How To Achieve Maximum Efficiency When Joining Busbar Connectors

Example of Efficient Copper Busbar Joining

Storm Power's Approach to Connecting (Joining) Busbar

Busbar Joining is a critical component of efficient busbar connections.

Incorrect joining methods result in higher resistance causing bus systems to run hot with undesirable temperature fluctuations. This can degrade the efficiency of joints, leading to down time due to maintenance issues. 

Storm strives for 100% efficiency with every busbar joint we design and build. To this end, Storm engineers employ the highest electrical standards to meet this challenge. They have learned that the best method of proper busbar joining involves science and experience.

From switchgear to complex busbar laminations, their goal is to eliminate the use of less efficient joint that reduce heating. Here's a quick list of design factors to be considered:

• Busbar thickness, width and length

• Overlap length, bolt pressure, surface condition and more

• The resistance ratio or resistivity of the conductor whether it's bare or plated

• Use of oversize bus conductors to reduce resistivity

• Compensating for expansion between different conductors like copper to aluminum bus bar that may include using Belleville or spring washers to compensate for expansion

• Hole diameter and the number and position of holes on bolted joints

• Method of joining, e.g. solder, angled connections or other methods such as clamping that may employ Bus bar clamps, edgewise bus bar clamps or vertical bus bar clamps.



Here's an example of a common bolt joint that achieves full efficiency:

Example of Efficient Placement of Bolts Used in Busbar Joining

Engineering and Design Know-How: When Science and Experience Combine to Create a Simple but Elegant Solution

In a bolted overlapping joint, the flow of electric current may be distorted at the joints. In fact, even a perfectly made overlapping joint will have higher resistance than a single busbar of the same length as the jointed busbars.

This is known as “streamline effect” which is created by the ratio between the overlap and busbar thickness.

One example results from the alignment of the slot (or hole) placement of the adjoining busbars - this is where Storm's engineering staff employ the design factors listed above.

The correct placement (see left) is often the simplest pattern.

Combined with matching busbar thickness, material, surface treatment and more, resistance, heating, and voltage drop will be reduced or eliminated.

Current flow is "streamlined" to achieve maximum energy efficiency.



Please call 1-800-394-4804 to connect with one of Storm's talented engineers today!

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