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

DC Choke Flexible Bus Bar
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DC Choke Flexible Bus Bar

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.

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Highlights of this Press Welding Project

Product DescriptionThis choke flex bus is used within Power generation / mining equipment
Press Welding Capabilities
Press Welding
Nickel Plating
Equipment Used to Manufacture PartPress Welder
Overall Part DimensionsLength:
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 UsedCopper Coil
Material FinishNickel Plated
In process testing/inspection performedFirst Article of Inspection
Industry for UseMining
Delivery/Turnaround Time2 weeks
Delivery LocationVermont
Standards MetCustomer supplied print, 2D CAD Drawing
Product NameDC Choke Flex Bus
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