Copper busbar fabrication for switchgear and power distribution
A finished busbar must fit its mounting points and contact faces. We select the shearing, punching and bending configuration from your copper grade, width, thickness and part drawing. The process order depends on tool access and bend geometry, with checks before the parts reach assembly.
| Step | Equipment | Why it's needed |
|---|---|---|
| 1. Release the part drawing | Copper specification and controlled drawing | Confirm material condition, width, thickness, hole locations, bend geometry and the inspection requirements. |
| 2. Shear the blank | Busbar processing machine WM-9400 | Maximum shearing width × thickness is 160 × 12, 260 × 16 or 300 × 20 mm for the three configurations respectively. |
| 3. Punch the required holes | Matched punch and die on WM-9400 | Match hole or slot geometry, thickness and tool clearance. Punching limits must be checked separately from shearing limits. |
| 4. Bend and verify the geometry | CNC-controlled bending station on WM-9400 | The operator loads and repositions the part. Agree the bend order, radius, clearance and finished angle from the drawing. |
| 5. Inspect before assembly | Dimensional and contact-face inspection | Check burrs, hole positions, bends and mounting fit. Finish, insulation and assembly checks follow the approved design. |
Watch copper punching and bending
The existing demonstration shows hole punching, end-corner rounding, bending and the processed parts. We confirm the proposed configuration and sample trial against your drawing.
More clips on these questions:How are copper busbar holes and bends made?
One configuration, different limits at each station
Our punching, shearing and CNC bending machine WM-9400 has 160, 260 and 300 mm configurations. Their maximum shearing sizes are 160 × 12, 260 × 16 and 300 × 20 mm. The thickness allowed at a punching or bending station is not automatically the shearing thickness. Send the most demanding part drawing and the full part mix; we check each operation and tool position. Our busbar machine selection guide explains this comparison.
Check the drawing and a representative part together
Hole spacing, contact faces, burrs and finished angles affect whether the conductor fits the assembly. Tool access can change after a bend, so agree the sequence with the actual geometry. The existing video shows hole punching, end-corner rounding and bending; we confirm the shearing requirement separately in your trial. Use our sample-trial checklist to agree measurements and our busbar defect guide to organize the inspection.
Keep copper fabrication distinct from wiring and joining
This route prepares the shaped copper conductors for switchgear and distribution assemblies. For terminal wiring, ferrules and identification, use our control-panel wiring application. For battery-module interconnect joining, use our battery-pack assembly application. If the incoming part is an already insulated flexible copper connector needing exposed contact ends, see our busbar insulation stripping machine WM-195; this is a separate branch, not a required step for every rigid copper bar.
Switchgear busbar fabrication questions
Is this an automatic continuous busbar production line?
Our processing machine WM-9400 combines hydraulic punching, shearing and CNC-controlled bending. Workpieces are loaded and repositioned by the operator. We assess the full part mix, handling and tool changes before agreeing a production layout.
Can the 160 mm configuration shear 16 mm thick copper?
Its listed maximum shearing size is 160 × 12 mm. The 16 mm thickness listed for punching and flat bending is a different station limit. The larger configurations list maximum shearing sizes of 260 × 16 and 300 × 20 mm; every operation still needs to be matched to your drawing.
How many finished busbars can the machine make per hour?
Finished output depends on the number of cuts, holes and bends, manual handling, tool changes and inspection. We use representative drawings and an agreed sample trial to assess the batch. A single demonstrated operation does not establish finished-parts output for a different drawing.
What should a copper busbar inquiry include?
Send the copper grade and condition, width and thickness, incoming length, hole and slot dimensions, bend drawings and quantities per part. Include the inspection criteria, any finish or insulation requirements and supply voltage. We confirm the capacity configuration and tooling in the quotation.
Get a price in 12 hours
Send the copper grade, dimensions and part drawing. We will match each operation and its tooling to the required busbar.
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Your reference:
Our engineering and sales team will contact you with a quotation proposal within 12 hours from sales@wiromac.com.