benlong 
Ligne de production automatique de dispositifs de protection contre les surtensions (SPD)
Fully automatic SPD production line for Type 1/2/3 surge protection devices. Automatic base feeding, precision varistor welding (resistance/laser), module insertion, laser marking & pad printing. Unmanned operation, IEC 61643‑11 compliant. Customizable for 1P/2P/3P/4P.
Fully Automatic SPD Assembly & Welding Production Line
The production line for this surge protection device (SPD) automatic is a complete system designed to manufacture SPD surge protectors, including everything from core module welding to final base assembly. The line operates unmanned on the following critical processes: automatic feeding of SPD bases, high accuracy welding of varistor modules (using either resistance or laser welding), automatic insertion of modules into bases, laser marking of modules and bases, and printing module and base pads. It ensures product consistency, traceability and high throughput in compliance with global lightning protection standards (IEC 61643‐11).
Initially, SPD base material is fed into the process continuously and automatically. MOVs or MOV varistor modules are then assembled by precision automated soldering or resistance welding to provide an optimal electrical contact and reliable performance of the MOVs. After that, the completed MOV modules are automatically transferred to the assembly station where they will be assembled into the finished protective bases. Laser marked and printed for CE, UL, TUV or other regulatory labels, quality control is also built into the process as all modules will have a permanent identification number and the pad printing will provide for regulatory labels and barcodes. The entire digitalized workflow of the process will provide for complete material traceability and consistent assembly quality and be perfectly suited to the high-volume production of Type 1, Type 2, and Type 3 SPDs.
Standard delivery: 60-90 days | Unmanned operation | Customizable for various SPD form factors
What is an SPD Automatic Production Line?
A fully automated surge protection device production line is an integrated system that can manufacture surge protective devices (SPDs) used in distribution of low-voltage power to protect against transient overvoltage conditions (lightning strikes, switching surges). This line automates the entire assembly process, including feeding plastic bases, precision welding of varistor modules (single or multi-chip), inserting the welded module into the plastic base, applying thermal disconnects (if required), and marking the finished product using laser and pad printing. The system is designed to operate continuously and independently from human operators, therefore reducing the reliance on labor and maintaining a consistent quality of produced parts. This line meets all IEC 616439-11 standards for SPDs (low voltage surge protective devices) and is designed for residential, commercial and industrial installations for the three different types (Type 1, Type 2, and Type 3) of SPDs. As we offer custom solutions that are non-standard, we can build a line specific to your SPD design, number of varistors in each unit, base design and production quantity requirements.
Continuous vibratory or magazine feeding of SPD bases, minimizing manual handling.
Resistance welding or laser welding for MOV modules; ensures low contact resistance (<0.1 mΩ).
Robot or pick‑and‑place transfers welded modules into bases with force‑monitored insertion.
Permanent marking (serial number, rating, date code) and regulatory labels (CE, UL, TUV).
Caractéristiques et processus de la ligne de production
Spécifications techniques
| SPD types supported | Type 1, Type 2, Type 3 (single‑port or two‑port), 1P/2P/3P/4P configurations |
|---|---|
| Base feeding | Vibratory bowl or magazine stacker, continuous operation |
| Varistor welding method | Resistance welding (MFDC) or fiber laser welding (optional) |
| Welding accuracy | Position repeatability ±0.1mm; weld energy monitoring ±2% |
| Module insertion | Servo‑controlled press, force monitoring (50‑200N), auto‑reject on force deviation |
| Laser marking | Fiber laser (20W/30W), marking area 110x110mm, supports barcode/QR/ text |
| tampographie | 1‑2 colors, automatic ink cup, quick‑release cliché |
| Système de contrôle | PLC (Siemens/Mitsubishi) with HMI, recipe storage for 20+ SPD models |
| Traçabilité | Barcode reader at module welding and final test; data uploaded to MES |
| Alimentation électrique et en air comprimé | 380 V ±101 V 3 T 50 Hz | Air comprimé 0,6-0,8 MPa |
Principaux avantages techniques
Unmanned operation for high‑volume production
From base feeding to final marking, the line runs without operator intervention. One technician can oversee multiple lines, drastically reducing labor cost and eliminating human variability.
Precision varistor welding – low contact resistance
The resistance welding station uses medium‑frequency DC control with real‑time energy monitoring. Welds achieve contact resistance <0.1 mΩ, ensuring reliable surge current conduction and long MOV life.
Integrated traceability for regulatory compliance
Each SPD receives a laser‑marked unique ID linked to welding parameters, module insertion force, and final inspection data. Full traceability supports IEC 61643‑11 certification and customer audits.
Flexible modular design
The line can be configured for different base sizes, varistor counts (1‑4 MOVs), and optional thermal disconnect assembly. Changeover between product families typically takes 30‑60 minutes with quick‑change tooling.
Customer Success Story – Type 2 SPD Manufacturing
To meet their growing demand, European SPD Brand needed to rapidly increase monthly output of Type 2 Surge Protection Devices (SPDs) from 5,000 to 20,000. Their challenge was poor weld quality and excessive rework of varistors. Working with Benlong, they created an automatic production line that included: a custom-designed surge protection device assembly fixture; dual-station resistance welding; and inline monitoring of the quality of the welded varistors.
The line self-funded its costs in a period of 14 months. The customer received a factory audit on IEC 61643-11 without any non-conformances due to full laser marking traceability.
Intégration des applications et de la production
Ingénierie et livraison sur mesure
Request a Custom SPD Production Line Quote
Please provide us with your SPD base sample, varistor module samples, and target output. Our engineering team will design a customized automatic production line for you, including welding, assembly, marking, and full IEC 61643‐11 compliance.
Renseignez-vous dès maintenant
WhatsApp : +86 150 5837 0007 | Courriel : xsb@benlongkj.cn | Assistance en anglais et en chinois
Why Choose Benlong for SPD Automation?
- Plus de 15 ans d'expérience en conception SPD automatic production lines for global lightning protection brands
- Proven varistor resistance welding (MFDC) and laser welding expertise
- Integrated laser marking + pad printing for full traceability and regulatory labeling
- Unmanned operation – one operator can manage multiple lines
- Réseau de service mondial (Europe, Asie, Amériques, Moyen-Orient)
La gamme personnalisée typique comprend
Automatic Feed Bowl – Vibro ( സാഹചര ) | Food Grade – Foil In Filler -Metal Detector / Control System Metal Detector – Varistor weld Station – (R/S or Laser) – Modular Insertion Press with Force Monitoring – Laser Printing Module ( Fibres ) – Pad Printing machine – PLC W / HMI – (Siemens) – Conveyor System – Safety Guards – MES Interface (OPC UA) – 1 set of change Tooling provided – 1 YEAR Warranty.
Foire aux questions
Type I, II, or III, with 1 to 4 modules of MOVs per board, can all be installed using either a single or two-port option on this line. There are tooling change kits available for different board sizes and MOV layouts.
For high-volume manufacturing of MOV modules, resistance welding (MFDC) is a more efficient and cost-effective process than traditional methods. Conversely, laser welding is used to create welded connections between parts that are too small or cannot be touched (thermal disconnects) or where minimal heat-affected area would be detrimental.
To ensure you select the best welding method for your application, we recommend performing a test weld – with your actual sample parts.
Should your SPD have a thermal disconnect (a mechanism for indicating to a user that the SPD has reached the end of its useful operational life), we can include a dedicated station where we can pre-apply low-temperature solder paste to the product assembly and cure with controlled heat. The configuration will be unique to the design of the product.
An in-line test station can be installed after the welding process to determine the V1mA (varistor voltage) and Ie (leakage current) of each module. This allows for all modules that pass testing to move on to assembly. Final test of SPD could be added at the end of the production line.
The number of cycles at each work station determines capacity. A standard line that welds and assembles two module SPDs can produce 1,000 to 1,500 units per shift. Dual station welding heads or parallel assembly modules may also permit increased throughput.
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