Machined Busbars

Reliability, efficiency, and precision are key in power distribution systems. Machined busbars are the perfect fit if you’re looking for a solution that ensures minimal downtime, precise power flow, and easy integration into complex electrical systems. These components are essential for connecting and distributing electricity in various industries, and choosing the right busbar is critical to achieving optimale performance.

Material Core

Copper, Aluminum, or Copper Alloy

Tin Coating Thickness

10 – 50 microns (depending on application)

Bus Bar Thickness

2 mm to 10 mm (customizable)

Bus Bar Width

10 mm to 100 mm (customizable)

Electrical Conductivity

Copper: 58 MS/m, Aluminum: 35 MS/m

Product Description

Machined busbars are crafted from high-conductivity materials such as copper or aluminum, ensuring optimale electrical flow with minimal resistance. This high conductivity reduces energy loss, translating into more efficient systems and lower operating costs. You can count on these busbars for commercial, industrial, or high-performance applications to deliver superior power transmission, reducing system inefficiencies and boosting your overall operational performance.

Thermal Conductivity

Copper: 390 W/m·K, Aluminum: 205 W/m·K

Voltage Rating

Up to 1000 V (customizable for higher ratings)

Current Rating

Up to 5000 A (depending on size and design)

Operating Temperature

-40°C to 150°C (with high-temp options)

Corrosion Resistance

High resistance to corrosion in industrial environments

Mechanical Strength

Tensile strength up to 250 MPa (for copper)

Plating Adhesion

99% adhesion under standard testing conditions

Surface Finish

Smooth, Polished, or Matte (depending on requirement)

Customization Options

Custom dimensions, hole patterns, and finishes

Standards Compliance

RoHS, UL, ISO 9001, IEC, and other industry-specific standards

Technical Advantages

Unlike traditional stamped or extruded busbars, machined ones are manufactured with precision CNC. This allows for tight tolerances, which means the busbars can be custom-designed to fit unique system requirements. Whether integrating these bars into complex panels or custom machinery, you get a solution that fits seamlessly, reducing the need for additional adjustments during installation.

The robust construction of machined busbars ensures long-lasting performance. These bars are engineered to withstand harsh environments, including high temperatures and corrosive conditions, which is crucial for automotive, aerospace, and energy industries. By choosing machined busbars, you’re investing in a solution that minimizes the risk of wear and tear, ultimately extending the life of your power distribution system and reducing costly maintenance and replacements.

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Industry Applications

Electric Vehicles (EVs)

This system connects battery packs to inverters, motors, and control systems, optimizing energy flow and performance.

Industrial Control Systems

Provides reliable power distribution in automation equipment, protecting critical machinery and minimizing downtime.

Data Centers

This system distributes electrical power across servers, cooling units, and backup systems, ensuring constant uptime and performance.

Luft-und Raumfahrt

Used in aircraft power distribution systems to manage electrical connections in critical flight and navigation systems.

Telecommunications

Facilitates power distribution in cell towers and communication equipment, ensuring minimal signal disruption.

Öl & Gas

Provides power connections in offshore platforms and refineries, supporting high-load operations in harsh environments.

Streamlined Integration and Reduced System Complexity

Integrating busbars that are easy to install and maintain is a huge benefit for complex electrical systems. Machined busbars are designed for quick, efficient assembly with reduced need for additional hardware or wiring. This not only saves installation time but also reduces the chance of errors, contributing to a more reliable and cost-effective electrical system overall.

Machined busbars must carry high current loads in many industrial applications without flexing or degrading. Their strength and stability ensure that they maintain their integrity under heavy electrical loads, minimizing the risk of power failures. Their rigid design ensures reliable performance even in high-demand systems.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How do the material properties of machined busbars affect their electrical conductivity?

Machined busbars are typically made from high-conductivity metals like copper or aluminum. With its superior conductivity, copper reduces energy losses during power transmission, while aluminum offers a lightweight alternative with good conductivity. The precision machining process ensures smooth surfaces, which minimizes contact resistance and further enhances the efficiency of the electrical flow, reducing power loss and heat generation.

How does thermal expansion impact the performance of machined busbars?

Thermal expansion can cause significant issues in power distribution systems, especially when busbars experience high currents. Machined busbars are designed with materials with a low coefficient of thermal expansion, such as copper or aluminum alloys, ensuring that they pflegen their shape and size under thermal stress. This minimizes the risk of mechanical failure, misalignment, or loose connections, enhancing the safety and longevity of your system.

How do the tolerances of machined busbars contribute to system reliability?

The precision of machined busbars allows for tight manufacturing tolerances. This level of accuracy ensures that the busbars fit perfectly into electrical enclosures, connectors, and mounting systems. Such precision helps reduce the risk of electrical arcing or poor connections, which could otherwise lead to system failure, short circuits, or downtime. With machined busbars, you can trust that every Komponente will perform as expected.

Can machined busbars handle high short-circuit currents without failure?

Machined busbars are engineered to handle high short-circuit currents without failure. Their robust design and strong material choices, such as copper or tinned copper, allow them to withstand the intense heat and forces generated during a short circuit. This capability ensures the busbars remain intact, preventing catastrophic system failures and ensuring the power distribution system operates safely under extreme conditions.

How does the surface finish of machined busbars affect their electrical and mechanical performance?

The surface finish of machined busbars plays a crucial role in electrical and mechanical performance. A smooth, polished surface minimizes contact resistance, reducing energy loss and heat generation during operation. Additionally, a well-finished surface provides better corrosion resistance, ensuring the busbars last longer in harsh environments. The precision machining process also reduces the chance of surface irregularities, which could lead to mechanical stress points or weak connections.

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LOCATIONS

Sitz

10-A, First Floor, V. V Komplex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, Indien.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti Coimbatore-641035, Tamil Nadu, Indien. ㅤ

Machined Busbars

Material Core

Tin Coating Thickness

Bus Bar Thickness

Bus Bar Width

Electrical Conductivity

Product Description

Thermal Conductivity

Voltage Rating

Current Rating

Operating Temperature

Corrosion Resistance

Mechanical Strength

Plating Adhesion

Surface Finish

Customization Options

Standards Compliance

Technical Advantages

Let's Get Started

Industry Applications

Streamlined Integration and Reduced System Complexity

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