Full analysis of Electrical bus bar processing technology standards

Adequate preparation work should be done in the early stage of Ground bus bar processing. Firstly, the optimal processing and wiring plan should be planned based on the design drawings and production task list to ensure efficient and compliant subsequent processing flow; At the same time, it is necessary to comprehensively inspect the models and specifications of supporting electrical components and accessories, verify whether they are consistent with the requirements of the drawings and material lists, confirm that product licenses, certificates of conformity and other qualification documents are complete, and control the quality of supporting components from the source.

Busbar electrical material selection must strictly follow the design requirements. The specifications and materials of the main busbar must be selected according to the design drawings. When there are no special requirements, the material of the branch busbar should be consistent with that of the main circuit busbar; When the wire diameter of the branch circuit busbar is not marked, the selection should be based on the current of the circuit breaker release.

The Electrical copper busbar of both the main circuit and the branch circuit should be matched with cross-sectional specifications not lower than the corresponding current carrying capacity according to the rated current. In addition, the cross-sectional area of the grounding busbar for high-voltage distribution equipment shall not be less than 30 square millimeters, and the cross-sectional area of the grounding wire for passing through doors shall not be less than 4 square millimeters. The selected busbar surface shall be smooth and flat, without cracks or impurities, to ensure that the substrate quality meets the standard.

The production of Electrical bus bars is the core process of processing. Firstly, the direction and size of the bus bars need to be determined. The wiring method of the same type of switchgear needs to be consistent to ensure overall regularity; Before processing, the busbar needs to be straightened with a busbar rolling machine and locally adjusted with a wooden mallet to ensure that the vertical bending (side bending) degree of the busbar is not greater than 2mm/m, the flat bending (wide bending) degree is not greater than 3mm/m, the cutting surface is flat and smooth, and there are no quality defects such as burrs or cut deformation.

The bending of Copper solid bus bars should be selected according to actual needs, and right angle bending should be minimized as much as possible. After bending, cracks and obvious wrinkles should not appear, and reverse bending is strictly prohibited at the already bent position; When processing multiple busbars simultaneously, the degree of bending should be consistent, and a gap equal to the thickness of the busbars should be reserved between the busbars.

The distance between the bending and overlapping parts of the Copper busbar bending should be maintained at 10mm, and the distance between the bending and overlapping parts and the support point should not be less than 20mm (adjustable according to space limitations). The surface of the processed busbar should be continuously smooth and flat, without deformation, distortion, wrinkles, and other problems.

The punching and drilling process of the Power busbar requires precise operation. First, draw the centerline at the corresponding position of the busbar, use a punch to drill the positioning hole, and then select the busbar processing machine or drilling machine according to the processing requirements for operation; The diameter of the busbar holes should be 0.5-1mm larger than the bolt diameter. Punching and drilling should be kept vertical and not skewed, and the center distance error between holes should not exceed 0.5mm to ensure connection accuracy.

Burrs generated after hole processing need to be removed with a countersunk drill, with a removal depth not exceeding 0.8mm. It is forbidden to use a regular file for rough polishing; The overlapping contact surface of the High voltage busbar needs to be treated with a special embossing leveling mold. After treatment, the contact surface has no oxide film, and the reduction in copper busbar cross-section does not exceed 3% of the original cross-section to avoid affecting the current carrying capacity. Standardized contact surface treatment can effectively reduce contact resistance, prevent local overheating, poor contact and other faults during later operation, and ensure the stability of copper bar connections.

Busbar connector protection and assembly are key steps in the final processing. The three-phase busbars in the modular substation must undergo heat shrink insulation treatment, and the color of the heat shrink tubing must comply with industry standards. The corresponding size of the heat shrink tubing should be matched according to the specifications of the busbar.

After cutting according to the requirements, it should be uniformly heated with a hot air blower until the heat shrink tubing is tightly attached to the busbar and the surface is flat without wrinkles; Zero and ground wires do not require heat shrink treatment, but corresponding labels need to be affixed. Busbars with a width of less than 40mm should be labeled with a diameter of 20mm, while busbars with a width of 40mm and above should be labeled with a diameter of 30mm.

When assembling the Industrial busbar connection, the connections between busbars and busbars, as well as between busbars and electrical components, are fastened using through bolts. Steel fasteners are used for the bolts, and the flat busbar bolts are threaded from bottom to top. In other cases, the nuts are placed on the maintenance side. When tightening, it is advisable to flatten the spring washer and then screw it in half, with the bolts exposed 2-5 times from the nut. Install washers on both sides of the bolt, with a spacing of no less than 3mm between adjacent bolt washers.

Install spring washers or locking nuts on the nut side to ensure even force distribution and prevent additional stress on the electrical component terminals. After installation, the Solid copper bus bar will not experience any additional stress, and the connection can be protected with a dedicated insulation box. The overlapping contact surface can be coated with electrical compound grease as needed to further improve the connection reliability.

Strictly following the Electrical bus bar processing technology standards is necessary to ensure the conductivity, mechanical strength, and long-term operational stability of the finished product, and to meet the needs of various power engineering and complete distribution equipment. Welcome to contact us anytime for compliant product solutions and professional technical support.