Application Methods of Tubular Busbars

Tubular busbars are primarily applied in high-current and high-voltage switchgear systems using round copper tubes, offering compact, efficient, and reliable power distribution.

Key Applications

Air-Insulated Switchgear (AIS): Tubular busbars are widely used as main or branch conductors in medium- and high-voltage air-insulated switchgear. Their round copper tube design allows for optimized electric field distribution, reducing environmental impact and enhancing safety and reliability . They are often employed to connect generator circuit breakers to step-up transformers and in high-voltage gas-insulated lines (GIL).

High-Current Industrial Systems: Tubular busbars are suitable for applications requiring high current-carrying capacity. Compared to rectangular copper bars of the same cross-sectional area, tubular busbars can achieve an AC current-carrying ratio of approximately 1:2, enabling smaller switchgear dimensions and more compact layouts .

Battery and Power Distribution Systems: In electric vehicles and renewable energy systems, tubular busbars provide rigid, low-resistance connections between battery packs or distribution boards, improving efficiency and reducing energy losses .

Installation and Joining Methods

Mechanical Joining: Tubular busbars can be connected using compression fittings, semi-tubular rivets, or dovetail interlocking systems. These methods generate high contact pressure along overlapping areas, ensuring low electrical resistance and mechanical stability .

Forming and Progressive Tool Systems: Some installations use progressive forming techniques, including lancing, bending, and forging, to join busbar sections without auxiliary elements. This reduces galvanic corrosion risks and improves long-term reliability .

Mounting Considerations: Busbars are typically mounted using studs, holes, or support frames, sometimes with a ground plane for structural stability. Insulation materials such as Nomex®, Mylar®, or epoxy coatings may be applied to prevent short circuits and improve dielectric performance .

Smart Integration: Modern tubular busbars may include built-in sensors for temperature and current monitoring, enabling intelligent switchgear systems that support predictive maintenance and operational efficiency .

Advantages of Tubular Busbars

• Compactness: High current density allows smaller switchgear dimensions.
• Longevity: Optimized electric field distribution reduces wear and environmental impact.
• Efficiency: Lower resistance and improved cooling compared to flat bars.
• Flexibility: Suitable for high-current, high-voltage, and battery applications.
• Intelligence: Integration with sensors enables smart monitoring and control .

In summary, tubular busbars are applied in high-current, high-voltage, and compact power distribution systems using mechanical or forming-based joining methods, with optional insulation and sensor integration to enhance performance, safety, and longevity.