Weizhi Hardware manufactures heavy-duty IP54/IP65/IP66 outdoor battery storage enclosures (BESS), modular lithium battery rack trays, solar inverter brackets, and high-conductivity copper/aluminum busbar stampings. Supported by our 9,000 m² production base in Nanpi, we provide integrated sheet metal fabrication, robotic seam welding, C5-M high-durability outdoor powder coating (1000h+ salt spray), and pre-installed EPDM gasket seals compliant with UL 9540A and IEC 62619 structural standards.
1. Energy Storage Hardware Fabrication Capabilities
| Component / Subsystem | Manufacturing Processes | Material Options | Key Quality & Performance Specs |
|---|---|---|---|
| Outdoor BESS Battery Cabinets | CNC Laser Cutting, Press Brake Bending, Continuous Robotic Seam Welding | Galvanized Steel (SGCC), Stainless 304, Aluminum 5052-H32 | IP65/IP66 Weatherproof Sealing, Polyurethane Foam Gasket, 1.5mm–3.0mm Robust Wall Structure |
| Modular Battery Pack Trays | High-Precision Stamping, CNC Turret Punching, PEM Clinch Fastening | Cold Rolled Steel (SPCC), AL 6061-T6 | Load-bearing capacity up to 150 kg per tray, ±0.1 mm slide-rail alignment tolerance |
| Solar Inverter Housings | Deep Drawing, CNC Machining, Louvered Stamping for Ventilation | Marine Grade AL 5052, Stainless Steel 316 | Natural convection louvers, insect-proof stainless mesh, anti-vibration rubber isolation studs |
| High-Current Busbar Stampings | High-Speed Precision Stamping, Deburring, Edge Rounding | Electrolytic Copper (C11000), AL 1060 | Tin plating / Nickel plating, heat shrink insulation sleeve, <0.5 mΩ contact resistance |
| Rooftop & Ground Solar Brackets | Continuous Roll Forming, Heavy Stamping, Robotic Welding | Hot-Dip Galvanized Steel (Q235B / Q355B), AL 6005-T5 | 80–120 μm HDG coating thickness, 25-year structural design life in C4/C5-M environments |
2. Weatherproofing & Corrosion Resistance: Meeting C5-M Outdoor Standards
Energy storage enclosures deployed in coastal or utility-scale desert environments require stringent corrosion protection. Weizhi implements a multi-stage pre-treatment and powder coating workflow:
- Automated Zinc-Phosphating / Zirconium Pre-treatment: Removes all surface mill oils and creates a nano-ceramic bonding layer for optimal paint adhesion.
- Outdoor Polyester / Epoxy-Polyester Powder Coating: Applied electrostatically at 80–120 μm thickness, meeting Qualicoat Class 2 outdoor durability requirements.
- Automated PU / EPDM In-Place Gasketing: CNC continuous robot dispensing provides seamless IP65 water and dust ingress protection.
- 1000-Hour Neutral Salt Spray (ASTM B117 / ISO 9227): Batch-tested with zero blistering, rust creeping, or adhesion failure.
3. Structural Strength & Thermal Management Design
Reinforced Frame Geometry: Heavy multi-tier battery racks incorporate roll-formed channel columns and diagonal gussets to withstand seismic loads (Zone 4) and shock transit tests (ISTA 3A).
Optimized Airflow & Liquid Cooling Integration: Precision CNC punched louver patterns maintain airflow while preventing water spray. We also fabricate integrated liquid cooling cold-plate trays with vacuum brazed or laser-welded channels.
Frequently Asked Questions (FAQ)
Can you produce custom battery enclosures compliant with UL 9540A structural fire containment?
Yes. We fabricate heavy-gauge steel enclosures (2.0–3.0 mm SPCC/SGCC) with internal fire-barrier baffles, ceramic fiber insulation channels, and pressure relief vents designed to contain thermal runaway events according to client engineering specs.
What is the lead time for BESS enclosure prototypes and mass production?
For custom prototypes, lead times range from 7 to 10 days (via laser cutting and CNC bending). Once approved, progressive tooling and production fixture lead times are 20 to 25 days, with recurring batch shipments produced at a rate of 500+ enclosures per month.
Do you provide full mechanical pre-assembly?
Yes. Beyond sheet metal fabrication, our 9,000 m² base includes dedicated assembly lines for installing drawer slide rails, locks, hinges, grounding copper studs, sealing gaskets, and transparent acrylic insulation dividers.