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真空遮断器（VCB）自動生産ライン
Fully automatic VCB production line for 12KV/24KV vacuum circuit breakers. Servo‑aligned vacuum interrupter assembly, mechanism characteristic test (speed/travel/timing), HV insulation test, mechanical endurance cycling. IEC 62271‑100 compliant. 25‑30 units/shift, full traceability, remote diagnostics.
Automated VCB Assembly & Test Line for Medium‑Voltage Switchgear
The above-mentioned automatic assembly line for VCBs is a fully integrated assembly and testing facility for the medium and high voltages of 12KV and 24KV vacuum circuit breakers. The assembly line has a variety of motorised carriers, custom tooling, robotic handling, and functional test stations for verifying the high voltage capabilities of the finished products. These four integrated functions give various advantages and allow the precision and reliable manufacture of important products used to distribute power. Compliance with IEC 62271‑100 standards is achieved and the production capability on the line is from 25 to 30 units every 8 hour shift.
The primary processes include assembly of vacuum interrupter (system for relative positioning through servomechanical control) mechanical operation mechanism, testing of the mechanical operation mechanism (open/close speed, open/close travel, timing), testing insulation at high voltage (withstand voltage and loop resistances), mechanical testing for endurance operation for each product. Honeywell barcode scanning systems provide full traceability of material processed at each production point, while Benlong’s HMI/PLC software allows remote diagnostic capability. This is an ideal production line for manufacturers of switchgear products who need to meet Industry 4.0 standards, maintain quality consistency, and comply with IEC standards.
Standard delivery: 120-150 days | Customizable for 12KV/24KV | MES ready
What is a VCB Automatic Production Line?
An automatic production line for a Vacuum Circuit Breaker (VCB) is a specialized manufacturing system that produces vacuum circuit breakers (VCB) used in the medium voltage power distribution (12kV, 24kV, etc). The automatic production line automates the complete assembly process, from aligning and installing the vacuum interrupter (the central component for extinguishing electrical arcing) to assembling the spring-operated mechanism and completing electrical tests. The VCB assembly line consists of servo-controlled actuators that can accurately position the vacuum interrupter. There are automated test stations that measure mechanical characteristics of the VCBs (i.e., opening/closing speeds, travel, timing), perform high-voltage insulation tests (i.e., insulation withstand voltage, loop resistance), and perform mechanical endurance testing by completing thousands of operations to demonstrate and validate the long-term reliability of the VCB. Bar code readers are incorporated throughout the line to maintain full traceability, and the production line can be connected to a Manufacturing Execution System (MES) for data logging. The assembly line is a non-standard, custom solution that can be designed to fit your voltage rating (i.e., 12 kV, 24 kV, 40.5 kV), production volume and component design specifications.
Custom jigs and servo-controlled actuators guarantee perfect micron-level alignment of the vacuum interrupter, which is important for breaking performance.
There is inspection of the speed at which the spring mechanism of an automated station opens/closes; distance travelled by the spring mechanism in opening/closing; and time taken for each.
Before leaving the line, all circuits must be tested for 100% in-line withstand voltage and loop resistance in accordance with IEC 62271-100.
Repetitive operation cycles are exceeded by the automated endurance test stations which carry out these cycles in an automated fashion.
生産ラインの特徴とプロセス
Production Line Parameters (Standard Configuration)
| Applicable product specifications | 12KV, 24KV |
|---|---|
| Daily output | 25 – 30 pcs / 8H |
| Floor area (L×W×H) | 38m × 7.7m × 3.0m (≈300 m²) |
| Input voltage | 380V ± 10% (three‑phase five‑wire) |
| Voltage frequency | 50Hz ± 1% & 60Hz ± 1% |
| Total power | < 120 KW |
| Compressed air | ≥ 1 m³/min, ≥ 6.5 kgf/cm² (oil‑free, water‑free) |
| Production line noise | ≤ 75 dB (measured at 1m) |
| HMI / PLC software | Benlong Automation (remote service supported) |
| International standard | IEC 62271‑100 |
Key Component Brand Selection (Standard Configuration)
| # | Component | Brand |
|---|---|---|
| 1 | HMI | MCGS |
| 2 | Photoelectric Switches & Sensors | Omron |
| 3 | Pneumatic Components | Festo / Airtac / SMC |
| 4 | PLC | Omron |
| 5 | Linear Guides | HIWIN |
| 6 | Stepper Motors | Sanyo |
| 7 | Electrical Components | シュナイダー |
| 8 | Withstand Voltage Tester | Chinese Brand |
| 9 | Loop Resistance Tester | Chinese Brand |
| 10 | Drive Motors | Chinese Brand |
| 11 | Bearings | MISUMI |
| 12 | Barcode Reader | Honeywell |
主要な技術的利点
Precision vacuum interrupter assembly
The vacuum interrupter’s alignment (with micron accuracy) is achieved using custom jigs and servo-controlled actuators which are essential for maintaining both vacuum integrity and contact gap. Proper alignment is vital to the breaker’s ability to interrupt short circuiting correctly.
Comprehensive mechanical characteristic verification
Automated mechanisms measure the time for opening/closing, speed of opening/closing, path (stroke) distance, and over travel distance. A record will be maintained for these measures and to show compliance with IEC 62271‑100 values so that the switch will operate reliably.
100% in‑line high‑voltage insulation testing
Prior to shipment off the production line, every VCB has to pass a withstand voltage (power frequency) test and a loop resistance test. These tests ensure that the VCB has both dielectric strength and low contact resistance, which are required for the continued reliability of a VCB in the power grid.
Full traceability & remote diagnostics
The Honeywell Barcode Reader can connect to different components, as well as test results, using a Unit Serial Number. The HMI/PLC software will allow you to connect remotely for both diagnostics and software updates to reduce both downtime and your transportation costs.
Customer Success Story – Medium‑Voltage Switchgear Manufacturer
To enhance production efficiency and quality when manufacturing 24kV VCBs compliant with IEC 62271-100, a European switchgear supplier established a procedure to achieve traceability, establish mechanical characteristics, and develop a fully automated VCB assembly line by Benlong that included room to room vacuum interrupters, mechanical testing, and high voltage insulating testing facilities, before remounting for mechanical durability checks. The results are shown below after 6 months.
In 18 months, the investment in this line pays back, and the customer received full IEC-compliant to obtain a significant utility contract.
アプリケーションと統合
カスタムエンジニアリングと納品
Request a Custom VCB Production Line Quote
To receive your VCB specifications (voltage rating, frame size, expected product out), we will provide you with an engineer-designed automated production line (one that requires no human interaction) that includes: a vacuum interrupter assembly, mechanical and electrical testing, and MES traceability. Also, a full analysis of ROI will be included.
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 VCB Automation?
- 15年以上のデザイン経験 VCB assembly and test lines for medium‑voltage switchgear
- Proven vacuum interrupter assembly with servo alignment
- Integrated mechanical characteristic, HV insulation, and endurance testing
- Full MES traceability with Honeywell barcode readers
- グローバルなサービスおよびスペアパーツサポート
標準ラインに含まれるもの
Motorized Conveyors, Vacuum Interrupter Jig Assemblies, Spring Mechanism Assembly Workstations, Mechanism Characteristic Testing (speed, stroke length and timing), High Voltage Withstand Voltage Testing, Loop Resistance Testing, Mechanical Endurance Cycle Testing Workstation, Honeywell Barcode Readers, PLC with HMI (Omron), Remote Diagnostic Software, SafetyGuarding, Installation and Training Services, and One Year Warranty.
よくある質問
Our standard lines are built for 12 kV and 24 kV VCBs (modular, self-supporting with plastic housings), however we have custom-built (modular/supported) VCBs available for higher than that – up to 40.5 kV and any other preferred voltage rating by the customer.
Accurate positioning of the interrupter is achieved through servo-controlled actuators and custom made jigs with micron-level precision measurement. Prior to proceeding to the next assembly step, alignment is verified with sensors to ensure proper contact gap and integrity of vacuum seal.
Opening speeds, closing speeds, total actual travel, over travel, opening time, closing time, and contact bounce (if available) are measured by the automated test station. Then, test values can be compared to IEC 62271-100 tolerances.
The HMI/PLC application prepared by Benlong has an option for remote connections to allow the authorised service engineer to connect to the system via a secure VPN for troubleshooting and software updates.
A lead time of 120-150 days is typical from the date of contract signing to factory acceptance for a standard 12kV/24kV line. Additional lead time for custom voltage ratings or additional automation could increase by 30-60 days.
