benlong 
Linha de produção automática de MCCB
Fully automatic MCCB production line for 100A‑1600A frames. Integrates riveting, torque calibration, ETU digital calibration (L‑S‑I‑G), hi‑pot test, and MES traceability. 30 sec/pc, IEC 60947‑2 compliant. Customizable for medium‑to‑large MCCB manufacturing.
Fully Automatic MCCB Production Line for Medium‑to‑Large Frames
This MCCB automated production line is designed to produce moulded case circuit breakers (MCCBs) with medium or large currents in high volumes. The production line operates as a single continuous production process; hence, there are four integrated production processes within this single system, with automated riveting, torque calibration, testing of tripping characteristics, and deep MES integration in one continuous production process for every unit manufactured. Servo-driven tooling provides exacting precision in the alignment of arc chutes and contact systems during their fitting and operation; and the deep MES integration provides sufficient tracking of all parameters for each unit manufactured, thereby providing complete compliance with IEC 60947-2 and GB 14048.2 standards.
There are several important features to take into account including complete automation of every processing step (case loading, riveting, torque setting, electrical testing with no manual handoff), high accuracy servo drive, ETU digital calibration with Modbus communication confirmation, and quick change tooling for multiple frame sizes. The line will allow tests to be completed on approximately 30 seconds per part (depending on the rated current). In short, the line allows MCCB manufacturers to prepare for Industry 4.0, assure quality, and reduce labor costs.
Standard delivery: 90-120 days | Customizable for 100A‑1600A frames | MES ready
What is an MCCB Automatic Production Line?
A produced wholly automatic MCCB assembly line is a complete system for producing molded case circuit breakers that integrates all processes (assembly, riveting, torque measurement, and electrical testing) into one continuous stream of production. A fully automated MCCB production line is different from a semi-auto or automated production line since it uses servo-controlled actuators and rigid tooling to provide consistent forces/positions, which is a key factor in high-current applications, as arc chute alignment and contact pressure have a direct effect on the breaking capacity of the MCCB. This production line utilizes automated loading of cases, riveting of molded-case structure, torque-controlled fastening of operating mechanism screws, and inline ETU calibration with curve validation. All test data generated (torque levels, trip times, contact resistances) will be recorded against the unit’s serial number via MES. Since this is a custom non-standard solution, we can customize the assisted factory line to accommodate your frame sizes (100A-1600A), expected production volume, and specific ETU communication protocols.
No manual handoff between stations includes case loading, riveting, torque setting and electrical testing.
Servo-controlled actuators guarantee uniform force and exact location for arc chute and contact assemblies.
Preliminary test of the Modbus communication & an automatic calibration of electronic trip units (ETUs) and the trip curves.
All testing parameters, torque values and trip characteristics are tracked and associated with a unit’s serial number.
Características e processo da linha de produção
Especificações técnicas
| Line size (L×W×H) | 29.0 × 2.0 × 2.2 m |
|---|---|
| Total weight | 5,540 kg– |
| Fonte de energia | 220 / 380 V– |
| Air pressure | 0.6 MPa– |
| Test efficiency | Approx. 30 seconds per piece (varies by rated current)– |
| Supported frame sizes | 100A – 1600A (customizable)– |
| OEM customization | Appearance, HMI interface, control logic available– |
| Compliance | IEC 60947‑2, GB 14048.2– |
Major Components (Standard Configuration)
| Component | Brand | Origin |
|---|---|---|
| PLC | Omron | Japan |
| Control screen (HMI) | MCGS | China |
| Cylinder | SMC | Japan |
| Major sensors | Omron | Japan |
| Electric motor | Inovance | China |
| Robotics | Epson / Fanuc | Japan |
Principais vantagens técnicas
Full‑process automation eliminates manual bottlenecks
All stations use a conveyor to move products from case feed into the final ETU calibration with no manual handling between process steps. This reduces labor dependency by as much as 70%, while eliminating quality inconsistencies resulting from operator fatigue.
Servo‑driven precision for high‑current components
Alignment of arc chutes and assembly of the contact system require the accurate positioning to within a micron. To achieve this, programmable force and positioning are accomplished through the use of servo-controlled actuators. As such, all MCCBs will have the same breaking capacity consistently.
ETU digital calibration with communication verification
Automated ETU calibration stations are a component of the line that can create faults and (simulate) measure output currents (L-S I-G curves) and verify Modbus communication. Each trip curve is recorded and compared against IEC 60947-2 standards for automatic pass/fail sorting.
Full MES traceability for quality audits
Each unit is recorded by the following parameters as per each serial number: torque values, riveting forces, trip times and contact resistance. This also enables the export to your MES granting you with total traceability to ISO 9001 and/or customer audits.
Customer Success Story – Global MCCB Manufacturer
A major manufacturing firm of mold breakers sought to produce more than 225 A and 630 A frame MCCB in accordance with IEC 60947-2. The semi-automatic line they currently were using had unreliable torque measurements and no traceable production processes. Benlong offered to provide them with an Fully Automated MCCB Production Line with ETU Calibration and MES Integration for 6 months and here are the results of that production:
The line paid for itself in 14 months and enabled the customer to pass a major utility audit with full data records.
Aplicações e Integração
Engenharia e entrega personalizadas
Request a Custom MCCB Production Line Quote
Specification, frame sizes & Target outputs for your MCCB will be sent to us so our engineers can design an Automated line for you to support ETU Calibration and achieve full Visibility of MES Traceability. The proposal will include a full Return on Investment (ROI) Analysis.
WhatsApp: +86 150 5837 0007 | E-mail: xsb@benlongkj.cn | Suporte em inglês e chinês
Why Choose Benlong for MCCB Automation?
- Mais de 15 anos de experiência em design. MCCB automatic production lines para marcas globais
- Proven servo‑driven assembly and ETU calibration technology
- Full MES integration – torque, riveting force, trip curves, and serial number binding
- Quick‑change tooling for multiple frame sizes (100A‑1600A)
- Serviço global e suporte de peças de reposição
A linha padrão inclui
Automated Loading Conveyor System · Three Servo-Riveting Workstations · Torque Control With (3) Screw Driving Modules · Calibration Bench For ETU Use (L-S-I-G Curves) · High Pot Tester (DC or 3AC) · MES Guaranteed For Barcode Scanner Utilization · PLC With HMI (Omron) · Safety Guards · System Installation & Operator Training · 1 Year Warranty
Perguntas frequentes
The standard configuration supports 100A‑630A frames. Custom versions are available for 800A‑1600A frames, with upgraded riveting and testing stations.
Yes. The line has an automated ETU calibration station that injects simulated fault currents (long delay, short delay, instantaneous, ground fault) and verifies trip curves. Communication via Modbus (or other protocols) is also tested.
Servo‑controlled electric screwdrivers with torque and angle monitoring are used for all screw fastening operations. Each fastener’s final torque value is logged and linked to the unit serial number.
Yes. We provide OPC UA or Modbus TCP interfaces. Test results, torque values, and trip curves are uploaded in real time. We also provide example integration code for popular MES platforms.
Using quick‑change tooling and recipe‑based parameters, changeover takes 30‑60 minutes. For frequent changeovers, we can supply an additional tooling kit to reduce downtime.
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