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Máquina de soldadura automática para bastidor de soporte bimetálico MCB
Máquina de soldadura automática Benlong para bastidores de soporte bimetálicos de disyuntores miniatura (MCB): soldadura por resistencia de precisión para tiras bimetálicas. Precisión de ±0,05 mm, 1400-2400 piezas/hora, monitorización de energía, conforme a la norma IEC 60898-1. Ideal para el montaje de disyuntores miniatura de alto volumen con disparo térmico.
MCB Bi-metal Support Frame Automatic Welding Machine
MCB Bi-metal Support Frame automatic welding machine: The bi-metal strip, the indispensable core of the MCB thermal trip mechanism, is welded onto its support frame or carrier with sub-millimeter alignment accuracy and flawless joint strength, therefore enhancing the overload tripping performance of the miniature circuit breakers.
This includes a servo driven workpiece positioner, a programmable welding power supply (capacitive discharge or inverter DC), machine part feeder, accurate pick‑and‑place of bimetal strips, alignment against a preadjusted distance, application of specified welding energy, and finally verification of product quality by either pull‑test or monitoring welding resistance. The whole cycle is PLC‑controlled, and parameters can be entered for each different type and size of bimetal and support frame. Outputs are in the range 1200 to 2000 welds per hour and defects are usually reduced to nil.
Lead time: 30 to 45 days. Precise positioning is ensured within ±0.05mm. Thermal trip time satisfies requirements of IEC 60898‑1.
What is an MCB Bi-metal Support Frame Automatic Welding Machine?
An MCB Bi-metal Support Frame automatic welding machine. This machine joins the thermal strip to the metal support frame (or carrier); this is a very important subassembly of the thermal trip unit in miniature circuit breakers. The bimetal strip deforms when heated by the overload current, and this position, together with the integrity of the weld, determines the trip accuracy (IEC 60898‑1). This is a precision resistance welding (or capacitive discharge welding) machine that creates a consistent, low‑resistance joint without damaging the bimetal. Vision‑guided or mechanical part alignment, automatic part feeding, and in‑process quality checks (monitoring pull force or weld energy, for example) are featured, and the system is designed for 24/7 running in high‑volume MCB manufacturing plants.
Servo‑controlled axes ensure weld placement accuracy of ±0.05mm.
Capacitive discharge or inverter DC, adjustable for different bimetal thicknesses.
Vibratory bowls or tray loaders for bimetal strips and support frames.
Optional weld force or resistance measurement; rejects out‑of‑spec assemblies.
Machine Features & Welding Process
Especificaciones técnicas
| Welding type | Resistance welding (capacitive discharge or inverter DC) |
|---|---|
| Applicable bimetal strip size | Length 10-40mm, width 3-12mm, thickness 0.3-1.2mm |
| Support frame material | Copper alloy, brass, or steel (tin-plated) |
| Welding accuracy | Position repeatability ±0.05mm |
| Welding cycle time | 1.5 – 2.5 seconds per assembly (approx. 1,400-2,400 pcs/hour) |
| Welding energy / current range | 10 – 500 J (capacitive discharge) or 500 – 5,000 A (inverter DC) |
| Sistema de control | PLC (Siemens/Mitsubishi) with HMI, recipe storage for up to 20 product models |
| Sistema de alimentación | Vibratory bowl feeders (bimetal & support frame) or tray stacker |
| Quality monitoring (optional) | Weld energy monitor, resistance measurement, pull-test station after weld |
| Fuente de alimentación | 380V ±10% 50Hz | Aire comprimido 0,5-0,7MPa |
Key Advantages of Automated Bi‑metal Welding
Consistent thermal trip performance
The weld position and energy directly control bimetal deflection. Automation eliminates variation from manual welding, ensuring every MCB trips within its IEC time‑current curve.
Zero‑defect quality target
In‑process energy monitoring and optional pull‑test verification reject defective welds immediately, reducing field failures caused by loose bimetal attachments.
Cambio rápido
Recipe‑based parameters and quick‑change welding electrodes allow switching between different bimetal/frame sizes in under 15 minutes.
Higher throughput
Manual welding achieves 200‑300 assemblies per hour; this machine produces 1,400‑2,400 per hour – a 600‑800% increase.
Caso de éxito de un cliente
An MCB manufacturer in Vietnam was encountering a 3% bimetal weld failure using a manual resistance welding system resulting in thermal trip rejects at final calibration. By utilising our automatic welding machine the defect rate fell to 0.1%. The automating energy monitoring also took into account electrode wear and warned operators of impending drift before actual quality standards were reached. The increase in production varied from 800 to 2,000 welded assemblies per shift and the equipment was eventually paid for in 8 months.
The customer has since ordered three additional machines for their 2P and 4P MCB lines.
Aplicaciones e integración
Entrega y puesta en marcha estándar
Request a Custom Welding Machine Quote
Send us your strip and support frame samples together with your production goals, and we’ll advise which welding technology (capacitive discharge or inverter DC) would be best for you and provide a ROI analysis.
WhatsApp: +86 150 5837 0007 | Correo electrónico: xsb@benlongkj.cn | Soporte en inglés y chino
Why Choose Benlong for Bimetal Welding Automation?
- Más de 15 años diseñando MCB component welding machines for thermal trip assemblies
- Proven ±0.05mm positioning accuracy
- Flexible welding power supplies (capacitive discharge / inverter DC)
- In‑process energy monitoring and optional pull‑test integration
- Global installations in MCB factories across Asia, Europe, and the Americas
La máquina estándar incluye
Servodriven positioning system · welding head with programmable force · The capacitive discharge or inverter DC power supply · Vibratory bowl feeders (bimetal & frame) · PLC with HMI (Siemens) · Safety enclosure · One set of welding electrodes · Operation manual · 1year warranty.
Preguntas frecuentes
Resistance welding with capacitive discharge (CD) or inverter DC is preferred. CD welding concentrates a short high‑energy pulse minimizing heat‑affected zone so that the calibration curve of the bimetal is not altered. Inverter DC is more controllable for thicker materials. We can recommend best, given the thickness of your bimetal and the material of your frame.
The system provides feedback through a real-time energy monitoring system which compares the weld to an energy profile stored in memory. If the weld is not of the desired energy (due to for example to worn electrodes) then the machine warns the operator or automatically compensates. An optional weld resistance measurement feature adds further control to the process.
Yes. This has different current ratings, using bimetal strips of different thicknesses and widths. The machine “remembers” the welding “recipes” (position, energy, force etc.) for each product and changeover is usually less than 15 min.
Every day, clean the welding electrodes and check the compressed air supply. Every week, check the condition of the deposited electrodes and dress or replace outworn electrodes. Every month, check the weld energy against a reference shunt. The PLC in the machine also tracks the life of the electrodes and prompts the operator when it is time for a replacement.
A post‑weld pull‑test station is optional. Most customers rely on energy monitoring and destructive sampling once in a while. However, we can supply an inline pull‑test station that samples at a set rate (e.g., 1 per 500 welds) automatically.
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