benlong 
Máquina de soldadura automática bimetálica + contacto móvil + trenza de cobre
Máquina de soldadura automática trifuncional para interruptores automáticos bimetálicos, contactos móviles y trenzado de cobre. 20-22 ppm, corte de hilo integrado, soldadura por resistencia/láser, monitorización de la energía de soldadura, rechazo automático. Baja resistencia de contacto, alta resistencia. Personalizable según las dimensiones de su componente.
High‑Precision Automatic Welding Machine for MCB Bimetallic, Moving Contact & Copper Braid
The MCB bimetallic moving contact connector (copper) automatic welding machine (a high-precision automatic assembly machine specifically designed to install the bimetallic connection (the electrical path) in miniature circuit breakers and also install the copper braid connector to create a complete functional mechanism. This machine will weld the bimetallic (moving) contacts onto the moving contact arm and create very low resistance and reliable electrical joints between the moving contact and the copper braid connector; therefore, providing the highest possible electrical performance and durability long-term.
Features include automatic delivery of copper braids, moving contacts, bimetal strips, and wire cutting are combined with inline quality inspection and welding using several different stations. The production cycle time will be 20 to 22 per minute. The welding process consists of programmable resistance welding (multi-frequency direct current) with computer controlled force and energy. An automatic (pass/fail) sortation area for rejection of defective assemblies. This machine is perfect for high volume manufacturing of MCBs; reducing the labor cost and variability associated with manual welding. The end result will be consistency in finished products.
Standard delivery: 45-60 days | Cycle time ≥20 pcs/min | Resistance or laser welding optional
What is an MCB Bimetallic, Moving Contact & Copper Braid Automatic Welding Machine?
An MCB bimetallic, moving contact, and copper braid automatic welding machine is an automated system that carries out three crucial weld tasks in one process: (1) welding a bimetal strip (thermal trip element) to the moving contact arm, (2) welding the silver-based moving contact to the arm (if not pre-assembled), and (3) welding flexible copper braid to the moving contact assembly. Together, these three welds are all part of the MCB’s main current path. Performing these three welds manually or semi-automatically is slow and can have a lot of variances. The machine automates the full sequence of events; it will feed the components, weld them either with resistance or laser, cut the copper braid to length, check the quality in-line, and sort parts between ‘good’ and ‘bad.’ The net effect is less variability in contact resistance usually (
Bimetal to moving contact, moving contact to arm, copper braid attachment – all in one cycle.
Automatic feeding, cutting to length, and positioning of copper braid before welding.
Part presence sensors, weld energy monitoring, and automated pass/fail sorting.
20‑22 pieces per minute (approx. 1,200‑1,320 units/hour).
Welding Process & Key Stations
Especificaciones técnicas
| Fuente de alimentación | 380V ±10%, 50Hz ±1Hz (three‑phase) |
|---|---|
| Total power | 30 kW (maximum) |
| Resistencia de aislamiento | ≥10 MΩ– |
| Production cycle time | ≥20 – 22 pieces per minute (approx. 1,200‑1,320 pcs/hour)– |
| Welding methods | Resistance welding (MFDC) standard; fiber laser welding optional– |
| Welding force range | 50 – 500 N (programmable, servo‑controlled)– |
| Applicable components | Bimetal strip, moving contact (silver alloy), copper braid wire (1‑6mm²)– |
| Feeding systems | Vibratory bowls for bimetal & moving contact; wire feeder + cutter for copper braid– |
| Control de calidad | Part presence sensors, weld energy/displacement monitoring, auto reject– |
| Sistema de control | PLC (Siemens/Mitsubishi) with HMI, recipe storage for 20+ product types– |
Detailed Process Flow (Operator & Machine Sequence)
The automated welding process follows these steps:
- Parameter setup – Operator sets welding parameters (force, energy, time) on the HMI per product specifications.
- Component loading The operator takes the bimetal strips and moving contacts and pours them into the vibratory feeders. Then they take the copper braid wire coils and put them into the proper rack fixture.
- Automatic wire feeding & cutting The copper braid is automatically supplied to the preset length, and then it is cut to length and loaded into the fixture by the machine itself.
- Bimetal & moving contact feeding – Vibratory bowls separate and orient components of bimetal and moving contacts, then feed them into welding nests for placement and picking.
- Part presence check – Sensors verify that all components are present before welding; missing parts trigger a reject.
- Automatic positioning & welding – The welding head will take programmed moves to reach the proper position (weld first, then weld second; together = 3 weld heads).
- Control de calidad The weld energy and displacement are compared to specified curves, and any assembly that is out of tolerance will be classified as reject.
- Sorting & unloading Qualified products are placed onto an exit conveyor or bin with no manual intervention; while rejected products are routed to a separate reject box.
Ventajas técnicas principales
Tri‑function integration saves floor space & handling
Instead of three separate machines (bimetal welding, contact welding, copper braid welding), this single station performs all three welds in one cycle – reducing work‑in‑progress and operator intervention.
Precision wire cutting & positioning
The copper braid is automatically fed, cut to exact length (±0.5mm), and presented to the welding electrode – eliminating manual cutting errors and ensuring consistent braid length for each MCB.
Real‑time weld quality monitoring
Each weld is monitored for energy, current, and displacement. Out‑of‑tolerance welds are immediately rejected, preventing defective electrical paths from reaching final assembly.
High throughput with minimal operator attention
At 20‑22 ppm, the machine replaces 4‑6 manual welding operators. One operator can load components and monitor multiple machines, drastically reducing labor cost and human variability.
Customer Success Story – High‑Volume MCB Manufacturer
A Southeast Asian manufacturer of miniature circuit breakers (MCBs) previously used separate stations to weld bimetal strips, move contacts, and connect copper braids together using manual methods. Their defects were 2.5% and could only produce 800 units per shift before the installation of our tri-function automated machine. After installing our automated welding machine, they were able to:
After 9 months, this apparatus will have recovered its cost and will also have stopped the need for customers to return due to a loose wire (braided copper).
Aplicaciones e integración
Ingeniería y entrega a medida
Request a Custom Tri‑Function Welding Machine Quote
Please provide your bimetal strip samples, the sample of your moving contact, and your copper braid samples. Our engineers will create a customized automated welding process that includes a wire-cutting device and a quality-control check as well as an ROI analysis.
WhatsApp: +86 150 5837 0007 | Correo electrónico: xsb@benlongkj.cn | Soporte en inglés y chino
Why Choose Benlong for MCB Welding Automation?
- Más de 15 años diseñando automatic welding systems for MCB components
- Proven tri‑function integration (bimetal, contact, braid) in a single cell
- In‑house wire cutting & feeder design – precise, reliable
- Real‑time weld monitoring (energy, force, displacement) with auto reject
- Soporte técnico y de repuestos a nivel mundial
La máquina personalizada típica incluye:
Features include:
– Vibratory feeders (both bimetallic and with a moving contact pain feature)
– Copper braided wire feeder/precision cutter
– Servo-controlled welding heads (2 or 3 stations)
– RF welding power supply (medium frequency direct current)
– Welding energy monitoring system
– PLC with HMI (Siemens)
– Automatic reject diverter
– Safety enclosures for equipment in use
– One (1) Year Manual Warranty.
Preguntas frecuentes
The recipes for welding parameters (Force, Energy and Time) are programmed into the machine’s memory. The fixture has quick change tooling that allows the change from one type of MCB rating to another in less than 20 minutes.
The welding head has a servo profile for soft landings, as well as using controlled energy to both melt and forge the braid onto the connect without melting the individual strands. Braid can also be attached using ultrasonic welding as an option.
Electrodes are usually good for between 50,000 and 100,000 welds, while the cutter blade used for cutting copper braid can expect to last 200,000 cuts. This machine will let you know when the parts are due for replacement by counting how many times they’ve been used.
Yes, this machine supports Industrial Ethernet communication and provides input/output (I/O) as well as Ethernet communications (Modbus TCP or Profinet) to indicate a pass or fail condition to any device downstream from it. Additionally, we can add a bar code printer so that every assembly produced has a label with a bar code.
The most widely used form of resistance welding is MFDC due to it being a solid-state bond that does not melt the braid. However, laser welding may be used in situations involving very fine braids or heat-sensitive components. Once you send in a sample; we will test it and provide you with the most appropriate recommendation.
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