Problems and solutions in copper busbar manufacturing process

As an important conductive material, copper busbar is widely used in motor windings, high and low voltage electrical appliances, switch contacts, and wires for power supply and distribution installation. However, various problems are often encountered during its production process, affecting product quality and production efficiency. This article will discuss in detail the common problems in the copper busbar manufacturing process and propose corresponding improvement measures.

 

 

Excessive oxygen content
In the manufacturing process of copper busbars, excessive oxygen content is a common problem. The oxygen content of oxygen-free copper should be ≤10ppm, but it is often difficult to achieve this standard in actual production. Excessive oxygen content will cause pores on the surface of the copper busbar, reducing its conductivity and mechanical strength.

 

Coarse and loose grains
Coarse and loose grains are caused by poor quality of raw materials or improper processing technology. This not only affects the conductivity of the copper busbar, but also leads to a decrease in its mechanical strength.

 

Cold shut and surface cracks
Cold shut refers to defects formed due to improper temperature control during the production of copper busbars, which manifests as local discontinuity; surface cracks are caused by stress concentration or material defects.

 

Surface oxidation
When the copper busbar is exposed to high temperature, surface oxidation is prone to occur, which will seriously affect its conductivity and service life.

 

Difficult bending and forming
For copper busbars with larger specifications, how to ensure the forming accuracy and aesthetics during bending and forming is a technical difficulty.

 

Equipment failure
The transmission chain of copper busbar processing machines mostly uses rolling friction pairs, so it is easy to have problems such as reduced motion quality, such as increased reverse clearance and positioning accuracy that does not meet requirements.

 

Insufficient tinning process
The existing tinned copper busbar technology has many shortcomings, and it is necessary to improve its anti-oxidation and anti-corrosion properties by improving the process flow.

 

 

 

Optimize raw materials and auxiliary materials
The first step to improve the quality of copper busbars is to purify raw materials and auxiliary materials and reduce the oxygen content. For example, remove copper beans, verdigris, screen and dry charcoal, etc. In addition, ensuring the use of high-purity copper materials is also key.

 

Improve processing technology
In continuous extrusion technology, by optimizing the finish of the die sizing belt, the stripes generated in the extrusion process can be effectively reduced. At the same time, the use of advanced drawing technology can also significantly improve the quality and production efficiency of copper busbars.

 

Surface treatment technology
For surface oxidation problems, surface treatment technologies such as cleaning, anti-oxidation and passivation can be used to improve the surface properties of copper busbars. In addition, the use of fully automatic environmentally friendly continuous high-speed tinning methods can also effectively improve the quality of the coating.

 

Equipment maintenance and optimization
Regularly maintain and optimize copper busbar processing equipment to ensure its normal operation. For example, adjust the parameters of the preload, loose ring and compensation link of the kinematic pair to reduce mechanical creep and bearing noise.

Process improvement
By improving the process flow and reducing repetitive labor and waste in the production process, production efficiency can be significantly improved. For example, optimize equipment layout and production schedule, and arrange production tasks reasonably.

 

Introduction of automated equipment
Introducing semi-automatic or partial process automated equipment can improve production efficiency and capacity, and meet the development needs of the new energy industry.

 

Quality control and management
Strengthening quality control and management is an important means to improve the quality of copper busbars. Through fine management and careful operation of the production process, the defects on the surface of the copper busbar can be effectively reduced. In addition, assigning responsibilities to individuals and clarifying the division of responsibilities of various departments will help to discover and solve quality problems in a timely manner.

 

Technological innovation and R&D
Continuously increase R&D investment, adopt advanced production processes and technologies, and improve the accuracy and consistency of copper busbars. For example, develop high-performance copper alloy materials with special microstructures to improve conductivity, strength and corrosion resistance.

 

 

There are many problems in the copper busbar manufacturing process, but the quality and production efficiency of copper busbar can be effectively improved by optimizing raw materials, improving processing technology, introducing advanced equipment and strengthening quality control. In the future, with the continuous advancement of technology and the growing market demand, the copper busbar manufacturing industry will usher in a broader development prospect.

 

Our Laminated Copper BusBar has strict quality control during the production process to ensure that each product meets the highest industry standards. Our technical team has many years of operating experience and a solid theoretical foundation. They are proficient in the technology of copper busbars and can provide high-quality products.