Busbar Cutting Machines: Definition, Types and Features

As a conductive carrier connecting electrical equipment in the power system, busbars must have high precision, high conductivity and structural stability. Busbar cutting machines process conductive materials such as copper and aluminum into busbar components that meet power transmission standards through shearing, bending, punching and other processes. They are widely used in busbar cutting in high and low voltage switchgear, transformers, electrical complete equipment and other fields.

The busbar cutting machine ensures that the length and cross-section of the busbar after cutting are accurate and highly consistent with the design drawings through precise cutting operations. This not only ensures the smooth progress of electrical installation and avoids installation errors and rework caused by busbar size issues, but also meets the use requirements of the power system, ensures the stability and safety of current transmission, and lays the foundation for the reliable operation of power engineering.

Busbar cutting machine is a busbar processing equipment specially designed for busbar cutting in high and low voltage switchgear, power distribution panel, transformer and electrical complete equipment. It is mainly used for cutting copper and aluminum busbars. According to the technical principle and structural characteristics, it can be divided into two categories: hydraulic busbar cutting machine uses high pressure hydraulic system to drive the cutter to complete the shearing, which has the characteristics of large cutting force and high efficiency; CNC busbar cutting machine combines computer programming technology, controls the cutting die path through servo motor, and realizes high-precision automatic and fast cutting.

• High-precision cutting capability: The busbar cutting machine using CNC technology can achieve a cutting accuracy of ±0.2mm. It can directly import drawings through CAD/CAM software, automatically complete the processing of complex shapes, and completely get rid of the traditional manual operation errors.
• Multi-process integrated processing: Some high-end models integrate multi-functional modules such as shearing, punching, and embossing. Only one clamping is required to complete the whole process of busbar processing, greatly shortening the production cycle. 
• Intelligent operation experience: Equipped with a touch screen human-machine interface, it supports graphical programming and parameter presets, and operators can quickly get started without professional training. Some models also have intelligent maintenance functions such as automatic lubrication.

In the field of high and low voltage switchgear and electrical complete equipment, busbar cutting is mainly powered by hydraulic systems to drive the tool to shear or punch to complete high-intensity processing actions such as cutting and punching. Some high-end models are also equipped with CNC systems, which can automatically program to achieve continuous processing of complex processes, improve accuracy and efficiency, and the cutting accuracy can reach ±0.2mm. If the busbar cutting error is controlled within ±0.05mm, most customers will choose laser cutting, but the cost will be higher.

The principle of scissor-type cutting is to use the shear force of the upper and lower blades to separate the copper busbar material. It has the advantages of strong adaptability and no waste. It can handle a variety of thicknesses and materials (such as aluminum busbars, copper-aluminum composite busbars), and is suitable for scenes with diverse requirements such as power equipment and customized switchgear production.

The principle of stamping cutting is to stamp and form through a die, and complete the cutting in a single action. It has the characteristics of high efficiency and better incision flatness than shearing, but it has high requirements on material ductility, brittle materials are prone to microcracks, and waste will be generated. It is suitable for fields with a high degree of standardization such as automotive electrical and new energy battery packs.

According to the busbar processing principle and application scenarios, busbar cutting machines are mainly divided into CNC busbar cutting machines, semi-automatic busbar cutting machines, economical busbar cutting machines and portable busbar cutting machines.

The CNC busbar cutting machine adopts computer numerical control (CNC) technology, integrates multifunctional units such as punching, shearing, embossing and laser marking, realizes automatic processing through programming, can achieve ±0.1mm processing accuracy, meet the needs of precision electrical connection, and is suitable for mass production of high-precision busbars. We recommend that medium and large busbar production enterprises should choose  MX602K-8C CNC busbar punching and shearing machine developed by MAC, a CNC busbar machine manufacturer. It adopts German Beckhoff PLC and Swiss ABB motor, closed-loop servo control, and has the characteristics of high cost performance and high performance.

Semi-automatic busbar cutting machine and economical busbar cutting machine belong to the same series of products. They have bending, cutting and punching functions, and can allow 3 people to operate at the same time. They are suitable for small-scale busbar processing by small and medium-sized enterprises. Compared with the economical busbar cutting machine, the semi-automatic busbar cutting machine is equipped with servo motors and roller screws in the bending unit, punching unit and cutting unit respectively, which realizes the automatic positioning of the busbar processing coordinates. The processing efficiency is 10 times that of the economical busbar machine. We recommend that small and medium-sized busbar processing companies choose SS-50-3CNC PRO busbar machine from SUNSHINE, a professional busbar machine supplier. It can process up to 16*250mm copper busbars and can meet the processing needs of most companies.

The portable busbar cutting machine is a multifunctional busbar machine with the characteristics of small size and portability. It is suitable for narrow space operations and project site construction. This series of products, the portable busbar processing machine produced in China, has become the preferred portable equipment for overseas customers due to its price advantage and good quality reputation.

1.MAC

• The independently developed MX602K series busbar machine adopts German Beckhoff PLC, closed-loop servo control, and self-developed 2D/3D programmable program, breaking the foreign CNC busbar machine technology monopoly and becoming the leading enterprise of CNC busbar machine in China.
• Advantages: strong technical strength, strong stability of busbar machine, high cost performance, suitable for high-end market needs, and providing customized solutions.

2.SUNSHINE

• The multifunctional 3 in 1 busbar machine produced by SUNSHINE has a high market share. For every 10 busbar machines produced in China, SUNSHINE occupies 7. In terms of economical and multifunctional styles, SUNSHINE has an absolute monopoly.
• Advantages: economical, multifunctional, good corporate reputation, suitable for the needs of the mid- and low-end markets, exported to more than 50 countries.

3.EHRT

• Dieter Ehrt revolutionized precision measurement with his prism technology. His patents allow EHRT press brakes to measure angles with precision. Unique features such as springback compensation make our machines among the most precise on the market.
• Advantages: Focus on press brakes, strong technical background, suitable for high-end market needs, and customized solutions.

4.PAYAPRESS

• PAYAPRESS is a knowledge-based company and a pioneer manufacturer of busbar processing equipment, sheet metal punching machines and hydraulic tools. It provides a wide range of busbar processing equipment, such as busbar bending machines, busbar punching machines, busbar cutting machines, three-in-one busbar processing machines, CNC busbar punching machines, etc.
• Advantages: Covering the Middle East region, supporting 4.0 industrial technology, and very accurate in cutting, punching, and especially bending.

Related Reading: TOP 3 Busbar Cutting Machine in 2025

As the core equipment of electrical manufacturing, the technological development of busbar cutting machine directly affects the efficiency and reliability of the power system. When choosing, users need to comprehensively consider processing requirements, budget and equipment performance, and make reasonable selections to maximize production benefits. With the popularization of CNC technology and new materials, busbar cutting machines will continue to evolve towards intelligence and efficiency, injecting new momentum into the development of the industry.

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