducted using finite element simulation. The most suitable materials and necessary equipment are defined. The production process and work cycles are planned.

3 – SOLUTION

PROPOSAL

Pettarini defines and designs a new overall geometry for the anchoring bushing. The solution is developed thanks to the experience gained in cold forming of metal wire. Pettarini proposes the sampling of the bushing through a cold forming process and subsequent machining. Concurrently, each step of the process advancement is validated by the Quality Office.

The result of this activity are the first samples produced through the new process and the new design.

4 – RESULTS

WHAT WE HAVE ACHIEVED

The Pettarini solution:

Is robust and high-performing, with increased tensile strength;
Effectively distributes the loads it is subjected to, with reduced risk of breakage;
Guarantees the customer practicality, efficiency, and cost-effectiveness.

The Pettarini Bushing proves to be more efficient and economical.

TO KNOW BETTER HOW WE WORK

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Frequently asked questions

What is the minimum batch size required for production by cold forming? +

Minimum batches can start from 30,000 pieces, depending on the complexity and types of parts. In general, the ideal batch size to maximise production efficiency is 250,000 pieces.

What is your production capacity? +

It largely depends on the type and complexity of the item. Generally, our capacity exceeds 10,000,000 pieces.

What materials do you use for production? +

Carbon Steels (C4C, C10C, C35C, etc.)

Boron Alloy Steels (23MnB4, 30MnB4, etc.)

Chromium Alloy Steels (16NiCr4, 42CrMo4, 100Cr6, etc.)

Austenitic Stainless Steel (AISI304, AISI316, etc.)

Titanium (TI6AL4V/TI6A, etc.)

Waspaloy (AMS 5708, 2.4654 / UNS N07001)

Nickel-Based Alloys (Inconel, Monel, A286, etc.)

Aluminum and its alloys

Brass and its alloys

What size range can I request for the final product? +

Our product diameters range from 1mm to 40mm.

What lengths can you manufacture? +

We produce components with lengths ranging from 0.6mm to 160mm.

What tolerance levels can be achieved with cold forging? +

We achieve dimensional tolerances in the range of hundredths of a millimeter (0.02 ÷ 0.05mm).

Do you provide heat treatment as part of the production process? +

Yes, we ensure heat treatment through qualified suppliers.

Do you offer coatings and surface treatments? +

Yes, we can provide coatings and surface treatments as part of our services.

Do you have standard products available in stock? +

Yes, we have stock availability for some types of standard products. Contact us for more details.