There are several ways to thread conductors through a small busbar

Threading conductors into a small busbar involves creating a pre-drilled hole, forming a collar-shaped threaded hole, and inserting a thread to secure the conductor.

Step-by-

Step Process

Drill a Pre-Hole Begin by introducing a hole with a specific diameter into the busbar piece. This initial hole serves as the base for the threaded connection and ensures proper alignment for the conductor insertion. Create an Annular Groove On one side of the busbar, form an annular groove surrounding the pre-drilled hole.

The groove diameter is slightly larger than the collar that will be formed later. This groove allows for increased thread engagement and mechanical stability. Deep Draw the Threaded Hole From the opposite side of the groove, deep draw a threaded hole with a collar-shaped projection.

The outer diameter of this collar is smaller than the annular groove, which ensures that the thread is securely anchored and prevents loosening under electrical load. Insert the Thread Finally, insert a threaded fastener or tap a thread into the collar-shaped hole. This allows the conductor to be securely bolted to the busbar, providing both mechanical strength and reliable electrical contact.

Additional Considerations

Material Selection: Copper or aluminum busbars are commonly used. Copper provides higher conductivity, while aluminum requires a slightly larger cross-section for the same current capacity. Precision: CNC drilling and threading machines are recommended to maintain tight tolerances, especially for small busbars, to ensure proper alignment and minimize resistance.

Joint Integrity: When connecting multiple busbars or conductors, ensure that the threaded connection is torqued correctly to maintain low electrical resistance and prevent overheating. This method ensures a secure, electrically efficient, and mechanically stable connection for conductors in small busbars, suitable for switchgear, panel boards, and other electrical distribution systems.