benlong 
Línea de producción automática de disyuntores inteligentes IoT
Custom IOT Smart MCB automatic production line with precision riveting, communication protocol validation (Wi‑Fi/Zigbee/RS485), remote switching test, and accelerated aging chamber. MES traceability, 800‑1,500 units/shift. Ideal for smart home, smart grid, and IIoT applications.
Fully Automated IOT Smart MCB Production Line
This automatic production line for IOT Smart MCB is an advanced manufacturing facility for next-generation smart miniature circuit breakers. This line was developed in collaboration with the Benyi New Energy Group and provides an integrated approach to ensuring the quality and reliability of IoT-enabled MCBs through thorough electrical testing, precision riveting, and extensive aging validation. Features include: standard magnetic trip verification, withstand voltage testing (hi-pot), communication protocol testing (Wi-Fi, Zigbee, RS485), remote switching verification, and long-term stability testing.
This completely automated production line allows for full integration of smart features into every breaker. This line will automatically assemble IoT modules, flash firmware onto the circuit breaker, and conduct final tests of functionality at the end of the line. The aging or endurance test will be performed under real-world conditions over an extended amount of time in order to identify potential problems before they leave the factory. All data collected during these tests (trip curves, communication handshaking, remote operation status, aging logs) will be stored in the Manufacturing Execution System (MES) which will allow for complete traceability of the product. The number of circuit breakers produced per shift can be expected to range from 800 to 1,500 based on the configuration of the line. These products are ideal for smart grids, smart homes, and other industrial IoT applications.
Standard delivery: 60-90 days | Integrated aging & communication test | MES ready
What is an IOT Smart MCB Automatic Production Line?
The IoT Smart Miniature Circuit Breaker (MCB) production line utilizes an integrated manufacturing process for producing MCBs with IoT functionalities such as remote monitoring, energy metering, and wireless control. Unlike traditional MCB production lines, the IoT smart MCB production line incorporates additional processes, including IoT module assembly, communication protocol testing (e.g., Wi-Fi, Zigbee, RS485, and NB-IoT), remote switching testing using cloud commands (open/close), and aging tests under simulated load and environmental conditions (temperature and humidity). In addition to standard electrical testing of MCBs (magnetic trip, hi-pot), the line performs smart tests, making it particularly well suited for manufacturers who wish to enter the smart grid, smart home, and industrial automation markets. The IoT smart MCB production line is non-standard and can be customized to your specific IoT module design, communication protocol, and production quantity.
Automated mechanical and electrical connection of IoT modules to MCB.
Magnetic trip, hi‑pot, contact resistance – all per IEC 60898‑1.
Verifies handshake, data exchange, and remote switching commands.
Simulates months of field operation under load to catch early failures.
Production Line Features & IoT Test Process
Especificaciones técnicas
| Supported IoT protocols | Wi‑Fi, Zigbee, RS485, NB‑IoT (customizable) |
|---|---|
| Assembly modules | Precision riveting, IoT module placement, firmware flashing |
| Standard electrical tests | Magnetic trip (5‑10× In), hi‑pot (up to 4kV), contact resistance |
| Communication protocol test | Handshake validation, data transmission, command response time |
| Remote switching test | Simulated cloud command, open/close verification, response time logging |
| Aging test | Multi‑station chamber, programmable voltage/current cycles, real‑time monitoring |
| Rendimiento de producción | 800‑1,500 units per shift (depending on IoT module complexity) |
| trazabilidad de datos | Barcode scanning, test data linked to serial number, MES upload via OPC UA |
| Sistema de control | PLC (Siemens/Mitsubishi) with HMI, recipe storage, remote diagnostic access |
| Fuente de alimentación | 380V ±10% 50Hz | Aire comprimido 0,5-0,7MPa |
Ventajas técnicas principales
Seamless integration of IoT module assembly
The line automatically places and solders IoT communication modules onto the MCB PCBA, ensuring reliable electrical connections and mechanical fit – eliminating manual handling errors that could compromise wireless performance.
Comprehensive communication & remote switching test
A dedicated test station simulates a real IoT cloud platform: it sends pairing requests, reads energy data, and executes remote open/close commands. Response time and success rate are logged for each unit, guaranteeing smart functionality before delivery.
Accelerated aging under real‑world load
The integrated aging test bench applies rated current and voltage while cycling communication commands for up to 72 hours. This uncovers early failures in electronic components (e.g., power supply, wireless module) that standard tests would miss.
Full traceability for IoT firmware version control
Each MCB’s firmware version, test results (trip time, hi‑pot leakage, communication success rate), and aging data are linked to its serial number. This is essential for field troubleshooting and over‑the‑air (OTA) update planning.
Customer Success Story – Benyi New Energy Group
Benyi New Energy Group was in search of a production line that produced their latest series of IOT Smart MCBs. The new line required thorough verification of the electrical protection and the internet-capability features such as Wi-Fi control of the MCB and measurement of electrical consumption. Benlong provided Benyi with a fully automated IOT Smart MCB production line with integrated precision riveting, an extensive electrical operation test station, and an accelerated life test stand.
After 3 months of operation:
Through the development of the production line, Benyi was able to cut its manual testing activity by 75% as part of achieving full traceability for IEC 60898‑1 and IoT certification.
Aplicaciones e integración
Ingeniería y entrega a medida
Request a Custom IOT Smart MCB Production Line Quote
Please provide your IoT MCB specs, comms protocol and output. Our engineers will design a custom line including precision assembly, comms validation, remote switch test and aging bench including full ROI calculation and analysis.
WhatsApp: +86 150 5837 0007 | Correo electrónico: xsb@benlongkj.cn | Soporte en inglés y chino
Why Choose Benlong for IoT Breaker Automation?
- Más de 15 años diseñando smart MCB assembly and test lines for IoT applications
- Proven integration of communication protocol testers (Wi‑Fi, Zigbee, RS485)
- Comprehensive aging test bench with real‑time monitoring of electrical and IoT performance
- Full MES traceability – firmware version, test data, aging logs
- Soporte técnico y de repuestos a nivel mundial
La línea personalizada típica incluye:
· Riveting station for accuracy
· Module placement operators for IoT and soldering
· Magnetic trip tester/hipot tester
· Communication Protocol Testers Wi-Fi / Zigbee / Rs485
· Remote power switching test station
· Multiple zones for Aging Tests
· Laser marking equipment
· Complex conveyor system
· Programmable logic controller with HMI (Siemens)
· MES Interface (OPC UA)
· Safeguards/Safety guarding equipment
· Installation & Training
· 1 Year Warranty
Preguntas frecuentes
Each device from this line is equipped with built-in support for Wi-Fi (802-11b/g/n), Zigbee, Modbus, and NB-IoT. For customers who wish to integrate additional protocols (LoRa, Thread, Matter, etc.), we can offer a Custom Integration service.
An emulator of a cloud-based system is a testing station. This testing station sends a closed/open command to the actual communication protocol and waits for confirmation from the MCB that the transaction has taken place. Once the confirmation has been received, the testing station will document the time of response and whether or not the transaction was successful.
The MCB is continually cycled through communication commands (for example, every ten minutes) while supplying a rated current and voltage. The amount of time that has elapsed since the last command was sent can be set to vary between 24 and 72 hours. Performance of the MCB with respect to electrical and communication performance will be measured, and failures will be recorded.
The test stations and assembly fixtures have been set up to allow for rapid exchange of tools. There are recipe-based settings that can be used to change from one rating to another in 20 minutes or less.
Yes, This line delivers OPC UA, Modbus TCP, and REST API protocols for connection. The ability to send test results, communication logs, and aging data from this line to your MES or Cloud IoT system; therefore providing them with data for real time analytics.
Productos relacionados
Línea de producción automática de contadores monofásicos
Ver detalles
Línea de producción automática de interruptores automáticos neumáticos (ACB).
Ver detalles
Línea de producción automática de cargadores de CC
Ver detalles
Línea de producción automática de MCCB
Ver detalles
Línea de producción automática de contadores eléctricos trifásicos
Ver detalles
