China Bus Bar Laminated Bar Power Supply

Experience from design to manufacturing
Zhecheng is aglobal expert in the electronic, electrical and advanced materials sectors. Zhecheng is able to develop various renovation solutions regarding the special needs of the clients, helping them to improve their production technology of several industrial departments. It has more than 65 years of extensive experience.With the addition of Eldre companies from the United States and France respectively to the large Zhecheng family in 2012, the laminated bar system has been added to acombination of ZheMachinery for Packaging Supplies cheng's large products, plus other energy management solutions (pj heat sink, fuse), Zhecheng has created aset of products with powerful functions, which can offer circuit protection and energy management for electrical and electronic components.Zhecheng has areputation famous for its professional technology, product quality and project safety, this is due to the sedimentation of design and manufacturing know-how of more than acentury, plus advanced equipment equipped in the three factories registered by ISO -9001 Each factory in the same time to produce single layer bar and laminated bar, can offer completely integrated solutions, among which the laminated bar can be used as aplatform to load various individual elements:• In Europe, we located in Angers de France with a5,000 m2 factory that functions as an excellent center for rolled bar solutions. The factory in Angers has been certified by IRIS and can better serve the railway sector.• In North America, we located in New York's Rochester with a110,000 square-foot factory that functions as an excellent vertical integration center operating mainly electrical distribution solutions of various types. It has AS910OC certification and has been certified by ITAR.• In Asia, we located in Shanghai, China, in the factory with an area of 6,500 m2 that has the capacity to manufacture several types of collective busbar solutions.Quality control is the first objective
From the first design consultation to the shipment of the products, Zhecheng offers innovative solutions to its customers. We always look for customer satisfaction. We offer service to many companies that benefit from our quality and technology:• Advanced metal processing technology is akey factor in the production of quality products. Our factory has advanced metal processing technology, we have CNC machining machines, photochemical machining equipment, production presses up to 200 tons, CNC bending machines and various edge treatment equipment. We offer awide range of metal bonding processes that include ultrasonic welding and induction welding.• Coating: our electroplating workshop is capable of producing almost any coating to meet your needs. These coatings include tin, tin lead, nickel, copper, silver and gold. Coating operations are carried out under rigorous laboratory control conditions, we monitor and control the thickness of the coating to meet all customer needs. The combination of rigorous monitoring, process control and X-ray inspection technology ensures the production of high quality coatings.
The manufacture of precision insulation is fundamental in the production of laminated bus bars. To guarantee quality, we always store insulating materials under constant temperature and humidity conditions. The insulating materials are cut with precision cutting dies to ensure auniform size for the high quality bus bars.• Choosing the correct insulation material is akey factor in guaranteeing the electrical performance of the busbar. We use awide range of dielectric materials, including Nomex, Tedlar, Mylar, Kapton, Epoxy-Glass, GPO, Gatex and Phenolic, which are available to meet virtually any specification. In addition to the traditional lamination system, we also have our powder electrostatic coating workshop with our own development systems for the production of high quality epoxy coatings, providing superior insulation for busbars of various shapes or for use in aggressive environments .• The assembly and lamination use the precision lamination system, specifically for the design and manufacture for each busbar. Hardware and interconnecting devices can be added before and after the lamination and coating process.Excellent quality and performance to meet the needs of various fields
Zhecheng is well aware of the challenges that customers face in all areas of our service. We offer extensive product experience and technical assistance with secondary applications to help our customers improve their products. We are experts in design, simulation, manufacturing and testing of busbar solutions for power conversion for broadband semiconductor materials (SiC, GaN) and silicon materials (IGBT, thyristors) or for battery-related products. Support for DC power electronics applications. We also provide customized services tailored to the specific needs of the market and the relevant applications.Service areas:
Applications of silicon carbide (SiC) devices, industry, defense and aerospace, transportation, EV /HEV and electric energy storage (EES), renewable energy, IT, telecommunications, value-added service, power management expansion solution.Optimal design
Zhecheng engineers can work with integrator manufacturers in the early design stages to incorporate passive components such as heat sinks, busbars and fuses in the inverter. With avariety of element simulation tool sets, Zhecheng engineers can evaluate the thermoelectric performance of the heat sink and the busbar during the entire design phase of the converter. This approach, known as integrated architecture approach, optimizes the design of the entire inverter assembly by using the same source of heat solutions and semiconductor protection bars and fuses. We provide engineering support and testing services for each design.Modeling
Due to many professional processes involved, the construction of the sample of the busbar, although fast, requires acertain time, because although the production of the sample has been completed, the execution test is also not easy and it has to analyze its use in many situations Extremely high temperature conditions or application scenarios in complex and high voltage situations are difficult to simulate in experiments.A traditional experiment could not fit avery large structure. As aresult, the costs of this type of testing could be high and increase development time. This is the reason why simulation can effectively accelerate the development process.By adding pre-test steps during the conceptual design phase, design flaws can be found and eliminated before starting sample manufacture. Because the problem of overheating or excessive thiTelecommunication & Broadcasting ckness of the sheet can not always be ascertained by calculation, the simulation must be performed.
Temperature field and electrical simulationZhecheng application engineers can perform temperature increase simulations in the busbar model. This ensures that the most efficient distribution bar design is put into production from the thermal point of view, offering customers the best product performance and the least heat loss. In addition to the simulation of temperature increase, it is also possible to perform the current simulation in the model while calculating the inductance value and the film effect. Zhecheng has perfected its design specifications with years of experience and has been able to provide very efficient designs from the start.High pressure test and partial discharge
Before shipment, each product must pass astrict test to ensure long-term reliability. Except the voltage support test or insulation break test (also referred to as "HiPot"), Zhecheng also uses the most advanced form of partial discharge test in the Hipotronics PD test station. The engineering and quality team of Zhecheng uses the DFM (Design for Manufacturing) technology, such as the FMEA (failure mode analysis) evaluating each step, all this process serves to ensure that this process is appropriate, without any problem.We can help you with any design or specification
At Zhecheng, we offer free consulting services to our clients, which allows them to analyze the design requirements directly with the experts in applications and products.
We are proud of our commitment to respond quickly to the customer (usually in abusiness day). We offer individualized design and engineering support to ensure you have the best solution.Unique characteristics of the mechanical design
The physical structure of the busbar has unique mechanical design characteristics. For example, the entire distribution subsystem can also be used as astructural component of the entire system. The scientific design of the busbar depends on the structural and electrical requirements of the application. The basic formulas and data covered in this section are intended to help design engineers specify busbars for power distribution systems. once the general idea of bus bar design is established, your specific design and manufacturing considerations will entail acost.We offer basic design standards designed to help you specify distribution bars based on your application. The information required to specify the bar includes conductive material, number of conductors (including earth), dimensions (length, width and thickness), interconnection scheme, assembly configuration (if necessary), type of coating and choice of insulation.Driver
The selection of the conductor material is essential to meet the requirements of electrical and mechanical resistance. The commonly used materials are copper, aluminum and various copper alloys. The selected material, structural constraints and electrical properties of the particular application will determine the minimum mechanical size of the conductor (see "Conductor Dimensions" in the Electrical Design section).Thermal considerations may require ventilation of the design system to dissipate excess heat from the busbar. In this case, the busbar configuration may have alower position, changing the direction of the busbar structure and the air flow. The bus bar can also act as aheat sink to dissipate the heat of the components.If bolts, nuts, pins or threaded inserts are required, the choice of terminal or terminals can determine the thickness of the conductor. It must be considered that the minimum requirements for mechanical riveting performance of the chosen connection increase overall efficiency and profitability.Ground
The size and millisecond return area of the conductor to ground must be equal to the value of the corresponding voltage conductor. Some of the advantages of aseparate ground loop are the following:
1. Multiply the effective capacitance;
2. Increase the cooling area to minimize the voltage drop caused by the increase in temperature;
3. Significantly reduces the effects of parasitic coupling
4. Effective protection between levels through the use of interconnected grounding.Installation
To assemble the busbar in the structure of the assembly, the pieces (bolts, holes, etc.) can be machined in the conductor. In addition, aground plane can be added as support for the set of busbars and aplatform for mounting the mechanism.Covering
Zhecheng can provide surface treatment of tin, tin lead, nickel, silver or gold. Performing electroplating is an important consideration in busbar design because the coating is the contact point for all busbar electrical connections. The coating provides excellent electrical performance and reducesSafety Products & Supplies voltage drop. When gold is used as acoating, it is usually only necessary to place the surface of the terminStone Processing Machinery al to minimize the cost.Insulation
Of sticks of adhesive material that insulate by coating. From an electrical point of view, insulation also has other advantages. The insulating materials provide internal and external barrier in their environment. An insulating material is used to reduce the inductance and capacitance and increase of impedance. Commonly using Nomex®, Tedlar®, Mylar®, Kapton®, Ultem®, Mylar /Tedlar, Tedlar /Mylar /Tedlar, Valox®, epoxy glass fiber, as well as heat shrinkable tubing and epoxy powder coating. These insulating materials are available in avariety of thicknesses. For more information, please contact us. The sound insulation layer can be provided on request.Consideration of cost
The price of the components of the bar varies according to the quantity. In addition, the respective dimensional characteristics of busbars, the materials, manufacturing techniques, interconnection scheme, acoating lUniversal Hardware Parts ayer, the insulating material and the total cost of necessary parts, all these factors come into consideration to calculate the cost. Engineers can help develop the most efficient and most cost effective design and offer solutions for all problems. The sooner we are involved in its design, the more profitable and easy the solution will be. Early participation also helps us optimize manufacturing processes and delivery times.Electric design
Resistance, series inductance and capacitance are important characteristics of the laminated busbar. We consider the performance parameters of equipment and electronic components increasingly demanding, these characteristics are also increasingly important.In the determination of the impedance of the energy distribution system, these two characteristics are fundamental to solve the most important problem (that is, the resistance and intererencias) faced by the designers. Therefore, understanding the electrical properties of the laminated bus bar is critical.Driver size
The calculation of the size of the conductor is important for the electrical and mechanical properties of the busbar. The electrical current transport requirements will determine the minimum width and thickness of the conductor. The mechanical characteristics include hardness, mounting holes, connections and other components of the subsystem. The width of the conductor must be at least three times the thickness of the conductor.Zhecheng busbar -36 "(length) x1.5" (width) x0.010 "(thickness)
Insulation thickness =0.006 "AMRonTM 2-5
Driver area =0.015 in2
RDC (calculation result) =0.0032 ΩZhecheng busbar -36 "(length) x0.125" (width) x0.010 "(thickness)
Insulation thickness =0.006 "AMRON 2-5
Driver area =0.00125 in2
RDC (calculation result) =0.038 Ω
For further information please contact us:
Shanghai Zhecheng Electric Co., Ltd.
Hotline: +86(0)-21-5748997956317229
Fax: +86(0)-21-57489310
www.sh-zhecheng.com/en/