{"id":107,"date":"2026-06-01T10:38:31","date_gmt":"2026-06-01T10:38:31","guid":{"rendered":"https:\/\/khkrh7q1ur.wpdns.site\/product\/surge-protection-device-%ef%bc%88spd%ef%bc%89-automatic-production-line\/"},"modified":"2026-06-09T01:57:36","modified_gmt":"2026-06-09T01:57:36","slug":"surge-protection-device-spd-automatic-production-line-product","status":"publish","type":"product","link":"https:\/\/benlongkj.com\/ru\/product\/surge-protection-device-spd-automatic-production-line-product\/","title":{"rendered":"\u0410\u0432\u0442\u043e\u043c\u0430\u0442\u0438\u0437\u0438\u0440\u043e\u0432\u0430\u043d\u043d\u0430\u044f \u043f\u0440\u043e\u0438\u0437\u0432\u043e\u0434\u0441\u0442\u0432\u0435\u043d\u043d\u0430\u044f \u043b\u0438\u043d\u0438\u044f \u0443\u0441\u0442\u0440\u043e\u0439\u0441\u0442\u0432 \u0437\u0430\u0449\u0438\u0442\u044b \u043e\u0442 \u043f\u0435\u0440\u0435\u043d\u0430\u043f\u0440\u044f\u0436\u0435\u043d\u0438\u044f (SPD)."},"content":{"rendered":"
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IEC 61643-11 \u00b7 Unmanned operation<\/div>\n

Fully Automatic SPD Assembly & Welding Production Line<\/h1>\n

The production line for this surge protection device (SPD) automatic is a complete system designed to manufacture SPD surge protectors, including everything from core module welding to final base assembly. The line operates unmanned on the following critical processes: automatic feeding of SPD bases, high accuracy welding of varistor modules (using either resistance or laser welding), automatic insertion of modules into bases, laser marking of modules and bases, and printing module and base pads. It ensures product consistency, traceability and high throughput in compliance with global lightning protection standards (IEC 61643\u201011).<\/p>\n

Initially, SPD base material is fed into the process continuously and automatically. MOVs or MOV varistor modules are then assembled by precision automated soldering or resistance welding to provide an optimal electrical contact and reliable performance of the MOVs. After that, the completed MOV modules are automatically transferred to the assembly station where they will be assembled into the finished protective bases. Laser marked and printed for CE, UL, TUV or other regulatory labels, quality control is also built into the process as all modules will have a permanent identification number and the pad printing will provide for regulatory labels and barcodes. The entire digitalized workflow of the process will provide for complete material traceability and consistent assembly quality and be perfectly suited to the high-volume production of Type 1, Type 2, and Type 3 SPDs.<\/p>\n

Standard delivery: 60-90 days | Unmanned operation | Customizable for various SPD form factors<\/span><\/p>\n<\/p><\/div>\n

\n \"SPD<\/p>\n
SPD assembly and welding line (actual product)<\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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What is an SPD Automatic Production Line?<\/h2>\n

A fully automated surge protection device production line is an integrated system that can manufacture surge protective devices (SPDs) used in distribution of low-voltage power to protect against transient overvoltage conditions (lightning strikes, switching surges). This line automates the entire assembly process, including feeding plastic bases, precision welding of varistor modules (single or multi-chip), inserting the welded module into the plastic base, applying thermal disconnects (if required), and marking the finished product using laser and pad printing. The system is designed to operate continuously and independently from human operators, therefore reducing the reliance on labor and maintaining a consistent quality of produced parts. This line meets all IEC 616439-11 standards for SPDs (low voltage surge protective devices) and is designed for residential, commercial and industrial installations for the three different types (Type 1, Type 2, and Type 3) of SPDs. As we offer custom solutions that are non-standard, we can build a line specific to your SPD design, number of varistors in each unit, base design and production quantity requirements.<\/p>\n

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\n \u0410\u0432\u0442\u043e\u043c\u0430\u0442\u0438\u0447\u0435\u0441\u043a\u0430\u044f \u043f\u043e\u0434\u0430\u0447\u0430 \u043a\u043e\u0440\u043c\u0430 \u043d\u0430 \u0431\u0430\u0437\u0443<\/strong>
\n Continuous vibratory or magazine feeding of SPD bases, minimizing manual handling.\n <\/div>\n
\n Precision varistor welding<\/strong>
\n Resistance welding or laser welding for MOV modules; ensures low contact resistance (<0.1 m\u03a9).\n <\/div>\n
\n Automated module assembly<\/strong>
\n Robot or pick\u2011and\u2011place transfers welded modules into bases with force\u2011monitored insertion.\n <\/div>\n
\n Laser marking & pad printing<\/strong>
\n Permanent marking (serial number, rating, date code) and regulatory labels (CE, UL, TUV).\n <\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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\u041e\u0441\u043e\u0431\u0435\u043d\u043d\u043e\u0441\u0442\u0438 \u0438 \u043f\u0440\u043e\u0446\u0435\u0441\u0441 \u043f\u0440\u043e\u0438\u0437\u0432\u043e\u0434\u0441\u0442\u0432\u0435\u043d\u043d\u043e\u0439 \u043b\u0438\u043d\u0438\u0438<\/h2>\n
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\n \"Intelligence<\/p>\n
\u0418\u043d\u0442\u0435\u043b\u043b\u0435\u043a\u0442 \u0438 \u043f\u0440\u043e\u0437\u0440\u0430\u0447\u043d\u043e\u0441\u0442\u044c<\/div>\n<\/p><\/div>\n
\n \"Efficiency<\/p>\n
\u042d\u0444\u0444\u0435\u043a\u0442\u0438\u0432\u043d\u043e\u0441\u0442\u044c \u0438 \u0443\u0441\u0442\u043e\u0439\u0447\u0438\u0432\u043e\u0441\u0442\u044c<\/div>\n<\/p><\/div>\n
\n \"Design<\/p>\n
\u041f\u0440\u043e\u0435\u043a\u0442\u0438\u0440\u043e\u0432\u0430\u043d\u0438\u0435 \u0438 \u0438\u043d\u0442\u0435\u0433\u0440\u0430\u0446\u0438\u044f<\/div>\n<\/p><\/div>\n
\n \"Safety<\/p>\n
\u0411\u0435\u0437\u043e\u043f\u0430\u0441\u043d\u043e\u0441\u0442\u044c \u0438 \u043d\u0430\u0434\u0435\u0436\u043d\u043e\u0441\u0442\u044c<\/div>\n<\/p><\/div>\n<\/p><\/div>\n<\/p><\/div>\n

\u0422\u0435\u0445\u043d\u0438\u0447\u0435\u0441\u043a\u0438\u0435 \u0445\u0430\u0440\u0430\u043a\u0442\u0435\u0440\u0438\u0441\u0442\u0438\u043a\u0438<\/h2>\n
Fully automated SPD assembly line. Automatic base feeding, varistor welding, module insertion, laser marking, pad printing. Compliant with IEC 61643\u201111.<\/div>\n
\n\n\n\n\n <\/tr>\n\n\n\n <\/tr>\n\n\n\n <\/tr>\n\n\n\n\n\n <\/tr>\n\n
SPD types supported<\/th>\nType 1, Type 2, Type 3 (single\u2011port or two\u2011port), 1P\/2P\/3P\/4P configurations<\/td>\n<\/tr>\n
Base feeding<\/th>\nVibratory bowl or magazine stacker, continuous operation<\/td>\n<\/tr>\n
Varistor welding method<\/th>\nResistance welding (MFDC) or fiber laser welding (optional)<\/td>\n<\/tr>\n
Welding accuracy<\/th>\nPosition repeatability \u00b10.1mm; weld energy monitoring \u00b12%<\/td>\n<\/tr>\n
Module insertion<\/th>\nServo\u2011controlled press, force monitoring (50\u2011200N), auto\u2011reject on force deviation<\/td>\n<\/tr>\n
Laser marking<\/th>\nFiber laser (20W\/30W), marking area 110x110mm, supports barcode\/QR\/ text<\/td>\n<\/tr>\n
\u0422\u0430\u043c\u043f\u043e\u043d\u043d\u0430\u044f \u043f\u0435\u0447\u0430\u0442\u044c<\/th>\n1\u20112 colors, automatic ink cup, quick\u2011release clich\u00e9<\/td>\n<\/tr>\n
\u0441\u0438\u0441\u0442\u0435\u043c\u0430 \u0443\u043f\u0440\u0430\u0432\u043b\u0435\u043d\u0438\u044f<\/th>\nPLC (Siemens\/Mitsubishi) with HMI, recipe storage for 20+ SPD models<\/td>\n<\/tr>\n
\u041f\u0440\u043e\u0441\u043b\u0435\u0436\u0438\u0432\u0430\u0435\u043c\u043e\u0441\u0442\u044c<\/th>\nBarcode reader at module welding and final test; data uploaded to MES<\/td>\n<\/tr>\n
\u042d\u043b\u0435\u043a\u0442\u0440\u043e\u043f\u0438\u0442\u0430\u043d\u0438\u0435 \u0438 \u043f\u043e\u0434\u0430\u0447\u0430 \u0432\u043e\u0437\u0434\u0443\u0445\u0430<\/th>\n380 \u0412 \u00b110% 50 \u0413\u0446 | \u0421\u0436\u0430\u0442\u044b\u0439 \u0432\u043e\u0437\u0434\u0443\u0445 0,6-0,8 \u041c\u041f\u0430<\/td>\n<\/tr>\n<\/tbody>\n<\/table><\/div>\n

\u041e\u0441\u043d\u043e\u0432\u043d\u044b\u0435 \u0442\u0435\u0445\u043d\u0438\u0447\u0435\u0441\u043a\u0438\u0435 \u043f\u0440\u0435\u0438\u043c\u0443\u0449\u0435\u0441\u0442\u0432\u0430<\/h2>\n
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Unmanned operation for high\u2011volume production<\/h4>\n

From base feeding to final marking, the line runs without operator intervention. One technician can oversee multiple lines, drastically reducing labor cost and eliminating human variability.\n <\/p><\/div>\n

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Precision varistor welding \u2013 low contact resistance<\/h4>\n

The resistance welding station uses medium\u2011frequency DC control with real\u2011time energy monitoring. Welds achieve contact resistance <0.1 m\u03a9, ensuring reliable surge current conduction and long MOV life.\n <\/p><\/div>\n

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Integrated traceability for regulatory compliance<\/h4>\n

Each SPD receives a laser\u2011marked unique ID linked to welding parameters, module insertion force, and final inspection data. Full traceability supports IEC 61643\u201111 certification and customer audits.\n <\/p><\/div>\n

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Flexible modular design<\/h4>\n

The line can be configured for different base sizes, varistor counts (1\u20114 MOVs), and optional thermal disconnect assembly. Changeover between product families typically takes 30\u201160 minutes with quick\u2011change tooling.<\/p><\/div>\n<\/p><\/div>\n<\/p><\/div>\n

\n \u041d\u0430\u043c \u0434\u043e\u0432\u0435\u0440\u044f\u044e\u0442 \u043b\u0438\u0434\u0435\u0440\u044b \u043e\u0442\u0440\u0430\u0441\u043b\u0438.<\/span><\/p>\n
\n
\n \"ABB\"\n <\/div>\n
\n \"DELIXI\"\n <\/div>\n
\n \"EKF\"\n <\/div>\n
\n \"KRIPAL\"\n <\/div>\n
\n \"HPL\"\n <\/div>\n
\n \"CHAC\"\n <\/div>\n
\n \"Schneider\"\n <\/div>\n
\n \"IEK\n <\/div>\n
\n \"SUNIR\"\n <\/div>\n
\n \"Bevone\"\n <\/div>\n
\n \"Weg\"\n <\/div>\n
\n \"HUYU\"\n <\/div>\n
\n \"RAAD\"\n <\/div>\n
\n \"WALTONE\"\n <\/div>\n
\n \"HAVELLS\"\n <\/div>\n
\n \"C&S\n <\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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Customer Success Story \u2013 Type 2 SPD Manufacturing<\/h3>\n

To meet their growing demand, European SPD Brand needed to rapidly increase monthly output of Type 2 Surge Protection Devices (SPDs) from 5,000 to 20,000. Their challenge was poor weld quality and excessive rework of varistors. Working with Benlong, they created an automatic production line that included: a custom-designed surge protection device assembly fixture; dual-station resistance welding; and inline monitoring of the quality of the welded varistors.<\/p>\n

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20,000 units\/month<\/strong> Achieved within 3 months<\/div>\n
99.5%<\/strong> \u0432\u044b\u0445\u043e\u0434 \u043f\u0440\u0438 \u043f\u0435\u0440\u0432\u043e\u043c \u043f\u0440\u043e\u0445\u043e\u0434\u0435<\/div>\n
-60%<\/strong> \u041f\u0440\u044f\u043c\u044b\u0435 \u0437\u0430\u0442\u0440\u0430\u0442\u044b \u043d\u0430 \u0440\u0430\u0431\u043e\u0447\u0443\u044e \u0441\u0438\u043b\u0443<\/div>\n<\/p><\/div>\n

The line self-funded its costs in a period of 14 months. The customer received a factory audit on IEC 61643-11 without any non-conformances due to full laser marking traceability.<\/p>\n<\/p><\/div>\n

\u0418\u043d\u0442\u0435\u0433\u0440\u0430\u0446\u0438\u044f \u043f\u0440\u0438\u043b\u043e\u0436\u0435\u043d\u0438\u0439 \u0438 \u043f\u0440\u043e\u0438\u0437\u0432\u043e\u0434\u0441\u0442\u0432\u0430<\/h2>\n
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SPD manufacturing plants<\/strong> \u2013 High\u2011volume production of Type 1\/2\/3 surge protectors<\/div>\n
Power distribution component suppliers<\/strong> \u2013 OEM production for global brands<\/div>\n
Renewable energy systems<\/strong> \u2013 PV surge protection devices<\/div>\n
Telecom & data center protection<\/strong> \u2013 Rack\u2011mount SPDs<\/div>\n<\/p><\/div>\n<\/p><\/div>\n

\u0420\u0430\u0437\u0440\u0430\u0431\u043e\u0442\u043a\u0430 \u0438 \u043f\u043e\u0441\u0442\u0430\u0432\u043a\u0430 \u043f\u043e \u0438\u043d\u0434\u0438\u0432\u0438\u0434\u0443\u0430\u043b\u044c\u043d\u043e\u043c\u0443 \u0437\u0430\u043a\u0430\u0437\u0443<\/h2>\n
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1. Product analysis<\/strong> 15-30 days \u00b7 SPD samples, base & varistor dimensions<\/div>\n
2. Line layout & fixture design<\/strong> 20-40 days \u00b7 3D simulation<\/div>\n
3. \u041f\u0440\u043e\u0438\u0437\u0432\u043e\u0434\u0441\u0442\u0432\u043e<\/strong> 60-90 \u0434\u043d\u0435\u0439<\/div>\n
4. \u041f\u0440\u0435\u0434\u0436\u0438\u0440<\/strong> \u041d\u0430 \u0437\u0430\u0432\u043e\u0434\u0435 \u0411\u0435\u043d\u043b\u043e\u043d\u0433<\/div>\n
5. Installation & commissioning<\/strong> On-site 10-15 days<\/div>\n
6. \u0418\u0442\u043e\u0433\u043e\u0432\u044b\u0439 \u044d\u043a\u0437\u0430\u043c\u0435\u043d SAT \u0438 \u043e\u0431\u0443\u0447\u0435\u043d\u0438\u0435.<\/strong> 5-7 \u0434\u043d\u0435\u0439 \u00b7 \u0430\u043a\u0442 \u043f\u0440\u0438\u0435\u043c\u043a\u0438<\/div>\n<\/p><\/div>\n
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Request a Custom SPD Production Line Quote<\/h2>\n

Please provide us with your SPD base sample, varistor module samples, and target output. Our engineering team will design a customized automatic production line for you, including welding, assembly, marking, and full IEC 61643\u201011 compliance.<\/p>\n

\u0417\u0430\u043f\u0440\u043e\u0441\u0438\u0442\u044c \u0438\u043d\u0444\u043e\u0440\u043c\u0430\u0446\u0438\u044e \u0441\u0435\u0439\u0447\u0430\u0441<\/a><\/p>\n

WhatsApp: +86 150 5837 0007 | \u042d\u043b\u0435\u043a\u0442\u0440\u043e\u043d\u043d\u0430\u044f \u043f\u043e\u0447\u0442\u0430: xsb@benlongkj.cn | \u041f\u043e\u0434\u0434\u0435\u0440\u0436\u043a\u0430 \u043d\u0430 \u0430\u043d\u0433\u043b\u0438\u0439\u0441\u043a\u043e\u043c \u0438 \u043a\u0438\u0442\u0430\u0439\u0441\u043a\u043e\u043c \u044f\u0437\u044b\u043a\u0430\u0445<\/p>\n<\/p><\/div>\n

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Why Choose Benlong for SPD Automation?<\/h3>\n