In the design and operation of electrical systems, ensuring efficient connections between devices is crucial, and busbars are one of the indispensable components. They are widely used in low-voltage switchgear as the medium for current transmission. However, to ensure the safety and efficiency of these busbars in use, their surfaces must be adequately protected. This is because bare busbars can oxidize when exposed to air, which not only reduces their conductivity but also shortens the lifespan of the equipment.
In fact, the use of bare busbars in good environments not only meets the basic electrical safety requirements but also demonstrates their excellent performance advantages. By applying bolts of appropriate specifications and precise torque to fasten them, the contact surfaces of bare busbars can effectively avoid direct contact with air and moisture, thus preventing the formation of oxidation layers. This practice also ensures a tight fit between busbars, maintaining low contact resistance, which is crucial for operational safety.
Furthermore, although bare busbars gradually form an oxidation layer when exposed to air, the characteristics of this oxidation layer provide additional protection. Especially in the high-temperature environment of low-voltage switchgear, this thin film-like oxidation layer that forms rapidly on the surface of the busbars can effectively prevent further oxidation of the internal busbars, maintaining their excellent conductivity. Notably, the heat dissipation capability of copper oxide far exceeds that of untreated bare copper, approximately 14 times greater. Since about 15% of the heat from busbars is dissipated through radiation, the formation of the oxidation layer significantly enhances the heat dissipation efficiency of bare busbars, thereby optimizing their current carrying performance.
However, copper oxide is almost non-conductive because it lacks free-moving electrons and ions. 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. For example, methods like pickling and chemical deposition are commonly used to passivate the busbar surface, forming a protective film that effectively prevents further oxidation.
Depending on different application environments and requirements, the surface of busbars may require additional treatments, especially at the contact points. Common surface treatment methods include tin plating, nickel plating, silver plating, and insulation treatment. These treatments not only provide better corrosion resistance but also improve the electrical performance and mechanical strength of busbars. Notably, tin plating offers good corrosion resistance and can reduce the contact resistance of the busbar surface to some extent.
The surface treatment of busbars is a complex yet crucial process. By adopting appropriate treatment methods and techniques, the performance and reliability of busbars can be significantly enhanced. Whether through passivation, plating, or other means, proper surface treatment ensures that busbars perform optimally in various environments and extends the overall lifespan of the equipment.
In power systems, as important conductive components, the surface treatment technology of busbars is crucial to system stability and efficiency. Nickel plating on busbars significantly enhances corrosion and oxidation resistance, and its high hardness improves adhesion and wear resistance. This makes nickel-plated busbars particularly suitable for applications requiring frequent sliding connections, such as drawer cabinet primary connectors and vertical bus contact points. Moreover, nickel plating gives busbars a brighter appearance, enhancing aesthetics while extending their lifespan.
On the other hand, silver plating on busbars primarily aims to enhance electrical performance. Silver plating can effectively reduce contact resistance of busbars, thereby improving overall conductivity. Due to the high chemical stability of silver, this treatment ensures that busbars maintain good performance in various environments. However, considering the cost factors, this treatment method is usually applied to components requiring extremely high conductivity or busbar contact surfaces aiming for optimal temperature performance. Some financially strong owners may also opt for this premium treatment based on personal preference.
As for the insulation treatment of busbars, its main purpose is to enhance electrical isolation between busbars, ensuring safe operation. Common insulation treatment methods include epoxy resin spraying and applying heat shrink tubes. Although these methods effectively improve insulation performance, they also increase processing difficulty and costs. Many experienced electricians prefer using heat shrink tubes because, in addition to providing good insulation performance, they can also enhance operational safety to some extent.
Depending on different working environments, busbars require various surface treatment methods. These treatments, though increasing costs, can enhance busbar performance in certain aspects. However, they may also sacrifice others. For instance, nickel plating or full insulation using heat shrink tubes can reduce the heat dissipation ability of busbars, thereby affecting their current carrying capacity.
When deciding whether to surface treat busbars or keep them bare, manufacturers and clients must clarify this point during technical disclosures. Switchgear products provide multiple options without particularly favoring any method. Bare busbars can be used in any switchgear unless specific environmental and positional requirements dictate otherwise. It is recommended to use bare busbars to save costs.
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