The journey of creating brazed busbars begins with the water cutting of Copper sheets. This initial step ensures precision and accuracy in shaping the base components. Water cutting, known for its ability to create intricate designs without inducing heat-related distortions, lays the foundation for the superior quality of the final product.
Following the water cutting process, the components move to the next phase where the bosses are machined on a bar fed lathe. This step highlights the commitment to precision machining, a crucial aspect in achieving the desired specifications and ensuring a seamless fit when the components are assembled.
To enhance the structural integrity and cohesion of the Copper components, a meticulous brazing process is employed. Brazing, a technique that uses a filler material to join the Copper pieces, ensures a strong bond without compromising the material properties. This step contributes to the longevity and robustness of the final product.
Recognising the significance of corrosion resistance, the copper components undergo a nickel plating process. Nickel plating not only provides an additional layer of protection against environmental factors, but also enhances the aesthetic appeal of the components. The commitment to durability and functionality is evident in this attention to detail.
Taking a step further in ensuring product longevity, the copper components are subjected to a powder coat insulation process. This not only adds an extra layer of protection against external elements, but also provides insulation for electrical applications. The combination of nickel plating and powder coat insulation creates a robust barrier, making the components suitable for a wide range of applications.
The final stage of the manufacturing process involves rigorous quality testing. The powder coat insulation is meticulously examined using an MIT515 megger tester at 5000V DC. This high-voltage test serves to check the integrity of the coating, ensuring that it meets the required standards for electrical insulation.
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