Lugs9 min read
Lug and terminal RFQ checklist: what to send for a useful quote
A lug price is only comparable when the conductor, interface, material, finish and test are all stated. The fourteen items that remove the guesswork.
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Sourcing notes for custom parts
Drawings, tooling, quality and landed cost, from the team that runs the programmes.
All guides, page 29
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Lugs8 min read
Tubular compression lugs vs mechanical lugs
Two ways to land a cable on a terminal, with different tooling, different failure modes and a different case for field service.
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Busbars9 min read
Busbar temperature rise: test vs calculation
A calculation is a model, a test is a measurement. Knowing which one your design needs, and what each can prove, saves time and argument.
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Busbars9 min read
Busbar testing: millivolt drop, pull test and thermal cycling
Four tests answer four different questions. Running one and calling it a qualification is how a joint passes the bench and fails the panel.
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Busbars9 min read
Busbar thickness and width: what drives the choice
Two bars can have the same cross-section and behave differently. Current, heat, bending, space and joint layout decide whether the section should be wide and thin or narrow and thick.
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Busbars9 min read
Laminated busbar insulation and partial discharge
Where partial discharge starts in a laminated busbar, which dielectric tests find it, and the design and inspection calls that keep a void from becoming a failure.
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Contacts9 min read
Overmoulded coils and sensors
Sealing, strain relief and melt flow decide whether an overmould protects a winding or quietly damages it. Here is how to control all three.
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Busbars9 min read
Silver plating for busbars: when it is worth it
Silver lowers contact resistance and holds it over more mating cycles. The case for paying for it depends on current, temperature, joint access and the cost of a hot joint.
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Busbars9 min read
Busbar inspection: dimensions, plating and conductivity
A busbar can measure correctly and still fail in service. The inspection plan has to check the current path, not only the shape.
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Busbars9 min read
Busbar short-circuit withstand: Icw, Ipk and what they mean
One number covers heating, the other covers force. Both have to be met by the bar, the joints and the supports together.
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Contacts9 min read
Coils for sensors and antennas
Frequency, Q factor and stability decide whether a sensor coil measures the target or the weather. Here is what to specify and how to check it.
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Busbars9 min read
Copper busbar temper: soft, half-hard and hard
Temper decides how a copper bar bends, how much it springs back and how well it holds a joint face. It is a design choice, not a mill default.
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Go from reading to checking
The guides are built around the same questions as the free tools. Size a busbar, check an ISO 2768 callout, build a first article report or compare landed cost.
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