Production solution for copper busbar

(I) Welding process upgrade
Equipment selection: Use high-power medium-frequency DC diffusion welding machines, such as 1500kva, 2000kva, 3000kva, and other models. This equipment can meet the production needs of different scales. For example, 1500kVA welding machines are suitable for small enterprises or small batch production, while 3000kVA welding machines are suitable for large-scale production. Taking a low-voltage electrical manufacturer as an example, after using a high-power welding machine, the conductive busbar can be welded at one time, and 7 grooved large Copper BusBars can be welded at the same time, with the fastest time of 60 seconds per piece, which greatly improves production efficiency.

Precise control of process parameters: According to the thickness of the Copper Foil Bus Bar, the number of layers and the performance of the equipment, the welding current, time, pressure and temperature parameters are accurately adjusted. For example, for a 0.1 mm thick, 10-layer copper foil stack, the welding current is about 3000-5000 amperes, the welding time is 5-10 seconds, the welding pressure is 50-150 kPa, and the temperature is 800℃-1000℃. Through precise control, the copper foil is fully diffused and fused, the weld is firm and defect-free, and the welding quality is improved.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(II) Improvement of material pretreatment and post-treatment
Pretreatment: Strictly test the purchased copper materials and select copper materials with low impurity content and high purity, such as T2 copper strip with a copper content of more than 99.9%. Grind and clean the surface of the copper foil to remove impurities such as oil and oxides. If necessary, pickling is performed to enhance the cleanliness and bonding strength of the welding surface and provide a good foundation for welding.

Post-treatment: In addition to conventional passivation, burr removal, stain removal and other treatments, surface treatment processes are added according to application scenario requirements. If used in harsh environments such as humidity, acid and alkali, the Copper BusBar for Siemens can be tinned, silvered or nickel plated as a whole or in part to improve corrosion resistance; for scenes with insulation requirements, the soft connection parts can be covered with insulating sleeves as a whole or in part.

 

 

(I) Welding quality control
Process monitoring: During the welding process, sensors are used to monitor welding current, voltage, temperature, pressure and other parameters in real time to ensure that the parameters fluctuate within the set range. Once the parameters are abnormal, the machine will automatically stop and alarm immediately to avoid welding defects.

Finished product inspection: Non-destructive testing technology, such as ultrasonic flaw detection and X-ray flaw detection, is used to detect whether there are cracks, pores, slag inclusions and other defects inside the weld; tensile tests and bending tests are performed on the welding AC BusBars to detect whether the welding strength meets the requirements and ensure welding quality.

(II) Material and dimensional accuracy control
Material purity detection: Regularly analyze the chemical composition of copper materials, detect the copper content and impurity content, and ensure that the copper materials meet the quality standards. Each batch of Solid Copper Bus Bar materials is sampled and tested, and only qualified batches can be put into production.

Dimensional accuracy control: During the production process, high-precision measuring equipment, such as micrometers and calipers, are used to measure and monitor the dimensions of the copper foil flexible connector busbar in real time. The dimensional tolerance is strictly controlled according to the design requirements, generally within ±0.5mm. For products with high precision requirements, the tolerance is controlled within ±0.1mm to ensure the dimensional accuracy of the product.