Bent Busbars

The new Busbar Bending Machine offers several advantages that align with the evolving needs of electrification production:

• Precision Bending Capabilities: The machine can perform highly complex multi-angle bends in copper and aluminum busbars, enabling precise routing paths that meet specific electrical architecture requirements in each vehicle.
• Unmatched Repeatability: The system ensures consistent accuracy with tight tolerances, crucial for seamless integration into automated assembly lines and high-volume manufacturing environments.
• Integrated Process Flow: It allows for simultaneous bending and insulation stripping, improving production efficiency and reducing the need for additional steps or manual labor.
• Machine-Bent Busbars: Wiegel now offers machine-bent busbars with and without insulated materials, providing flexibility to meet various design needs in EV applications.

In addition to busbar bending, Wiegel now has the capability to produce extruded copper or aluminum busbars. These busbars can be manufactured with or without insulation materials such as PA (polyamide), allowing us to offer solutions that meet specific voltage, current, and environmental requirements. Whether your application requires insulated busbars for electrical protection or bare metal for direct electrical conductivity, Wiegel can accommodate these needs with precision and efficiency.

Our Busbar Bending Machine brings several cost and environmental benefits that set it apart:

• Low-Cost Tooling: The machine is designed to minimize upfront tooling costs, making it an ideal solution for Wiegel to reduce capital expenditure while maintaining high-quality production standards.
• Low Minimum Order Quantities: This system enables cost-effective production even for small runs, making it perfect for prototype development or low-volume production without compromising quality or efficiency.
• Essentially Zero Scrap Process: The machine’s precision reduces material waste to an absolute minimum. By maximizing material usage, it ensures that virtually no scrap is produced during the manufacturing process, reducing costs and contributing to Wiegel’s sustainability goals.

As the demand for high-performance electrification growns, so do the requirements for advanced busbar designs. The new machine supports these evolving needs with:

• Material Flexibility: Whether using copper for high-temperature applications or aluminum for lightweight designs, the machine can handle both materials, enabling optimization for weight, power, and cost efficiency.
• Advanced Insulation Handling: It can work with modern insulation materials like PA 12 and XLPO, ensuring durability and excellent dielectric properties needed for high-voltage systems while maintaining flexibility for complex shapes and bends.
• Design Complexity: Capable of producing busbars with intricate bends, thermal compensation features (like V-bends), and the flexibility to add shielding or sealing, the machine supports even the most demanding EV applications.

In addition to the core busbar manufacturing process, Wiegel now offers a range of secondary operations to meet the specific needs of our customers. These operations include:

• Hole Punching: This allows for precise hole placement in busbars, which is essential for mounting, bolting, or routing electrical components.
• PEM Nut Insertion: Our ability to integrate PEM nut insertion provides a seamless solution for creating threaded fastening points directly in the busbars, streamlining assembly and reducing the need for additional components.

This new machine is a game-changer for Wiegel’s automated EV production processes. With features like laser stripping with out removing the base material, and precise terminal preparation, the machine not only streamlines manufacturing but also reduces errors and improves overall throughput. This is crucial for producing busbars that consistently meet the performance and quality standards required in modern electric vehicles.

By reducing material waste, optimizing tooling, and enabling small-run manufacturing, the machine supports both cost-effectiveness and sustainability in Wiegel’s production process. The ability to create high-quality busbars with minimal scrap aligns with our commitment to sustainable practices, ensuring that our processes are both economically and environmentally responsible.

As electrification continues to evolve, so do the demands on busbars. Wiegel’s new Busbar Bending Machine positions us to stay ahead of these trends, offering customized, cost-effective, and high-performance solutions that meet the specific needs of each vehicle, now and in the future.

At Wiegel, we understand the importance of speed to market, especially in industries like electric vehicle manufacturing, where time-sensitive production schedules are critical. Our advanced busbar bending technology and extrusion capabilities allow us to efficiently produce high-quality, customized busbars with rapid turnaround times. With low minimum order quantities and a flexible production process, we can quickly adapt to customer needs, whether for small runs or large-scale production. By reducing tooling costs, optimizing material usage, and offering essentially zero scrap production, we ensure that our customers get the right product, at the right time, with minimal lead time. This efficiency not only accelerates your time to market but also provides a competitive edge in an industry that demands fast innovation and reliable delivery.

Please let us know if you have any questions, or if you need us to send over any other information.