What Are the Applications of Busbar Processing Machines in the Power Industry? – Lijian Busbar Processing Machine's Industry Application Scenarios

2025-09-24 11:15:35

As the "main current-carrying lines" in power systems, the processing quality of busbars directly determines the safety and performance of electrical equipment. Leveraging their characteristics of "high precision, high adaptability, and high stability," Lijian Busbar processing machines have been widely applied in multiple core scenarios across the power industry, covering the entire chain from "power generation - transmission - distribution - consumption." Specific applications are as follows:

1. High-Voltage Substations: High-Specification Busbar Processing Ensures Grid Stability
High-voltage substations (110kV and above) are "hub nodes" of the power grid. They require the use of large-cross-section, high-hardness busbars (e.g., 60×10mm copper busbar, 80×8mm aluminum busbar) and impose extremely high demands on busbar straightness and punching precision (deviation ≤0.1mm). Failure to meet these can lead to overheating faults due to poor contact.
Targeting high-voltage substation scenarios, Lijian offers large busbar processing machines: Equipped with a 630kN ultra-large bending force, they can easily bend copper busbars up to 16mm thick. The punching mechanism, driven by dual servo motors, achieves a positioning accuracy of ±0.05mm, ensuring precise alignment of connection holes for busbars, insulators, and circuit breakers. They also support "multi-step bending" functionality, enabling the processing of special-shaped busbars like "Z-type" and "U-type" required by substations to meet complex layout needs. Currently, this Lijian model has been used in busbar fabrication projects for several 500kV substations domestically.

2. Low-Voltage Switchgear / Distribution Cabinets: Batch Standardized Processing for Equipment Mass Production
Low-voltage switchgear (0.4kV) is core equipment for power distribution in buildings and factories. Their internal busbars are mostly small-cross-section rectangular busbars (e.g., 20×3mm, 30×5mm). Processing needs primarily involve "batch punching and shearing," and dimensional consistency for each busbar must be guaranteed (error ≤0.2mm); otherwise, the assembly efficiency of components within the cabinet is affected.
For mass production scenarios in low-voltage distribution equipment, Lijian has developed fully automatic busbar processing machines: Featuring a "multi-station turntable" design, they can simultaneously complete punching and shearing, achieving a processing speed of 60 pieces/hour. They come with built-in memory for 100 sets of commonly used parameters, pre-setting processing programs for different switchgear models (e.g., GGD, GCK), eliminating the need for re-debugging when switching orders. Additionally, they are equipped with automatic sorting mechanisms that categorize finished busbars by specification for storage, reducing manual sorting time. After a large domestic switchgear manufacturer introduced this equipment, their daily busbar processing volume increased from 300 sets to 800 sets, and the assembly qualification rate rose from 92% to 99.5%.

3. New Energy Power Stations (PV / Wind Power): Anti-Corrosion Busbar Processing for Outdoor Environments
Busbars in photovoltaic and wind power stations are exposed long-term to outdoor conditions (high temperature, high humidity, sandy/dusty). Therefore, they require the use of "surface-treated anti-corrosion busbars" (e.g., tin-plated copper busbars, anodized aluminum busbars), and processing must avoid damaging the anti-corrosion layer. They also need to adapt to the "irregular installation spaces" of these stations (e.g., curved busbars inside wind turbine towers).
For new energy scenarios, Lijian offers specialized processing machines for anti-corrosion busbars: Utilizing a "scratch-free processing technology," the shearing blades and busbar contact surfaces are coated with PU anti-scratch coating to prevent damage to the anti-corrosion layer. The bending mechanism features "progressive pressure control," applying bending force gradually to prevent the anti-corrosion layer from cracking due to instantaneous stress. Furthermore, they support "on-site mobile processing." With a weight of only 300kg, the equipment can be transported by forklift to the PV station site for direct processing of long busbars (up to 6 meters supported), reducing deformation during busbar transportation.

4. Special Power Equipment: Customized Processing for Unique Requirements
In special scenarios like rail transit (subways, high-speed rail) and marine power systems, busbars need to meet specific requirements such as "narrow spaces, vibration resistance, and high-temperature resistance." For example, busbars inside subway traction converters need to be "thin, curved busbars" (thickness 3-5mm, bending radius ≤10mm), while marine busbars require "anti-salt spray corrosion" properties and higher processing precision.
Lijian provides customized processing solutions for special power equipment: Machine parameters (like bending radius, punching diameter) can be adjusted according to client needs, and specialized molds (e.g., special punching molds for anti-salt spray busbars) are available. Additionally, Lijian offers "process simulation" services, using 3D modeling to simulate the busbar processing process beforehand, optimizing the sequence, and avoiding processing errors due to special requirements. For instance, Lijian once customized an "anti-salt spray busbar processing line" for a shipbuilder, integrating busbar processing and surface spraying, boosting production efficiency by 35%.

In summary, through "scenario-based customization and precise adaptation," Lijian Busbar Processing Machines cover the full spectrum of processing needs in the power industry, from high voltage to low voltage, and from fixed to mobile scenarios, providing reliable busbar processing assurance for the safe operation of power systems.