Baotou Aluminum Industrial Park — IP68 Flexible Busbar Power Distribution Room Retrofit
Confidential
This project is located in the Aluminum Industrial Park, Donghe District, Baotou City. The flexible busbar product is primarily used for connections from transformers to low-voltage cabinets. The original design called for conventional busbar connections, which generate numerous nodes and hot spots at connection points. The busbars were connected and then covered with heat shrink sleeves, but under sustained high-current operation the sleeves would melt due to overheating — a serious safety hazard with no effective protection rating. Yanghua's flexible busbar solution provides point-to-point connection without intermediate nodes. The copper conductor is enveloped by an integrated insulation layer and outer protective layer, achieving IP68 protection rating and greatly improving operational safety in the metallurgical environment.
Project Background & Challenges
The aluminum industrial park's power distribution room used conventional busbar connections between transformers and low-voltage cabinets. Multiple nodes created hot spots, and heat shrink sleeve insulation would melt under sustained high current, posing serious fire and safety risks with no protection rating.
- Conventional busbar connections created numerous intermediate nodes, each generating hot spots under sustained high-current operation
- Heat shrink sleeves used as insulation on traditional busbars would melt when overheated, posing severe fire and safety risks
- Original busbar system lacked any protection rating, leaving copper conductors exposed to environmental contamination
- The aluminum processing environment demanded robust, sealed electrical connections resistant to dust, moisture, and high temperatures
Solution
Yanghua replaced the conventional multi-node busbar system with point-to-point flexible busbar connections. Each busbar features an integrated insulation layer and outer protective jacket, achieving IP68 protection. The joint-free design eliminated hot spots entirely and delivered a sealed, safe connection for the demanding metallurgical environment.
- Deployed point-to-point flexible busbar connections eliminating all intermediate nodes and associated hot spots
- Integrated insulation layer and durable outer protective jacket on each flexible busbar achieved IP68 protection rating
- Joint-free architecture eliminated the need for heat shrink sleeves, removing the melt-risk failure mode entirely
- Sealed, fully insulated design provided comprehensive protection suitable for the harsh metallurgical industrial environment
Project Results
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