For a 14-series, 9-parallel lithium-ion battery pack, the busbar sizes have been taken as 16 mm 2 based on the industry standard current density of 3A/mm 2 (Total current: 48 A).
The ability to accurately calculate busbar current is vital in the design and operation of electrical power distribution systems. It ensures that busbars are neither overloaded nor underutilized, contributing to the overall efficiency and safety of electrical installations. What affects the current carrying capacity of a busbar?
The efficiency and safety of busbars depend largely on their material composition and physical dimensions, which determine their current carrying capacity. The busbar current (\ (I_ {bb}\)) calculation is given by the formula: \ [ I_ {bb} = w \times t \times MF \] where: \ (MF\) is the material carry capacity factor in amps/mm\ (^2\).
Let us do a simple example of aluminium busbar size calculation. Assume that we need a busbar to carry 2000 A current and have to withstand 35 kA current fault for 1 second. Looking back at the table above, the minimum cross-section area of the busbar we need is 443 Sq.mm. To get this 443 Sq.mm aluminium busbar, we can use a 100 x 5 mm busbar.
Both aluminium and copper have their own ability to withstand currents. A 1 Sq.mm of aluminium busbar can withstand 0.7 Amperes. A 1 Sq.mm of copper busbar can withstand 1.2 Amperes. Of course the examples above did not come from an international standard because we can’t find the tolerance values.
Ambient temperature, ventilation, and installation conditions can impact the current carrying capacity. This calculator provides a straightforward method for determining the current carrying capacity of busbars, which is critical for electrical engineers and technicians in the planning and safe operation of power distribution systems.