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MCB多極自動組立機
Benlong MCB多極自動組立機 – 1極ユニットを2極/3極/4極に変換します。CCDビジョンアライメント、サーボリベット打ち、工具不要の段取り替え。 <5 min. 1,000-1,800 units/hour. Reduces defects, improves consistency. Ideal for high-volume MCB production.
MCB Muti-Pole Automatic Assembly Machine
The MCB multi-pole automatic assembly machine is a unique automated machine which enables the conversion of individual single-pole (1P) miniature circuit breakers into multi-pole (2P, 3P or 4P) configurations through precision alignment, indexing and servo-controlled riveting/pinning to provide a strong mechanical and electrical connection that meets IEC 60898-1 standards for multi-pole breakers. The MCB multi-pole automatic assembly machine is necessary for manufacturers needing high volume output with guaranteed quality, as well as the flexibility to change poles as necessary.
This system uses CCD Vision Sensors for verifying spatial alignment; a turntable with multiple stations that index; and programmable rivet machines. Each pole is automatically aligned, indexed, and assembled by using high-strength rivets/pins. The Control system (PLC) has stored recipes for assembling 2-Pole, 3-Pole and 4-Pole Breakers allowing tool-less changeover time of under 5 minutes. Typical throughput can range from 1,000 to 1,800 Breaker Assemblies per hour, depending on the number of Poles in each unit. These systems will ensure consistent electric safety, reduce labor cost and eliminate potential variances in the assembly process.
Standard delivery: 30-45 days | Changeover <5 min | CE certified
What is an MCB Multi-Pole Automatic Assembly Machine?
A multi-pole MCB assembly machine automates the process of joining together pre-assembled single pole MCBs into 2, 3, or 4 pole MCBs while also providing visual evidence of the alignment of adjacent components, the number of fastening methods used, and the mechanical/electrical continuity between components. Unlike using hand tools to assemble MCBs manually, the MCB assembly machine aligns components automatically via a series of alignment fixtures and applies a predetermined amount of mechanical force (rivet or pin) during each assembly operation. The machine is usually located at the end of the assembly line before the MCB undergoes calibration and testing to verify that all poles are in a co-planar configuration, the distance between each pole conforms to standard dimensional tolerances, and that the internal busbars of each pole are properly connected – all of which are essential for multi-pole MCBs to properly function in residential and commercial applications.
Automatically joins multiple single-pole units with precision riveting.
Verifies spatial positioning before riveting; rejects misaligned units.
Recipe‑based switching between 2P, 3P, and 4P configurations in under 5 minutes.
Real‑time riveting force and depth control; auto‑stop on abnormal values.
機械の特徴と組み立て工程
技術仕様
| Supported configurations | 2P, 3P, 4P (from single-pole units) |
|---|---|
| Cycle time (per assembled breaker) | 2.0 – 3.5 seconds (depends on number of poles) |
| Output capacity | 1,000 – 1,800 units/hour (for 2P/3P/4P) |
| Joining method | Servo-controlled riveting or pin insertion (force range 500N–5kN) |
| 位置決め精度 | ±0.05mm (vision-aligned) |
| Vision system | CCD camera with edge detection; checks sidewall alignment and pole gap |
| 切り替え時間 | <5 minutes (recipe-based, no tool change required) |
| 制御システム | PLC (Siemens/Mitsubishi) with HMI, recipe storage for 20+ product types |
| 故障検出 | Vision misalignment, riveting force out-of-range, missing pin – auto reject |
| 電源 | 380V ±10% 50Hz | 圧縮空気 0.5～0.7MPa |
主要な技術的利点
Eliminates manual joining variability
Manual assembly often results in uneven gaps, loose rivets, or misaligned poles. This machine applies consistent force and alignment, ensuring that all poles are coplanar and electrically connected per IEC standards.
CCD vision for zero defect alignment
The integrated vision system checks sidewall flatness and relative position before riveting. Any misalignment triggers rejection, preventing downstream test failures.
Rapid configuration changeover
Operators select 2P, 3P, or 4P on the HMI; the PLC adjusts indexing positions and riveting parameters automatically. No mechanical parts need replacement – changeover under 5 minutes.
Full traceability
Each assembled multi-pole breaker is linked to its constituent 1P serial numbers. Riveting force, vision pass/fail, and assembly timestamp are logged for quality audits.
顧客成功事例
A manufacturer of mini circuit breakers in Turkey has been using manual assembly techniques to produce 3 pole breakers from single pole components. For this manufacturer, defects were occurring at a rate of 1.2% (loose pole components and misaligned labels). After installing an automated assembly machine that accommodates multiple poles, the defect rate dropped to 0.1%. Additionally, the rate of production increased from 600 units/shift to 1,500 units/shift. The tool-less changeover feature of the automated assembly machine allowed for switching between producing two pole and three pole breakers in less than three minutes, allowing the customer to produce on a just-in-time basis for various customer orders. The automated assembly machine paid for itself in ten months.
The customer now uses the machine for all 2P and 4P production as well.
アプリケーションと本番環境の統合
標準納品および試運転
Request a Custom Multi-Pole Assembly Machine Quote
Provide us with samples of your single pole MCBs and configuration types (2P, 3P or 4P) for target poles as well as your daily output requirements. Based upon that information, our engineering team can create a recommended optimal riveting force and vision set up; along with a complete ROI summary analysis.
WhatsApp: +86 150 5837 0007 | メール: xsb@benlongkj.cn | 英語と中国語でのサポート
Why Choose Benlong for Multi-Pole Assembly?
- 15年以上のデザイン経験 MCB assembly machines グローバルブランド向け
- Proven CCD vision alignment for zero-defect pole joining
- Tool‑less changeover between 2P, 3P, and 4P – less than 5 minutes
- Real‑time riveting force monitoring with auto-reject
- Seamless integration with upstream 1P assembly and downstream test lines
標準マシンに含まれるもの
The system has the following components: rotary/turntable, vision camera system, servo driven riveter (2-4 head), vibratory feeder for pins/rivets, PLC w/ HMI (Siemens), safety enclosure, 20+ recipes stored, all change parts, operators manual, 1 year warranty.
よくある質問
Hand tools (rivet guns) and screws are generally used for manual pole assembly. However, there are often discrepancies concerning the amount of force applied to a pole during riveting and the alignment of each of the poles being assembled, resulting in either loose poles or poles and circuit breakers that are not coplanar. Our automatically operated machine utilizes programmed and consistent riveting force (±3%) and CCD verification for pole alignment before the poles are joined to eliminate the risk of human error.
The vision system has the ability to be taught the sidewall characteristics for all brands of MCBs. The installer can program the spacing between poles through the HMI. Usually, we will ask for one sample of the 1 Pole to create a custom alignment recipe for that brand.
The machine has the option to carry out a continuity test upon completion of assembly, using spring probes to make contact at the line/load terminals of each pole, which allows for verification of proper connection of the internal busbars. The continuity test will use the same cycle time as the connection of components.
The operator uses the HMI to select a target configuration. The PLC adjusts all of the required parameters (including the indexing positions, riveting head space, and stroke limits) automatically in under five minutes. Additionally, no mechanical parts need to be changed.
The servo rivet unit checks force and movement to determine if a rivet has been inserted correctly. If the machine determines a rivet has not been inserted correctly (for example, the rivet is missing, too shallow, or too deep), the machine will reject the rivet and record the failure. An optional vision inspection system is also available to confirm the presence of the rivet.
