Copper Busbar Knowledge Introduction

What is copper busbar? First to introduce the definition of copper busbar: copper busbar, refers to conductors that take the form of a bar or bars of copper conductor.Used as a transmission current copper row, copper busbar has good electrical conductivity, thermal conductivity, corrosion resistance, high mechanical strength, no low-temperature brittleness, easy welding, easy pressure processing.

Overview of Copper Busbar

Busbar copper is currently widely used in switchgear busbar and generator, transformer lead wires. Its cross-section range: thickness of 2-60m, width of 8-320mm.

Busbar conductor allowable current and common AC resistance and heat dissipation surface area, round although there is a smaller skin effect, but its heat dissipation surface area is small, generally not used.

Rectangular conductors have a large heat dissipation surface area, due to the common cross-sectional area of a single conductor does not exceed 1200mm2, when used to carry large currents, the need to use multiple rectangular busbar parallel busbar group, but due to the parallel rectangular busbar heat dissipation becomes worse, generally should not use more than 2 ~ 3 busbar.

For conveying larger currents flat copper busbar, slot busbar is generally used, compared with multiple rectangular busbars, the skin effect can be greatly reduced, the current distribution is more uniform, heat dissipation conditions are also good. The copper busbar size should be determined according to the specific load size when selecting.

Standard: Implementation of national standard GB/T5585.1-2005.EN13601,JISH3140,ASTM B187-B187M-2016

Classification:

• Conventional: slightly round edge & Full round edge (commonly known as straight edge rounded edge).

• Shaped: produced according to the requirements of design drawings.

Copper Bus Bar Specification

Common cross-section range: 16~6000mm2, common thickness of 2-60m, width of 8-320mm.

Conductive performance: closely related to the busbar working environment temperature.

Calculation of current-carrying (40 °) can be simply calculated in accordance with the following formula: (specification number of units are taken mm).

Busbar specifications: A (thickness) * B (width).

Single piece of current-carrying ≈ B * (A + 8.5) amp.

Copper Bus Bar Weight Calculation

At present,  Chinese manufacturers produce electrical copper busbar factory length is mostly 3-6 meters long, so after simplifying the copper busbar weight calculation formula is:

(specification number of units are taken mm)

A * B single weight ≈ A * B * 0.0534KG

A * B weight per meter ≈ A * B * 0.0089KG

Production Process of Copper Busbar

Purchase of electrolytic copper (copper cathode) - on the lead furnace process (melting process) - continuous extrusion process - drawing process - straightening process - cutting and sawing process - inspection process - packaging process - shipping.

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FAQs of Copper Bus Bar

1. What are the primary benefits of using copper for busbars?

The combination of high electrical and thermal conductivity, mechanical strength, corrosion resistance, and ease of fabrication makes copper an ideal material for busbars in a wide range of electrical applications. These benefits contribute to the efficiency, reliability, and longevity of electrical systems, making copper a preferred choice for busbar material.

2. What is the copper busbar current density?

The current density of copper busbar is a measure of the electric current per unit cross-sectional area, typically expressed in amperes per square millimeter (A/mm²) or amperes per square inch (A/in²). The current density is an important parameter in the design of busbars because it affects the temperature rise, efficiency, and overall performance of the electrical system. For copper busbars, typical current density values used in practice can vary depending on the application, cooling conditions, and safety margins.

3. How to select copper busbars for transformers?

• Meet the requirements for current capacity of copper busbar.

• Consider the rated current of the transformer with a 1.1 times overload factor.

• Meet the safety distance and adapt to the component terminal.

• Meet dynamic thermal stability.

4. Is surface treatment absolutely necessary for copper busbars?

Yes. It is essential to check for oxidation on busbars before installation. If any signs of oxidation are present, immediate measures must be taken to remove these oxides. This step usually involves physical or chemical methods to ensure the purity of the busbar surface.