Flexible Busbars for Switchgear up to 10,000 A

Why Flexible Busbars in Switchgear?

In switchgear and transformer applications, electrical connections must carry high currents while absorbing mechanical loads. Rigid copper bars transfer thermal expansion and vibration directly to insulators, bushings and terminals. Over the years, bolted joints loosen and ceramic components crack.

Flexible busbars, commonly called expansion joints in switchgear construction, act as compensating elements. They absorb thermal expansion, contraction and vibration without passing the mechanical load on to adjacent components. Thanks to the solid welded terminal ends, contact resistance remains stable throughout the service life of the installation.

Compared with rigid bars, which must be precisely preformed and aligned, flexible busbars also simplify installation. They bend around obstacles and compensate for manufacturing tolerances between connection points, reducing assembly time in confined switchgear panels.

Applications

Low- and medium-voltage switchgear
Busbar trunking and busbar systems
Power and distribution transformers
Generator connections
Circuit breaker connections
Capacitor bank connections
Disconnector connections
Rectifier and reactor connections

Surface Treatment

For switchgear, tin plating is the standard recommendation: it prevents oxidation at bolted joints and keeps contact resistance low for decades. Silver plating offers the lowest contact resistance and is suitable for very high currents or frequently switched connections. Bare copper is sufficient for dry, regularly maintained indoor installations.

Technical Data

Parameter	Specification
Rated current	100 A – 10,000 A
Current-carrying capacity	Designed in accordance with DIN 43670
Conductor material	High-conductivity copper, e.g. Cu-ETP or Cu-HCP (purity ≥ 99.9%), as required
Lamination thickness	0.1 – 0.3 mm
Terminal options	Press-welded, solid; undrilled or with holes to DIN 43673 or customer drawing
Surface	Bare, tin-plated, silver-plated
Insulation	Optional; operating temperature depends on insulation material
Operating temperature	Depending on insulation material

Custom Busbars for Your Switchgear

Send us your drawing or your requirements for current, voltage and installation space. We manufacture flexible busbars for switchgear manufacturers and power distribution companies worldwide.

Inquire now

Need advice? Our experts assist you in choosing the optimal solution for your application.

Kai Kleinevoß

Head of Sales Wirbalit®
kleinevoss@svs-schweisstechnik.de
+49 208 99 328 15