Processes
Busbar twisting
Twist length, section warping and when a twist is the right answer instead of an edgewise bend.
A twist rotates the bar about its own long axis, usually to bring a connection face into a different plane without the radius an edgewise bend would demand. The geometry that matters is twist length: the longer the transition, the lower the strain at the edges, and too short a twist thins and distorts the section at the corners. In practice a twist is often the right answer precisely where an edgewise bend is the wrong one, because edgewise force scales with the square of bar width and the inner fibre wants to buckle. Getting the choice right is usually a tooling and cycle-time question rather than a capability one.
Machines
EMAC-BB-H12
Hybrid hydraulic 3D busbar bending machine, 400 kN, ±0.1°
EMAC-BB-S12
Servo 3D busbar bending machine, 400 kN, ±0.1°, no hydraulics
SMART-303CNC-S
300 kN all-in-one punching, shearing, bending and forming machine
SMART-603CNC-S
600 kN all-in-one busbar processing machine, 260 × 20 mm
SMART-603CNC-6S / 8S
600 kN all-in-one machine with 6 or 8 station turret
BPM-303CNC-6S / 8S
350 kN standard three-in-one busbar processing machine
Technical background
Bending
Edgewise versus flatwise busbar bending
Why edgewise busbar bending force scales with the square of bar width, where buckling sets the limit, and how to choose between twisting, joints and plate.
9 min read
Bending
Busbar twisting: geometry, limits and tooling
Twist length as a function of bar width, the shear strain it imposes, section warping, edge thinning, torsional springback, and when to twist not bend.
8 min read
Standards referenced
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