DSL Busbars for Industrial Overhead EOT Cranes

DSL Busbars are made up of highly electrically conductive metals and they distribute & carry power from a source to a destination or multiple destinations.They are used in EOT Cranes to supply power from the grid to the crane control panel. Full Form of DSL busbar is Down Shop Lead.

When it comes to industrial overhead EOT cranes, power distribution is crucial for safe and efficient operation. DSL busbars provide a reliable and cost-effective solution for power distribution, allowing for smooth crane operation and minimizing downtime. Our DSL busbars are made with the highest quality materials to ensure maximum conductivity and durability.

In addition to improving power distribution, using DSL busbars can also help increase the overall efficiency of your crane operations. They are easy to install and maintain, and can help reduce energy consumption and costs.

If you're looking for a high-quality and reliable power distribution solution for your industrial overhead EOT crane, consider investing in DSL busbars. Browse our selection of DSL busbars today and find the perfect fit for your crane.

A Busbar Assembly of 4 individual busbars

Overhead EOT Crane DSL Busbar Manufacturer in India

To Manufacture DSL Busbars for EOT cranes requires significant investment in equipment ,time and skilled technicians. With decades of experience and facilities spread across India, Anand Systems Engineering has become the top Eot Crane DSL busbar manufacturer with over 1000+ businesses using different profiles of DSL busbars manufactured by us.

Different Profiles of DSL Busbars For Electric Overhead Cranes

DSL Busbar profiles reduce the overall weight of the system as compared to flat busbars and provide the cost benefit to the user. Prefabricated Busbar Profiles are advantageous to flat busbars because profiles optimize the space of installation, help make the installation easy. Long installation busbars should be using profiles to reduce the skin effect. Depending upon the electrical frequency of the AC voltage, due to skin effect the AC current tends to flow near the surface of the conductor. Hence areas of the busbar with low current density can be removed, thereby saving weight and cost. The skin depth of copper busbar is 8.5mm at 60 hz frequency.

As the frequency of the AC voltage increases, the skin depth reduces. Using DSL busbar profiles helps reduce the effect of skin depth by optimizing the areas of higher and lower current density and achieving better performance even when utilizing less weight than flat busbars. Current density can be uniformly spread across the cross section of the profile.

The Impact of DSL Busbars

Power flows through the DSL busbars, Efficiency in every crane,
A spark of progress, a gleam of hope, Empowering every man.

These busbars, strong and true, Guide the energy with care,
Ensuring smooth crane operation, With minimal downtime to spare.

With every lift and every load, We see the potential within,
The power of the busbars, Guiding industry to new win.

So let us all embrace, The strength of the DSL,
For in its power lies, A future bright and successful.

What are DSL Busbars?

DSL Busbars are made up of highly electrically conductive sheet metal and they distribute and carry power from source to a destination or multiple destinations. They can be used in all kinds of Factories, Buildings, Malls, Airports etc.

DSL Busbars come in a variety of configurations, shapes, sizes, materials and current carrying capacity.

Conductor bar assembly

When you need to conduct a significant amount of current, DSL busbars are your best bet. For example, if you want to power many of your heavy duty cranes in one bay, you use a system of DSL busbars.

The efficiency of a busbar will depend upon the Ratio of the Input Power to the Power Output.

Bus bar feeder system

In Low Power Systems Such as a ‘pcb’ in a household or industrial appliance,the ground or Power plane can be thought of as a bus bar.Current in these low power systems tend to be in the milli ampere range.

In High Power Systems, where you have to transfer 1000 Amperes of Current through a three phase busbar system, it is a different game. The design, Installation, Safety during such an installation become critical factors.

What is the Need for DSL Busbars?

They are a very efficient system to carry significant amounts of current between different electrical subsystems.

Where are DSL Busbars used?

  • Factories

  • Buildings

  • Airports

A busbar is not the only solution to deliver power to your machinery but it can be used in many different configurations.

Busbar Configuration

What is the Current carrying capacity of DSL Busbars?

The Current carrying capacity of the busbar are highly dependent on the operating temperature. In an Industrial environment, most of the heat lost by the busbar will be due to Convection. Current carrying capacity of a busbar can range from 1 Ampere to 1200 Amperes.

Thick copper busbar installation
Current Carrying Capacity of busbars
  • 40 Ampere DSL Busbar

  • 60 Ampere DSL Busbar

  • 100 Ampere DSL Busbar

  • 140 Ampere DSL Busbar

  • 200 Ampere DSL Busbar

  • 250 Ampere DSL Busbar

  • 300 Ampere DSL Busbar

  • 400 Ampere DSL Busbar

  • 500 Ampere DSL Busbar

  • 600 Ampere DSL Busbar

  • 700 Ampere DSL Busbar

  • 800 Ampere DSL Busbar

  • 900 Ampere DSL Busbar

  • 1000 Ampere DSL Busbar

  • 1200 Ampere DSL Busbar

Does the Resistance of a Busbar Matter?

Yes, it matters.
Heat generated by the busbar = I2R
Where I = Current Carried By the Busbar
R = Resistance of the busbar
Increase in resistance of the dsl busbar, produces more heat which in turn reduces the total power efficiency of the dsl busbar system decreases.

Resistance of DSL Busbars

Which DSL Busbar Should I choose for my application?

  • Energy Efficiency Required
  • Current Carrying Capacity Required
  • Life Time Cost
  • Length of DSL Busbar Installation
  • Maintenance Procedures of Different DSL Busbars
  • Cooling Method Provided to the DSL Busbar
  • Inductance & Capacitance of Longer DSL Busbars
  • Space Constraints
  • Cost Constraints

Materials Used in DSL Busbars

DSL Busbars are typically made of high-conductivity materials, such as GI ,copper and aluminum, that are able to transmit electrical power effectively with minimal loss. The choice of material depends on the specific requirements of the application and the operating conditions of the EOT crane.

Copper is a popular choice for DSL Busbars due to its excellent electrical conductivity, durability, and resistance to corrosion. It is also a flexible material, making it ideal for customizing the busbars to fit the specific requirements of different EOT cranes. However, copper is also a relatively expensive material, making it a less economical choice for some applications.

Aluminum is another common material used for DSL Busbars. It has lower conductivity compared to copper but is lighter and more economical. Aluminum is also resistant to corrosion and can last for many years with minimal maintenance, making it a reliable choice for industrial applications.

Upto 125 Amps GI DSL Busbar is the most economical choice. When there is highly corrosive environment Stainless Steel DSL Busbars are used if Amperes required in low.

In some cases, other high-conductivity materials, such as silver, may be used for DSL Busbars. However, these materials are typically more expensive and are only used in specialized applications where their high conductivity is critical.

In addition to the conductive material, the busbars are usually supported by insulating material, such as ceramic or fiberglass, to prevent electrical accidents and ensure the safety of workers. These materials are chosen for their high resistance to electrical and thermal stress, as well as their ability to withstand the harsh conditions of industrial environments.

SS DSL Busbar

Used in corrosive atmosphere, chemical plants, 60 Amps in W type.

Stainless Steel DSL Busbars

Galvanized Iron DSL Busbar

Let's go through the important technical parameters of Iron as a metal:
Melting point of Iron: 1538 °C
Boiling Point of Iron: 2862 °C
Density of Iron: 7.874 g/cm 3
Electrical Resistivity of Iron: 96.1 nΩm

Applications of Iron DSL Busbars are in trolleys, over head cranes, hoists.

Galvanized Iron DSL Busbars

Aluminium DSL Busbar

Let's go through the important technical parameters of Aluminium as a metal:
Melting point of Aluminium: 660.32 °C
Boiling Point of Aluminium: 2470 °C
Density of Aluminium: 2.7 g/cm 3
Electrical Resistivity of Aluminium: 26.5 nΩm

Properties of Aluminium:

Aluminium is ready available because it makes up almost 10 percent of the earths’ crust. Aluminium has almost 33% density of copper or Steel. When exposed to air, aluminiums’ outer layer oxidizes and helps in making aluminium excellent at corrosion resistance and hence aluminium maintains a good silvery finish at all times.

Aluminium is a good material for DSL Busbars because of its very High electrical and thermal conductivity, low Density, excellent corrosion resistance and high mechanical strength.

Aluminium DSL Busbars are cheaper than copper DSL Busbars but offer about 60 % of coppers electrical conductivity. Aluminium also weighs almost half of copper DSL Busbars. Since Aluminium is a soft metal, Aluminium DSL Busbars can be made with the help of rolling machines or extrusion machines.

Aluminium DSL Busbars

Copper DSL Busbar

First lets go through the important technical parameters of Copper as a metal:
Melting point of Copper: 1082 Degrees
Boiling Point of Copper: 2564 Degrees
Density of Copper: 8.96 g/cm 3
Electrical Resistivity of Copper: 16.78 nΩMeter

Since Copper is malleable and Ductile it can be formed into many different kinds of shapes. It also has a high thermal conductivity to spread out the heat evenly. Due to all these parameters, copper is the most favoured material to be used in DSL Busbars.

Copper DSL Busbars are much superior to aluminium DSL Busbars in terms of conductivity but the trade off here is cost and weight. Since the density of copper is high, it is more robust to external mechanical disturbances and damage.

Copper DSL Busbars will transfer significant amounts of current, hence, there will be a small percentage of power lost in transmission and converted into heat. This heat will be lost to the external environment through convection and radiation.

Copper DSL Busbars

Cost Comparison of DSL Busbars For Overhead Cranes

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Steel Busbar

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GI DSL Busbar

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Aluminium DSL Busbar

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Copper DSL Busbar

Electrical performance of DSL Busbars for Overhead Cranes

Steel Busbar

Steel Busbar


GI Busbar

GI Busbar


Aluminium Busbar

Aluminium Busbar


Copper Busbar

Copper Busbar


Different types of Joints for DSL Busbars

Bolt type joint diagram

Bolt Type Joint

Pin type Joint diagram

Pin Type Joint

Weld type joint diagram

Weld Type Joint

Rivest type joint

Rivet Type Joint

Busbar Protection

Protection from Short Circuits

In a three phase power delivery system, a minimum of three parallel DSL Busbars will be used to deliver power to the crane machinery. The gap between the DSL Busbars is an important parameter to avoid short circuits.

If there is a short circuit, the current will rise until the protection device kicks in. This very high current will heat the DSL Busbars and will cause mechanical stress to the busbar as well as its support units.

Protection from Human Touch

We only recommend insulated DSL Busbars, because like every other electrical circuit, DSL Busbars need to be protection from human touch. No live or HOT sections are exposed to the external environment.

Safe distance should also be maintained between two parallel DSL Busbars. Insulation will also help in prevention of short circuit in the presence of foreign material touching two DSL Busbars.

Warning - Risk of electric shock

Lifetime cost of Busbar


Installation Design

The design of the electrical system will play a major role in the installation price. The design of installation should focus on minimizing the time required to install the busbar and all its supporting components ,should minimize maintenance time,should provide easy and safe access to the maintenance and installation personnel. A well designed electrical system ,will allow for connections and disconnections in the future without stopping the production of a factory. The design should also allow for extensions to the busbar if required.

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Cost of Installation

Cost to erect the busbar to the particular height, complexity of the busbar installation. Time to install all the number of supporting components such as joints, brackets,pins,etc play a major role in installation cost.

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Recurring Cost

Maintenance cost of a busbar will be reduced if the busbar is used correctly. Using the busbar at lower working temperatures and not overstressing the DSL Busbars will cause the DSL Busbars to increase their life and reduce the maintenance costs.

graph depicting Cost of Energy

Energy Cost

The amount of voltage drop in a busbar will affect the cost of energy you pay . Selecting the right conductor size will greatly minimize the voltage drop.As the weight of material increases the cost of the busbar increases, and the cost of energy decreases.

End of life of busbar

End of Life Cost

At the End of Life of the system, the DSL Busbars and its supporting components have to be removed.The cost of material used for the DSL Busbars will be of significant value. As the cost of metal increases the cost of material used for the busbar might appreciate. All other supporting plastic components will have to be recycled.Keeping all these points in mind, you can get a very practical view of the overall cost of a busbar system.

Current Collectors for DSL Busbars

What is the Current collector of DSL Busbars?

One key component of DSL Busbars is the current collector, which is used to collect the electrical current from the conductor rail and transfer it to the moving equipment. Current collectors are typically made of a copper-based material and come in various shapes and sizes depending on the application. They are designed to be in constant contact with the conductor rail, ensuring a reliable transfer of power and signals as the moving equipment travels along the busbar system.

Current collectors also come with additional features such as spring-loaded arms that maintain constant contact with the conductor rail, even in bumpy or uneven terrain.

Proper maintenance and inspection of current collectors are crucial for ensuring a safe and reliable operation of the DSL Busbar system. Wear and tear can occur over time, leading to decreased performance and potentially hazardous conditions. Regular inspections and replacement of worn or damaged current collectors can help prevent accidents and equipment failure.

Current Collectors come in 60 Ampere , 125 Ampere and 250 Ampere rating. Two Current Collectors can be used in Tandem to be used for higher current requirements and for expansion assemblies.

Design Considerations When selecting current collectors for DSL busbars, several factors need to be considered, including: Electrical Conductivity - Current collectors must be made of a material that has excellent electrical conductivity to ensure the efficient flow of current.

Corrosion Resistance - DSL busbars are often used in harsh environments, such as data centers or industrial plants. As a result, current collectors must be made of a material that is resistant to corrosion and oxidation.

Thermal Conductivity - Current collectors must be able to transfer heat away from the electrical system to prevent overheating.

Contact Resistance - The contact resistance between the current collector and the busbar must be as low as possible to reduce energy loss and heat generation.

Copper Current Collectors - Copper is the most commonly used material for current collectors in DSL busbars. Copper has excellent electrical conductivity and thermal conductivity, which makes it ideal for use in high current applications. Copper current collectors are also highly resistant to corrosion and oxidation, making them a durable and reliable choice.

These current collectors use a spring-loaded mechanism to maintain constant contact with the conductive rail, ensuring that electrical signals and power are efficiently transferred.

The sliding copper current collector consists of a copper head that slides along the conductive rail, and a spring-loaded mechanism that ensures continuous contact between the copper head and the rail. The spring-loaded mechanism applies a constant force to the copper head, ensuring that it maintains contact with the rail even when there are small variations in the rail height or movement.

The spring-loaded mechanism is designed to provide a constant force that allows the current collector to move along the rail without losing contact. This ensures that the electrical signal or power is continuously transmitted without any interruptions. The amount of force applied by the spring-loaded mechanism can be adjusted to suit the specific requirements of the application.

The copper head is designed to minimize the contact resistance between the collector and the rail. This is achieved by using high-quality copper with a low contact resistance and ensuring that the copper head is smooth and clean. This helps to reduce the voltage drop and ensures that the electrical signal or power is efficiently transferred.

Sliding copper current collectors are commonly used in applications where there is a need to transfer electrical power and signals between stationary and moving components. These applications include cranes, hoists, and other types of machinery that require electrical power to be transmitted from a stationary power source to a moving load.

Voltage Drop

Voltage drop of a busbar is very important parameter to consider.In laymans terms - the amount of voltage not reaching the desired equipment from the power supply = Voltage Drop.
It is highly dependent on the resistance of the busbar being used and the amount of current being consumed.
Temperature also affects the voltage drop to some degree.

List of some common spare parts for DSL busbars

Current collectors: These are the components that make contact with the conductor and transmit electrical current. They are available in a variety of designs including sliding, rolling, and fixed. The type of current collector used will depend on the application.

PVC Insulators: These are used to separate the conductor from the housing and other components. They are typically made of high-quality insulating materials such as PVC.

End caps: These are used to seal the ends of the busbar system and prevent moisture and dust from entering. They are typically made of durable materials such as plastic or metal.

Expansion joints: These are used to compensate for the thermal expansion and contraction of the busbar system. They are typically made of stainless steel and come in a variety of lengths and designs.

Joint covers: These are used to protect the joints between busbar sections from damage and corrosion. They are typically made of durable materials such as aluminum or stainless steel.

Fasteners: These are used to secure the busbar system to the mounting structure. They are typically made of high-strength materials such as stainless steel and are available in a variety of sizes and designs.

Bolts and nuts: These are used to fasten the various components of the busbar system together. They are typically made of high-strength materials such as stainless steel and come in a variety of sizes and designs.

Gaskets: These are used to seal the joints between busbar sections and prevent moisture and dust from entering. They are typically made of durable materials such as rubber or silicone.

DSL Busbar MS Web Brackets: These are used to support the weight of the DSL busbar system and ensure proper alignment. They are typically made of durable materials such as powder coated Mild Steel and come in a variety of sizes and designs.

It is important to note that the specific spare parts required will depend on the make and model of the DSL busbar system. It is always best to consult the manufacturer's documentation or seek the advice of a qualified technician to ensure that the correct spare parts are used.