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Transportation

Transportation

Whether it’s carrying the high current necessary to power heavy equipment, rail, and subway cars—or reducing weight and enhancing packaging efficiency for the latest aircraft and hybrid vehicles—Mersen laminated bus bars bring unique advantages to the transportation industry that are not available with traditional wiring or single conductor bars. A properly engineered laminated bus bar provides the lowest overall system inductance and the most balanced and distributed capacitance, making it the perfect match for the high demands of the transportation equipment industry. Mersen laminated bus bars help transportation equipment manufacturers achieve their reliability goals.

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Locomotive

The laminated bus bar shown here represents a single-phase leg for a large three-phase inverter powering modern AC locomotives. Long term durability and continuous operation in hostile environments demand high quality and consistency. The laminated bus bar has mold-sealed edges and fully insulated mounting holes, built and tested to meet customer partial discharge requirements.

 

Size: 10” x 14” x 30” | Conductors: .030” | Voltage: 1200VDC | Current: 1000A

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High Speed Traction Drive

Size is never a problem for MERSEN! Modern Traction Inverters are large and so are their components. This three layer, laminated bus bar design delivers low inductance while optimizing the DC capacitor arrangement. Note the use of embossments & soldered bushing “vias” for interconnections.

 

Size: 10” x 14” x 30” | Conductors: .0340” | Voltage: 1200VDC | Current: 1000A

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Locomotive Traction Drive

High horsepower traction drives benefit from the low inductance power path made possible by MERSEN laminated bus bars. Laminated bus bars are the essential component that connect IGBT, SiC or GaN modules and capacitors together. By minimizing system inductance, transient over-shoots are reduced which greatly simplifies the need for complex snubber circuitry. Laminated bus bar designs for motor drives can contain a number of modular bus bars, linked together, to connect all of the system components into one complete system.

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Hybrid Vehicles

Designed with automotive reliability in mind, this two-layer, laminated bus bar joins parallel rows of batteries together in a hybrid vehicle application.

 

Size: 3” x 4” | Voltage: 60VDC | Thickness: .093” | Current: 40A

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Alternative Fuel Systems

Fuel cells and hybrid electric vehicles require rugged, reliable power distribution. Heavy duty construction with epoxy powder coating as a dielectric allows this laminated busbar design to perform to specifications in harsh environments.

 

Size: 6” x 14” | Conductors: .125” | Voltage: 600 VDC | Current: 150A

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Electric Vehicle Power Distribution

When power has to be routed through tight confines that twist and turn, MERSEN’s epoxy powder coating provides 100% dielectric protection. This two-conductor laminated assembly includes bonded ceramic chokes, nylon reinforced mounting holes, and floating clinch hardware for easy installation and optimized electrical performance in an automotive environment.

 

Size: 4” x 9” | Conductors: .125” | Voltage: 150VDC | Current: 100A

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Mass Transit

This rugged two-layer, four conductor laminated bus bar is production built for a Hybrid Transit Inverter application. The perimeter is a laminated, sealed-edge construction, and the design shows the simplicity of combining electrolytic capacitors, resistor networks, and power modules (IGBT, SiC or GaN) into a single, compact bus bar system.

 

Size: 10” x 11” | Thickness: .125” | Voltage: 1015VDC | Current: 280A

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Public Transportation

When power has to be routed through tight confines that twist and turn, MERSEN’s epoxy powder coating provides 100% dielectric protection. This two-conductor laminated assembly includes bonded ceramic chokes, nylon reinforced mounting holes, and floating clinch hardware for easy installation and optimized electrical performance in an automotive environment.

 

Size: 4” x 9” | Conductors: .125” | Voltage: 150VDC | Current: 100A

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Electric Vehicle Power Electronics

Individually laminated, this two-conductor bus bar connects electrolytic capacitors and IGBT, SiC or GaN modules in a small, lightweight package for an EV Inverter.

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Surface Mount for Fighter Aircraft Power Electronics

Used in tandem, one as a high-temp, high-current board for switching components and the other is densely populated with chip capacitors. The use of Kapton insulation allows full solderability for surface mount components. Both bus bars are epoxy edge filled and designed to withstand extremely demanding conditions of temperature and altitude.

 

Length: approximately 4” each | Volts: 200VDC | Current: 260A | Conductors: .025” & .050”

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Military Fighter Aircraft

This complex, nine layer, low inductance laminated bus bar is engineered to perform at very high altitudes in a confined area. It interconnects custom power modules through brazed bushings and PEM hardware. The high temperature insulation is entirely epoxy edge filled around each individual layer.

 

Size: 6” x 11” | Thickness: .025” per layer | Voltage: 300VDC | Current: 60A