IEC 60947‑2 · Full‑process automation

خط تولید اتوماتیک MCCB
30 sec/pc | 100A‑1600A frames

An assembly and testing line that works automatically for molded case circuit breakers where a number of different steps will take place, including the following processes: Riveting, Torque Calibration, Calibration of ETU Digitally, Hi-Potential Testing, and MES Traceability. Created to operate in a large quantity of products being created.

30s
Test efficiency
100‑1600A
Frame support
99.5%
بازده عبور اول
100%
MES traceability
Core advantages

Why a fully automatic MCCB production line?

A fully automated production line for medium- to-large-size MCCB manufacturing eliminates manual bottlenecks and ensures consistent mechanical assembly. Additionally, each electrical assembly is traced back to an exact test conducted according to IEC 60947-2.

Full‑process automation
No manual handoff between stations – from case loading to ETU calibration. Reduces labor dependency by up to 70%.
Servo‑driven precision
Servo-controlled actuators for arc chute alignment and contact assembly – critical for consistent breaking capacity.
ETU digital calibration
Automated calibration of electronic trip units (L‑S‑I‑G curves) with Modbus communication verification.
MES traceability
Torque values, riveting forces, trip curves, and hi‑pot results linked to each unit’s serial number.
Field results

Real impact from automatic MCCB lines

Global MCCB manufacturer
Replaced semi‑auto line with our fully automatic line for 225A‑630A frames. Test efficiency improved from 90 to 30 sec/pc. First‑pass yield increased from 94% to 99.5%.
European OEM
Integrated ETU calibration and MES traceability. Achieved 100% data recording for IEC audit. Payback period 14 months.
Asian switchgear group
Custom line for 100A‑1600A frames with quick‑change tooling. Changeover time reduced from 2 hours to 45 minutes.
North American panel builder
Added hi‑pot and magnetic trip test stations to existing line. Detected 2.5% early failures, saving recall costs.
Technical specs

Traditional semi‑auto line vs. our fully automatic line

Understand the key differences in throughput, quality, and traceability.

Parameter Traditional semi‑auto line Benlong fully automatic line
Test efficiency (per piece)60 – 120 seconds30 seconds (typical)
Operator involvementManual load/unload between stationsFully automated conveyor
Assembly consistencyOperator dependentServo‑controlled, repeatable ±0.01mm
ETU calibrationManual or offlineInline automated L‑S‑I‑G curve test
قابلیت ردیابی داده‌هاManual log, partial100% MES, serialized, real‑time
Typical investment$150k – $400k$500k – $1.5M+

For an automatic line, the return on investment is less than 12 to 18 months if the production volume exceeds 50,000/unit/year. Determine your ROI here →

Design guide

How to specify an MCCB automatic production line – 5 steps

Plan your assembly and test line for maximum efficiency and future‑proofing.

Step 1: Define frame size range & volume
Determine your MCCB frames (100A‑1600A) and annual volume. This decides conveyor speed, station count, and tooling.
Step 2: List required assembly processes
Typical: case loading → riveting → torque calibration → mechanism assembly → arc chute insertion → cover closing.
Step 3: Specify electrical tests
Magnetic trip, thermal calibration, hi‑pot (dielectric), contact resistance, and ETU calibration for electronic breakers.
Step 4: Plan MES & traceability level
Barcode per unit, real‑time data upload (OPC UA / Modbus), SPC dashboards, and reject reason logging.
Step 5: Allow for quick changeover
If you produce multiple frame sizes, specify quick‑change tooling and recipe‑based parameters. Changeover under 60 minutes.

Do you require a complete MCCB manufacturing line? Provide your frame sizes and production volume and we will offer a comprehensive answer. Get in touch with our line integration team →

معرفی شرکت

یکپارچه‌سازی سیستم اتوماسیون در هسته

Benlong Automation Technology Co. Limited is a Chinese manufacturer that specializes in digital technology-based automated manufacturing equipment with a national High-Tech Enterprise; founded in Wenzhou, China in 2008. We provide our customers with customized automatic production lines, assembly machines and testing benches for low voltage electrical manufacturers around; the world.

To operate automatically, our MCCB production lines use hands-free automatic machinery along with an electronic control unit (ECU) that connects automatically to an operator’s workstation via Ethernet. Together, we offer circuit breaker plants making the switch to Industry 4.0 with all of these capabilities!

MCCB production line assembly workshop
شرکت ملی فناوری پیشرفتهMCCB Assembly & Test
2008تأسیس شد
۵۰.۸۸ میلیونسرمایه ثبت شده (تومان)
160+اختراعات ملی
26حق نشر نرم‌افزار
300+سوابق صلاحیت
1200+مشتریان خدمات رسانی شده
MCCB production line engineering
ENGINEERING & INTEGRATION

From assembly modules to full MCCB production line

Benlong creates and constructs a complete automatic MCCB production line with all the necessary processes – including rivets, torque calibration, magnetic breakout testing, thermal calibration, high-pot testing and ETU digital calibration. We also offer full turnkey installations and programming of PLCs as well as ensuring that you have an MES handshake.

MCCB automatic production line – up to 30 sec/pc, 100A‑1600A frames
MCCB semi‑automatic high voltage test bench – 125A‑1250A, OK/NG indicator
Request a custom MCCB line quote
محیط کارخانه

Built for reliable MCCB production lines

We assemble, wire, and pre‑commission every automatic MCCB line in our facility before shipment. Full FAT with your product samples.

GLOBAL INSTALLATIONS

Trusted by MCCB manufacturers worldwide

From Europe to Asia, our automatic production lines are improving quality and throughput for molded case circuit breakers.

Algeria MCCB line

Algeria plant

Azerbaijan customer

Azerbaijan facility

Ethiopia workshop

Ethiopia plant

India customer

India facility

Iran customer

Iran factory

Russia customer

Russia site

Saudi Arabia

Saudi Arabia line

گواهینامه‌ها و افتخارات

فناوری، ثبت اختراع و تشخیص کیفیت

بنلونگ گواهینامه ملی شرکت‌های پیشرفته، اختراعات متعدد، حق چاپ نرم‌افزار و افتخارات صنعتی را کسب کرده است که نشان دهنده سرمایه‌گذاری مستمر در توسعه فناوری و نوآوری در تولید هوشمند است.

ISO9001 Certificate

گواهینامه ISO9001

ISO14001 Certificate

گواهینامه ISO14001

ISO14001 Certificate

گواهینامه ISO14001

ISO9001 Certificate

گواهینامه ISO9001

ISO 45001 Certificate

گواهینامه ایزو ۴۵۰۰۱

TUV Certificate

گواهینامه TUV

Got Questions?

MCCB Automated Production Line

What is an Automated Production Line?

An Automated Production Line consists of a series of machines and workstations that are connected together via a material handling system to complete assembly and testing with little or no manual labor. Our MCCB Automated Production Line consists of riveting, torque calibration, mag trip test, thermal calibration, Hi-Pot test, and ETU digital calibration all centrally PLC controlled and data logged to MES.

How does Motorized MCCB work?

Motorized MCCBs (Molded Case Circuit Breakers) use an electric motor versus manual handle to open or close the breaker remotely. These devices are used where remote tripping or automatic reclosing is desired. Our production lines can assemble and test all components of the motorized MCCBs and confirm operation of the motor and auxiliary contact status.

What is the Full Automatic Production Line?

Full Automatic Production Line means the entire manufacturing process from feeding of raw components until final testing are performed by machines with no manual intervention required. We have a complete MCCB assembly line: automatic loading, servo rivet assembly, controlled-torque screw assembly, magnetic testing of trip mechanisms, thermal calibration of thermal trips, high voltage testing of MCCB components, ETU calibration, and uploading of MES data all occur on a single conveyor. The operator simply monitors the equipment while feeding magazines of various component parts.

What is the difference between MCP and MCCB?

The motor circuit protector (MCP) is designed for short-circuit protection of motors with no thermal overload protection; instead, it relies on a thermal overload relay for that function. The molded case circuit breaker (MCCB) provides both thermal (overload) and magnetic (short-circuit) protection. Our production lines can produce both types – with or without the need for thermal calibration.

What is ETU Calibration?

The ETU (Electronic Trip Unit) calibration process verifies that the trip curve of an ETU matches its intended setup, measuring and verifying the trip time of simulated fault currents and confirming Modbus communication automatically.

What is the typical payback period for an Automatic MCCB Line?

A production facility producing 50,000 MCCBs per year could expect less than 12 to 18 months to pay back investment in fully automated assembly versus semi-automated – through labor savings (60%-70%), higher first-pass yields (94%-99.5%) and lower field returns. Contact us to develop ROI projections specific to your production volume.
پروژه خود را شروع کنید

Need a Turnkey MCCB Automatic Production Line?

Tell us your target throughput, frame sizes (100A‑1600A), and assembly requirements. Our engineers will design a custom inline system with full MES integration and ETU calibration.

نسخه آزمایشی فرم تماس
WhatsApp
+86 150 5837 0007
Email
xsb@benlongkj.cn