Electrical busbars are predominantly rectangular rather than circular for several practical and performance-related reasons:
Manufacturing and Assembly
Rectangular busbars are comparatively easier to fabricate as well as to incorporate in the power system than circular busbars.
The flat rectangular busbar has smooth surfaces, which makes it possible to cut, bend and join it with ease as is required in industries.
Surface Area for Cooling
The shape is all rectangular and this makes it bigger and hence has a large surface area for heat dissipation.
This is especially important because busbars usually conduct high currents and, therefore, proper cooling is required to avoid excessive temperature and increase on the current-carrying capability.
Electrical Resistance
This is because when one wants to compare two busbars then the shape will determine the resistance between the two busbars.
Compared with circular ones but holding the same volume, rectangular busbars furthermore resist less, improving the efficiency of power supply.
This characteristic is particularly important in high demand power applications, where even slight change in resistance value may produce considerable amounts of energy dissipation.
Current Carrying Capacity
Compared to the circular shaped busbars, the rectangular ones are capable of transmitting more current without attaining the same level of temperature.
This makes them more appropriate for applications where they need to convey large currents such as in sub stations, and other industrial power control systems.
Space Efficiency
Rectangular busbars can be positioned in a rather more compact manner in comparison with circular ones in many installations, so the use of panel space of electrical apparatus and switchgear is more effective.
Conclusion
In summary, the method of arrangement of busbars is rectangular this makes manufacturing easier, has better thermal conductivity, has lower electrical resistance, and higher carrying capacity thus making them the best in electrical systems.