How to use 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 ApplicationsAir-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.