Comparison of Copper Busbar Twisting and Lapping Processes
In the electrical industry, the arrangement and connection of copper busbars greatly influence electrical performance, mechanical strength, and environmental adaptability. The twisting and lapping processes are two common methods, each with unique features and applications. These techniques can also be combined to optimize performance.
1. Copper Busbar Twisting Process
Process Characteristics
The copper busbar twisting process involves using specialized equipment (twisting machines) to uniformly twist the copper busbar along its longitudinal axis into a spiral shape. This process helps maintain electrical conductivity while enhancing mechanical flexibility and vibration resistance.
Appearance Characteristics: The custom busbar takes on a spiral shape, offering some degree of elasticity.
Current Application: Mainly used in low to medium current scenarios, as higher currents may affect the busbar’s performance.
Usage Environment: Suitable for systems with significant mechanical vibration or where thermal expansion and contraction are prevalent.
Advantages
Vibration Resistance: The spiral structure can absorb mechanical vibrations and shocks, preventing fatigue or loosening of connections due to continuous vibration.
Thermal Expansion Adaptation: The spiral design provides elastic buffering, reducing stress accumulation caused by temperature changes.
Reduced Electromagnetic Interference: The spiral shape helps mitigate eddy current effects and electromagnetic interference in high-frequency current environments.
Space Flexibility: Spiral copper busbars can be easily installed in irregular or confined spaces.
Challenges and Disadvantages
Processing Difficulty: Requires high-precision equipment for twisting operations. Any slight deviation may cause deformation or cracks in the copper busbar.
Slight Loss in Conductivity: The twisting process may slightly reduce the effective cross-sectional area of the copper busbar, limiting its use in high-current applications.
Higher Costs: The complexity of the process and the need for additional mechanical processing increase production costs.
Application Scenarios
High Vibration Environments: Such as connections in rail transportation or motor vibration-prone areas.
Systems with Significant Temperature Variations: Like outdoor equipment or power devices exposed to high heat.
Complex Distribution Systems: Where flexible wiring arrangements are required.
2. Copper Busbar Lapping Process
Process Characteristics
The copper busbar lapping process involves connecting two sections of copper busbar by overlapping them, usually secured with bolts or welded joints, forming a reliable electrical and mechanical connection.
Connection Types: Common forms include flat overlap, cross overlap, or staggered overlap.
Insulation Treatment: The overlapping areas must be insulated to ensure safety.
Advantages
Reliable Connection: The large contact surface after bolting or welding ensures stable electrical and mechanical connections.
Excellent Electrical Conductivity: Maintains a high capacity for current transmission, making it suitable for high-power scenarios.
Simple Installation: The structure is relatively straightforward, making it easy to install or replace on-site.
Moderate Costs: This method does not require complex equipment, making it suitable for mass production and application.
Challenges and Disadvantages
Contact Resistance Management: Improper handling of the lapped joint may lead to increased contact resistance or overheating.
Vibration Sensitivity: In vibrating environments, bolts may loosen over time, leading to poor contact and requiring periodic maintenance.
High Insulation Requirements: Proper insulation is needed at the lapped joints to avoid leakage or short circuits.
Application Scenarios
Main Busbar Connections for High-Power Equipment: Such as in high-voltage switchgear or power transformers.
Extension and Connection of Multi-Branch Circuits: Temporary or Adjustable Power System Configurations: Suitable for situations where changes are frequent.
3. Combined Use of Copper Busbar Twisting and Lapping Processes
In certain special application scenarios, the copper busbar twisting and lapping processes can be combined to meet both mechanical and electrical performance requirements.
Combined Usage Scenarios
High Vibration and High Current Situations: In high-vibration equipment, the main busbar can use the lapping process to ensure large current transmission, while the branch circuits can employ the twisting process to absorb mechanical vibrations.
Systems with Significant Temperature Variations: In environments with extreme temperatures, the lapped busbars can be used for main power transmission, while twisted copper busbars buffer the mechanical stress from thermal expansion and contraction.
Constrained Spaces in Complex Wiring Systems: In systems requiring flexible wiring but with higher current loads, the main circuits can use the lapping process, while branch circuits can be arranged using twisted busbars.
Advantages of Combined Usage
Enhanced Overall Performance: Balances the need for electrical conductivity and resistance to mechanical stress.
Simplified Maintenance: The twisted sections reduce the impact of vibrations on the lapped joints, lowering maintenance frequency.
Adaptability to Diverse Needs: Improves the system’s ability to handle complex working conditions.