Alfred Kron GmbH from Solingen is your experienced partner for high-precision busbars and power rails. These components, also known as collecting rails, are central elements of modern power distribution. Whether in industrial plants, electromobility or building technology – our power rails ensure safe, space-saving and low-loss transmission of high electrical currents.
Busbars usually consist of copper, copper alloys or aluminum and, thanks to their large cross-sectional area, enable uniform current distribution with minimal resistance. Production at Alfred Kron includes:
- Precise stamping, bending and forming on modern BIHLER stamping-bending machines
- High-quality materials for maximum conductivity and mechanical stability
- Surface finishing, insulation and laminated systems for low inductance
- Integration of fastening elements and customer-specific assembly production
The power rails impress with high current carrying capacity, compact design, reduced heat generation and flexible expandability. They are durable, robust and optimized for industrial requirements.
Inquire about busbars & power rails "Made in Solingen" now!
Busbars cell connector
Busbars conductor strip
Busbars fork contact
Busbars & Power Rails – Production, Properties and Applications
Busbars as a key technology
Busbars and power rails are central components for efficient power distribution systems and play a decisive role, for example, in electromobility. Alfred Kron GmbH produces power rails for state-of-the-art industrial applications. Electromobility is just one example of the use of these efficient power distributors. In renewable energies and in modern building technology, powerful electrical connections are required – precise, robust and future-proof.
What are busbars / power rails?
Busbars are metallic conductors that distribute current within a system. They enable:
- Uniform current distribution
- Minimization of energy losses
- Space-saving and flexible installations
Materials: highly conductive copper Cu-ETP (or OF-Cu), copper alloys CuSn6 (with very good bending properties) or also more economical aluminum
Properties: high conductivity, mechanical stability, low inductance (in laminated systems)
Manufacturing Technologies at Alfred Kron
Material selection:
- Copper/copper alloys – good conductivity with different properties in conductive behavior and material strength
- Aluminum – lightweight, economical at large volumes, but lower conductivity
Mechanical processing:
- Stamping and forming (stamping-bending) of copper strip up to 4.0 mm material thickness
- CNC stamping-bending for complex geometries
- Adaptation to individual installation situations and functions
Surface finishing:
- Tin-plating or nickel-plating for contact quality and reduction of conductive resistance
- Corrosion protection and protection against oxidation through tin-plating
Insulation & lamination:
- Use of coatings at Alfred Kron GmbH through plastic injection molding (hybrid component with plastic as insulation material)
- Laminated busbars for lower inductance and higher performance
Assembly & integration:
- Integration of fastening elements and contact points through stamped forms and embossing
- Automated assembly production (e.g. resistance welding)
Result: power rails individually produced to drawing for maximum electrical, mechanical and thermal load capacity.
Properties of Busbars & Power Rails
- High current carrying capacity with minimal resistance
- Reduced heat generation and better cooling
- Compact design and space saving
- High mechanical stability and durability
- Low inductance (laminated systems)
- Flexible expandability
- Robust against environmental influences
Busbars cell connector with plug-in contact
Busbars grounding connector
Areas of Application
Industry & mechanical engineering: control cabinets, power distributions, frequency converters, production plants
Electromobility: battery systems, high-voltage applications, charging infrastructure, electric drives
Renewable energies: photovoltaics, wind power, energy storage solutions
Building technology: power distribution in building complexes, flexible power supply systems
Power electronics: inverters, UPS systems, telecommunications
Practical Example
Production of a busbar variant in several dimensions, for a customer from the power electronics industry, from multiple cavities in the stamping process for automated circuit board assembly (PCBs).
The parts packaged by Kron via fully automated hexapod placement machines in "tape & reel" are placed on circuit boards and soldered at the customer's site using the reflow process.
Various busbars and connectors with integrated fastening elements and bends for downstream laser and resistance welding are part of Kron's portfolio.
On customer request, all items are ultrasonically cleaned in-house and packaged in applied cleanroom technology with low particle load – either in a tray or on a reel.
Advantages Over Cable Systems
- Faster installation, lower assembly effort
- Reduced space requirement
- Higher efficiency, less electrical resistance
- Flexible expansion possible through modular design
- Increased operational safety through secure contacting
- Higher short-circuit resistance than cables, due to the larger cross-sectional area
- Individual insulation in combination with plastic injection molding (also possible at Kron)
Alfred Kron – Your Partner for Busbars
As an experienced manufacturer from Solingen, Alfred Kron produces busbars and power rails from the first drawing to the ready-to-assemble unit from a single source:
- Precise production on BIHLER stamping-bending machines
- High-quality materials and surface finishing
- Tailor-made series production and prototype manufacturing
- Focus on efficiency, durability and flexibility
Busbars power rail
Busbars tin-plated power rail
Busbars cell connector with locking tab
FAQ
What are busbars / power rails?
Busbars are conductive power rails used in electrical switchgear and distributions to conduct current between different components. They offer an efficient way to create electrical connections.
For which applications are busbars suitable?
Busbars are mainly used in electrical engineering and power distribution, for example in transformer stations, power distributors, but also in electromobility as well as in solar modules and wind turbines.
Which materials are used for busbars?
Busbars usually consist of copper or aluminum, as these materials offer high conductivity. At Kron, we process copper strip and aluminum strip up to 4.0 mm strip thickness. Tin-plated surfaces are also common to prevent corrosion.
What advantages do busbars offer compared to conventional cables?
Busbars offer a higher current carrying capacity and a more compact design. They enable efficient power distribution and save space compared to cables. In addition, at Kron, insulation can be applied through plastic injection molding, up to a ready-to-assemble unit.
How are busbars manufactured?
Busbars are stamped out of copper strip or aluminum strip using stamping and bending processes on various stamping and stamping-bending machines from Bihler, with precision and strength being decisive. As a rule, production requires the manufacture of a stamping or stamping-bending tool.
Can busbars also be manufactured in specific shapes?
Yes, busbars can be manufactured in a wide variety of shapes and sizes to meet the specific requirements of the electrical installation.
What protective measures are necessary for busbars?
Busbars often have to be provided with insulation or a protective coating to avoid short circuits and other electrical hazards.
Are busbars corrosion-resistant?
Busbars made of copper or aluminum are generally corrosion-resistant. Additional surface treatments such as tin-plating, painting or plastic coating prevent oxidation of the surface.
How are busbars installed in electrical switchgear?
Busbars are installed in switchgear by attaching them to the electrical connections. The assembly process requires precision and expertise to ensure the safety and efficiency of the power distribution.
What advantages does the use of busbars offer in industry?
The use of busbars enables reliable, space-saving and efficient power distribution, which is necessary for the safe operation of machines and plants in industry.
Conclusion
Busbars & power rails from Alfred Kron – precision from Solingen
As an experienced manufacturer of busbars and power rails, Alfred Kron GmbH combines technical expertise with high-performance series production on BIHLER stamping-bending machines. From the first drawing through in-house toolmaking to the finished power rail, you receive everything from a single source – certified to IATF 16949 and ISO 14001.
Whether high-voltage applications in electromobility, power distribution in switchgear or laminated busbars for power electronics: Kron produces your power rails individually to drawing from copper, copper alloys or aluminum – including surface finishing, plastic injection molding insulation and ready-to-assemble units.
Are you looking for a reliable partner who manufactures busbars according to your requirements? Contact us for a non-binding consultation – we implement your requirements precisely and economically.
Request your free quote for busbars from Kron now!
Direktkontakt
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Unser Vertriebsteam berät Sie zu Material, Toleranz und Wirtschaftlichkeit – schnell, kompetent und unverbindlich.
Please send us the relevant technical drawing, a sketch and/or CAD data (STEP, DWG, DXF, IGES) for your request, along with the desired quantities and batch sizes.
If available, technical information regarding installation and use, or specific quality requirements, could also be important for us.
If you have any specific requests regarding delivery and packaging, please feel free to let us know.
We look forward to your inquiry and will get back to you as soon as possible.
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