The Manufacturing Process Of Copper Busbar

Copper busbar has low electrical resistivity, high mechanical strength, and strong corrosion resistance. It is an indispensable conductive material for manufacturing motor windings, high and low voltage electrical appliances, switch contacts, and wires for power supply and distribution installation. It has been widely used in various power transmission and transformation, electrical equipment, and other fields.
The production process and method of busbar are as follows:

a. Measurement and cutting of busbars
Before cutting the busbar, a survey of the busbar wiring inside the distribution cabinet should be conducted to test the actual dimensions required for busbar installation.

b. Straightening of hard busbar
The straightening methods include manual straightening and mechanical straightening, with moderate force to ensure that the busbar does not deform.

c. Busbar marking
Determine the position, bending shape, and other parameters of the busbar positioning hole, and then mark the busbar.

d. Busbar punching processing
The processing of busbar holes generally uses circular holes, requiring the centerline of the hole to be perpendicular to the busbar and not skewed. Busbar punching requires deburring treatment.

e. Busbar embossing
The contact surfaces between busbars and busbars, as well as between busbars and terminals, should be smooth and embossed. The contact surfaces should be deburred to ensure good contact.

f. Busbar bending
There are generally three bending methods for busbars: flat bending, vertical bending, and twisted bending. After bending the busbar, there should be no defects such as cracks, scratches, peeling, etc. When the busbar needs to be heated, attention should also be paid to controlling the temperature.

g. Surface painting treatment of busbar
Busbars without heat shrink tubing should be painted with phase paint according to the corresponding regulations. Paint yellow, green, and red on phases A, B, and C in a three-phase AC circuit, respectively; The positive and negative poles of the DC circuit are painted brown and blue; Paint the neutral or neutral wire in light blue; The safety grounding wire is coated with yellow and green alternating colors.

h. Correct connection of busbar
Keep the busbar overlap surface flat, without any bumps or scratches. When connecting the busbar with bolts, install tin plated flat pads on both sides of the busbar.

i. Bus installation regulations
The busbars comply with electrical clearance and creepage distance regulations; Overlap between different types of busbars according to relevant regulations; Connect correctly in the order of busbar arrangement.