The project used metal housings and end covers to protect and bond overhead busway sections in a data center.
The customer’s challenge
Poor bonding at joints increased resistance, while the housing experienced excessive temperature rise.
Material and fabrication route
3.0 mm aluminum housing; 2.0 mm steel end covers.
Process route: Profile extrusion → sheet metal end-cover fabrication → anodizing → assembly → bonding-continuity testing.
Manufacturing changes
Larger grounding contacts and revised spring-contact geometry improved the joints. Housing fins increased the available heat-dissipation area.
Engineering analysis
Joint continuity and housing temperature were both important, but they were not the same acceptance check. Revised contacts addressed the bonding path, while fins addressed available heat-transfer area. The current and temperature figures belong to the configured busway assembly. A replacement housing needs defined contact surfaces and installation details so its finish and mechanical joints do not undermine the intended electrical interface.
Inspection and project results
The configured assembly achieved grounding resistance ≤0.1 Ω and met the reported temperature-rise acceptance test.
| Project measurement or production detail | Recorded value |
|---|---|
| Grounding resistance | ≤0.1 Ω |
| Housing temperature rise | ≤30 K |
| Assembly current | ≥630 A |
| Protection test | IP42 |
These figures describe the project configuration and production scope above. Dimensional, material and production details are identified separately from performance tests. For a new order, the inspection method and acceptance criteria should be agreed against the released drawings.
Planning a similar OEM component
A useful RFQ for this application should make the following interfaces and acceptance requirements clear:
- Busway current and section layout.
- Bonding contacts and joint geometry.
- Finish masking at electrical interfaces.
- Assembly temperature and continuity checks.
Include the current drawing revision, mating-component information, quantities and required delivery sequence. Identifying unresolved requirements at quotation stage helps distinguish fabrication work from the equipment-level checks that the project needs.
For related manufacturing support, review our Data Center Busway Housing and sheet metal quality capabilities. Use the existing quotation form below to share the drawing package for review.
