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Safety busbar, also known as: busbar, safety slide wire, slide wire. The safety busbar is an energy-saving busbar developed by drawing on advanced foreign experience and combining with national conditions. It is safe, reliable, and has excellent mechanical and electrical properties, and is easy to install and maintain. The phase spacing is 80mm, the protective shell is made of two materials: engineering plastic and aluminum-plastic alloy, and the conductor is aluminum alloy (with stainless steel strips embedded) or pure copper. It is not affected by rain, snow, frost, and is suitable for harsh environments such as open air, water mist, acid mist, and conductive dust. For specifications below 300A, circles and arcs of various radii can be made according to user needs.
The safety busbar is used to supply power to moving equipment. It consists of two parts: the slide rail (fixed part, connected to the power supply, usually made of single lengths of 4m/piece or 6m/piece connected together), and the current collector (sliding part, which can slide on or inside the slide rail and contact the copper strip to collect electricity, and is used to connect with the moving motor).
Commonly used are safety busbars (tubular, enclosed), single-pole combined safety busbars, rigid safety busbars, multi-pole tubular safety busbars, seamless safety busbars, cable safety busbars, I-beam cable trolleys, etc. They have made great improvements in protection level and insulation, and are safe and reliable.
The quality of safety busbars can be measured according to the following standards:
1. Carbon brush service life - it is a consumable item, and the travel distance affects the equipment maintenance cycle.
2. Quality of the busbar shell - applicable temperature, environment, etc.
3. Performance of the current collector - mainly from the wheel service life, turning wheel design, and whether the current collector can be used in various environments.
4. Expansion problem of the busbar - after the length exceeds 100 meters, expansion must be considered.
5. Voltage drop problem - the voltage drop varies according to the length of various copper strips.
1. Product structure: The M-type busbar consists of a guide rail, protective cover, current collector, hanger, connector, fixing clamp, end cap, etc. According to user requirements, expansion sections (thermal compensation devices), maintenance sections (isolators), etc. can also be configured.
2. Guide rail and protective cover: The guide rail is made of aluminum alloy profile with good conductivity and strong environmental adaptability (grade 6063, state T5). A "V"-shaped stainless steel groove is embedded in the lower part of the guide rail to ensure that the carbon brush of the current collector is wear-resistant, stable, and has good contact when sliding along the groove. The guide rail is generally fixed at 6 meters. The protective cover is made of engineering plastic with toughness, wear resistance, anti-aging, and flame retardant properties, providing good insulation protection for the guide rail and ensuring personal safety.
3. Current collector: The current collector is a support-type structure and is the main component that supplies power to moving equipment. It consists of special carbon brushes, terminals or lugs, plastic protective covers, support arms, etc. It applies appropriate contact pressure, slides smoothly along the guide rail, and supplies power to the equipment. When the equipment needs maintenance, the carbon brush of the current collector can be pulled away from the guide rail to cut off power, ensuring safety and convenient operation.
4. Connector (also serves as power supply): The connector is specially used for end-to-end connection between guide rails. It is reliably connected by pressing plates and bolts, and the shell is made of engineering plastic as a protective cover. The protective sleeve that also serves as a power supply can introduce the power inlet wire at the port and is fastened together with the connector pressing plate and bolts.
5. Hanger, fixer, and end cap: The hanger is a special part for hoisting and fixing the busbar guide rail. The fixer is a device that limits the guide rail at the bracket. When the guide rail expands and contracts due to temperature changes, it guides the guide rail to extend to both sides of the fixer. The end cap is installed at both ends of the guide rail for insulation protection. The hanger and end cap are both made of engineering plastic.
6. Expansion section (thermal compensation device): The expansion section is also called an expansion joint or thermal compensation device. It consists of connector pressing plates, compensating aluminum or copper plates, lead wires, etc., and the shell is made of engineering plastic. When the guide rail expands and contracts due to temperature changes, the expansion joint adjusts the gap to avoid deformation of the guide rail. Generally, when the workshop length exceeds 200 meters, one set is configured for every additional 100 meters.
7. Maintenance section (isolator): The maintenance section is made of connector pressing plates and high-strength insulating materials, with an engineering plastic shell as the protective cover. It is selected according to user needs and is mainly convenient for maintenance of busbars, moving equipment, etc.
Safety busbar: For dusty, humid environments, dust-proof sealing strips and hand protection can be configured (hand protection is required when the busbar is very close to people). The current collector speed is less than 300 meters/minute.
Single-pole combined safety busbar: Easy to install, fast speed, up to 500 meters/minute (imported busbars can achieve this).
Rigid safety busbar: Used for high-current equipment, with current up to several thousand amperes.
Tubular busbar: Combined according to different pole numbers, the current can also reach thousands of amperes.The first is single-pole safetybusbar, the second is multi-pole safetybusbar, and the third is single-pole rigidbusbar. They are collectively called safety busbars. Of course, there are also some special models of busbars, such as seamless busbars, etc.
Single-pole safety busbar is suitable for most power supply systems of moving equipment. Its simple material, easy installation, easy maintenance and repair, and low price make it one of the first choices for many customers among safety busbar specifications. Single-pole busbar is suitable for moving equipment with current between 150A and 2500A.
The material of multi-pole safety busbar is copper bar. Its conductivity and energy saving are significantly improved compared to single-pole safety busbar, but its cost also increases a lot. Moreover, due to the different structure, its current carrying capacity is far lower than that of single-pole busbar. It is generally used on small-power moving equipment, with an operating current between 50A and 300A.
Rigid busbar is mainly used in some special occasions, such as high temperature, high corrosion, and high humidity environments. It is suitable for operation in all occasions, but because of its high cost, it is mostly selected only in these special occasions.
Note: The above information and technical parameters are compiled and released by Yangzhou Darui Electric Co., Ltd.
