Copper Braided Busbars For Electrical
Products Description
As a core conductive component in industrial power distribution, new energy equipment, and rail transportation, copper braided busbars for electrical applications are specifically designed for scenarios requiring "flexible transmission of high current, installation in complex spaces, and adaptation to vibration environments." They represent an engineering-grade power transmission solution integrating "high conductivity and flexible structure, low-loss transmission, vibration resistance and fatigue prevention, and safe redundant heat dissipation." Unlike rigid copper busbars, which suffer from inflexible installation, weak current-carrying capacity of ordinary copper conductors, and the vulnerability of single-strand copper busbars to vibration, these products utilize a core concept of "multi-strand copper braiding + integrated crimping." They address four key pain points faced by professional buyers: inability to adapt rigid connections in complex equipment layouts, severe heat generation during high-current transmission, conductor fatigue fracture under vibration, and loosening of connections due to thermal expansion and contraction.
Main Functions: Focusing on the core needs of flexible high-current transmission
Flexible Complex Installation
The multi-strand braided structure possesses high flexibility, easily adapting to confined spaces, complex wiring, and multi-angle bends, improving installation efficiency by 60% and avoiding stress damage from rigid connections. Copper Braided Flexible Connectors are suitable for internal equipment wiring, modular switchgear layouts, and other scenarios.
01
High-Current Low-Efficiency Transmission
High-purity copper + optimised conductive path provides strong current-carrying capacity, low conductivity loss, and controllable temperature rise. Braided Wire Copper Bus Bar is suitable for high-power equipment, smart grids, new energy vehicles, and other high-current transmission scenarios, reducing energy loss.
02
Vibration Resistance, Fatigue Prevention, and Stability
The elastic buffering characteristics of the braided structure eliminate the risk of breakage under severe vibration environments. Contact resistance remains stable over the long term, making insulated flexible copper bars suitable for vibration scenarios such as rail transit, vehicle-mounted equipment, and industrial robots, ensuring continuous power transmission.
03
High-Efficiency Heat Dissipation and Safety Redundancy
The mesh structure has a large heat dissipation area and strong overload capacity. Combined with insulating sheath protection, it prevents electric shock and short circuits, offering high safety redundancy. Flexible Insulated Copper Busbars are suitable for power equipment requiring long-term continuous operation and high safety requirements.
04
Thermal expansion and contraction compensation
The flexible structure can expand and contract freely to compensate for thermal expansion and contraction caused by temperature changes, avoiding deformation and loosening of rigid conductors, and is suitable for high-temperature equipment, outdoor power distribution and other scenarios with large temperature fluctuations.
05
Design Advantages: The Art of "Customised" Braiding Parameters
We don't simply produce standard products. We customise the number of Flat Copper Braid Flexibles, the wire diameter per strand, the braid density (mesh count), and the angle based on your specific needs-current magnitude, flexibility requirements, vibration frequency. For example, a tighter braid structure is used for high-vibration scenarios, while a looser braid is used for applications requiring extreme flexibility.
Metallurgical-Grade Bonding of Terminal Connections: The connection between the terminals and the braided tape is the weakest point of the entire assembly. We abandon simple crimping or soldering, instead employing advanced "cold pressure welding" or "diffusion welding" technologies. Under immense pressure, copper atoms interpenetrate, forming a metallurgical bond approaching the strength of the component itself. This connection exhibits extremely low resistance and exceptional fatigue resistance, ensuring long-term reliability of the connection points.
Core Application Advantages: Solving System-Level Pain Points in Specific Scenarios
| Dynamic Compensation for New Energy Power Generation Systems | In wind turbines, the internal high-power electrical connection points experience periodic displacement due to nacelle yaw and blade pitch. In photovoltaic power plants, diurnal and seasonal temperature differences cause thermal expansion and contraction in the support structure and combiner box. Our Tinned Copper Braid Earthing Tapes, acting as pre-designed displacement compensators, perfectly absorb these displacements, preventing bolt loosening, contact surface deterioration, and even breakage caused by stress fatigue in rigid connections, thus ensuring the long-term output and safety of the power generation system. |
| Current Collection and Vehicle Body Connection in Rail Transit | In high-speed rail and subway systems, the vibration and deformation of the vehicle body during operation are continuous between the pantograph and main transformer, or between various high-voltage boxes within the vehicle body. Tinned Copper Braid Wire Grounding Jumper replaces some rigid busbars, forming "elastic connection sections," effectively isolating vibration from transmission to precision electrical equipment while ensuring the absolute reliability of the current path under vibration conditions. This is a key measure to improve the reliability of the vehicle's electrical system. |
| Seismic Resistance and Thermal Expansion Management of Industrial Electrical Equipment | In the power distribution rooms of large steel and chemical enterprises, heavy equipment such as transformers, circuit breakers, and capacitor compensation cabinets generate vibration and heat during operation. Rigid connections between equipment transmit vibration and accumulate thermal stress. Using our flex bus bars for connection is equivalent to setting up "electrical flexible connections" between equipment, which can efficiently transmit power, absorb vibration, and compensate for thermal displacement, significantly reducing equipment failures caused by connection stress. This is particularly suitable for earthquake-prone areas or process industries with extremely high requirements for operational continuity. |
| High-Power Variable Frequency Drive (VFD) Systems | At the output of a frequency converter driving a high-power motor, a high-frequency PWM waveform generates high-frequency oscillations and additional electrodynamic force in the line. Grounding Braids Wire Tin Plateds, due to their low inductance and the skin effect advantage of multiple parallel strands, can better transmit high-frequency current, reducing line losses and heat generation. At the same time, their flexibility can absorb vibrations during motor startup and operation, protecting the output terminals of the frequency converter. |
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