12/16/2015

CopperBusbarJointingMethods|EEP

5CopperBusbarJointingMethods

5 Copper Busbar Jointing Methods (photo credit: donalmccann.com)

Efficientjointsincopperbusbarconductors
Efficientjointsincopperbusbarconductorscanbemadeverysimplyby:
1.
2.
3.
4.
5.

Bolting
Clamping
Riveting
Soldering
Welding

Boltingandclampingareusedextensivelyonsite.Shapedbusbarsmaybe
prefabricatedbyusingfrictionstirwelding.

1.Boltedjoints(mostcommon)
Boltedjointsareformedbyoverlappingthebarsandboltingthroughtheoverlap
area.Theyarecompact,reliableandversatilebuthavethedisadvantagethatholes
mustbedrilledorpunchedthroughtheconductors,causingsomedistortionofthe
http://electricalengineeringportal.com/5copperbusbarjointingmethods

1/5

12/16/2015

CopperBusbarJointingMethods|EEP

currentflowinthebar.

Boltedjointsalsotendtohavealessuniformcontactpressurethan
thosemadebyclampingbut,despitetheseissues,boltedjointsarevery
commonlyusedandhaveproventobereliable.

Theycanbeassembledonsitewithoutdifficulty.

Figure 1 A typical bolted joint

GobacktoMethods

2.Clampedjoints(mostcommon)
Clampedjointsareformedbyoverlappingthebarsandapplyinganexternal
clamparoundtheoverlap.Sincetherearenoboltholes,thecurrentflowisnot
disturbedresultingin lowerjointresistance.Theextramassatthejointhelpsto
reducetemperatureexcursionsundercyclicloads.
Welldesignedclampsgiveanevencontactpressureandareeasytoassemble,
buttakeupmorespacethanaboltedjointandaremoreexpensiveto
manufacture.
Figure 2 A simple clamped joint

GobacktoMethods

http://electricalengineeringportal.com/5copperbusbarjointingmethods

2/5

12/16/2015

CopperBusbarJointingMethods|EEP

3.Rivetedjoints(difficult,but)
Rivetedjointsaresimilartoboltedjoints.Theycanbeefficientifwellmade.Itis
difficulttocontrolthecontactpressure.Theycannoteasilybedismantledor
tightenedinserviceandtheyaredifficulttoinstall.

Figure 3 A riveted joint

GobacktoMethods

4.Solderedorbrazedjoints(rare)
Solderedorbrazedjointsarerarelyusedforbusbarsunlesstheyarereinforced
withboltsorclampssince heatingundershortcircuitconditionscanmakethem
bothmechanicallyandelectricallyunsound.

Figure 4 A soldered joint

http://electricalengineeringportal.com/5copperbusbarjointingmethods

3/5

12/16/2015

CopperBusbarJointingMethods|EEP

GobacktoMethods

5.Weldedjoints(notverysafe)
Weldedjointsaremadebybuttingtheendsofthebarsandwelding.Theyare
compactandhavetheadvantagethatthecurrentcarryingcapacityisunimpaired,
asthejointiseffectivelyacontinuouscopperconductor.However,itmaynotbe
safeordesirabletomakeweldedjointsinsitu.
WeldingofcopperisdiscussedinCopperDevelopmentAssociationPublication
98,CostEffectiveManufacturing:JoiningofCopperandCopperAlloys(
Downloadhere).

Get
PDF

Figure 5 A welded joint

TOP

GobacktoMethods
SHARE

JointResistanceCalculation

Inprinciple,aclampedorboltedjointismadebybringingtogethertwoflatsurfaces
undercontrolled(andmaintained)pressure,asshowninFigure6.

Figure 6 An overlapped joint

Theresistanceofajointismainlydependentontwofactors:
1. Thestreamlineeffectorspreadingresistance,Rs,duetothediversionof
thecurrentflowthroughthejoint
2. Thecontactresistanceorinterfaceresistanceofthejoint,Ri.

http://electricalengineeringportal.com/5copperbusbarjointingmethods

4/5

12/16/2015

CopperBusbarJointingMethods|EEP

Thetotaljointresistance,Rj,isgivenby:

Rj = Rs+ Ri
Thisappliesspecificallytodirectcurrentapplications.Wherealternating
currentsareflowing,thechangesinresistancedueto
skinandproximityeffectsinthejointzone mustalsobetakenintoaccount.

GobacktoMethods
Reference//CopperforBusbarsGuidanceforDesignandInstallationCopper
DevelopmentAssociation(Downloadguidance)

RecommendedEEstuff//
Sharewithengineers//

AboutAuthor//

Edvard Csanyi
EdvardElectricalengineer,programmerandfounderof
EEP.HighlyspecializedfordesignofLVhighpowerbusbar
trunking(<6300A)inpowersubstations,buildingsand
industryfascilities.DesigningofLV/MV
switchgears.ProfessionalinAutoCADprogrammingand
webdesign.PresentonGoogle+

2015EEPElectricalEngineeringPortal.AllRightsReserved|PrivacyPolicy|TermsofService |37queriesin
0.128seconds.
PoweredbyCsanyiGroup

http://electricalengineeringportal.com/5copperbusbarjointingmethods

5/5