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Electrical contacting on aluminium busbar

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langwadt:

--- Quote from: David Hess on March 05, 2019, 08:02:02 pm ---
--- Quote from: T3sl4co1l on March 03, 2019, 08:00:11 pm ---
--- Quote from: David Hess on March 03, 2019, 03:52:04 pm ---I would love to use Belleville washers more for power transistor mounting but pricing and availability has always been a problem.
--- End quote ---

That never made sense to me... they can potentially be produced in a single stroke like any other washer.  Is it just a quantity thing -- they're expensive because no one wants them because they're expensive?... :palm:
--- End quote ---

I have always assumed it is a quantity issue.  Wave washers have more applications than Belleville washers and people use split washers in place of both even when they should not.

--- End quote ---

random hit from google, https://www.amazon.com/Belleville-Washer-Stainless-Steel-Pack/dp/B01J2XR93G

$8 for 100 M4 washers isn't what I'd call expensive


David Hess:

--- Quote from: langwadt on March 05, 2019, 08:11:59 pm ---
--- Quote from: David Hess on March 05, 2019, 08:02:02 pm ---I have always assumed it is a quantity issue.  Wave washers have more applications than Belleville washers and people use split washers in place of both even when they should not.
--- End quote ---

random hit from google, https://www.amazon.com/Belleville-Washer-Stainless-Steel-Pack/dp/B01J2XR93G

$8 for 100 M4 washers isn't what I'd call expensive
--- End quote ---

Oh, they can be found *now* but go back 20 or even 10 years and it was a problem.  The same thing from McMaster Carr is 10 times the price.

And them someone in the field loses the washer during a repair and cannot find a replacement at even the local industrial hardware store.

tooki:

--- Quote from: damien22 on February 27, 2019, 07:14:53 am ---Posting here after Months of unsuccessful research and I hope there gonna be some smart guys with good idea.

--- End quote ---
Surely, with all the heavy electrical industry here in Switzerland, this is a problem that's been solved over and over domestically. There must be some industry groups that you could meet up with and talk about it with, including finding a supplier. It seems absurd to me that, in a country known expressly for precision manufacturing, that you can't get what you need made.

tooki:

--- Quote from: coppercone2 on February 27, 2019, 01:55:01 pm ---read about the oxide growth on aluminum to get an idea of whats going on. finishing101.com has some insight (linked directly in one of my previous posts).

When I read that I wanted to no longer ever use aluminum and just pay the piper at 10x cost. fuck it. Not an option? its infrastructure essential to the function of a modern society!!!

its a train they are in service for like 70+ years sometimes, look at cuba or Switzerland. Why are you going cheap for that? people actually like trains. Its not a going obsolete in 2 years equipment. Transportation is important.

How much does a damn bus bar cost in the scheme of a fucking train even if you consider a order of magnitude cost increase??????? MTA is already going to fuck it up with unknown unpredictable means, don't make it worse. Train fires suck. They can burn in tunnels etc.

--- End quote ---
Bruh… take it down a notch, mmkay?

tooki:

--- Quote from: MagicSmoker on March 03, 2019, 12:32:50 am ---
--- Quote from: kony on March 02, 2019, 09:59:55 pm ---Stock material in -T6 temper...

--- End quote ---

Finally someone gets it!

The type of lock washer most commonly used in the US for high-reliability bus bar applications is called "Belleville." It is a conical in cross-section with radial ribbing or teeth; I'm not sure how popular Belleville washers are in the EU, though, so Nord-Lok are an excellent - albeit more expensive - alternative. I also agree that directly threading the bus bar - even with Helicoil inserts - is not ideal, but it can work just fine for small small ring terminals such as #6 (M3) through #10 (M5); once you go past 1/4" (M6), though, you really can't generate enough clamping force with threads in aluminum (unless the bus bar is unusually thick). I also agree that alodine is not an appropriate choice of surface finish as it's effectively an insulator.

--- End quote ---
Just a little bit of nationalist pedantry: Switzerland (where the OP is) is in Europe, but is not part of the EU.  ;D

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