benlong 
آلة إدخال التلامس الأوتوماتيكية لموصل التيار المتردد
Automatic AC contactor contact insertion machine for main and auxiliary contacts. Multi‑station rotary table, vibratory feeding, servo insertion (±0.05mm), vision and force monitoring. 1.5‑3 sec/contact. Quick changeover, MES ready. Ideal for high‑volume contactor assembly.
High‑Precision Automatic Contact Insertion Machine for AC Contactor Assembly
Our system uses a rotary indexing table or linear transfer system and has several stations including: vibratory bowl feeders to feed and prepare contacts and holders for insertion, servo driven grippers with force control, a machine vision system for verifying the position of the parts prior to insertion, and an optional insertion force monitor. This system can handle all types of contacts (main & auxiliary) as well as holders with different geometries. Typical cycle times are between 1.5 seconds to 3.0 seconds for each contact inserted into the appropriate holder, with insertion position repeatability of ±0.05mm. These machines are able to interface to the equipment used for winding coils, assembling cores, and electrically testing parts. As this is a custom (non-standard) solution, the solution provided is based on your specific contact dimensions, holder designs, and your anticipated production volume.
Standard delivery: 30-45 days | Vision & force monitoring options | Multi‑station rotary table
What is an AC Contactor Automatic Contact Insertion Machine?
The automatic contact insertion machine is an advanced type of automated workstation for inserting main (cop-per tipped) and auxiliary contacts into the plastic contact holder of An AC contactor. It is important to accurately align and seat each contact with respect to each other because the placement and depth of the inserted contacts will affect both the unit’s overall electrical performance and its mechanical life. The complete pro-cess is automated using this machine through bulk vibrating feeds to feed in contact holders and contacts, determine their orientations, pick contacts from holders using a servo driven gripper, insert contacts into specified cavities using controlled force, and verify that inserted contacts are seated properly using vision or force monitoring. Any defective assemblies are rejected by the machine. The design of this machine is typically a rotary indexed machine with a table design using four to 16 stations or an inline transfer system. Both types of machines allow us to integrate additional steps within the process such as inserting the contact springs, assembling the coil and attaching the arc chutes. Since this is a custom non-standard solution, we will adapt the machine to meet your product specifications based on the electrical power contactors you have (3 main + 2 auxiliary), the number of contacts required per contactor and the number of units you need per day.
Simultaneous feeding, insertion, and inspection for high throughput.
Automatic orientation and delivery of contacts and holders.
Programmable force and depth; ±0.05mm positioning accuracy.
Detects missing, tilted, or improperly seated contacts in real time.
Key Features & Assembly Process
المواصفات الفنية
| Insertion type | Main contacts (e.g., 3‑pole) and auxiliary contacts (e.g., 1NO+1NC) | |
|---|---|---|
| Contact types | Silver‑copper or silver‑alloy contacts, various geometries (flat, domed)– | |
| Holder materials | Thermoplastic (PA66, PBT) or thermoset– | |
| نظام التغذية | Two or more vibratory bowls (contacts + holders); tape feeder optional– | |
| Insertion accuracy | Position repeatability ±0.05mm, depth control ±0.1mm– | |
| Insertion force range | 5 – 100 N (servo‑controlled, programmable)– | |
| Cycle time | 1.5 – 3.0 seconds per contact (depending on number of stations)– | |
| Vision inspection | 2D camera for contact presence, orientation, and seating depth check– | |
| Force monitoring (optional) | Load cell records insertion force curve; auto‑reject on deviation– | |
| نظام التحكم | PLC (Siemens/Mitsubishi) with HMI, recipe storage– |
المزايا التقنية الأساسية
Multi‑station integration eliminates handling errors
The rotary indexing table allows feeding, insertion, vision check, and reject sorting in one compact footprint. Contacts are never touched by human hands, eliminating contamination and misalignment.
Real‑time vision verification
A high‑resolution camera checks that each contact is correctly oriented, fully seated, and not tilted before the part advances. Rejected assemblies are automatically diverted without stopping the machine.
Servo‑controlled insertion with force feedback
The servo gripper applies a programmable force and insertion depth. Optional load cell monitoring captures the force‑displacement curve; if the curve deviates (e.g., missing holder, oversized contact), the part is rejected.
Rapid changeover for multiple contactor models
Quick‑change tooling (feeder bowls, gripper jaws, nests) and recipe‑based parameters allow changeover between different contactor ratings in under 20 minutes.
Customer Success Story – AC Contactor Manufacturer
A global manufacturer of AC contactors was experiencing 2.5 percent failures in the field because of improperly inserted main and auxiliary contacts (loose or tilted) that were inserted manually. By using our automatic machine with vision and force monitoring—they were able to achieve:
After 10 months, the equipment had returned its investment through increased production and eliminated problems from the consumer regarding alignment of contacts.
التطبيقات والتكامل
الهندسة والتسليم حسب الطلب
Request a Custom Contact Insertion Machine Quote
Provide us with the contact and holder samples and specify the expected production volume for your project. Our engineering team will develop a custom multi-station insertion system with vision environmental features, along with a complete ROI analysis.
واتساب: +86 150 5837 0007 | البريد الإلكتروني: xsb@benlongkj.cn | دعم باللغتين الإنجليزية والصينية
لماذا تختار شركة Benlong لأتمتة تجميع الموصلات؟
- أكثر من 15 عامًا في مجال التصميم contact insertion machines for AC/DC contactors and relays
- Proven multi‑station rotary indexing technology
- In‑house vision and force monitoring integration
- Quick‑change tooling for multiple contactor models
- خدمة عالمية ودعم قطع الغيار
تتضمن الآلة المخصصة النموذجية ما يلي
Vibratory bowl feeders (with holders and contacts) – Rotary indexing table with 4-16 stations – Servo gripper using force sensor – Vision camera system – PLC with HMI (Siemens) – Reject diverter – Safety cage – Rapidly change tooling – Operations manual – 1 year warranty.
الأسئلة الشائعة
Both main contact devices (larger one often three-pole) and auxiliary contact devices (smaller one, usually one or two-pole) can be used together or in sequence on this machine. Each type of contact geometry has its own dedicated feeding bowl and gripper manufacturing specification.
Parts that are properly oriented will come out of the vibratory bowls via tool orientation rails. Prior to inserting a part into the machine, the vision system will evaluate whether or not the part is oriented correctly and reject any that are either upside down or incorrectly aligned within the machine.
As part of the process, each station has sensors that will identify whether there is a holder available to insert. If no holder is at the insertion station, it will be skipped, and the operator will be notified of the missing base through the flagging of an empty station.
Certainly! The rotary table can be enlarged, or the conveyor interface can be modified so that finished contactors can be passed to the next module. In addition, we will support Data, and/or I/O handshakes between modules using Ethernet/IP or Modbus TCP.
Usually, with suitable pre-curved tools (feed bowls, grippers, and nests) and standardised programme parameters to follow, the process of changing tools takes between 15 and 20 minutes. We can help you by providing changeover kits which are available for purchase as complete kit with separate box and can be changed out in five minutes or less from your previous design.
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