Benlong 
MCB-Magnetkern-Automatikmontagemaschine
Automatic MCB magnetic iron core assembly machine for bobbin and pin insertion. Servo‑controlled pressing, force‑depth monitoring (±0.05mm), vibratory feeding. 1.5‑2.5 sec/unit, quick changeover. Reduces defect rates, ideal for high‑volume MCB magnetic trip production.
Automatic MCB Magnetic Iron Core Assembly Machine
The MCB Core Completion Machine is a precision-built, automated system used to manufacture the exact assembly of magnetic core parts utilized by miniature circuit breakers (MCBs). The machine’s ability to accurately position the plastic bobbin within the robotic tooling and accurately drive the metal pins (magnetic cores / iron cores) into position at consistent forces and alignment provides for high-speed operation, stable performance, and minimal manual intervention, resulting in repeatable assembly quality for production runs of large volumes. The MCB Core Completion Machine reduces costs associated with labor, provides a greater level of accuracy when assembling, and enhances reliability for the manufacture of MCB Magnetically Tripped Modules.
The machine has several key functions including automatic plastic bobbin and metal pin feeding via vibratory bowl or tray stackers, servo-controlled pressing with force/position monitors and Integrated part presence verification. It will accommodate multiple-sized bobbins, as well as pin lengths, by using a quick-change tooling method and recipe driven parameter adjustments. In terms of machine processing, the machine is typically used for assembly of magnetic yokes, coil bobbins, and armature pins for MCB magnetic trip units. Since this machine is not a standard commercial unit, we will customize it to meet your specifications regarding component geometry and production volume.
Standard delivery: 30-45 days | Force accuracy ±5% | Quick‑change tooling
What is an MCB Magnetic Iron Core Automatic Assembly Machine?
The Automatic Assembly Machine for The MCB Magnetic Iron Core is an Automated system designed to assemble the magnetic core components (iron core) of the miniature circuit breaker type magnetic trip unit. The full assembly of the magnetic trip unit consists of a plastic bobbin (coil former), a metal pin (iron core/magnetic core), and a possible spring. During assembly, the pin must be aligned with the bobbin in such a manner that it has precise alignment, controlled force, and the appropriate depth of insertion. If the pin is not inserted correctly, the Magnetic Francis & trip response will be affected. The MCB Magnetic Iron Core Automatic Assembly Machine automatically feeds, orients, places, and press fits each component, assuring the same insertion force and depth is used in each location. This is an essential part of mass-producing MCBs due to the high level of defects associated with manual assembly, and the inconsistency in MCB trip response caused by the variations associated with manual assembly. The MCB Magnetic Iron Core Automatic Assembly is a non-standard custom solution that is modified to accommodate your specific bobbin geometry, pin size, and production volume requirements.
Vibratory bowls or tray stackers for bobbins and metal pins.
Programmable force and depth, real‑time monitoring, ±5% accuracy.
Sensors detect missing bobbins or pins before insertion.
Rapid changeover between different bobbin/pin sizes (under 20 minutes).
Assembly Process & Key Features
Technische Spezifikationen
| Assembled components | Plastic bobbin (coil former) + metal pin (magnetic core / iron core) + optional spring | |
|---|---|---|
| Bobbin types | Various sizes for MCB magnetic trip units (custom fixture per bobbin design) | |
| Pin length range | 5 – 25 mm (customizable) | |
| Insertion force range | 10 – 200 N (servo‑controlled, programmable, accuracy ±5%) | |
| Insertion depth accuracy | ±0.05mm | |
| Fütterungssystem | Vibratory bowls (bobbin + pin) or magazine/tray stacker | |
| Montagezykluszeit | 1.5 – 2.5 seconds per unit | |
| Qualitätsüberwachung | Force‑displacement curve, part presence sensors, optional vision check | |
| Steuerungssystem | SPS (Siemens/Mitsubishi) mit HMI, Rezeptspeicher für über 20 Produktmodelle | |
| Strom- und Luftversorgung | 380 V ±101 TPS 3T 50 Hz | Druckluft 0,5–0,7 MPa |
Technische Kernvorteile
Eliminates manual insertion inconsistency
Manual assembly of magnetic pins often results in tilted or under‑inserted pins, leading to weak magnetic flux and inconsistent trip performance. Servo‑controlled pressing ensures perfect alignment and depth every cycle.
Force‑displacement monitoring
The system records the force vs. displacement curve for each insertion. If the force deviates from the stored profile (e.g., missing bobbin, oversized pin, or debris), the machine rejects the part and triggers an alarm.
Quick changeover for multiple MCB ratings
Different MCB current ratings use different bobbin and pin sizes. Quick‑change tooling and recipe‑based parameters allow changeover between product families in under 20 minutes.
Full traceability
Each assembled magnetic core can be linked to its production data (insertion force, depth, cycle time) via barcode integration – essential for quality audits and process improvement.
Customer Success Story – MCB Manufacturer
One of the top manufacturers of MCBs was putting in magnets with a manual method on a bobbin at a rate of 800 bobbins per shift. They had a defect rate of 2% (pinned wrong or none). Once they installed our Automatic MCB Magnetic Assembly Machine, they achieved:
Customer Returns have been eliminated due to the fact that the machine had paid for itself in 8 months by eliminating the number of customer returns related to magnetic trip malfunctions.
Anwendungen und Integration
Kundenspezifische Entwicklung & Lieferung
Request a Custom MCB Magnetic Core Assembly Quote
Please send in samples of your bobbins and pins, as well as the target quantities for production so that we can create a custom assembly machine with servo press control, force monitoring and fast-change tooling. We will also provide a comprehensive return on investment (ROI) on your assembly machine system.
WhatsApp: +86 150 5837 0007 | E-Mail: xsb@benlongkj.cn | Support in Englisch und Chinesisch
Why Choose Benlong for Magnetic Component Assembly?
- Mehr als 15 Jahre Erfahrung im Designbereich automated assembly machines for MCB magnetic components
- Proven servo pressing with force‑displacement monitoring (±5% force accuracy, ±0.05mm depth)
- In‑house feeder and tooling design – fast, custom solutions
- Quick‑change tooling for multiple bobbin/pin sizes
- Weltweiter Service und Ersatzteilsupport
Eine typische Sondermaschine umfasst:
Vibratory bowl feeders (bobbins) Vibratory bowls or pin feeder Servo press unit with a load cell Part presence sensors PLC with HMI (Siemens) or a safety enclosure Quick change tooling system Reject bin Operating manual with one year warranty.
Häufig gestellte Fragen
In the magnetic trip unit, the steel/iron pin (the core) is located at the center of the coil. The magnetic field will act on the core when a short-circuit current flows through the coil; the resulting force will cause the core to move and strike the trip lever. When the trip lever is struck, it opens the contacts. For an instantaneous trip response, the core must be placed correctly and aligned with the trip lever.
A programmable limit for the starting point of the servo printer is utilized. The system measures the height of the final pin compared to the bobbin after installing it; if there is a variation greater than ±0.05mm from the intended installation height, the press will reject the assembled Finn. If additional pins need to be processed, cameras may be used to confirm that the pin is flush with the surface of an adjacent component.
Yes. The configuration is adjustable so that the spring is either assembled to pin before inserting or into a bobbin, then inserted. In addition feeding or placing stations can be added.
Typically, 15 to 20 minutes are required for changing tooling using quick change tooling such as feeders, insertion tool, or nests. Recipe parameters such as force, depth and speed can be automatically changed through the HMI in less than 1 minute.
Of course. The insertion force, insert depth, cycle time, and pass/fail results can all be recorded for every cycle. The data can be downloaded via USB or transferred to the MES using OPC UA or Modbus TCP.
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