Copper-Aluminum Transition Bar for Motor Controller
Copper-Aluminum Transition Bar for Motor Controller
The technical specification for the bar:
| Item | Parameter Value | Test Standard |
|---|---|---|
| Material | Copper end: T2 oxygen-free copper (conductivity ≥ 98% IACS); Aluminum end: 1060 pure aluminum (conductivity ≥ 61% IACS) | GB/T 5231, GB/T 3190 |
| Bonding Process | Atomic diffusion welding (explosion welding / flash welding optional), interface shear strength ≥ 70MPa, no delamination | DL/T 247 |
| Contact Resistance | Transition interface resistance ≤ 0.05mΩ, overall resistance 30% better than industry average | GB/T 6145 |
| Rated Current | 300A ~ 3000A (customized by cross-sectional size: width 20–120mm, thickness 3–12mm) | GB/T 11022 |
| Operating Temperature | -40℃ ~ 125℃, short-term peak 150℃ | IEC 60068-2-14 |
| Surface Treatment | Copper end: tin-plated / nickel-plated (5–10μm, anti-oxidation); Aluminum end: chemical passivation / anodization (salt spray resistance ≥ 72h) | GB/T 13913 |
| Insulation Option | Heat shrinkable sleeve / epoxy coating available, withstanding voltage ≥ 2500V AC / 1min | GB/T 1408.1 |
| Mechanical Performance | No cracks after 90° bending; Vibration test meets automotive electronics standards (10–2000Hz, 10g) | IEC 60068-2-6 |
Application Scenarios for the bar:
New Energy Vehicles Motor controllers, high-voltage distribution units (PDU), OBC charging modules of passenger cars / commercial vehicles, and connection between battery packs and electronic controls.
Industrial Automation Servo motor controllers, frequency converters, robot joint electronic controls, and servo systems of injection molding machines.
Rail Transit Traction converters of subways / high-speed rails, and auxiliary power controllers of trains.
Wind Power / Photovoltaics Wind power converters, and motor-side output connections of photovoltaic inverters.
Product Advantages
Metallurgical Bonding for High Reliability Atomic-level fusion at the interface, no contact gap, no heating or loosening during long-term high-current operation; Avoids electrochemical corrosion problems of traditional crimping / brazing.
Cost and Weight Reduction 56% lighter than pure copper bars, material cost reduced by more than 40%, facilitating the lightweight design of the controller.
Precise Adaptation to Electronic Control Scenarios Customizable length, bending angle, hole diameter / hole position according to the internal space of the controller; Supports single hole / double hole / slotted hole to meet bolt fastening requirements.
Resistance to Harsh Working Conditions Salt spray resistance, damp heat resistance and electromagnetic interference resistance, suitable for new energy vehicle outdoor and industrial servo vibration environments.
Specification Selection & Customization
5.1 Standard Specifications
- 50×5mm (rated current about 800A); 60×6mm (about 1000A); 80×8mm (about 1500A)
- Length: 50–300mm optional; Hole diameter: M6/M8/M10 standard threaded holes
5.2 Customization Services
- Size Customization: Arbitrary width / thickness / length, special-shaped bending, multi-section transition.
- Surface Treatment: Silver plating, gold plating (for high-frequency / high-corrosion scenarios).
- Insulation Treatment: Partial / overall heat shrinkable tube, dip coating, spray coating.
- Bulk Marking: Laser marking of model, batch number and rated current.
The package&Shipment:
