Benlong 
Automatische Fertigungslinie für DC-Trennschalter
Custom DC isolating switch automatic production line for PV applications. Automates terminal assembly, rotary torque/stroke calibration, arc‑chute placement, multi‑pole stacking (2P‑8P), hi‑pot test (5kV), and MES traceability. UL/IEC compliant. 3‑4 operators per shift. Ideal for solar combiner boxes and inverters.
Fully Automatic DC Isolating Switch Production Line for PV Applications
A fully automated DC Isolating Switch production line is an advanced manufacturing system for Photovoltaic (PV) DC Disconnect Switches (2P-8P). To ensure PV Switch performance, this line meetsPV Switch product requirements for the following areas:
1. Constant contact pressure
2. Accurate shaft torque
3. Reliable arc extinguishing structure positioning
4. Insulation reliability for high voltage meets both UL and IEC requirements. The line automates all processes involved in the manufacture of PV switches, including; housing feeding, terminal assembly, main contact assembly, rotary mechanism calibration, arc chute assembly, multi-pole stacking and complete testing.
Automated systems – such as automatic housing and terminal module feeders, CCD guided copper busbar insertion, spring pressing, torque controlled screw tightening, contact pressure monitoring, knob, cam and shaft press-fitting, stroke angle detection (ON / OFF), arc extinguisher plate placement, multiple pole riveting and Hi-Pot Testing (up to 5000 volts) – all contribute to increased productivity on the line. An integrated traceability system using laser marking, Datamatrix, and MES records all test results. The line is able to achieve an extremely high throughput with only 3 to 4 operators per shift (material handler, maintenance, QC, and packaging). Products manufactured on this line are used in a variety of applications such as two, four, six, and eight pole DC isolators for Solar Combiner Boxes, inverters and battery storage systems.
Standard delivery: 90-120 days | Customizable for 2P‑8P | UL/IEC compliant testing
What is a DC Isolating Switch Automatic Production Line?
A complete automated production system that manufactures PV DC disconnect switches is known as a DC isolating switch production line (or DC isolators or load break switches). These switches are designed to assist in safely disconnecting solar arrays, inverters, and battery storage systems from each other. This production line automates the process from the assembly of the housing and terminals, the insertion of the copper busbars, the crimping of the spring, the tightening of the screws, the assembly of the contacts, the calibration of the rotary mechanisms (torque & stroke), the placement of the arc extinguishers, the stacking of the poles (2P through to 6P), and the final testing. The production line has been designed to meet the high standards demanded by the PV industry, e.g., even contact pressure to avoid arcing, knob torque being stable (ON/OFF forces comply with UL 508I or IEC 60947-3), hi-voltage insulation (hi-pot tests up to 5 kV for 1000V/1500V systems) and full traceability of components. This production line is non-standard/custome made, according to your switch type/design, current rating (16A through to 200A) and production quantities.
Copper busbar alignment, spring pressing, and torque‑controlled screw tightening with CCD verification.
Knob/cam/shaft press‑fitting, torque curve recording, and ON/OFF stroke angle detection.
Automatic feeding, insertion, and positioning of arc plates and insulating partitions with ultrasonic verification.
Automatic alignment, riveting, and CCD flatness inspection for 2P‑8P modular stacks.
Production Line Modules & Process
Technische Spezifikationen
| Supported pole configurations | 2P, 4P, 6P, 8P (modular stacking) |
|---|---|
| Switch current rating | 16A – 200A DC (customizable) |
| Hi‑pot test voltage | Up to 5,000V AC/DC, programmable, multi‑pole simultaneous |
| Torque test range | 0.5 – 10 N·m, automatic curve recording, ON/OFF force detection– |
| Stroke angle detection | 0‑180°, accuracy ±0.5°, OFF‑ON position verification– |
| Contact pressure monitoring | Load cell (10‑200N), real‑time data logging– |
| Assembly modules | Housing feeder · Terminal module feeder · Spring insertion · Copper busbar placement · Screw tightening (torque controlled) · Contact assembly · Rotary mechanism press‑fit · Arc‑chute feeder · Multi‑pole riveting · CCD inspection– |
| CCD inspection | Missing parts, assembly position, label correctness, flatness– |
| Rückverfolgbarkeit | Laser marking (model, batch, UL File No.) · DataMatrix/QR · MES integration– |
| Line personnel | 3‑4 operators per shift (material handler, maintenance, QC, packaging)– |
Technische Kernvorteile
Consistent contact pressure & torque
PV switches demand precise contact pressure to prevent arcing. The line uses servo‑controlled pressing with force monitoring and automatic screw tightening with torque feedback – eliminating manual variability.
High‑voltage insulation reliability
Every switch undergoes hi‑pot testing (up to 5kV) with automatic leakage current determination. Multi‑pole simultaneous testing ensures compliance with UL 508I or IEC 60947‑3.
Complete rotary mechanism calibration
The knob‑drive mechanism (cam, shaft, handle) is automatically assembled, press‑fitted, and tested for operating torque and stroke angle (ON/OFF position). Torque curves are recorded and must pass UL force limits.
Full MES integration for traceability
Each switch receives a laser‑marked DataMatrix code (model, batch, UL File No.). All test results (hi‑pot, torque, stroke, contact resistance) are bound to the serial number and uploaded to MES for full traceability and remote OEE monitoring.
Customer Success Story – PV Switch Manufacturer
A manufacturer of European PV combiner boxes required the automation of manufacturing for their 4P and 8P DC isolators (1000V/32A). They were experiencing field failures due to inconsistent assembly processes resulting from manual handling with the incorrect amount of torque and contact pressure applied.
Benlong’s company was able to design and provide a custom-built DC isolating switch production line with eight total workstations (terminal assembly, rotary mechanism calibration, arc‑chute assembly, multi‑pole riveting, hi-pot testing, torque/stroke measuring, laser marking and automatic packing). The results reported six months later:
The 14-month payback period for this line also aided this customer in obtaining UL 508I certification, as well as providing full traceability documentation.
Anwendungen und Integration
Kundenspezifische Entwicklung & Lieferung
Request a Custom DC Isolator Line Quote
Provide us with your drawings of the switch, the pole configuration (2p-8p), as well as the current ratings and intended output. Our engineering team will create a fully loaded line that includes terminal assembly, torque/stroke testing, hi-pot testing, and MES. Each proposal will also include a complete ROI analysis.
WhatsApp: +86 150 5837 0007 | E-Mail: xsb@benlongkj.cn | Support in Englisch und Chinesisch
Why Choose Benlong for DC Switch Automation?
- Mehr als 15 Jahre Erfahrung im Designbereich automatisierte Montagelinien for PV disconnect switches and isolators
- Proven expertise in contact pressure monitoring, torque calibration, and hi‑pot testing (5kV)
- Multi‑pole stacking (2P‑8P) with CCD flatness inspection
- Full MES integration – laser marking, DataMatrix, serial number binding, OEE monitoring
- Weltweiter Service und Ersatzteilsupport
Eine typische kundenspezifische Produktlinie umfasst:
A list of product options includes:
* housing and terminal feeders
* copper busbar insertor
* spring press module and screw tightening module
* contact assembly station
* rotary mechanism press-fit and torque test
* arc-chute feeder and inserter
* multi-pole riveting machine
* hi-pot tester – 5000V
* torque and stroke measurement station
* CCD Inspection
* laser marker
* conveyor system
* PLC-HMI
* MES Interface
* automatic pack
* installation and training
* 1 yr warranty
Häufig gestellte Fragen
This line is capable of supporting DC isolators at 2P, 4P, 6P and 8P. Changing from one configuration to another requires either changing the number of modules stacked together or reprogramming the riveting stations. This process generally takes less than one hour to complete.
Force applied to contacts during assembly in servo-controlled press stations using load cells is measured. The pressure of each switch contact is recorded and must be within a programmable range (for example: 50-80N). Any assembly that is out of acceptable range will automatically be rejected.
The Hi-Pot station can be set up to test to customer’s requirements, UL 508I, or IEC 60947-3. Test voltage is typically 3 – 5 kV AC/DC for 1000 – 1500 volt DC isolators with adjustable leakage current thresholds.
Yes. The line has OPC UA or Modbus TCP interfaces available. Test results (torque, stroke, hi-pot and contact resistance) and serial numbers are uploaded in real-time, along with example integration code for the most commonly used MES platforms.
Three or four people are all that is needed to operate an automated production line. A typical shift will require one material handler, one equipment technician, one quality inspector, and one packaging worker. This results in only three or four employees needed to operate an automated assembly line versus 15-20 employees required for a manual production line.
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