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Real production issue: “As a low-voltage electrical manufacturer, our MCB contact tips tend to misalign post-punching; we are looking for a mechanism that will allow us to achieve ±0.02mm precision and allow for 1P/2P/3P/4P conversion in under 5 minutes.”— Process Engineer, Low Voltage Electrical Manufacturer. “Punching” as it relates to MCB production means the rapid machining process used to create metal components, including silver-based contact materials, copper terminals, bimetallic strips, and magnetic yokes, at high rates. An MCB punching machine is a precision machine and should not be classified as a standard metal press — it is directly integrated with other automatic assembly lines or welding systems. This article describes […]

Real purchasing dilemma: According to a plant manager of a switchgear manufacturer, “We purchased a circuit breaker testing device that claimed to test everything but it couldn’t handle the high-voltage requirements of our load isolation switch, nor is the supplier familiar with IEC 60947-3”. When choosing an automatic inspection machine, it’s not just searching for the finest quality or upgraded devices. Instead, you want to make sure the machine has the appropriate testing capabilities for your particular product, amount produced, and government regulations. When production lines start to become more adaptable in 2025, a poorly selected tester could result in bottlenecks, neglect significant defects, or not meet auditing standards. This […]

Field failure cost: An undetected vacuum leak on a 24KV VCB led to failure to interrupt a short circuit. This substation outage cost our utility company more than $200,000, and we missed it due to our testing procedures. – Maintenance engineer, regional utility company. Testing a VCB breaker is not the same as testing a low voltage circuit breaker or MCB. VCBs operate at high/medium voltage levels (typically between 12 kV and 24 kV) and utilize the ability of the vacuum interrupter to operate correctly. In 2025, with the automation of electrical networks being implemented, it is necessary to have specific equipment available to ensure proper functioning of VCBs, which […]

Real production bottleneck: “We do a manual check of 10,000 MCBs on each shift, but we can perform only one function of the MCB test at a time. The escape ratio for testing defective MCBs is 0.8%; there is no way for us to track the MCB tests.” – Quality Manager of a mid-sized electrical company. An inspection conveyor at an MCB may serve more than one purpose — there are a number of possibilities, and some of those possibilities include, but are not limited to, an MCB inspection conveyor integrates automated testing stations, sorting systems, and acquisition of data, providing a continuous flow from one method to the next, […]

Real need from the shop floor: According to the production supervisor of an electrical product manufacturing company, the old pneumatic riveter causes 1.2% of loose connections on MCB’s. In response to that, he has requested another machine capable of handling different types of product(s) (1P-4P) at one time without having to make constant adjustments. As of 2020, with MCB manufacturers trying to achieve greater efficiencies and lower defect rates, there has been a dramatic increase in demand for high-quality MCB riveting machines. These machines are very different from conventional riveters, as they were specifically designed for rivet applications with silver contact sub assembly tips/copper terminal assemblies (with a plastic housing) […]

Specialized Industrial Equipment for Riveting Contactors – The contractor riveter is designed exclusively to create permanent connections between contact tips typically composed of silver-alloy material and terminals, springs or armature components comprised of copper or brass (see Figure 3). Unlike conventional riveters, contractor riveting machines are dedicated to the assembly of small and fragile pieces while maintaining mechanical and electrical reliability. To put it simply, this is the machine that ensures that the contacts in the contactor remain tightly fastened for many millions of switchings. If the riveting is not done properly, the contact tips can become loose, causing an increase in contact resistance, creating arcing and/or overheating, and ultimately […]