Customized Busbars vs. Cables

EMS Szynoprzewody vs. kable

Holistic system solutions for electrical connectivity

We have the facts

Why busbars are better than cables:

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Busbars have a higher current carrying capacity

Despite having the same cross-section, cables have a smaller surface area than rectangular busbars due to their round shape. Cables therefore have a lower heat dissipation and also a lower current carrying capacity. If busbars are used instead of cables, a smaller cross-section can therefore be selected.

In short: larger surface area = higher current carrying capacity.

In addition, the larger surface area of busbars compared to cables ensures that the current flow is better distributed and the so-called skin effect is reduced. The efficiency of the power transmission is improved.

We will be happy to advise you.

Busbars offer flexibility

Installing busbars is easier than with cable systems thanks to fewer mounting points. They are used for power distribution in, for example, generators, transformers, switchgears, as a supply line to machine switches and immersion baths or as a riser in switchgears. Whether as flexible components, assembly units or as massive busbar systems, our busbars are innovative electrical connections.

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Busbars have the better operational reliability

Particularly with busbar systems, parallel installation with bars always results in the same conductor lengths. With cable systems, on the other hand, different lengths with different loads can result depending on how they are installed. Busbars therefore have a high level of operational safety and a low fire load. We will be happy to advise you.

Busbars save working time

The use of busbars not only saves time in the planning, but also in the installation and execution of the power distribution. A small busbar can be mounted at two points, while a cable requires much more work in terms of cutting to length and crimping.

If required, we can assemble your busbar solutions at your site or take over the pre-assembly of your assemblies ex works.

Busbars can be extended as required

Thanks to their modular design, busbars are extremely flexible and can be expanded almost infinitely. Installing busbars does not usually require any complex laying work, as is the case with conventional cables. This makes busbars the ideal solution in many areas, from electrical engineering to solar technology.

Busbars are recyclable

Metals such as aluminum and copper are valuable raw materials.

Copper is one of the metals that is easiest to recycle, as it does not lose any of its quality during the recycling process. It can be melted down and reused as often as you like without any impairment to its properties.

Recycling busbars not only makes economic sense and helps to save energy, but also helps to conserve natural resources. Contact us and we will give you sustainable advice.

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Our service

Consulting

+ Individual offer
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Engineering

+ Project management
+ Technical engineering
+ Cross-section design
+ Magnetic field calculation
+ 3D layout creation
+ Feasibility check

Customized manufacturing

+ Fabrication & Manufacturing
+ Highly flexible busbars
+ Flexible busbars
+ Solid busbars
+ Flat busbars
+ Busbar systems
+ Busbar assemblies
+ Further processing
+ Personalizations

Logistics

+ Worldwide shipping
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+ Upon request according to specification
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+ Dynamic capacity adjustment

Installation

+ Pre-assembly ex works
+ On-site installation
+ Supervision

After Sales

+ Maintenance
+ Spare parts requirement
+ Retro-fit

Flexible or solid

FAQs about our Busbars

Busbars or conductor rails are used, among other things, as electrical conductors in high-current engineering, high-voltage engineering, the electrical industry, the chemical industry, power supply, regenerative energies, storage technology, mechanical engineering and the e-mobility.

In order to achieve the lowest possible voltage drop, we use only highly conductive pure copper Cu-ETP (E-Cu) or OF-Cu for your copper busbars. In addition, copper busbars can be electroplated very well, which is why they are often used in electrical engineering for shunts or similar applications.

Aluminum busbars are also used as conductors for optimized heat transfer at contact surfaces. Under certain environmental conditions, pure aluminum forms a closed aluminum oxide layer (Al2O3). This property makes aluminum highly resistant to corrosion from external influences.

CoppAl® is a bi-metal composite used as an electrical connection in control cabinets, switchgear and distribution boards. CoppAl® bars are more cost-effective than copper busbars with the same current-carrying capacity.

Flexible busbars are electrical conductors that provide individual connection options for safe current flow. Our flexible busbars are made of highly conductive materials such as copper lamellae or Braided Flexible Busbars and are available in customer-specific cross-sections. In contrast to solid busbars, flexible busbars can be installed even in confined spaces and at angles, making them a space-saving and reliable solution for power distribution in industrial applications. They also offer increased safety as they are generally resistant to wear, abrasion and fire.

Flexible busbars offer greater flexibility and are easier to install than fixed busbars.

They can also be better adapted to their surroundings and require less installation space. Furthermore, they are often lighter and cheaper than solid busbar systems. Flexible busbars are usually attached to machines, devices, or walls using clamps or screws. They can be mounted in straight or curved forms as needed.

Our laminated copper busbar Isoflexx® can be used for all electrical connections in low-voltage systems. The loose copper lamellae in the insulation offer excellent flexibility and are also suitable for drilling or punching.

Our laminated expansion busbars with pressure-welded connections have low contact resistance and are easy to install. Expansion Busbars prevent damage to device connections during switching shocks, for example.

There are indeed flexible busbars that are suitable for high currents. However, it is important that the busbars meet the requirements of the electrical installation and that the maximum current is not exceeded. We will be happy to advise you.

U-shaped busbars provide continuous and reliable connections. The reason for this is that the U-shape has a better weight distribution, which avoids deformation due to excessive forces.

They are easy to extend, reconfigure or reposition, and they apply constant pressure to each connection.

U-shaped busbars provide a solid connection and require no routine maintenance.

Please feel free to contact us.

To increase energy efficiency and manage demand fluctuations, busbar systems are often the solution. They not only reduce system costs and improve reliability, they also increase capacity and help to avoid wiring errors. The physical structure of a busbar is an advantage because it offers unique mechanical design features. For example, busbar consisting of multiple layers provides better structural integrity than other wiring methods.

Some busbar offers the option of current monitoring as a stand-alone system that can be panel mounted or integrated into busbar and feeder circuit applications. We would be happy to advise you.

Busbars are made of corrosion-resistant copper, Cuponal or Aluminum. Although copper oxidizes over time, its conductivity remains, but more energy is needed to conduct the current over the surface. Therefore, three main purposes for the coating of busbars are usually pursued:

  • prevention of corrosion
  • increasing conductivity
  • for optical purposes

 

Our coating and insulation options can be found here: https://ems-power.com/en/plating

 

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We ensure that all components meet the defined requirements and, if required, we also take on the engineering, assembly and delivery of your flexible busbars.
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System solutions for your market

Flexible Customized Busbars

Whether you need flexible busbars made of highly conductive Cu-ETP1 copper mesh or lamellar components, we manufacture everything from simple components to fully pre-assembled assemblies individually according to customer requirements.

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EMS Elektro Metall Schwanenmühle GmbH
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