21Design and Simulation Study on Busduct System in the Prediction of Temperature Variation Using CFD

Abstract

Busduct systems are key components in industrial and commercial power distribution, but their thermal performance often limits reliability and safety. Excessive heating in busducts due to high currents, poor ventilation, and suboptimal materials can lead to failures. This paper presents a 3D CFD model to predict temperature variation in busducts under different operating and design scenarios. Variants such as material selection, airflow (forced/free), vent geometry, and insulation are simulated. The study also applies TRIZ (Theory of Inventive Problem Solving) methods to guide design improvements. Results reveal critical hotspots, temperature gradients, and the influence of copper and aluminium busbars under air velocities of 10 m/s and 20 m/s. Forced convection significantly reduces peak temperatures, while copper shows superior thermal performance.The work can help in optimizing busduct design for better energy efficiency, safety, and lifetime.

Introduction

Busduct (busbar trunking) systems are widely used in large buildings and industrial plants for efficient high-current power distribution, but excessive heating caused by ohmic losses, eddy currents, and inadequate convection can degrade insulation, reduce efficiency, and pose fire risks. To address these issues, Computational Fluid Dynamics (CFD) is an effective tool for analyzing airflow and heat transfer, enabling the identification of hotspots and thermal weaknesses without extensive physical testing.

This study focuses on developing a 3D CFD model of a busduct section to predict temperature distribution under steady and transient loading conditions. The research evaluates the impact of design parameters such as ventilation (natural and forced convection), conductor materials (copper and aluminium), geometry, spacing, and insulation. Additionally, the TRIZ (Theory of Inventive Problem Solving) methodology is integrated to systematically propose innovative design solutions for reducing thermal issues.

A detailed CFD methodology is implemented using ANSYS Fluent, including refined meshing near conductors, appropriate thermal and flow boundary conditions, and Joule heating based on current load. Multiple simulation cases compare copper and aluminium busbars under varying airflow velocities and operating temperatures. Key outputs include temperature distribution and maximum steady-state temperatures.

The literature review confirms that conductor material, geometry, clearances, and ventilation significantly influence busduct thermal performance. By combining CFD analysis with TRIZ-based design thinking, the study aims to identify effective strategies—such as improved ventilation, optimized busbar geometry, selective material use, and composite structures—to minimize hotspots, enhance thermal performance, and improve the safety and reliability of busduct systems.

Conclusion

CFD simulation has demonstrated strong effectiveness in predicting temperature variation in busduct systems and identifying thermal hotspots critical to system performance. The analysis shows that design variables such as material selection, ventilation characteristics, conductor geometry, and insulation significantly influence maximum temperature and overall thermal distribution. These insights provide a scientific basis for improving thermal management and enhancing operational reliability. The integration of TRIZ methodology further strengthens the design process by offering a systematic approach to identifying contradictions and generating innovative solutions. Through TRIZ, design enhancements such as segmented busbars, optimized spacing, and selective material use can be conceptualized to effectively address thermal limitations. Overall, combining CFD analysis with TRIZ-driven design innovation yields a more robust, efficient, and thermally optimized busduct system suitable for modern electrical infrastructure demands.

References

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Copyright

Copyright © 2026 Manivel N. K., Melavasal Pandian D., Merunkumar A., Mohammed Salman R., Thirumurugaveerakumar S.. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.