Press Welding of a DC Choke Flexible Bus Bar for the Mining Industry

A customer in the mining industry needed a durable inexpensive flexible bus bar for a power generation application for one their mines. Their drawings called out the use of multiple layers of a 1.5" wide by 0.016" thick, copper coil material. The manufacturing process consisted of press welding, drilling, bending, and nickel plating. The finished bus bar had a flat length of 24.937, the formed part featured a min./max. of 5.937"/6.187", and met tolerances of ± 0.062". We produced 15 of these bus bars in two weeks for this customer in Vermont. For more information on this product see the table below.