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 of 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.
Highlights of this Press Welding Project
| Product Description | This choke flex bus is used within Power generation / mining equipment |
| Press Welding Capabilities Applied/Processes | Primary: Press Welding Secondary: Bending Drilling Nickel Plating |
| Equipment Used to Manufacture Part | Press Welder |
| Overall Part Dimensions | Length: Min: 5.937" Max: 6.187" Width: 1.5" Height: 4.687" Gage: 0.375" Flat length: 24.937" |
| Tightest Forming Tolerances Tightest Machine Tolerances | ± 0.062" ± 0.010" |
| Material Used | Copper Coil |
| Material Finish | Nickel Plated |
| In process testing/inspection performed | First Article of Inspection |
| Industry for Use | Mining |
| Volume | 15 |
| Delivery/Turnaround Time | 2 weeks |
| Delivery Location | Vermont |
| Standards Met | Customer supplied print, 2D CAD Drawing |
| Product Name | DC Choke Flex Bus |