The bending radius-to-thickness ratio is crucial in copper busbar design, ensuring optimal electrical performance, mechanical strength, and reliability. Precise design and accurate bending are essential for long-term performance in power systems, EVs, and industrial applications.
In the electrical and busbar manufacturing industries, copper busbars play a critical role as key components in electrical connections. The design of their bending processes is crucial to ensuring system stability and safety. Specifically, the relationship between the bending radius (R) and the thickness of copper busbars directly impacts both electrical performance and mechanical strength.
The bending radius (R) refers to the inner radius at the bend. A properly designed R not only prevents cracks on the surface of the copper busbar, but also maintains excellent conductivity and mechanical strength after bending. Based on experience and industry standards, the ratio of the bending radius to busbar thickness (T) typically ranges from 1:1 to 2:1, meaning the bending radius should be 1 to 2 times the thickness (T) of the busbar.
Preventing Material Damage
During the bending process, an excessively small bending radius concentrates stress on the busbar surface, causing cracks or structural damage. This is especially critical for thicker busbars, where insufficient R can lead to excessive stress, compromising both electrical performance and mechanical stability.
Ensuring Stable Electrical Contact
For busbars used in electrical connections, the surface smoothness and shape at the bend are vital. A proper R ensures good contact between the busbar and connecting components, reducing resistance and ensuring stable current transmission. This minimizes overheating or electrical failures caused by poor contact.
Enhancing Mechanical Strength
A well-designed R reduces stress concentration and prevents deformation or breakage of the busbar under external forces. This is particularly important under high current or heavy load conditions, ensuring long-term reliable operation of the system.
For Thin Busbars (1-3mm):
A bending radius equal to the thickness (1x thickness) is typically sufficient to prevent surface damage while maintaining electrical performance.
For Thick Busbars (10mm or More):
The bending radius should be increased to 1.5 to 2 times the thickness. This reduces stress concentration during bending and ensures the integrity of the busbar.
The bending radius-to-thickness ratio is crucial in copper busbar design, ensuring optimal electrical performance, mechanical strength, and reliability. Precise design and accurate bending are essential for long-term performance in power systems, EVs, and industrial applications.