Benlong 
Prüfstand für magnetische Ringströme
Automatic magnetic ring current test bench with HIOKI tester (15‑50mA). Fully automated feeding, wire connection, test, and 10‑bin sorting (9 pass + 1 NG). 20,000 pcs/8h, OEE data, bilingual HMI. Ideal for RCCB/RCBO magnetic core grading.
High‑Speed Automatic Magnetic Ring Current Test Bench
The current test bench for this type of apparatus utilizes high-speed automatic machinery to accurately detect and classify currents through magnetic rings (often referred to as toroidal cores) that are used in current transformers, device leakage protection devices, and sensors. This apparatus can achieve efficient mass production of through the implementation of completely automated processes from the feed and arrangement of wires to the test and sort of products prior to shipping; approximately 20,000 pieces can be completed with this apparatus in one 8-hour period.
Using HIOKI’s Leakage Current Tester, this workbench is designed to reliably measure and program a 15-50mA range of current values to automatically classify a product into 10 separate classes of current (9 qualified and 1 NG bin) then sort them into the correct bin locations. This automation greatly reduces the amount of manual handling required through material separation, wire positioning, and connection. The workstation was built using high-quality materials and components: Omron PLC’s and sensors, AirTac cylinders, and Inovance motors to insure continued long-term performance. Its built-in OEE data storage system, and a simple to use HMI that operates in both Chinese and English, provides assistance to bilingual users.
Standard delivery: 30-45 days | 10‑bin intelligent sorting | HIOKI tester integrated
What is a Magnetic Ring Current Test Bench?
An automated test system is called a Magnetic Ring Current Test Bench. This test bench will measure leakage current and/or sensitivity threshold for the magnetic rings (also known as toroidal cores) in Residual Current Devices (RCDs), Current Transformers and Magnetic Sensors. The test bench will automatically feed the magnetic rings, connect test leads, apply a programmable current (15‑50mA) and measure the actual trigger current that caused the ring to be triggered. The system will sort the magnetic rings into up to 10 different current range bins (9 Pass Range + 1 Reject Bin) depending on the measured value. The purpose of this system is to ensure that only those rings with the proper current sensitivity value will be used in safety sensitive applications (such as RCCB & RCBO). There are many manufacturers producing high volume quantities of electrical component magnetic components and the use of this test bench is essential to them. In addition to our non‑standard; custom solution for the Magnetic Ring Test Bench, we can customize it to the customer’s requirements for the test current range, number of bins, and feeding system based on the customer’s ring size and production volume.
Fully automated feeding, testing, and sorting for mass production.
High‑precision current measurement, programmable 15‑50mA.
9 qualified current ranges + 1 reject bin, automatic classification.
Real‑time production monitoring, efficiency tracking, bilingual HMI.
Test Process & Key Features
Technische Spezifikationen
| Test capacity | 20,000 pieces per 8‑hour shift |
|---|---|
| Test current range | 15 – 50 mA (programmable) |
| Measurement instrument | HIOKI leakage current tester (high precision) |
| Sorting bins | 10 bins total: 9 qualified current ranges + 1 reject (NG) bin |
| Automation features | Automatic feeding, wire positioning & connection, automatic sorting |
| Steuerungssystem | Omron PLC with sensors |
| Pneumatic components | AirTac cylinders |
| Drive motors | Inovance motors |
| HMI & data | Bilingual touch screen (Chinese/English), OEE data storage system |
| Stromversorgung | 220 V ±101 TPS 3T 50 Hz | Druckluft 0,5–0,7 MPa |
Technische Kernvorteile
High throughput with minimal labor
The fully automated process (feeding, wire connection, testing, sorting) replaces 5‑8 manual operators. At 20,000 pieces per shift, the bench pays for itself within 6‑9 months in labor savings alone.
Precision HIOKI measurement
Integration with a HIOKI leakage current tester ensures measurement accuracy and repeatability. The system automatically adjusts the test current and records the exact trigger point, eliminating operator reading errors.
10‑bin intelligent sorting
Nine pass bins allow fine‑grading of magnetic rings by sensitivity (e.g., 15‑18mA, 18‑21mA, … up to 47‑50mA). Tight‑tolerance applications (e.g., 30mA RCDs) benefit from this precision classification, reducing product rejects and improving final assembly yield.
OEE & production management
The built‑in OEE data storage system tracks shift output, test pass rates, bin distribution, and equipment downtime. The bilingual HMI provides real‑time dashboards, making it easy for operators and management to monitor performance.
Customer Success Story – Magnetic Component Manufacturer
A company that manufactures Toroidal Cores for RCCB was trying to increase their testing throughput and improve the accuracy of the classification process. They had a manual test set-up that had inconsistent contact resistance and only three current bins; therefore, they were doing rework. Benlong provided them with a magnetic ring current test bench along with a HIOKI tester and ten bin sorting. The results after three months were:
A significant RCD manufacturer was able to use precise, graded magnetic rings because the bench has already made up for its purchase with a return on investment in less than seven months.
Anwendungen und Integration
Kundenspezifische Entwicklung & Lieferung
Request a Custom Magnetic Ring Test Bench Quote
We require your magnetic ring samples, target-test current range, and number of bins for your test. Our engineers will design an HIOKI-based high-speed testing bench and derive the OEE data and the complete ROI analysis for testing your magnetic rings.
WhatsApp: +86 150 5837 0007 | E-Mail: xsb@benlongkj.cn | Support in Englisch und Chinesisch
Why Choose Benlong for Magnetic Ring Test Automation?
- Mehr als 15 Jahre Erfahrung im Designbereich automated test and sorting systems for magnetic components
- Proven integration with HIOKI leakage current testers
- Up to 10‑bin classification for precision grading
- OEE data storage and bilingual HMI for production management
- Weltweiter Service und Ersatzteilsupport
Typical Custom System Includes
A vibratory bowl feeder will help you move your products from container to assembly line. You can use it along with a wire positioning / connection mechanism and a HIOKI leakage current tester. The entire system will be controlled by an Omron PLC controller. In addition to all of this, there is also: 10-bin sorting array (9-pass, 1-reject) HMI with touchscreen (bilingual) OEE data logging software safety guarding Installation and training. You receive a one-year warranty on all parts and equipment.
Häufig gestellte Fragen
Residual current devices (RCDs) use magnetic rings to detect leakage current at a specific amount (i.e. 30mA). Test benches measure the actual level of current that makes the magnetic core saturate and thus trip the circuitry of the residual current device. By sorting the rings according to sensitivity, only those that meet the necessary tolerance for use in the final product can be selected.
Certainly! The normal standard operating range of a resident current detector (RCD) is between 15-50mA (which will work for most RCD projects). However, there is the option to customize HIOKI’s testers and additional system settings for specialty magnetic components in other ranges, such as 5-30mA, 30-100mA, or from 100-300mA.
Precision pneumatic or servo actuators position the magnetic ring on the bench and automatically connect test leads to the ends of the secondary winding. This removes manual wire manipulation and provides consistent contact resistance for improved test repeatability.
All pieces tested, passed and failed by bin/piece#, average cycle time, downtime events, shift summary, data exports to a USB or ethernet connection are available in this system.
For a different ring diameter, changing the bowl feeder tooling and wire contact mechanism usually requires 15 – 20 minutes of time. The HMI allows you to quickly change test current parameters and bin assignments.
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