PP200 - How to fabricate busbars or collector bars

Special request

We have designed and manufactured a special die that, when coupled to the PP200 Horizontal Press Brake, bends copper flat bars to manufacture busbars or collector bars.

One of our clients from Korea sent us the material specifications and the blueprints of the parts that needed to be produced. Based on these premises, our technical department has designed and manufactured this die for bending copper flat bars.

Its particularity is that with the same die, we can bend copper bars of different thicknesses and at different radii, just by changing the set of bending washers. These copper pieces are used to make busbars for electrical panels, requiring great precision. Once the die fabrication was completed, we created a demonstrative video for the client, explaining how to set up the tools and adjust the machine.

What are busbars or collector bars?

In electricity and electronics, busbars or collector bars are flat or three-dimensional conductive elements made of conductive materials such as copper or aluminum. These are used to make electrical connections and efficiently and safely distribute electrical current in different applications.

Main functions and uses of busbars

• Current distribution: Busbars allow the efficient distribution of electrical current from a power source (such as an electrical panel) to different devices, equipment, or electrical systems. The current is distributed in an organized and safe manner through the conductor bars.
• Connection between components: Busbars are used to connect and join electrical and electronic components of a system, such as switches, circuit breakers, relays, contactors, fuses, and other devices. This facilitates the interconnection of the electrical elements necessary for the operation of a system.
• Facilitate maintenance: By using busbars, maintenance and repair operations in an electrical system are simplified. Technicians can easily access the connection and disconnection points, reducing the time and complexity of maintenance tasks.
• Ground connection: Busbars are also used to connect electrical and electronic systems to ground, which is crucial to ensure safety and protection against electrical discharges.
• Reducing wiring complexity: By using busbars, the number of individual cables needed to connect electrical components is reduced, decreasing the system's complexity and facilitating organization and order on the electrical panel.
• Facilitate expansion and modularity: Busbars are designed to be scalable and modular, allowing for easy addition or modification of connections and components according to the expansion needs of the system.
• Distribution in electrical panels: In electrical panels, busbars are used to connect and distribute electrical current to different circuits and sections of the panel, providing efficient and safe organization of the electrical system.

Advantages of using the PP200 Horizontal Folding Press to manufacture copper busbars

Bending copper using a horizontal hydraulic press has several advantages compared to other forming methods:

Precision and consistency: The horizontal hydraulic press allows precise control over the applied pressure, resulting in more precise and consistent bends in copper. This is essential to ensure that the manufactured parts meet the required specifications and tolerances.

Greater bending force: Horizontal hydraulic presses have a high bending force capacity, making them an efficient choice for bending copper, especially when working with thicker or stronger copper sheets or sections.

Versatility in work: The horizontal hydraulic press can be equipped with different types of dies and tooling, allowing for a wide variety of shapes and bends in copper, adapting to various design requirements and applications.

Reduced physical effort: Using a horizontal hydraulic press reduces the physical load and effort required by operators, as much of the force needed to bend copper comes from the hydraulic system of the machine, minimizing fatigue and improving efficiency at work.

Efficiency in production: The horizontal hydraulic press allows efficient and continuous production, which is essential for large-scale manufacturing of copper components. Cycle times are fast, and multiple bends can be made in a single operation.

Time savings: Using a horizontal hydraulic press reduces the time required to make complex bends compared to manual methods. This contributes to speeding up production processes and meeting shorter deadlines.