John Vincent March 2012

Bus Bar Design

This document describes rule-of-thumb design laws for unconfined bus bars operating at or near dc conditions in open space. At higher frequencies the skin effect must be considered. In multiconductor systems (such as magnet coils) the proximity effect must be accounted for and the thermodynamics gets tougher. In modern power electronics based equipment switching at high frequency, all of these effects occurring simultaneously contribute to the conductor heating. Theoretically it is possible to go into this subject in great depth and consider the surface emissivity, air properties and movement, radiation, convection, and conduction for different geometrys in differing orientations; this is not the approach taken here. This note describes a practical rule-of-thumb for the conductor surface heat transfer limit and from it derives some useful design relationships. Experimentally, it is found that bus bars run near room temperature when the heat transfer is limited to 0.1 (Watts/in2). The bus bars run hot when the heat transfer approaches 0.25 (Watts/in2). (note: since the bus bar temperature is principally a function of the surface area, the best shape is a very thin ribbon whereas the worst shape is cylindrical as are all wires!). Using this empirical knowledge, rule-of-thumb design relationships can be established. 1. (Power Lost)/(Unit Length) in (Watts/cm) !! !! ! !! ! ! !! where; : resistivity in (Ohms*cm), Ac : Conductor crossectional area in cm2, Io : Amperes 2. (Heat Transfer)/(Unit Area) in (Watts/cm2)

QA =

Pl I 2! = o As Ac As

where;

As: conductor surface area in (cm2/unit length)

! ! 3. Rules-of-Thumb boundary conditions for heat transfer limits 3. Rules-of-Thumb boundary conditions for heat transfer limits
2 in Watts/in2 0.1 ! QA 0.1 ! 0.25 ! Qexpressed A ! 0.25 expressed in Watts/in

0.015 ! Qexpressed expressed in2Watts/cm2 Watts/cm 0.015 ! Q A ! 0.04 in A ! 0.04 cool " hot cool ! hot
2 2 Io ! A = I 0 ! with Q expressed in2 Watts/cm2 A A in Watts/cm QA expressed Ac As = c with s QA QA

4. Rectangular Bus Bar 4. Rectangular Bus Bar

h w

A+ (w cA Ac As = 2 ( w hs) (= wh ) + h )(wh )
hence:
2

2 Ac As & "h %h +Ac ) h w= Ah * with h constant s $ + ' w = ! + $ '2+ ( 2 %with hhconstant #4& 4 2h

or
2

or

2 Ac As w ) w& "w % w h= * + Ac'As $with + w with w constant h=! + $ ' + 2 2(h2 % wconstant #4& 4

if w >>h as is typical then: if w >>h as is typical then:

w=

Ac As 2 hw =

Ac As h

5. Cylindrical Bus (like wire)

5. Cylindrical Bus (like wire) 5. Cylindrical Bus (like wire)

Ac As = !r 2 * 2!r = 2! 2 r 3 Ac As = ! r 2 * 2! r = 2! 2 r 3

! Ac As = !r 2 * 2!hence: r = 2! 2 r 3
1

6. Test against known values 6. Test against known values

' Ac As $ 3 1 r =% ! " $3 !A A ! 2c #2s & r&=2# " 2! 1% ' A A $3 r = % c 2s " & 2! #

The following table illustrates the use of this formulation versus NEC data for The following unconfined table illustrates the use of this formulation versus NEC data for confined 6. Test againstand known values cables rated at 90 degrees Celcius. confined and unconfined cables rated at 90 degrees Celcius.

The following table illustrates the use of this formulation versus NEC data for confined and unconfined cables rated at 90 degrees Celcius. Circular Conductor Current Rating
1800 1600 1400 1800 1200 1600 1000 1400 800 1200 600 1000 400 800 200 600 0 400 0

Circular Conductor Current Rating

Amperes Amperes

500000

1000000 Circular Mils

1500000

2000000

200 0 0

NEC 90 DEG C Rating Q=0.04 500000 1000000NEC 90 1500000 2000000 Q=0.015 DEG C Confined Circular Mils

NEC 90 DEG C Rating Q=0.015

Q=0.04 NEC 90 DEG C Confined