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News > Technical Articles > Punching > Punch Into Busbar

Punch Into Busbar

Here’s an in-depth look at busbar manufacturing, and what it takes to manipulate the thick materials typically involved. 

October 29, 2019

What is Busbar? Where is it Commonly Used? 

A busbar is a connective piece of metal made from copper, brass, or aluminum. The primary task of a busbar is not to provide structural rigidity, but rather to act as an electrical conductor, allowing for the transfer of a substantial current of electricity. Batteries, distribution boards, switchboards, and substations are common applications for busbar connections.

Although it is not tasked with providing structural stability, a busbar needs to be rigid enough to support its own weight, as well as any vibrations caused by machinery or even earthquakes. Busbars must be supported on or surrounded by insulators. Busbars can be connected to other busbars, or to an electrical apparatus using a bolted, clamped, or welded connection. If not out of normal reach, busbars are protected from accidental contact, typically with a metal barrier.

What is the Shape of Success?  

The maximum amount of current that can safely travel through a busbar is determined by the cross-sectional size of the given busbar. A busbar is typically a flat bar, often with holes drilled down the center of the busbar. Both the flat shape and the drilled holes are designed to dissipate heat. EHRT’s standard line of tooling can handle material from 3mm to 16mm thick, with EHRT’s professional line punching up to 20mm thick material.

What sets wilson tool apart from the competition?  

Wilson Tool International offers OEM replacement EHRT-style tooling in standard, maxi, and 4 or 6 station multi-tool sizes. The maxi, or professional line, is ideal for high volume applications, whereas multi-tools promote greater capacity while saving time otherwise spent on tool changes. Wilson Tool’s adjustable holders for EHRT standard machines feature a proprietary driver system, eliminating the need for shimming and cutting downtime.

Wilson Tool’s EHRT-style punches and dies are made from high-grade tool steel that stands up to copper, aluminum, even steel for maximum grind life and more hits between regrinds. Add a layer of protection to your tooling with optional Slip-Max®, Optima® and Wearbeater™ coatings, tailored to your application. 

View our comprehensive selection of busbar tooling or contact a tooling technican for more information.

See Busbar Tooling

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