copper busbars
copper busbars
Copper Busbars are essential components in electrical power distribution systems, widely used in industries requiring high current carrying capacity, superior conductivity, and durability. As a leading manufacturer and exporter from India, we specialize in producing high-quality Copper Busbars tailored for applications such as Transformers, Switchgear, Power Distribution Panels, and Industrial Electrical Systems. Our Tin plated Copper busbars as well as bare Copper Bus bars are used by leading electrical companies in the world.
These rigid Copper bubars are made of high-conductivity copper, ensuring minimal energy loss and excellent thermal performance. Unlike cables, which have higher resistance and can overheat under heavy loads, busbars provide a low-resistance path for current flow, making them ideal for high-power applications. They are commonly used in industrial, commercial, and renewable energy systems, where reliable and efficient electrical distribution is critical.
Copper busbars come in various shapes and sizes, including flat, solid, and hollow designs, depending on the specific electrical and mechanical requirements. Many busbars feature tin or silver plating to prevent oxidation and enhance conductivity. They are often drilled with precision holes for secure bolted connections, allowing easy assembly and maintenance. Their modular nature makes them highly adaptable to different installations, reducing the need for complex wiring. Additionally, copper’s superior durability and resistance to corrosion make busbars a long-lasting solution for power infrastructure.
Material Grades for Copper busbars
We manufacture Copper Busbars using the highest quality Copper alloys to meet international standards.
| Material | Grade (Equivalent Standards) | Conductivity (% IACS) | Typical Applications |
|---|---|---|---|
| Electrolytic Tough Pitch (ETP) Copper | C11000 (ASTM), Cu-ETP (DIN), C101 (BS) | ≥ 101% | Transformers, Switchgear, Electrical Panels |
| Oxygen-Free High Conductivity (OFHC) Copper | C10200 (ASTM), Cu-OF (DIN), C103 (BS) | ≥ 101% | High-performance electrical applications |
| Phosphor Deoxidized Copper | C12200 (ASTM), Cu-DHP (DIN) | 85-90% | HVAC, Refrigeration, Plumbing |
| Silver-Bearing Copper | C10500 | 98-100% | High-temperature electrical applications |
Manufacturing Process
Copper Busbars are precision-engineered using advanced processes to ensure superior electrical performance and mechanical strength.
- Raw Material Selection: High-purity Copper billets sourced from trusted suppliers.
- Hot & Cold Rolling: Copper is rolled to the required thickness and width.
- Annealing & Hardening: Controlled heating and cooling processes optimize mechanical properties.
- Precision Machining & Punching: CNC machining, stamping, and drilling for precise shapes and hole patterns.
- Surface Finishing & Plating: Options include Tin Plating, Silver Plating, Nickel Plating, or Bare Copper finish.
- Quality Inspection: Stringent checks for dimensional accuracy, electrical conductivity, and mechanical strength.
- Packaging & Dispatch: Custom packaging to prevent transit damage and ensure safe delivery.
Machinery Used to manufacture Copper busbars
| Process | Machinery Used |
|---|---|
| Rolling | Hot Rolling Mill, Cold Rolling Mill |
| Punching & Stamping | CNC Punching Machines, Hydraulic Presses |
| Machining | CNC Turning Centers, Milling Machines |
| Finishing | Electroplating Units (Tin, Silver, Nickel), Surface Grinding Machines |
| Inspection | Digital Micrometers, Vernier Calipers, Spectrometers, CMM (Coordinate Measuring Machine) |
Typical Parts Produced
- Flat Copper Busbars
- Bent & Custom-Shaped Busbars
- Hole-Punched & Drilled Busbars
- Tinned Copper Busbars
- Laminated Copper Busbars
- Flexible Copper Busbars
Finishes Available
| Finish Type | Benefits |
|---|---|
| Bare Copper | Maximum conductivity |
| Tin Plating | Corrosion resistance, improved solderability |
| Silver Plating | High conductivity, oxidation resistance |
| Nickel Plating | High-temperature resistance |
NEMA Spacing & Tolerances
We manufacture Copper Busbars according to NEMA (National Electrical Manufacturers Association) standards, ensuring compatibility with electrical panels and switchgear.
| Busbar Thickness (mm) | Typical NEMA Hole Spacing (mm) | Thickness Tolerance (mm) |
|---|---|---|
| 3.2 | 25.4 | ± 0.08 |
| 6.4 | 38.1 | ± 0.10 |
| 9.5 | 50.8 | ± 0.12 |
| 12.7 | 63.5 | ± 0.15 |
Industries Using Copper Busbars
- Power Transformers – Electrical conductivity for efficient energy transfer.
- Switchgear & Panels – Reliable power distribution components.
- Renewable Energy – Used in Solar & Wind Power Installations.
- Automotive & Electric Vehicles (EVs) – Battery connections, high-current pathways.
- Industrial Machinery – Motor control centers, manufacturing plants.
- Railway Electrification – Overhead lines, traction substations.
Lead Time & Turnaround
Our typical production and delivery schedule:
| Process | Time Required |
|---|---|
| First Article Development | 3 Weeks |
| Bulk Production | 4-6 Weeks |
| Transit to Port | 3 Days |
| Shipping & Delivery | 3-4 Weeks (International) |
Common Questions & Answers
Q1: What are the advantages of using Copper Busbars over cables?
A: Copper Busbars offer higher conductivity, better heat dissipation, lower power losses, and compact installation compared to cables.
Q2: What finishing options do you offer for Copper Busbars?
A: We provide Bare Copper, Tin Plated, Silver Plated, and Nickel Plated finishes based on customer requirements.
Q3: Can you manufacture custom-shaped busbars?
A: Yes, we produce customized Copper Busbars as per engineering drawings and specifications.
Q4: Do you comply with international electrical standards?
A: Yes, our busbars comply with NEMA, IEC, ASTM, DIN, and ISO standards.
Q5: What is your minimum order quantity (MOQ)?
A: MOQ depends on the size and complexity of the order. We cater to bulk as well as small orders for prototyping.
Q6: Do you provide Copper Busbars for renewable energy applications?
A: Yes, our busbars are widely used in solar, wind, and energy storage systems.
Q7: What is your production capacity?
A: We manufacture over 30 metric tons per day, ensuring timely fulfillment of large orders.
For bulk inquiries, technical specifications, or custom orders, contact us today! We ensure high-quality Copper Busbars with international standards and competitive pricing.
