Press-welded flexible connections with copper strips DB
Press-welded flexible connections with DB copper strips are among the most frequently ordered products for connecting high-current circuits to compensate for vibrations.
In addition to flexible GB connections with flat copper strips, they form the basis of all connections in the energy industry.
Press-welded, riveted or welded connections?
The production of flexible connections is a niche industry associated with the implementation of the needs of project companies in the energy sector. The machinery of such a company is a challenge because the machines and devices are designed for a specific manufacturer.
Our company has been making connections since 2000 and has therefore used various solutions throughout its history. Copper plate connections can be made using the following methods:
Rivets (at the ends of the connection we drill holes, put copper rivets and press).
Welding the ends - to the bundle of copper plates at the ends should be welded a copper flat bar of suitable thickness, which will serve as a ferrule and hold the plates in the set
Pressure welding of copper plates using a resistance welding machine using high current
Definitely press-welded joints are the best choice when it comes to quality and speed of execution, but they require the right welders and appropriate power in the plant.
What is the purpose of welding a joint of copper plates?
Copper material subjected to high current load and high pressing pressure shows adhesion properties and sticks together in a single element, resembling flat iron at the ends of the joint.
The resulting connection combines two advantages - it is flexible and at the same time rigid like a flat iron. We can use them wherever we do not need to manipulate the connection in different directions (the copper plate of course has limited mobility compared to an analog product made of flat braided copper tape).
What do the flexible DB connections consist of?
In flexible connections, copper plates with a thickness of 0.2 to 0.5 mm are used, which are packaged according to the cross-sectional requirement and then combined with each other. Cu-ETP copper plates, usually semi-hard or soft, are used for this.
By the way - it is worth considering the state of hardening of the material, because the soft copper will not be elastic and the connection will easily give up and change its shape.
The above-mentioned plates are usually connected by welding on a resistance welding machine equipped with a hydraulic press and graphite punches. KUVER GmbH uses high-performance welding machines to connect connections with large cross-sections.
Welding is not possible for analogous connections made from aluminum plates, as aluminum is known to oxidize, thereby preventing it from sticking together. We can only rivet or weld them.
For connections made of copper plates, the width is usually adjusted to the current output and the thickness to the load capacity. We provide a table of this resilience on our website and, for non-standard queries, we of course provide our knowledge and experience in calculating a specific cross-section.
Can flexible connections made of copper plates be tinned/silver plated?
Yes, welded joints can be tin plated or silver plated depending on project requirements. An additional layer is applied galvanically.
What forms can a connection have?
Flexible connections made of copper plates, unlike the flexible ones made of flat braids, should be formed ready in the production phase.
By default, the connections on the ferrule can be curved, but contoured connections, like in the picture below, are also very popular:
What are the advantages of pressure welded connections?
Above all, these connections are slightly cheaper than GB connections with flat copper strips. This is very important when ordering large quantities.
These connections have an approximately 40% lower ferrule height while maintaining the same material cross-section and are therefore ideal in situations where we do not have too much space to install the connection (rigid connectors close to each other).
These connections behave more stable with short-circuit currents. In addition, you can not only cover their surface galvanically, but also paint them with paints specially designed for this purpose.
These connections are very durable but less flexible than flexible braids. The choice belongs to the designer. If you are interested in more information about flexible DB connections with copper plates, please contact us using the form below or directly on 030 54907841 and speak to our expert about the possibilities such connections offer.
Are you interested in the rating or current capacity of your connection? Please send your request to the following email address: office@kuver-gmbh.de.
