Busbar Expansion Solution for Diesel Generator Cable Access in Narrow Spaces

Optimizing Cable Connections on Diesel Generator Busbars Under Tight Clearance Constraints

I. Core Issue Analysis

Standard Copper Busbar: 160×15mm (Cross-section: 2400mm²)

Rated Current: 720A (per unit) → Parallel Total Current: ≥1440A

Wiring Bottleneck

• Busbar terminals only accommodate single 300mm² cable (parallel 2×240mm² cables cause crowding)
•  
• Short distance between paralleling cabinet and generator → Insufficient bending radius → Terminal collision

II. 4 Optimization Solutions (Ranked by Feasibility)

Solution 1: Custom Extended Busbar (Recommended)

Specifications:

• Material: T2 tin-plated copper (Thickness ≥20mm)
• Dual terminal holes (for 2×240mm² OT lugs, hole spacing ≥50mm)

 Advantages:

Low cost (~$120/unit)

No structural modification (bolt-on connection)

Solution 2: Centralized Wiring at Paralleling Cabinet (No Generator Modification)

Procedure:

Connect generators to cabinet with single 240mm² cable (length ≤2m)

Upgrade cabinet busbar to 3200A capacity (6 terminals: 2 in, 1 out)

Key Points:

Short cables eliminate bending radius issues

Reconfigure cabinet busbar to horizontal layout

Solution 3: Hydraulic Angle Lugs

Application: Pre-installed cables that cannot be replaced

Procedure:

• Use dual-angle lugs (e.g., OT-2R type) for directional cable routing 

Recommended brands:

Torque: M16 bolts ≥110Nm (with antioxidant paste)

 Solution 4: Busbar Cooling Slots (Temporary Fix)

Procedure: 

Mill heat dissipation slots on non-contact surfaces (2mm deep × 5mm wide × 20mm spacing)

Increases cooling area → Allows 20% temporary overload → Reduces required cable size

• Warnings:
• 
  Requires manufacturer authorization (voids warranty if unauthorized)
  Only applicable when ambient temperature ≤40℃

III. Technical Verification

1. Current-Carrying Capacity Review:

• Original busbar: 2400mm² × 0.8A/mm² = 1920A (theoretical)
• Actual safe limit: 1600A (parallel load 1440A → 11% margin only)
• Conclusion: Busbar expansion mandatory!

Parallel Cable Standards:

IV. Implementation Steps (48-Hour Timeline) 

1. Site Survey:

• Photograph busbar dimensions/cabinet position/cable routes (annotate critical measurements)

 2.Options:

• Priority Solution 1: Provide photos → 3D design → Machining (24h) → Air freight (DHL optional)
• Priority Solution 2: Modify cabinet busbar → Fabricate short cables (requires 4h downtime)

3.Testing:

1-hour full parallel load test → Infrared thermography busbar ΔT ≤40K (ISO 8528 standard)