{"id":89,"date":"2026-06-01T10:38:15","date_gmt":"2026-06-01T10:38:15","guid":{"rendered":"https:\/\/khkrh7q1ur.wpdns.site\/product\/ac-contactor-automatic-contact-insertion-machine\/"},"modified":"2026-06-09T03:46:40","modified_gmt":"2026-06-09T03:46:40","slug":"ac-contactor-automatic-contact-insertion-machine-product","status":"publish","type":"product","link":"https:\/\/benlongkj.com\/de\/produkt\/ac-contactor-automatic-contact-insertion-machine-product\/","title":{"rendered":"Automatische Kontakteinsetzmaschine f\u00fcr Wechselstromsch\u00fctze"},"content":{"rendered":"
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Multi\u2011station \u00b7 Vision & force monitoring<\/div>\n

High\u2011Precision Automatic Contact Insertion Machine for AC Contactor Assembly<\/h1>\n

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 \u00b10.05mm. 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.<\/p>\n

Standard delivery: 30-45 days | Vision & force monitoring options | Multi\u2011station rotary table<\/span><\/p>\n<\/p><\/div>\n

\n \"Automatische<\/p>\n
Contact insertion module (actual product)<\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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What is an AC Contactor Automatic Contact Insertion Machine?<\/h2>\n

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.<\/p>\n

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\n Multi\u2011station rotary table<\/strong>
\n Simultaneous feeding, insertion, and inspection for high throughput.\n <\/div>\n
\n Vibratory bowl feeding<\/strong>
\n Automatic orientation and delivery of contacts and holders.\n <\/div>\n
\n Servo\u2011driven insertion<\/strong>
\n Programmable force and depth; \u00b10.05mm positioning accuracy.\n <\/div>\n
\n Vision & force monitoring<\/strong>
\n Detects missing, tilted, or improperly seated contacts in real time.\n <\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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Key Features & Assembly Process<\/h2>\n
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\n \"Informationstransparenz<\/p>\n
Intelligenz und Transparenz<\/div>\n<\/p><\/div>\n
\n \"Effizienz<\/p>\n
Effizienz und Nachhaltigkeit<\/div>\n<\/p><\/div>\n
\n \"Designintegration<\/p>\n
Design & Integration<\/div>\n<\/p><\/div>\n
\n \"Sicherheit<\/p>\n
Sicherheit und Zuverl\u00e4ssigkeit<\/div>\n<\/p><\/div>\n<\/p><\/div>\n<\/p><\/div>\n

Technische Spezifikationen<\/h2>\n
High\u2011speed automatic insertion of main\/auxiliary contacts into AC contactor holders. Multi\u2011station rotary design, vision and force monitoring, reject sorting.<\/div>\n
\n\n\n\n\n\n\n\n\n\n\n\n\n
Insertion type<\/th>\nMain contacts (e.g., 3\u2011pole) and auxiliary contacts (e.g., 1NO+1NC)<\/td>\n<\/tr>\n
Contact types<\/th>\nSilver\u2011copper or silver\u2011alloy contacts, various geometries (flat, domed)–\n <\/td>\n<\/tr>\n
Holder materials<\/th>\nThermoplastic (PA66, PBT) or thermoset–\n <\/td>\n<\/tr>\n
F\u00fctterungssystem<\/th>\nTwo or more vibratory bowls (contacts + holders); tape feeder optional–\n <\/td>\n<\/tr>\n
Insertion accuracy<\/th>\nPosition repeatability \u00b10.05mm, depth control \u00b10.1mm–\n <\/td>\n<\/tr>\n
<\/td>\nInsertion force range<\/th>\n5 \u2013 100 N (servo\u2011controlled, programmable)–\n <\/td>\n<\/tr>\n
<\/td>\nCycle time<\/th>\n1.5 \u2013 3.0 seconds per contact (depending on number of stations)–\n <\/td>\n<\/tr>\n
Vision inspection<\/th>\n2D camera for contact presence, orientation, and seating depth check–\n <\/td>\n<\/tr>\n
Force monitoring (optional)<\/th>\nLoad cell records insertion force curve; auto\u2011reject on deviation–\n <\/td>\n<\/tr>\n
Steuerungssystem<\/th>\nPLC (Siemens\/Mitsubishi) with HMI, recipe storage–\n <\/td>\n<\/tr>\n<\/tbody>\n<\/table><\/div>\n

Technische Kernvorteile<\/h2>\n
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Multi\u2011station integration eliminates handling errors<\/h4>\n

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.\n <\/p><\/div>\n

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Real\u2011time vision verification<\/h4>\n

A high\u2011resolution 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.\n <\/p><\/div>\n

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Servo\u2011controlled insertion with force feedback<\/h4>\n

The servo gripper applies a programmable force and insertion depth. Optional load cell monitoring captures the force\u2011displacement curve; if the curve deviates (e.g., missing holder, oversized contact), the part is rejected.\n <\/p><\/div>\n

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Rapid changeover for multiple contactor models<\/h4>\n<\/div>\n

Quick\u2011change tooling (feeder bowls, gripper jaws, nests) and recipe\u2011based parameters allow changeover between different contactor ratings in under 20 minutes.\n <\/p><\/div>\n<\/p><\/div>\n

<\/p>\n

\n Von Branchenf\u00fchrern gesch\u00e4tzt<\/span><\/p>\n
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\n \"ABB\"\n <\/div>\n
\n \"DELIXI\"\n <\/div>\n
\n \"EKF\"\n <\/div>\n
\n \"KRIPAL\"\n <\/div>\n
\n \"HPL\"\n <\/div>\n
\n \"CHAC\"\n <\/div>\n
\n \"Schneider\"\n <\/div>\n
\n \"IEK-GRUPPE\"\n <\/div>\n
\n \"SUNIR\"\n <\/div>\n
\n \"Bevone\"\n <\/div>\n
\n \"Weg\"\n <\/div>\n
\n \"HUYU\"\n <\/div>\n
\n \"RAAD\"\n <\/div>\n
\n \"WALTONE\"\n <\/div>\n
\n \"Havells\"\n <\/div>\n
\n \"C&S\n <\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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Customer Success Story \u2013 AC Contactor Manufacturer<\/h3>\n

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\u2014they were able to achieve:<\/p>\n

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2,800 units\/shift<\/strong> Throughput (manual was 800)<\/div>\n
0.1%<\/strong> Field failure rate (down from 2.5%)<\/div>\n
-80%<\/strong> Direct labor cost for insertion<\/div>\n<\/p><\/div>\n

After 10 months, the equipment had returned its investment through increased production and eliminated problems from the consumer regarding alignment of contacts.<\/p>\n<\/p><\/div>\n

Anwendungen und Integration<\/h2>\n
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AC contactor assembly lines<\/strong> \u2013 Upstream of coil winding and electrical testing<\/div>\n
Low\u2011voltage electrical component manufacturing<\/strong> \u2013 DC contactors, relays, switchgear<\/div>\n
High\u2011volume OEM production<\/strong> \u2013 Multiple contactor models with quick changeover<\/div>\n
Replacement of manual insertion cells<\/strong> \u2013 Improve consistency and reduce labor<\/div>\n<\/p><\/div>\n<\/p><\/div>\n

Kundenspezifische Entwicklung & Lieferung<\/h2>\n
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1. Sample evaluation<\/strong> 10-15 days \u00b7 contacts & holder samples required<\/div>\n
2. Feeder & tooling design<\/strong> 15-25 days \u00b7 vibratory bowls, grippers, nests<\/div>\n
3. Fertigung<\/strong> 30-45 Tage<\/div>\n
4. Pre\u2011FAT<\/strong> Im Werk Benlong<\/div>\n
5. Installation und Schulung<\/strong> On-site 5\u20117 days<\/div>\n
6. Abschlie\u00dfender SAT<\/strong> 3\u20115 days \u00b7 acceptance report<\/div>\n<\/p><\/div>\n
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Request a Custom Contact Insertion Machine Quote<\/h2>\n

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.<\/p>\n

Jetzt anfragen<\/a><\/p>\n

WhatsApp: +86 150 5837 0007 | E-Mail: xsb@benlongkj.cn | Support in Englisch und Chinesisch<\/p>\n<\/p><\/div>\n

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Warum Benlong f\u00fcr die Automatisierung der Sch\u00fctzmontage w\u00e4hlen?<\/h3>\n