We produce busbars to specification, down to 0.3mm (copper) and 0.5mm (ali). Our applications range from utilizing polyolefin and PVC for 11KVA switchgear in the energy and rail sectors, to more complex busbars for EV/Hybrid battery systems that are coated with a range of insulation materials, including resicoat HGF03R (red), HFG03R (orange) and Nylon BB, to achieve ratings between 1.5 and 5KV.
As a leading UK manufacturer, our diverse range of manufacturing techniques allows us to produce a wide variety of custom-designed busbars to meet specific requirements. This includes large-scale projects involving thousands of variants as well as small-scale, single part orders with minimal or no tooling costs.
Our technical team, equipped with state-of-the-art equipment and a customer-focused approach, delivers high-specification products to various industries.
Quality is of paramount importance to us, and as a leading British manufacturer, H V Wooding is fully certified to ISO9001:2015, OHSAS 18001 and 14001:2015. We are also members of the SMMT, the Confederation of British Metal Forming, British Safety Council, and Fit for Nuclear.”
As a premier busbar manufacturer, H V Wooding boasts an array of the most advanced manufacturing equipment, allowing us to achieve exceptional delivery performance. With many years of experience in taking over the production of copper busbars from major OEM’s through component transfer, we are able to offer a highly responsive service, even with tight lead-times, utilizing state-of-the-art EHRT Punching & Forming Machines.
Copper is a widely utilized metal due to its exceptional conductive properties, durability, and flexibility. It is commonly used in construction, power generation, and the fabrication of electrical components, including wiring and laminated busbars.
- Copper is a strong and durable metal known for its excellent conductive properties and its ability to withstand short circuit electrical currents and high thermal pressure. It is also a malleable and flexible metal, which makes it easy to work with and shape into various forms. Additionally, copper has good resistance to environmental factors such as air, salt, and water, making it one of the most durable and mechanically robust metals available.
- In comparison to other metals, copper is creep-resistant and does not deform or dent under constant stress, making it a safer option for electrical manufacturing. It also has a high resistance to fatigue failure, which is when constant vibrations during the manufacturing process can cause scratches and dents on the surface of the metal.
- Due to its high electrical conductivity, copper effectively carries heat, which reduces energy loss and cuts down on carbon emissions and costs. Additionally, its excellent thermal conductivity and heat transfer properties make it a popular choice for solar water heating and air conditioning systems.
- Copper is 100% recyclable and can be used repeatedly without losing its quality or integrity. It is also a compact and thin metal, which saves space and reduces material wastage and production costs. Copper’s durability and superior performance make it a cost-effective metal for precision engineering components.
Aluminum is a popular choice for busbar production where weight is a key consideration. At H V Wooding, we have extensive experience in fabricating millions of aluminium busbars for a wide range of industries, including power conversion, rail, marine, and aerospace.
Our aluminum busbars are suitable for use in transformers and are commonly produced for electrical panel boards and distribution boards.
Flexible Busbars are manufactured using a proprietary endless loop system, providing several technical advantages over other forms of flexible bars in terms of capability and performance. They are constructed from thin, typically soft copper, which is wound and compressed to achieve the necessary cross-sectional area to carry the desired current.
Value Added Busbar services
In addition to our in-house production capabilities, we also offer busbar assembly services. Our services for insulated busbars include powder coating, epoxy coating, heat shrink sleeving, and electroplating in tin, silver, and nickel to meet your specific requirements.
Our applications range from utilizing polyolefin and PVC for 11KVA switchgear in the energy and rail sectors, to more complex busbars for EV/Hybrid battery systems that are coated with a range of insulation materials, including resicoat EL HGC20R and Nylon BB, to achieve ratings between 1.5 and 5KV.
Science & Research - CERN
A twin-aperture, 10 m long, prototype magnet was designed by CERN to gain experience in the construction of full scale twin-aperture Dipole Magnets. HV Wooding were given the task to produce the Twin-aperture Dipole magnet Laminations. Click to read a Case study demonstrating our ongoing work with CERN on the Large Hadron Collider - and the positive impact from our input.
Ventilator Challenge UK
British engineering firms were called on to switch to making medical ventilators as concern grew about the effects of the coronavirus pandemic. This follows an appeal by Boris Johnson, who held an emergency conference appealing for an urgent effort to address the national shortage.
Next generation of Tidal Turbines
A Global manufacture in the “Renewables Sector” are developing the next generation of Tidal Turbines. In order to optimise engineering performance they needed a partner to help facilitate both the design and manufacturing solution of “Laminate Sections” for the Permanent Magnet Generator.
High Volume of Metal Stampings and Busbars
A leading Global manufacturer of Electrical Automation and Control Solutions have a high volume of Metal Stampings and Busbars used within their product groups. These include regular repeat items and also spot ordered parts that are delivered to multiple locations.
“Hybrid Drivetrain” for Motorsport and Transportation applications
A Global manufacturer of “Hybrid Drivetrain” for Motorsport and Transportation applications. A key market for flywheel energy storage technology is the public transport sector. This technology can save fuel and reduce green house gas emissions by up to 30% in a city bus for example.
Strategic outsourcing partner
A leading international manufacturer of electrical accessories were producing all components in house. In order to focus on core activities and increase profitability, they needed a strategic outsourcing partner that they could trust. After a detailed evaluation, they decided to outsource all presswork components to HV Wooding.
Related articles and news
We have a very busy exhibitions and conference calendar for 2024, meeting existing clients and introducing ourselves to new ones and learning more about the industries we serve. Click to find out where you can catch up with our team. Upcoming Exhibitions include: Battery Tech Show, The Battery Show, Electric & Hybrid Marine Expo, Cenex LCV, SMMT Electrified, Future Propulsion Show & Advanced Engineering Show.
PAST EVENT: The International Nuclear Manufacturing Summit 2022
Hosted by the Nuclear AMRC, the International Nuclear Manufacturing Summit 2022 will showcase opportunities in the major programmes and explore how suppliers can win work now and over the next 30 years. Our list of customers in this field include CERN, CEA, Elytt and Brookhaven internationally with UKAEA divisions Cullum, Harwell, Rutherford and Diamond Light in the U.K. We are also providing Switchgear suppliers such as Schneider Electric, GE Energy and Alstom with Busbars for products used with the sector.
Success in Busbar coating project with Nuclear AMRC & University of Sheffield
The project, supported by Innovate UK through the Faraday Battery Challenge, aimed to develop a new powder coating process to improve the quality and performance of busbars for the fast-growing electric vehicle market. "The results have allowed us to better understand the relationship between the dielectric strength of the busbar and the coating thickness produced by the processes investigated."
PAST EVENT: Coiltech Italia 2022
Coiltech is the most qualified electromechanical Meeting-Point in its sector. The range of products offered by companies that exhibit at Coiltech covers all the production steps of electric motors, generators, electric pumps, transformers, and windings in general. Following a fantastic show in Germany (April 2022) – we will be back at Coiltech Italia, 28-29th September in Podenone, Italy. We will be showcasing our Core Packs and Busbars for electric motor applications.
Investing in Quality
To assist the constantly evolving challenges that face our highly experienced quality team at H V Wooding, we have recently invested in the super accurate Trimos height gauge and the Vision inspection system ‘InspecVision Planer’ for fast and accurate measurement of multiple parts.
Electric Vehicle boost for HVW
Having been given a glimpse of a potential future should we make the switch to Electric Vehicles - with less air pollution and improved air quality being documented during the COVID-19 lockdown - more buyers are realising the benefits of moving away from petrol and diesel cars.