Busbars are used in numerous industries for energy distribution while maximizing efficiency. It has a broad range of electrical applications, so it’s imperative to have a manufacturer to provide you with the highest quality precision metal stamped parts. Fortunately, G & M Manufacturing is a reputable manufacturer that can deliver results designed to improve our customer’s bottom line.
Our in-house ISO 9001:2015 certified facility is fully equipped with cutting-edge technology to produce quality busbars to ensure the success of your operations. Furthermore, our thorough understanding of each industry allows us to deliver results that meet your specifications and exceed your expectations.
What is a Bus Bar?
Busbars or bus bars are metallic components commonly found in vehicles, devices and switch gears. These bars carry the electric power from incoming feeders and distribute it to outgoing feeders. It works as a junction where incoming and outgoing currents meet and exchange.
The main goal of a bus bar is to maximize the efficiency of the power distribution process. Due to its remarkable properties and purpose, it has become a staple in industries where electricity is the main element.
Learn How an Electric Bus Bar Works
Electrical bus bars work as a conductor of electricity, collecting power from low and high-voltage sources and distributing it across different outgoing feeders to low-voltage equipment. Apart from its ability to conduct electricity, it can also ground it, but it depends on the need.
Standard busbar systems have a circuit breaker and isolator. The circuit breaker works by tripping in case of an overload or fault in the design, while the faulty section switches off the current or is disconnected from the circuit to ensure safety.
Producing Quality Busbars through Precision Metal Stamping
The typical production method for bus bars is precision metal stamping, which is when flat metal coils are converted into desired shapes. At G & M Manufacturing, we can manufacture bus bars in large quantities and tight tolerances without compromising quality. Tolerances of up to +/- 0.025 mm can be achieved and verified using our Zeiss CMM system.
The automotive industry is shifting its focus towards electric vehicles, where electric bus bars are particularly critical. Its main application is to transmit power in all conventional and EV types, such as all-electric, hybrid, or hydrogen fuel cells. We can manufacture metal stamped bus bars in various sizes and complexities to transmit current from high-powered sources to different electrical applications.
Materials Used to Produce Bus Bars
A bus bar is commonly made from copper or aluminum due to its ability to fulfill various electrical current requirements. These materials can also meet the bus bar’s application performance seamlessly. Many times busbars are plated with tin, silver or nickel to prevent corrosion and oxidation. This plating can be done as a preplate (before stamping) or post plate (after stamping) depending on the performance and cost requirements.
Below are the different electrical applications of each material:
Copper Bus Bars
Copper offers high conductivity and is exceptionally resilient against extreme weather conditions and temperatures. Additionally, it acts as an extra precaution in case of short circuits.
Other benefits of using copper include the following:
- High Conductivity
- Long-lasting performance
- Resistant to damage
- Suitable in clamped joints
- Remarkable recovery value
- High modulus of elasticity
- Low coefficient of linear expansion
Aluminum Bus Bars
Aluminum is also conductive and ideal in electrical applications. What makes it stand out is that this material is lighter. It’s a perfect option in applications where weight is essential and highly considered.
Numerous Busbar Applications
The rise of hybrid and electric vehicles means that more electrical parts and components are in demand in the automotive industry. One of these is bus bars due to their wide range of specific applications.
Some of these applications are as follows:
- Charging cables
- Fuel cell systems
- Charging stations and transformers connections
- Fuse boxes (including high-current fuse boxes)
- Battery connections
- Power distribution
- Jump (jumper cable) points
Choose G & M Manufacturing to Supply You With High-Quality Busbars
We specialize in industrial standard metal stamped bus bars tailored to your specifications and requirements. We can deliver unparalleled outcomes with our years of thorough knowledge of the automotive industry and its latest innovations.
If you have any questions or concerns about our services, feel free to contact us today. Request a quote for large orders, and we’ll develop a solution that meets your quality and performance requirements. At the same time, we’ll work to fit it according to your budget.