Inline fully automatic testing

Автоматизированная линия тестирования автоматических выключателей
Up to 1,800 units/hour | Multi‑station

MCB, RCCB, andRCBO integrated inline test systems – Automatic loading, magnetic trip, thermal calibration, dielectric testing, and MES data logging; Designed for continuous operation (24/7).

1,800+
Units/hour
6
Test stations
100%
Inline inspection
99.9%
Uptime
Core advantages

Why an automatic testing line beats manual benches

A high-volume production line for circuit breakers with automatic inline testing minimizes delays, reduces errors from people, and provides you with quality information immediately.

Seamless line integration
Direct connection to assembly and packing lines – no intermediate handling. Synchronized PLC handshake.
Multi‑station architecture
Dedicated stations for thermal trip, magnetic trip, contact resistance, dielectric, leakage, and visual inspection.
Real‑time SPC & MES
Each unit’s test results are recorded with barcode. Instant reject sorting and full traceability.
Quick changeover
Change MCB family (1P/2P/3P/4P, B/C/D curves) in less than 10 minutes via recipe management.
Integrated test modules

Our MCB automatic testing line components

Modular stations that can be combined into a complete inline test system.

Each module can be ordered separately or as a fully integrated line.
Field results

Real impact from automatic testing lines

Major OEM in Europe
Replaced 5 separate test benches with one inline testing line – labor reduced by 80%, throughput increased from 900 to 1,650 units/hour.
Indian panel builder
Integrated magnetic trip + thermal calibration + MES. Detected 3.2% early failures, saving recall costs.
Middle East exporter
Automatic test line for RCBO – leakage current test at 30mA/100mA/300mA, 1,200 units/hour, payback 14 months.
Chinese smart factory
Full line integration: assembly → testing → laser marking → packaging. OEE improved from 68% to 84%.
Technical specs

Inline test line vs. standalone test bench – key differences

Understand why a fully automatic testing line is essential for high‑volume manufacturing.

Parameter Standalone test bench Inline automatic testing line
Throughput (units/hour)50 – 600 (manual/semi)800 – 1,800
Loading/unloadingManual or semi‑autoFully automatic conveyor
Test consistencyOperator dependentRepeatable ±0.3%
MES integrationOptional / manual entryStandard barcode & API
Floor space2‑4 m² per bench8‑15 m² (integrated)
Typical investment$5k – $35k$80k – $250k

An automatic testing line pays back within 12‑18 months for volumes above 5,000 units/day. Calculate your ROI →

Design guide

How to specify an MCB automatic testing line – 5 steps

Plan your inline test system for maximum efficiency and future expansion.

Step 1: Determine line speed match
Your testing line must keep up with assembly output. Calculate required tests per hour – we design for 10‑20% buffer.
Step 2: List required test sequence
Typical sequence: thermal trip → magnetic trip → contact resistance → dielectric → leakage (RCBO) → visual/OCR.
Step 3: Decide reject handling
Automatic reject sorting with reason code logging. Reject bins or conveyor diverter.
Step 4: Plan data & connectivity
MES connection via REST API or SQL. Real‑time dashboards and SPC alerts.
Step 5: Allow for future products
Choose modular test heads that can be swapped for new MCB types. Tooling changeover under 10 minutes.

Turnkey Test Line? Deliver assembly line specifications that allow us to engineer a complete solution! Speak to our Line Integration Team ->

ПРОФИЛЬ КОМПАНИИ

Интеграция систем автоматизации на самом базовом уровне

Established in 2008, Benlong Automation Technology Co., Ltd., located in Wenzhou, China, is a high-tech national enterprise specializing in digital intelligent manufacturing equipment. This company creates custom automatic test lines, assembly machinery, and entire production line solutions for low voltage electrical manufacturers in all parts of the world.

We created automatic testing lines for MCBs that can operate continuously with 24/7 uptime. Our lines feature integrated PLC control, servo drives, industrial vision, and MES connectivity, making them suitable for circuit breaker manufacturing plants that are transitioning toward Industry 4.0.

Testing line assembly workshop
Национальное высокотехнологичное предприятиеInline Test Systems
2008Основан
50,88МУставный капитал в юанях
160+Национальные патенты
26Авторские права на программное обеспечение
300+Документы о квалификации
1200+Обслуживаемые клиенты
Testing line engineering
ENGINEERING & INTEGRATION

From test modules to full production line

Benlong designs and builds complete automatic testing lines that integrate with your existing assembly and packaging systems. We provide turnkey installation, PLC programming, and MES handshake.

Custom inline test line – up to 1,800 units/hour, multi‑station
MES & traceability – barcode, SPC, reject analysis, API to ERP
Инструмент для быстрой смены оборудования – for different MCB families
Remote diagnostics & support – 24/7 monitoring via IoT
Request a custom testing line quote
ЗАВОДСКАЯ СРЕДА

Built for reliable testing lines

We assemble, wire, and pre‑commission every automatic testing line in our facility before shipment. Full FAT with your product samples.

Testing line assembly
Line integration
Control panel
Wiring
Pre‑commissioning
GLOBAL INSTALLATIONS

Trusted by circuit breaker manufacturers worldwide

From Europe to Asia, our automatic testing lines are improving quality and throughput.

Algeria test line

Algeria plant

Azerbaijan customer

Azerbaijan facility

Ethiopia workshop

Ethiopia plant

India customer

India facility

Iran customer

Iran factory

Russia customer

Russia site

Saudi Arabia

Saudi Arabia line

СЕРТИФИКАТЫ И НАГРАДЫ

Технологии, патенты и признание качества

Компания Benlong получила национальный сертификат высокотехнологичного предприятия, множество патентов, авторские права на программное обеспечение и отраслевые награды, что отражает непрерывные инвестиции в развитие технологий и инновации в области интеллектуального производства.

ISO9001 Certificate

Сертификат ISO9001

ISO14001 Certificate

Сертификат ISO14001

ISO14001 Certificate

Сертификат ISO14001

ISO9001 Certificate

Сертификат ISO9001

ISO 45001 Certificate

Сертификат ISO 45001

TUV Certificate

Сертификат TUV

Have Questions?

Automatic MCB Testing Line – Frequently Asked Questions

How can I tell if my MCB is working correctly?

In order to determine whether an MCB works, it should be tested with both a thermal trip test for an overload and with a magnetic trip test for a short circuit. In an automated testing line, the MCB is held in place with a clamp in the test chamber; a rated current will be applied (and multiplied by a factor of 1.45x In and 5x In), and the trip time of the breaker will be measured and compared to the IEC 60898 limit. The contact resistance and dielectric strength will also be checked. Our inline MCB testing system performs these tests automatically.

What is meant by the 125% rule in electricity?

The 125% rule in the National Electrical Code (NEC 210.20(A)) provides that any circuit breaker should not carry more than 80% of the load continuously. Accordingly, a breaker should be rated at 125% of continuous loads. This rule of thumb is used when testing and cementing thermal trip calibration; our MCB test lines ensure that traps thermal trip calibration by the breaker will occur within a specified time frame at 1.45x In (which is the conventional non-trip current used for thermal protection).

How do Ipk and Icw differ?

The Ipk is the short circuit withstand current (generally found on a bus bar or a switchgear); Icw is the short time withstand current for low voltage assemblies. For MCBs, these parameters are less common; instead, we test ultimate short-circuit breaking capacity (Icn) and service breaking capacity (Ics). Automatic testing lines can provide a means of performing short circuit testing if required.

How to test an automatic circuit breaker?

There are six general procedures to test Automatic Circuit Breakers (MCB/RCBO): Visual check, contact resistance (micro-ohm), thermal (overload) trip test (at 1.45 times In to check trip time), magnetic (short-circuit) trip test (at 5 – 10 times In to ensure instantaneous trip), dielectric withstand (2kV for 1 minute), leakage testing (30/100/300 mA). The automatic testing line performs all of these tests in sequence, records the results and rejects any failures.

What is the typical payback period for an automatic testing line?

For an automatic testing line in an environment producing MCB at 5000 units per day, the typical payback of transitioning from manual testing of MCBs to automatic testing would normally occur in a 12 – 18 month period due to labour savings of around 70%, a reduction in the defect rate and a reduction in field returns.

Can the testing line be integrated with existing assembly equipment?

Yes, because testing is performed where products are normally assembled, and electronic components are readily available to integrate testing lines into your existing assembly system via the PLC handshake, photo-eye type signals used in your assembly machine or manual load stations. We provide full integration support.
Начните свой проект

Need a Turnkey MCB Automatic Testing Line?

Tell us your target throughput, product range (MCB/RCCB/RCBO), and existing line configuration. Our engineers will design a custom inline test system with full MES integration.

Демонстрация формы обратной связи
Компания Benlong Automation Technology Co., Ltd. специализируется на интеграции систем автоматизации и разработке цифрового интеллектуального производственного оборудования для низковольтного электротехнического производства.
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