Copper & Aluminum Busbar Insulation Wrapping Machine – Busbar Taping Equipment
Brand: Benfa
Country of origin: China
Technical Support: Longlife
Application: New energy vehicle batteries Power distribution / switchgear cabinets Busway & bus duct systems Photovoltaic & energy storage systems EV charging stations Industrial power systems (UPS, inverters, motors)
Fully automatic mica tape wrapping — feeding, wrapping & cutting in one cycle, no manual work
6-axis robot + ground rail — wraps busbars up to 4 m long
Dual-arm option — wraps from both ends at once for double efficiency
Patented open wrapping head — even, wrinkle-free insulation every time
One-click changeover — saved recipes switch products in seconds
Auto tape-out stop — no wasted tape, no incomplete wraps
Surface-safe clamping — padded, 360° rotatable, no scratches
One operator, fully safe — light curtains + 10" touchscreen
busbar insulation wrapping machine
copper busbar wrapping machine
aluminum busbar wrapping machine
busbar insulation taping equipment
busbar taping machine
copper busbar wrapping machine.
a. Our busbar insulation wrapping machine is an automated mica tape wrapping machine designed for copper and aluminum busbars used in new energy vehicles and busway systems.
b. Replacing manual taping, this busbar insulation tapping equipment combines a 6-axis robot (30 kg payload) with a patented open-type wrapping head to deliver high efficiency and consistent wrap quality. As an advanced copper busbar wrapping machine and aluminum busbar wrapping machine, it handles both materials with equal precision.
c. The busbar taping machine supports full wrapping on both ends and spot wrapping in the middle section, with automatic tape feeding and cutting — operators simply load the product and press start.
1.6-axis robot with ground rail — extended travel allows this copper busbar wrapping machine to wrap busbars up to 4 m in length; single-arm or dual-arm configurations available (dual-arm wraps from both ends toward the center for higher efficiency)
2.Patented open wrapping head — balanced design with upper/lower clamping cylinders to flatten mica tape; twin tape reels for rotation balance
3.Servo positioning system — 3-axis module (left) + 2-axis module (right) for fast product positioning, with data storage and recipe recall via HMI
4.Auto tape-out detection — Keyence LR-W500 photoelectric sensor stops the busbar insulation machine when the mica tape runs out, preventing tape waste
5.Product-friendly clamping — pneumatic side-push clamps with nylon / polyurethane pads, 360° rotation, and φ6 mm POM positioning pins to protect product surfaces
6.Auxiliary support units — 250 mm servo electric lift cylinders and XY adjustable platforms prevent deformation of long busbars (2 units standard, 3 for extended products)
7.Safe operation — aluminum profile frame with transparent acrylic enclosure, safety light curtains with alarm buzzer, 10" PLC touchscreen, and LED lighting
Application:
New energy vehicle batteries
Power distribution / switchgear cabinets
Busway & bus duct systems
Photovoltaic & energy storage systems
EV charging stations
Industrial power systems (UPS, inverters, motors)
aluminum busbar wrapping machine.
1. Mechanical structure and drive system.
a. The machine is built around a 6-axis robot with a 30 kg payload. Solution 1 uses one robot on a ground rail, and Solution 2 uses two robots on ground rails for higher productivity. The platform supports both copper busbar wrapping machine and aluminum busbar wrapping machine applications on a single line.
b. The machine body is made of a 20 mm thick steel plate base welded with 5 mm square tubes, painted on both sides, and enclosed in a clean aluminum profile frame with transparent acrylic panels.
c. Four caster wheels and two fixed leveling feet are installed for easy movement and stable positioning.
d. Positioning is handled by a 3-axis servo module on the left and a 2-axis servo module on the right, supporting manual hand-wheel adjustment and HMI data input with recipe storage.
e. Pneumatic side-push clamps with 360° rotation and nylon / polyurethane pads hold the product securely without damaging the surface. A φ6 mm POM positioning pin ensures accurate alignment.
f. Auxiliary clamping uses an XY manual platform, a 250 mm servo electric lift cylinder, and a 150 mm shift cylinder to support long products and prevent deformation. The standard machine has 2 auxiliary stations, and extended models have 3.
2. Electric control system.
a. The machine adopts PLC control with a 10-inch touch screen HMI and a separate robot teach pendant for easy parameter setting and operation.
b. The operation area is protected by safety light curtains. If the light curtain is interrupted, the machine stops immediately and sounds an alarm buzzer.
c. Keyence LR-W500 photoelectric sensors detect tape-out status, stopping the machine automatically when mica tape runs out to avoid waste and incomplete wrapping.
d. The internal work area is illuminated by 5 high-brightness LED tubes for clear visibility during production and maintenance.
e. Electrical cabinets are equipped with access doors for convenient inspection and maintenance.
3. Technical indicators.
a. Overall dimensions (L×W×H): Standard model 3.2 × 2 × 2.2 m; Solution 1 5.5 × 2.5 × 2.3 m; Solution 2 7 × 2.5 × 2.3 m.
b. Max. wrapping length: 4 m.
c. Robot configuration: 6-axis, 30 kg payload; single-arm or dual-arm with ground rail.
d. Wrapping mode: full wrapping on both ends plus center spot wrapping; automatic tape feeding and cutting.
e. Wrapping direction: Solution 1 wraps from left to right; Solution 2 wraps from both ends toward the center.
f. Positioning accuracy: servo-driven modules with recipe recall for fast product changeover.
g. Applicable products: copper busbars, aluminum busbars, and busway conductors for new energy vehicles, power distribution, and bus duct systems.
Our busbar insulation wrapping machine is widely used in new energy vehicle battery production, power distribution cabinets, switchgear, busway systems, photovoltaic and energy storage systems, EV charging stations, industrial power systems, and transformer manufacturing. It works as a busbar taping machine and busbar insulation tapping equipment for both copper busbar wrapping machine and aluminum busbar wrapping machine applications, handling mica tape wrapping, busbar insulation, and automated taping, and supporting both full wrapping and spot wrapping modes to meet various insulation requirements.
Specifications:
