pembengkokan busbar tembaga

Busbar tembaga bending is a key process in the manufacture of power equipment; its accuracy directly affects the safety of equipment and conductivity. This article combines industry standards and experimental data to systematically analyze the copper bending pre-treatment, mechanical calculations, tool selection, and other 10 technical points and reveal the direction of process optimization through parameter comparison.

1. Pretreatment and material 

  1. Dimensional error control 
    Copper busbar bending before the need to accurately measure the length, width, and thickness, the permissible error ≤ 0.5mm (power equipment scenes), overshooting may lead to poor contact or local overheating.
  2. surface treatment process 
    Ultrasonic cleaning with a neutral cleaning agent can remove oil, and sandpaper (400 mesh or more) can polish the oxide layer and reduce the risk of bending cracks. Brass (yield strength 280 MPa) is easier to bend than pure copper busbar; you need to adjust the pressure according to the material.

2. Bending force and tool selection

  • Pressure parameter calculation 
    A thickness of 3mm copper rows needs 4.5-7.5 tons of pressure; thickness and pressure are positively correlated (formula: pressure = thickness × 1.5-2.5 MPa).
  • Mold selection criteria 
Copper busbar thickness Mold hardness (HRC) Recommended materials
≤5mm 50-55 Alloy tool steel
>5mm 55-60 High speed steel
  • Advantages of CNC equipment 
    CNC bending machine programming error ≤ 0.1 °; the efficiency is 3 times higher than manual; the scrap rate is reduced by 40% (the case of an auto parts manufacturer).

3. Process parameters and quality control

  • Inner and outer fillet ratio
    The radius of inner fillet should be 1.5-2 times of the thickness of the busbar(Example: R15-R20 is recommended for 10mm thick copper busbar) to avoid cracking of outer fillet.
  • Unfolding length calculation
    Formula: Unfolding length = sum of linear dimensions + n×π×(R inside + R outside)/2 (n is the number of bending), 45°beveled angle should be corrected by superimposing the collinear theorem.
  • Current Density Selection
 Current Range Allowable Current Density (A/mm²)
≤200A 3-4
200-500A  2-3
>1000A 0.8-1.2

4. Defect Prevention, Control and Detection

  1. Surface defect determination (
    Crack length >1mm or broken plating needs to be reworked; microscope inspection can identify micron-level damage.
  2. Safety protection specification
    Operators need to wear cut-resistant gloves (EN388 standard) and goggles (ANSI Z87.1 certification), and hydraulic equipment needs to be equipped with an emergency stop device.

Kesimpulan

Copper busbar bending needs to integrate material science, mechanical calculations, and precision manufacturing technology. Through the optimization of pre-processing, the application of CNC equipment, and data-based parameter control, it can significantly improve the finished product qualification rate.

Product Categories

  〉 Batang Bus Tembaga

  〉 Batang bus tembaga berlapis timah

  〉 Batang bus tembaga berlapis nikel

  〉 Batang Bus Tembaga Berlapis Perak

  〉 Busbar fleksibel

  〉 Busbar tembaga fleksibel

  〉 Busbar Fleksibel Laminasi

  〉 Batang bus terisolasi

  〉 Busbar Tembaga Terisolasi

  〉 Batang bus aluminium

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