High-voltage tubular busbar bushings are available in copper or aluminum, with heat-shrink or insulated designs, suitable for 11kV to 132kV applications in substations, switchgear, and electric vehicles.

Overview

High-voltage tubular busbars are essential components for transmitting electrical power in substations, switchgear, and electric vehicles. They consist of copper or aluminum tubes, either permanently welded or connected via flexible current bridges, providing high conductivity, short-circuit resistance, and low maintenance requirements . These busbars are often used in outdoor substations and high-voltage switchgear due to their thermal stability and operational reliability .

Types and Models

1. Tubular Busbars by Voltage Rating
   • 11kV–33kV: Commonly used in medium-voltage switchgear and substations, often with heat-shrink insulation tubing for flashover protection and reduced phase-to-phase or phase-to-earth clearances .
   • 33kV–132kV: Used in high-voltage substations, available in copper or aluminum tubular designs with optional accessories for bushings and connectors .
2. Insulation Options
   • Heat-shrink busbar tubing: Provides electrical insulation, reduces clearances, and protects against accidental bridging. Models include medium wall (BMT) and thick wall (BTT) tubes suitable for 6.6kV, 11kV, 15kV, 17.5kV, 24kV, and 33kV .
   • Bus Bar Insulation Tubing (BBIT): Used in confined spaces, such as near pantographs or circuit breakers in electric rail vehicles, to provide additional insulation .
3. Custom and Modular Designs
   • EV and automotive applications: Custom high-voltage busbars are designed to meet specific vehicle requirements, including size, shape, and material, optimized through computer simulation and advanced manufacturing .
   • Outdoor substation modular busbars: Tubular busbars can be configured as permanently welded pipes or modular sections connected by flexible current bridges, allowing for easy installation and maintenance .

Key Features

• Materials: Copper or aluminum, selected based on conductivity and mechanical requirements .
• Current-carrying capacity: High, suitable for short-circuit conditions.
• Corrosion resistance: Ensures long-term reliability in outdoor environments.
• Flexibility: Modular designs allow adaptation to different substation layouts.
• Insulation: Heat-shrink or BBIT options enhance safety and reduce clearance requirements .

Applications

• Substations: Medium and high-voltage busbar connections, including 33kV, 66kV, and 132kV systems .
• Switchgear: Insulated busbars for compact switchgear lineups, reducing phase-to-phase and phase-to-earth clearances .
• Electric Vehicles: Custom busbars for battery and power distribution systems, optimized for size, weight, and thermal performance . High-voltage tubular busbar bushings are therefore versatile components, available in multiple voltage ratings, materials, and insulation types, suitable for both industrial and automotive high-voltage applications. Manufacturers like TE Connectivity, Alcomet, Lorünser, and Intercable Automotive Solutions provide a range of standard and custom models to meet specific operational requirements .