An Injection Lap Riveting Tool System

This article is focused on the utilization of a joining by plastic deformation process known as double-sided injection lap riveting to fabricate aluminum busbar connections for energy transmission and distribution systems. Special emphasis is placed on a new cutting tool concept capable of machining the dovetail ring holes, which will later be filled by the injection of aluminum rivets to create form-closed joints. The methodology is based on the design, construction, and utilization of a flexible, modular, cutting tool for machining dovetail ring holes in metallic busbars. Experimental work validates the cutting tool concept, identifies the main operative parameters, and fabricates busbar connection samples by double-sided injection lap riveting, whose performance is then evaluated by means of thermo-electrical testing. Numerical modelling with finite elements gives support to fabrication and thermo-electrical characterization of the aluminum busbars connections. Comparisons are made against conventional busbar bolted joints.