Braided Copper Busbar Customizable
Products Description
braided copper busbar customizables are flexible conductors formed by precision braiding of multiple strands of high-purity oxygen-free copper wire. The outer layer can be fitted with an insulating sheath, terminal connectors, or silver/tin soldered end faces. They are suitable for compensating for equipment vibration, absorbing displacement errors, connecting dynamic mechanical modules, and carrying high currents.
Their core value lies in:
Strong flexibility and compensation capabilities: Reliable electrical connections can be achieved in space-constrained or dynamic structures.
Stable electrical performance: Uniform structure and conductivity approaching that of a braided connectors with a uniform cross-section.
Highly customizable: Braiding method, cross-sectional area, terminal shape, hole spacing, and insulation method can all be designed to meet specific needs.
Heat and corrosion resistance: Meets the stringent requirements of the new energy industry for high temperature, high current, and long lifespan.
Production Process: Six Precision Processes to Create a High-Quality Flexible Conductive Product
| Copper Wire Drawing | High-purity oxygen-free copper ingots are drawn into ultra-fine copper wires of 0.1-0.3mm through multiple drawing processes, ensuring uniform wire diameter, smooth surface, and no scratches or oxide layers. |
| Plating Treatment | According to customised requirements, the copper wires are tin-plated, silver-plated, or gold-plated using an electrolytic plating process to ensure uniform plating, strong adhesion (adhesion ≥5N/cm), and no missed plating or peeling. |
| Precision Braiding | According to the designed braiding density (8/16/32 strands) and cross-sectional shape, cross-braiding is performed using a CNC braiding machine to control uniform braiding tension, preventing copper wire breakage and fraying, and ensuring a tight braided structure. |
| Joint Forming | Depending on the customised joint type, the joints at both ends are processed using high-precision crimping or laser welding processes. The crimping process ensures uniform joint pressure, and the welding process ensures no incomplete welds, with a joint resistance ≤5mΩ; |
| Shaping and Protection | The copper braided flexible connectors undergoes shaping to ensure precise cross-sectional dimensions. Insulating sleeves are optional, and heat-shrinkable fixing ensures effective insulation and protection. |
| Finished Product Inspection | Full-item testing is conducted using equipment such as conductivity testers, bending fatigue testing machines, and tensile testing machines. Defective products are reworked immediately to ensure 100% compliance of all products leaving the factory. |
| Customized Packaging | Anti-static bags and customised foam support frames are used for packaging according to flexible braided copper busbar size and shape to prevent bending deformation and joint damage during transportation, suitable for international long-distance logistics. |
Application Scenarios: The "All-Round Player" of Flexible Connections
1. New Energy: Dynamic Connections from Wind Farms to Workshops
* Wind Turbines: Flexible connection between the converter and generator in the nacelle, resistant to ±15° sway and continuous vibration caused by rotor rotation, extending the maintenance cycle from 6 months to 3 years after replacing traditional rigid busbars;
* Electric Vehicle Battery Packs: Series/parallel connection between modules, adapting to battery expansion and contraction (resistance change <3% after 1000 cycles), contributing to a 5% increase in range.
2. Rail Transit: The Power Link in High-Speed Movement
* Pantograph Carbon Slip Ring Connection: Dynamic contact between the pantograph and the overhead contact line in subways and high-speed trains; the braided structure buffers contact pressure fluctuations (0.5-1.5kN), reducing carbon slip ring wear by 30%;
* Traction Motor Slip Ring: Current transmission between the rotor and stationary parts, resistant to high-speed rotation at 3000 rpm and electromagnetic vibration, with a lifespan twice that of traditional brushes.
3. Industrial Automation: The "Nerve Endings" of Precision Equipment
Robot Joint Power Supply: Flexible wiring at the joints of a six-axis robot, adapting to ±180° rotation and complex motion trajectories, avoiding cable tangling or breakage;
Semiconductor Equipment: RF power connection for wafer processing equipment, low inductance characteristics reduce signal distortion and improve chip yield.
Product Advantages: Core Value Created for You
Ultimate Reliability
Completely eliminates connection loosening and breakage caused by vibration, thermal cycling, and assembly errors, minimizing system failure rates and achieving truly "maintenance-free" connections.
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Design Liberation
No longer limited by the alignment precision of rigid components. The high fault tolerance of insulated flexible copper bars allows for more flexible modular design, simplifying assembly processes and significantly improving production efficiency.
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Performance Leap
In high-frequency, high-pulse current applications, its optimized electromagnetic performance and heat dissipation capabilities mean lower energy loss, lower system temperature rise, and higher overall efficiency.
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Optimal Space Utilization
Compared to thicker cables achieving the same flexibility, braided copper ground wires are more compact and lighter, making them particularly suitable for applications where weight and space are extremely sensitive, such as aerospace and new energy vehicles.
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Complete Customization
From cross-sectional area, length, and braiding density to terminal shape, hole positions, materials, and surface treatment methods, every parameter can be designed to your needs. We don't offer standard products, but rather "connection solutions" tailor-made just for you.
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