Sengrin's Custom Busbar Services

At Sengrin, we pride ourselves on delivering tailored busbar solutions that meet the unique demands of our diverse clientele across various industries. Our comprehensive range of products, coupled with advanced manufacturing techniques, ensures that we provide high-quality, reliable, and efficient busbars for any application. Whether you require rigid, flexible, or specialized busbars, Sengrin has the expertise and capabilities to deliver exceptional results.

Our Products

Sengrin provides a diverse selection of busbar solutions, including rigid, flexible, laminated, and copper-to-aluminum busbars, as well as specialized products like copper laminated flexible shunts, busbar connectors, copper jumpers, battery busbar shunts, power shunts, and shunts on bus bars. These offerings are engineered for efficient power distribution, reliable connections, and versatility across a wide range of applications in industries such as industrial manufacturing, power generation, data centers, electric vehicles, renewable energy systems, and aerospace.

Materials We Use

Aluminum

Aluminum busbars are favored for their lightweight properties, making them up to 70% lighter than copper while still offering good electrical conductivity. They are highly corrosion-resistant and cost-effective, making them ideal for applications where weight and cost are critical factors. Aluminum's excellent thermal conductivity also aids in efficient heat dissipation, enhancing the overall performance of power distribution systems.

Copper

Copper is renowned for its superior electrical conductivity, offering approximately 65% of the International Annealed Copper Standard (IACS). Our copper busbars, made from T2 Copper with a minimum copper content of 99.9%, provide excellent flexibility, durability, and oxidation resistance. Copper's high tensile strength ensures that busbars can withstand thermal expansion strains and mechanical stresses, making them ideal for demanding applications across various industries.

Nickel

Nickel plating is used to enhance the corrosion resistance and electrical conductivity of busbars. Nickel-plated busbars provide a protective layer that prevents oxidation and degradation in harsh environments. This plating option is particularly beneficial for applications requiring long-term reliability and minimal maintenance, ensuring that busbars maintain their performance over extended periods.

Advanced Techniques We Utilize

1. CNC Machining

Our state-of-the-art CNC machining ensures precise fabrication of busbars to exact specifications. This technique allows us to create complex shapes and sizes with high accuracy, meeting the stringent requirements of various applications.

2. Robotic Arm Automation

Utilizing fully automated robotic arms, we enhance production efficiency and maintain consistent quality. This automation reduces human error, accelerates manufacturing processes, and ensures repeatability in high-volume production runs.

3. Stamping

High-speed stamping presses are employed to form busbar components with precision and uniformity. This technique is ideal for producing large quantities of consistent parts quickly and efficiently.

4. Bending and Forming

Advanced bending and forming machinery enable us to create busbars with precise angles and curves, accommodating the spatial constraints of different applications while maintaining structural integrity.

5. Plating

We offer various plating options, including Nickel, Silver, Tin, and Copper plating, to enhance the conductivity, corrosion resistance, and overall performance of our busbars. Plating is meticulously applied to meet specific client requirements and industry standards.

6. Injection Molding

For busbars integrated with plastic components, our injection molding processes ensure high precision and quality, allowing for seamless integration of electrical and mechanical parts.

7. Precision Machining

Detailed and accurate machining processes allow us to produce intricate busbar designs that meet the highest standards of quality and performance.

8. Custom Mold Design and Fabrication

Our dedicated mold workshop can design and fabricate custom molds tailored to your specific busbar designs, ensuring that each product meets your exact specifications.

9. Quality Testing

We conduct rigorous quality testing, including thermal simulations, current load tests, bend tests, and salt spray tests, to ensure that every busbar we produce is reliable and performs optimally under various conditions.

10. Insulation Options

Offering a range of insulation materials such as PE, PVC, PA12, PET, and Epoxy Powder Coating, we ensure that our busbars are protected against electrical shorts, environmental factors, and mechanical stresses.

11. Punching and Drilling

Precision punching and drilling create accurate hole patterns and connection points, facilitating easy installation and integration into your electrical systems.

12. Brazing and Riveting

These techniques provide strong and reliable connections, enhancing the mechanical and electrical integrity of busbar assemblies.

13. Heat Shrink Tubing

For added insulation and protection, heat shrink tubing is applied to busbars, ensuring safe and durable connections.

Testing

At Sengrin, we understand that rigorous testing is paramount to ensuring the performance and reliability of our busbar solutions. Our dedicated testing laboratory is equipped with advanced 

equipment to conduct comprehensive evaluations of each designed part before delivery.

Key Testing Procedures

• Metallographic Test Metallographic testing typically uses microscopy to provide important information about the structure and properties of metal and alloy samples. We use this test to observe the gaps between layers after welding and to analyze the quality of polymer diffusion welding, ensuring structural integrity and consistency in our busbars.

• Thermal Simulation We simulate busbar working conditions, cooling conditions, and insulation to check temperature rise. Thermal simulation can be applied at an early design stage, helping engineers make better decisions and design more effective product parts, ensuring optimal thermal management in operational environments.

• Bending Test We perform bending tests to assess the fatigue resistance of flexible busbars. This test ensures that our flexible laminated busbars can withstand thousands of bending cycles without breaking, guaranteeing durability and long-term performance in dynamic applications.

  

• Pulling Force Test Pulling force tests evaluate the mechanical strength and connection integrity of our busbars. This test ensures that our connections can withstand the forces encountered during installation and operation, maintaining reliable electrical performance.

• Aging Test Aging tests simulate long-term usage conditions to evaluate the durability and performance stability of our busbars over time. This test helps us ensure that our products maintain their electrical and mechanical properties throughout their service life.

• Salt Spray Test To verify the corrosion resistance of our plating, we conduct salt spray tests. This test ensures that our plated busbars can resist corrosion in harsh environments, maintaining their appearance and electrical performance.

Why Testing is Important

• Quality Assurance: Comprehensive testing guarantees that every busbar meets our stringent quality standards and performs reliably in real-world applications.
• Performance Validation: Testing confirms that our busbars can handle the electrical and mechanical stresses they will encounter, ensuring optimal performance.
• Customer Confidence: Providing verified and tested busbars gives our customers peace of mind, knowing they are receiving products that are both safe and efficient.
• Continuous Improvement: Testing results inform our manufacturing processes, allowing us to continuously refine and improve our busbar solutions.

Customer Applications

Typical Uses and Markets

Customer Applications

Typical Uses and Markets

Industries We Serve

• Aircraft
• Automotive
• Electrical
• Switchgear
• Renewable Energy
• Data Centers
• Industrial Manufacturing
• Medical Equipment
• Telecommunications
• Transportatio

Technical Library

• Ampacities of Copper Alloy C11000 Busbars Chart
• Quick Busbar Design Selector
• Epoxy Design Guide (PDF)
• Flexible Braided Connector Design Guide
• Busbar Emissivity Ampacity Chart

Explore our technical resources to better understand the capabilities and design considerations of our busbar solutions.

By choosing Sengrin, you are partnering with a leader in custom busbar manufacturing, committed to delivering innovative and reliable solutions tailored to your specific needs.