Factors Affecting Current Carrying Capacity of Aluminium Busbars

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The current carrying capacity (CCS) of aluminium busbars is a measure of the maximum load that can be sustained by the busbar in a vertical position within an enclosed vehicle. CCS is directly proportional to the standard aluminium busbar sizes as well as to the weight of the vehicle in comparison with that of the busbar. For example, a van having a standard aluminium busbar size will normally have a lower CCS than a bus with a smaller standard aluminium busbar size. Therefore, the smaller the standard aluminium busbar sizes, the lower the CCS.

There are three manufacturers of aluminium busbars, namely Alco, Thule and Rhinoine. Each manufacturer of busbars follows a given manufacturing process to manufacture their aluminium busbars based on the specifications provided by the customers. The following factors are considered to be very important in determining the current carrying capacity of the busbars:

The thickness of the aluminium sheeting used in the manufacturing of the busbar plays a vital role in determining the current carrying capacity of the busbar. The thicker the aluminium sheeting, the higher is the current carrying capacity of the busbar. The thickest aluminium busbars are those busbars having a diameter of more than nine inches. However, the thickness of the aluminium does not have a direct bearing on the current carrying capacity. Instead, it affects the mechanical rigidity of the busbar as well as its overall strength and stiffness.

The current carrying capacity of aluminium busbars depends upon the mechanical rigidity of the bar as well as its strength and stiffness. Aluminium bars with a low mechanical rigidity are termed as stiffer bars while those having a high mechanical rigidity are termed as softer bars. The heavier the bar, the weaker its suspension system becomes. Hence, when buying high-quality aluminium busbars, the suspension system is also given due consideration. When the number of steel bars bearing the same weight as that of the busbar is more than eight, the suspension rigidity is given due consideration for determining the current carrying capacity of the busbar.

This is a general observation. When the number of steel bars bearing the same weight as that of the busbar is more than eight, the suspension system plays an important role in determining the current carrying capacity of the busbar. However, there is no hard rule regarding this. Rather, the actual weight of the busbar, its actual diameter and the strength and stiffness of the suspension system will determine the current carrying capacity of the busbars. The larger the diameter of the busbar, the larger the suspension system needs to be.

The greater the weight of the busbar, the stiffer it needs to be to prevent any flexing due to external stresses. Similarly, the smaller the diameter of the busbar, the flabbier it has to be to provide adequate stiffness. Thus, both small and large aluminium busbars are available to meet the varying requirements. They are manufactured as per specific requirements by using the best techniques and materials available ... (more)