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Individual tools for busbar machining

The individual tools from KW Hydraulik offer maximum flexibility and precision when processing busbars. From cutting and punching tools to bending and stripping tools and processing stands - you will find everything you need for your manual busbar process

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HC125 Busbar cutter
HC125 Busbar cutter
The HC125 busbar cutter from ERKO enables precise, burr-free and waste-free cutting to length of aluminium and copper busbars. With a pressure force of 190 kN and a compact design, the device is ideal for workshops and construction sites with high demands on accuracy and reliability. The cutter is operated hydraulically and is compatible with various pump solutions such as the H800 hydraulic foot pump and the AH100, AH500, AH550 and AH500L hydraulic power packs. This allows the device to be flexibly integrated into existing systems. Technical data Rail width: 30-125 mm Rail thickness: 5-12 mm Compressive force: 190 kN Operating pressure: 630 bar Dimensions (L×W×H): 310 × 240 × 475 mm Weight: 32 kg Special features: Burr-free and waste-free cutting of busbars High cutting force with compact dimensions Hydraulically operated - ideal for professional use Can be combined with various pumps and units Complementary products: HGP5010 - Cross bending device HSE100 - Processing device for slat busbars HGD125 - Bending and punching device HSK5010 - Axial bending device The HC125 is the ideal solution for the professional cutting to length of conductor rails - precise, robust and compatible with common hydraulic systems. Cutting device for hydraulic operation, for cutting aluminium and copper conductor rails:Rail width 30 ÷ 125 mmrail thickness 5 ÷ 12 mmBurr-free and waste-free cutting to lengthFor connection to hydraulic foot pump H 800 and hydraulic drive units AH 100, AH 500, AH 550 and AH 500L.Dimensions (LxWxH): 310x240x475 mmWeight: 32 kgCompressive force: 190 kNOperating pressure: 630 bar
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HGD125 - Busbar bending and punching device
HGD125 - Busbar bending and punching device
The HGD125 is a compact and powerful bending and punching tool from ERKO that has been specially designed for processing aluminium and copper busbars. It is ideal for use in the workshop and on the construction site and enables precise bends of up to 90° as well as the punching of round and oval holes.Thanks to the hydraulic actuation and a pressure force of 190 kN, the device effortlessly handles rails with a width of 30 to 125 mm and a thickness of 5 to 10 mm. The integrated length stop ensures exact positioning of the busbar during bending or punching.The HGD105 electric bending angle sensor ensures consistent angles and, in conjunction with an ERKO hydraulic unit, enables automatic switch-off when the desired angle is reached (sensor and unit available separately).Advantages at a glance:Bending and punching in one deviceProcessing of solid busbars up to 125 mm wideRound holes (Ø 6.6 - 21 mm) & oval holes (8.5 x 12 - 17 x 21 mm)Compact design and robust construction for continuous useCompatible with various hydraulic units such as AH500LAn indispensable tool for switch cabinet builders, industrial electricians and energy suppliers who value precision, repeat accuracy and efficiency. Bending and punching tool for hydraulic operation, for bending and punching aluminium and copper busbars:Rail width 30 ÷ 125 mmRail thickness 5 ÷ 10 mmBending angle up to 90 °Round holes 6.6 ÷ 21 mmOval holes 8.5 ÷ 21 mmEquipped as standard with length stop for positioning the conductor railselectric bending angle sensor (HGD 105 limit switch) guarantees the repeatability of the angle only with ERKO drive unit series AH (to be ordered separately)For connection to hydraulic foot pump H 800 and hydraulic drive units AH 100, AH 500, AH 550 and AH 500L.Dimensions (LxWxH): 370x260x585 mmWeight: 42 kgCompressive force: 190 kNOperating pressure: 630 bar
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HGP5010 Cross bender
HGP5010 Cross bender
The HGP5010 transverse bending device is the ideal solution for the precise bending of aluminium and copper busbars in a transverse position. It processes bars with a width of 20 to 50 mm and a thickness of 5 to 10 mm at a bending angle of up to 90°. Equipped with a complete bending insert including support rollers and punch, the device is ideal for professional use in switch cabinet and plant construction. The electric bending angle sensor (optional, HGD105) enables precise angle repetition - in combination with a suitable hydraulic unit. Powerful, robust and reliable - the HGP5010 can be easily connected to all standard hydraulic pumps from ERKO.
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HSE100 Slatted conductor rail machining centre HSE 100
HSE100 Slatted conductor rail machining centre HSE 100
The HSE100 laminated busbar processing device has been specially developed for punching, cutting and stripping laminated busbars made of aluminium or copper. It processes bars with a width of 30 to 100 mm and a thickness of 4 to 10 mm - ideal for professional switch cabinet or system construction.Thanks to the simple insert change and practical length stop with centring mask , precise and repeatable processing is guaranteed. The round hole diameters range from 6.6 to 21 mm. For full functionality, the limit switch and the cutting insert (HSE105)must be ordered separately.The HSE100 is compatiblewith all standard ERKO hydraulic units and foot pumps and impresses with its robust design and compact size.Processing device for punching, cutting and pre-stripping laminated busbars:Bar width 30 ÷ 100 mmBusbar thickness 4 ÷ 10 mmPunching of round holes 6.6 ÷ 21 mmSimple insertion of hole puncheseasy change of inserts for cutting and strippingLength stop and centring mask for precise cutting to lengthATTENTION: Limit switch and insert for cutting HSE105- to be ordered separatelyFor connection to hydraulic foot pump H 800 and hydraulic drive units AH 100, AH 500, AH 550 and AH 500L.Dimensions (LxWxH): 490x390x490 mm; Weight: 32.5 kg; Compressive force: 190 kNOperating pressure: 630 bar
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HSK5010 Busbar axial bending device
HSK5010 Busbar axial bending device
The HSK5010 busbar axial bending device from ERKO is ideal for the precise axial bending of aluminium and copper busbars. The integrated electrical bending angle sensor ensures reproducible results - particularly advantageous for repeated applications in switch cabinet construction or power distribution. Thanks to its compact design and the option of combining the device with standard hydraulic units from the AH series, it is ideal for use both in the workshop and on the move. A spacer sleeve for thinner rails and an adjustable width support guarantee maximum flexibility. Technical data: Rail width: 20 - 50 mm Rail thickness: 3 - 10 mm Bending angle: up to 90 Compressive force: 190 kN Operating pressure: 630 bar Dimensions (L x W x H): 720 x 300 x 190 mm Weight: 42 kg Special features: Suitable for aluminium and copper rails Integrated bending angle sensor for constant angles Spacer sleeve for rails up to 5 mm thick Adjustable width support for customised adjustment Can be combined with AH 100, AH 500, AH 550 and AH 500L hydraulic units
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SK60ALU - Hydraulic punching head 218 kN, single-acting
SK60ALU - Hydraulic punching head 218 kN, single-acting
The SK60ALU is a particularly lightweight, single-acting hydraulic punching head with 218 kN punching force, specially developed for working overhead and in confined working environments. The robust aluminium construction ensures low weight and high stability at the same time - ideal for installing electric rails or working on construction sites.It is connected to standard hydraulic pumps with 700 bar (10,000 PSI). The hole punch is suitable for punching copper and aluminium rails up to 12 mm thick. The swivelling connection with quick-release coupling makes handling considerably easier, even in difficult assembly situations.Punching range SK60ALU:CU/AL (up to 12 mm): Ø 21 mmScope of delivery:Hydraulic punching head SK60ALU, swivelling connection with quick-release couplingIdeal for mobile use in electrical system construction - fast, clean, reliable.At a glance:Extremely lightweight aluminium construction! Perfect for working overhead.For connection to hydraulic pumps with 700 bar (10,000 PSI) For punching bars (12x120 mm) made of copper and aluminium (470 N/mm²)Punching range SK60-ALU: - CU/AL up to rail thickness 12mm: D=21mm Rotatable connectionScope of delivery: - Hole punching head- Rotatable connection with quick coupling
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SK80D - Hydraulic punching head 500 kN, double-acting
SK80D - Hydraulic punching head 500 kN, double-acting
The SK80D is a particularly powerful hydraulic punching head with 500 kN punching force and double-acting hydraulics - ideal for the professional punching of round holes in metal materials up to high material thicknesses. Thanks to the double-acting design, the punch is retracted without blockage, which makes the work process significantly more efficient and safer. The tool is connected to a hydraulic pump with 700 bar (10,000 PSI) and is ideal for stationary or mobile use in steel and metal construction. At a glance:Hydraulic tool for connection to a hydraulic pump with 700 bar (10,000 PSI) Double-acting hydraulics for blockage-free extraction of the punch Scope of delivery:- Hole punching head- Punch inserts: Ø 10.5/13.5/17/5/20.5/25.5 mm (3/8"/1/2"/5/8"/3/4"/1")
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Individual tools for busbar machining - precision and flexibility for every work step

The individual tools for busbar processing from KW Hydraulik are the ideal choice for anyone who wants to process copper and aluminium busbars efficiently, precisely and safely. Whether in production, maintenance or assembly - each tool is designed for durability, precision and easy handling.

The range covers all processing steps - from cutting and bending to punching, stripping and twisting. This allows both solid and laminated busbars to be professionally adapted and connected.

Cutting tool for solid busbars

The cutting tool enables clean, burr-free cuts to be made on solid busbars. Thanks to the sturdy design and high cutting force, precise results are achieved without deforming the material. Ideal for use in workshops and production lines where precision and repeat accuracy are crucial.

Bending tool for solid rails

The bending tool for solid busbars can be used to bend copper and aluminium profiles to the exact shape required. The precise guide ensures uniform bending radii and prevents cracking. This tool is ideal for use in switch cabinet construction and power distribution.

Cross bending tool for solid rails

The transverse bending tool complements conventional bending technology with the option of forming rails transverse to the main axis. This means that even complex geometries and multi-dimensional bends can be realised efficiently - an important advantage for customised rail layouts.

Hole mould for solid busbars

The hole punching tool for solid busbars ensures precise holes with a clean hole pattern. It is suitable for material thicknesses of up to 15 mm and enables drilling diameters of up to 25 mm. The robust design guarantees a long service life and high repeat accuracy - ideal for industrial production environments.

Punching tool for laminated rails

The drilling tool for laminated busbars was specially developed for fine, flexible layers. It prevents splicing of the laminations and enables precise, centred punching with low material stress.

Stripping tool for laminated busbars

The contact surfaces of laminated busbars can be exposed quickly and precisely with the stripping tool. The tool is gentle on the material and guarantees uniform removal quality for reliable electrical connections.

Twisting tool for solid busbars

The twisting tool for solid busbars enables controlled twisting of busbar sections for precisely fitting connections of different designs. It offers high repeat accuracy and is suitable for a wide range of cross-sections and materials.

Machining stand

The processing stand forms the stable basis for manual or semi-automatic busbar processing. It ensures optimum working ergonomics, secure fixing and enables the combination of several tools in a stationary setup - ideal for precise series machining.

Advantages of the individual tools from KW Hydraulik

  • Precise machining of solid and laminated busbars

  • Robust industrial quality with a long service life

  • Can be flexibly combined with hydraulic drives

  • Ideal for production, service and reworking

  • Compatible with other solutions from the busbar machining category

The individual tools for busbar machining offer maximum flexibility and precision - for every machining scenario and every type of rail. With products from KW Hydraulik, you benefit from over 30 years of experience in hydraulic machining technology.

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