Electrical connections for cans

Customized solutions for automated can bonding in solar module production—from feeding to testing

Reliable contact bonding of enclosures – such as those used for sensors, actuators, power electronics, battery cells, solar modules, or pressure-tight assemblies – is a critical process step in many industries. Housings, covers, contact pins, and wires made of various materials and contact materials must be precisely positioned, joined, and electrically connected without compromising the function, sealing, or mechanical stability of the assembly. At the same time, demands on cycle times, traceability, and process reliability are increasing, while manual contacting processes are quickly reaching their limits in terms of quality, ergonomics, and cost-effectiveness.

Ulrich Rotte Anlagenbau & Fördertechnik GmbH develops automated cell contact systems for this application that ensure consistently high quality while maintaining cost-effective production. At the heart of the system is an automatable cell concept based on thermally free contacting, which sets new standards particularly in solar module production and can also be adapted to other applications. Each system is designed as a custom solution – tailored to can and housing geometries, contacting methods, integration levels, testing requirements, and the spatial conditions in your production facility. In doing so, Rotte combines its expertise in custom machine building, robotics, handling technology, measurement technology, and process control to create well-thought-out comprehensive solutions.

From development through design, manufacturing, and assembly all the way to commissioning, Rotte supports your system throughout its entire lifecycle. And if production volumes, product designs, or interconnection concepts change, we’re here to assist you with modifications, expansions, and retrofit solutions.

Talk to us – we’ll help you take your can contacting to an automated, reproducible, and future-proof level.

Efficient bonding technology for stable electrical connections

Rotte’s automated can contacting systems handle the entire process, from feeding the components to producing a fully tested assembly. Cans, lids, contact parts, pins, and wires are individually separated, positioned, and connected using the desired contacting technology.

A key component of this process is the thermally free can contacting method, which is used in particular in solar module production: Here, punching and riveting operations are combined into a single step. The contacts are mechanically attached to the can bottom via a riveting process, creating a riveted joint – one of the safest and most durable joining techniques, both mechanically and electrically. This approach ensures high process accuracy; the entire contacting process remains free of thermal stress, and the time-consuming process of filling the can to secure the contact is no longer necessary.

The combination of a defined die cut, a reproducible riveting technique, and real-time process monitoring ensures guaranteed process reproducibility and enables the production of even large quantities with a consistent level of quality.

Flexible system architecture for different can and product families

Since products, can dimensions, and contact tasks vary significantly from customer to customer, Rotte systems are designed to be modular. This allows for the integration of new product variants, additional contact points, or modified testing requirements without requiring fundamental changes to the system.

Depending on the specific requirements, the following functional modules, among others, can be integrated:

Feeding and separation units for cans, lids, and contacts
Camera or sensor systems for position detection and orientation
Handling systems and robotics for the precise positioning of components
Contact stations (e.g., punching/riveting processes, welding, crimping, pressing, soldering) in single-stage or multi-stage configurations
Test units for electrical, geometric, or process-related quality characteristics

The newly developed process is designed to allow for the flexible use of a wide variety of junction boxes. The processes are specifically tailored to the respective junction box design so as not to limit the desired flexibility and independence from suppliers – for example, when using different junction box suppliers. The resulting system architecture can be specifically adapted to cycle times, product changeover frequency, and the desired level of automation – ranging from semi-automated solutions with manual loading to fully automated lines capable of 24/7 operation, both offline and integrated into existing production lines.

Automated feeding, bonding, and testing

Modern can assembly involves more than just joining components. Automated systems can handle additional process steps – from labeling, marking, or coding to mechanical and electrical functional testing.

Typical features include:

Automatic feeding of cans and contact parts from magazines, trays, or conveyor lines
Verification of location and completeness prior to contact
Process-controlled contact operations with force, displacement, or energy monitoring
In-line tests (e.g., resistance, continuity, insulation test, and, if necessary, leak test)
Sorting into good and defective parts and transferring them to packaging or logistics systems

This creates a closed-loop process in which each can is uniquely tracked through the contact and testing sequence. Defects are detected early, documented, and can be analyzed in detail – providing a solid foundation for continuous improvement and standardized processes. The concept is intentionally designed to be customizable to meet specific customer needs, enabling a flexible response to changes in products, standards, or testing requirements.

Rugged mechanics for continuous operation

In everyday industrial operations, can-contacting systems must be reliable, easy to maintain, and durable. Rotte therefore relies on robustly designed frames, precise guides, and high-quality components that are engineered for continuous operation. Contacting stations are designed to reliably apply the forces and energies required for the respective joining process without compromising the can structure or sensitive internal components.

At the same time, Rotte places great emphasis on easy access for maintenance and setup procedures. Interchangeable tool sets, predefined adjustment points, and well-designed service concepts reduce downtime and simplify the process of switching between products . Upon request, areas that come into contact with the product can be designed to be easily cleaned and used even in demanding environments where cleanliness is critical – such as in photovoltaic production.

Intelligent control, quality monitoring, and traceability

Rotte’s can contact systems are controlled using high-performance automation and visualization technology. All relevant process parameters – from cycle times and contact energy to test results and error messages – are recorded, monitored, and made available for analysis and documentation.

Using user-friendly interfaces, operators can:

Select or customize product recipes
Define tolerance windows and thresholds
Monitor process data in real time
View service and maintenance status

Quality control can be standardized so that inspection procedures, limit values, and evaluations can be uniformly defined and documented for different products and production lines. Upon request, the systems can be integrated with higher-level control, MES, or ERP systems so that serial numbers, batches, and test results are directly linked to orders and quality data. This makes automated can contacting an integral part of transparent, data-driven manufacturing with fully traceable processes.

The various applications of automated can contacting

Rotte’s automated can-to-can connection technology is used in many sectors of the metal, plastics, and electrical industries – anywhere where can-shaped enclosures need to be electrically connected or wired, for example:

Sensor and Measurement Technology (pressure-sealed or wetted sensors)
Automotive and Commercial Vehicle Technology (Control Units, Sensors, Actuators)
Energy and battery technology (e.g., bonding of cell housings)
Photovoltaic and solar module production (bonding of junction boxes without potting)
Electrical Engineering, Industrial Electronics, and Safety Engineering
Special applications with hermetically sealed or rugged enclosures

Whether it’s small batch sizes with a wide variety of variants or large production runs with clearly defined quantities – Rotte ensures consistent contact processes, high product quality, and a precisely documented quality standard.

Your Application, Our Solution – Reliable Contacting for Every Intermediate and Final Product

Our systems for the automated production of electrical contacts combine precision engineering, advanced process technology, and intelligent control to deliver solutions tailored to your specific products and objectives. Customers benefit from customized layouts, clear interfaces with upstream and downstream processes, and system designs that can scale to meet future requirements.

The modular design makes it possible to integrate different joining methods (including punching/riveting, welding, and crimping), additional testing equipment, or new product variants into an existing production line. At the same time, manual intervention is reduced, workstations are made more ergonomic, and production efficiency is improved.

Your partner for custom electrical socket contact systems

Every can-sealing process presents its own unique geometric, electrical, and process-related challenges. That is why Ulrich Rotte Anlagenbau & Fördertechnik GmbH develops solutions that are not off-the-shelf but are tailored to your specific requirements. After a detailed analysis of components, the process chain, quality objectives, and layout, we develop a concept that integrates seamlessly into your production process from a technical, economic, and ergonomic standpoint.

From engineering and design to manufacturing, assembly, and commissioning, our team provides comprehensive support for your project. Training for your operating and maintenance staff, along with a comprehensive service and maintenance program, ensure that your plant operates reliably, stably, and with process integrity over the long term.

Rotte’s automated can tab bonding thus lays the foundation for consistent product quality, high process reliability, and manufacturing that meets the demands of modern industry—and, in particular, highly automated solar module production.

Contact us – we’d be happy to advise you on high-performance solutions for automated can contacting, thermal-free contacting methods, and their integration into your existing or new production lines.

One Company, Many Advantages

Ulrich Rotte Anlagenbau & Fördertechnik GmbH is your specialist in custom machinery. In addition to our innovative solutions in special-purpose machinery and automation technology, you also benefit from a wide range of customer and after-sales services:

Your Advantages at a Glance:

Decades of experience in special-purpose machinery
Extensive know-how across all areas of automation technology
High expertise in the latest technologies and applications for Industry 4.0
All services from a single source—from development and design to manufacturing, assembly, commissioning, and regular on-site maintenance
Optional training of your machine operators, technicians, and supervisors at your facility
Mechanical engineering made in Germany – we design and manufacture exclusively in Germany
Personalized customer support – you will always have a qualified contact person available