In the past several years, there has been a significant shift in how industrial plants will distribute electrical power, including what they expect to be able to do with these collected systems. Electric power systems were previously designed as simply an ever-growing conduit for the distribution of electrical power (and minor maintenance items), but now they are being engineered for other purposes such as real-time data visibility, predictive maintenance, energy efficiency, and pre-event alerts.
As the electrical distribution industry continues to move forward, many manufacturers are implementing customized copper busbars solutions with digital monitoring technologies. These modernized types of busbars function not just to carry electrical current but also to serve as computer-like devices that provide valuable information about how the electrical system is being utilized.
For industrial data centers, electric vehicle (EV) charging stations, manufacturing operations, commercial construction, and renewable energy facilities, smart busbars will accelerate the transformation of traditional distribution networks into future-proof, smart networks.
Smart busbars are advanced electrical conductor systems that include sensors and real-time monitoring devices that track operational parameters continuously. Unlike traditional busbars, which only distribute electricity, smart busbars provide real-time information regarding:
Current Load
Voltage
Temperature
Power Quality
Energy Use
System Health Indicators
The data collected will be accessible via monitoring software, dashboards, cloud-based applications, and building management systems. Essentially, a smart busbar does not only distribute electricity it tells you how your electrical circuit is performing.
A smart busbar is a power distribution conductor with built-in sensors and digital monitoring technology for instantaneous electrical parameter measurement (current, voltage, temperature, etc.). Smart Busbars allow for better safety and efficiency as well as improved maintenance planning because of real-time data.”
Digital monitoring systems serve as the intelligence layer for the electrical power distribution system.
Sensors located at critical locations continuously monitor and collect electrical and thermal information for transmission to a monitoring system, where the information can be analyzed by facility management to evaluate system performance.
Key functions of monitoring include:
Real-Time Monitoring
Managers have instant visibility to see:
Load distribution
Peak demand
Voltage fluctuations
Rise in temperature
Predictive Maintenance
The system detects early warning signs of impending failure rather than waiting until the equipment has failed.
For example, early detection can occur due to:
Unexpected increases in temperature
Unequal load distribution
Excessively loaded circuits
Degradation of connections
Remote Access
Engineers can remotely view critical infrastructure from almost anywhere with secure digital dashboards, which is especially helpful when monitoring:
Data Centers
Industrial Facilities
Renewable Energy Facilities
Large Commercial Buildings
The demand for electrical energy is increasing at a rapid pace.
Today’s facilities utilize the following:
Automated Equipment
Electric Vehicle Charging Stations
Robotics
Data Processing Equipment
Renewable Energy Technology
In order for these technologies to function properly, reliable and stable power must be delivered.
Typical methods of maintenance have relied heavily on spot inspections as a result, numerous electrical system failures occur between inspections and typically remain undetected until system downtime occurs.
Smart busways allow for continuous visibility into the performance of the electrical distribution system, providing:
Reduced downtime
Enhanced reliability
Lower maintenance costs
Improved management of energy usage.
A smart busbar solution typically consists of several interconnected parts.
Conductors
Conductors for busbars can be made from:
Copper
Aluminum
Tinned copper
Working with an experienced fabricated busbar manufacturer helps ensure proper material selection and long-term reliability.
Sensors
Sensors can gather data related to equipment usage in real-time throughout the lifetime of the equipment. These include:
Temperature
Current
Voltage
Humidity – in some cases
Communication modules
These devices establish communication between sensors and monitoring systems and can gather data using industrial communication protocols.
Monitoring Software
Monitoring software processes the electrical data collected by the sensors and creates actionable information through the following:
Real-time dashboards
Alerts
Reports made from historical data/trends
Analysis of performance data.
Benefits of a Smart Busbar System
System monitoring is done in real time
Electrical safety has improved
Predictions for maintenance are available
Downtime is reduced
More energy-efficient use of power
Lower cost to operate
Provides better control of power quality and
Increases the lifespan of equipment.
1. Enhanced Safety
Typically, electrical failure doesn’t occur without a warning sign, such as an increase in temperature, loose connection, or overloaded circuits. Smart monitoring systems identify potential problem areas before they develop into serious safety issues.
2. Less Downtime
Manufacturers can incur costs of thousands of dollars (or lakhs) for each hour that they are unable to operate. Monitoring the important signals provided by smart busbars will enable manufacturers to address maintenance issues before breaking down.
3. Improved Energy Efficiency
Energy costs are going to continue to increase throughout multiple sectors in industry. Smart monitoring systems will help to identify:
Inefficient loads
Energy waste
Peak demand problems
Unbalanced loads
This will allow manufacturers to develop improved energy optimization strategies.
4. Predictive Maintenance
Conventional maintenance has relied upon scheduled time intervals and set schedules to determine maintenance activity. The use of smart busbars allows equipment maintenance to be scheduled based on the monitoring of actual equipment condition. This will typically reduce maintenance costs associated with unscheduled maintenance and improve the reliability of the equipment.
5. Extended Equipment Life
Overheated and overloaded equipment will lead to shorter equipment lifetimes. Ongoing monitoring of operational conditions will allow manufacturers to maintain better operational conditions, allowing the assets to have a longer overall useful industrial lifespan.
Smart busbars are being employed in many industries.
Manufacturers need a consistent source of electricity for:
Centralized CNC machines
Automated equipment within factories
Factories with assembly lines
Data Centers
Downtime is something that no one wants in a data center.
To maintain consistent electrical flow, data centers utilize smart monitoring.
EV Charging Infratructure
Pending future growth in electric vehicles (EVs) will change how we build and operate charging networks through the use of
Dynamic load management
Power monitoring
Commercial Facilities
Large office buildings can enhance electric monitoring and electrical safety through the use of smart busbars.
Renewable Energy Projects
Many solar developers and wind developers use smart monitoring and busbars as a way to accommodate the varying levels of electric generation.
No technology is perfect in any space.
Smart busbars provide many functional benefits however, they also provide some limitations.
Typically smart busbars have a high initial cost due to their use of
Sensors
Communication Modules
Software Integration
If an organization decides to collect data from their smart busbars, there is a data analysis requirement that must be accomplished prior to extracting valuable insight.
Organizations with existing buildings established need to plan carefully to upgrade their existing electrical infrastructure.
That being said, most companies expressed that the savings they achieved due to operational efficiency outweighed the initial cost of their investment over time.
Contractors and professionals with practical experience recommend the following:
1. Look for Expandability
Always choose busbars that can be expanded to meet future needs.
2. Check Monitoring Capability
There are many different monitoring platforms available, but not all will provide the same level of information.
Look at:
Dashboard features
Report functions
Alert features
Integration ability
3. Examine Environmental Conditions
Humidity, dust, chemicals, and outdoors may necessitate special busbar design.
4. Quality of manufacturing
The busbar’s intelligence is critical, but the quality of the conductors must be considered as well.
The level of quality of fabrication, insulation, plating, and testing all play an important part in the long-term performance of Smart Busbars.
Most buyers have problems when they only focus on the price.
By making price the only determining factor, other significant criteria become overlooked.
The most common mistakes include, but are not limited to:
Ignoring future expansion needs
Choosing busbars that are undersized for the application
Not planning for thermal management
Not reviewing the monitoring software available
Ignoring that certification for the manufacturer’s quality
Focusing solely on the up-front purchase prices
If you can put out a little more money now, it could potentially save you a considerable amount in further upgrades tomorrow.
Picking a smart busbar manufacturer is important, just like choosing a smart busbar technology.
When looking for a smart busbar manufacturer, consider the following:
Engineering Expertise
Customizable design capability is normally necessary for industrial applications.
Quality Testing
Make sure that products have passed the following testing:
Electrical testing
Thermal testing
Dimensional Inspection
Material Options
An adequate smart busbar manufacturer will have the following:
Copper busbars
Aluminum busbars
Sleeved Aluminum busbars
Created custom busbars
Market Experience
Having industry experience (switchgear, panel boards, renewable energy (including solar), EV charging, and other industrial applications) can provide a manufacturer with a significant advantage.
The following list contains frequently asked questions on smart busbar technology and their answers.
1) What is the primary function of a smart busbar?
A smart busbar is designed to distribute electric power and provide real-time data on electrical and thermal parameters.
2) Are smart busbars applicable to older facilities?
Yes, by taking proper planning into account, there are a variety of options for adding smart monitoring solutions to existing facilities.
3) Will a smart busbar reduce my maintenance cost?
Many times, yes. Predictive maintenance through a smart busbar allows a facility to identify potential failures before they occur and helps eliminate needless service calls due to equipment failure.
4) What markets benefit most from using a smart busbar?
These are all markets that benefit greatly from a smart busbar: manufacturing, data centers, electric vehicle (EV) charging networks, commercial, and renewable energy markets.
5) Are smart busbars more costly than traditional busbars?
While there may be a higher initial investment, operating savings will offset these costs over time.
6) Will using a smart busbar improve overall energy efficiency?
Yes, real-time monitoring of energy losses, load imbalance, and inefficiency within an electrical system is possible through the use of a smart busbar.
7) What types of conductor material are available for use with a smart busbar?
Standard conductor materials used with a smart busbar include copper, aluminum, and tinned copper.
Power distribution is only one use case for the transportation of electrical energy at this point in time, there exists a need for visibility, intelligence, and dependability beyond the traditional form of power distribution. With the advent of smart busbar technology and digitized monitoring solutions, it is now possible to have a full understanding of power distribution as it relates to the organization and the safety of employees and customers while safely relying on electricity from multiple sources for increased efficiency in electrical operations.
Commercial and industrial businesses are both becoming increasingly automated, electrified, and driven to make decisions regarding energy consumption by the use of data, therefore creating a scenario in which smart power distribution will likely become the norm rather than an exception.
Looking for Assistance?
If you are in the process of designing a new electrical system or upgrading an existing electrical system, the ability to partner with a qualified busbar manufacturer can have an impact on the outcome of your project. Customized busbar solutions can be developed based on your individual load characteristics, physical environment, and future expansion needs to provide you with the longest-term value possible.
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