Method of pressing the distribution box

Pressing a distribution box involves shaping flat sheet metal into the enclosure using hydraulic or CNC press brakes, forming the sides, back, and top with precision.

Material Preparation

The process begins with selecting the appropriate sheet metal, typically steel, galvanized steel, stainless steel, or plastic composites for corrosion resistance and durability . The metal sheets are cut to precise dimensions using laser or plasma cutting machines, ensuring accurate shapes for the box panels . Edges and corners are smoothed with files to prevent sharp edges and ensure safety during assembly .

Pressing and Forming

Once cut, the flat metal pieces are moved to hydraulic or CNC press brakes. These machines use a die to bend the metal at specific angles, forming the sides, back, and top of the distribution box . The die consists of two halves (top and bottom) that imprint the desired shape onto the sheet metal. Pressing can involve multiple operations such as blanking, bending, drawing, and flanging, depending on the complexity of the box . Multi-stage presses allow several operations in a single stroke, improving efficiency and precision.

Assembly Preparation

After pressing, the panels are checked for dimensional accuracy and proper fit. Holes for screws, hinges, and cable inlets are prepared, often with additional stamping or punching operations . Porcelain or rubber sleeves may be added at wire inlets to protect cables during installation .

Wiring and Component Installation

Following pressing, the distribution box is ready for component installation. Busbars, circuit breakers, terminals, and neutral/ground bars are mounted, and wires are cut, stripped, and pressed into terminals using crimping tools . Proper spacing and alignment are ensured for safety, maintenance, and aesthetic appearance.

Quality Control

Finally, the pressed and assembled box undergoes rigorous testing: high-voltage insulation tests, resistance measurements, leakage current checks, and verification of breaker trip times . Only after passing all tests is the distribution box approved for packaging and shipping. This pressing process ensures that the distribution box is structurally sound, precise, and ready for safe electrical installation.