This project served a large steel production enterprise in Fujian Province, an industry with exceptionally demanding requirements for power transmission and distribution products. Stability under heavy loads, seismic resistance, and high protection ratings are fundamental prerequisites in steel plant environments. Beyond traditional bus duct and multi-joint solutions, this project adopted a new-generation high-current flexible busbar approach. The flexible busbar was primarily used to connect transformers to low-voltage distribution cabinets, meeting the facility's substantial 3200A current demand. A single flexible busbar unit provided the full current-carrying capacity, eliminating the need for multiple parallel conductor assemblies. Connections to distribution cabinets and transformers employed a copper bar drilling method for direct overlap, removing the requirement for additional transition joints. The product's cut-to-length capability eliminated pre-installation measurement and custom fabrication, enabling more flexible onsite construction. Despite the high 3200A rating, the compact dimensions and high flexibility of the busbar allowed for neat, organized laying within narrow cable bridges and distribution cabinets.
Project Background & Challenges
A large steel production facility required a 3200A power transmission system connecting transformers to LV cabinets with exceptional stability, seismic resistance, and high protection ratings, while the installation space in bridges and cabinets was physically constrained and demanded a neat, organized layout.
- Extremely high 3200A current demand requiring heavy conductor capacity that would traditionally need multiple parallel bus ducts with numerous joints
- Steel plant environment demanding uncompromising stability, seismic resistance, and high ingress protection for all power distribution equipment
- Limited installation space within narrow cable bridges and distribution cabinets requiring compact conductor profiles despite the high current rating
- Transformer-to-LV-cabinet connections requiring precise alignment and overlap without the space or tolerance for additional intermediate junction boxes
Solution
Yanghua deployed 3200A flexible busbars using copper bar direct drilling overlap connections, achieving full current capacity per single conductor without additional joints. The cut-to-length design allowed onsite adaptation without pre-customization, while compact dimensions enabled clean installation in narrow spaces.
- Supplied 3200A-rated flexible busbars delivering full current capacity in a single conductor unit, eliminating the complexity of multi-piece parallel assemblies
- Implemented copper bar drilling direct overlap technique for transformer and cabinet connections, removing the need for separate transition joints and junction boxes
- Enabled onsite cut-to-length installation without pre-measurement or factory customization, greatly improving construction flexibility and reducing lead time
- Achieved neat, organized cable bridge and cabinet layouts despite the high current capacity by leveraging the compact cross-section and high bendability of the flexible busbar design
Project Results
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