{"id":85,"date":"2026-06-01T10:38:10","date_gmt":"2026-06-01T10:38:10","guid":{"rendered":"https:\/\/khkrh7q1ur.wpdns.site\/product\/dc-isolating-switch-automatic-production-line\/"},"modified":"2026-06-09T21:41:41","modified_gmt":"2026-06-09T21:41:41","slug":"dc-isolating-switch-automatic-production-line-product","status":"publish","type":"product","link":"https:\/\/benlongkj.com\/tr\/urun\/dc-isolating-switch-automatic-production-line-product\/","title":{"rendered":"DC Ay\u0131rma \u015ealteri Otomatik \u00dcretim Hatt\u0131"},"content":{"rendered":"
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PV switch \u00b7 UL\/IEC compliant<\/div>\n

Fully Automatic DC Isolating Switch Production Line for PV Applications<\/h1>\n

A fully automated DC Isolating Switch production line is an advanced manufacturing system for Photovoltaic (PV) DC Disconnect Switches (2P-8P). To ensure PV Switch performance, this line meetsPV Switch product requirements for the following areas:
\n1. Constant contact pressure
\n2. Accurate shaft torque
\n3. Reliable arc extinguishing structure positioning
\n4. Insulation reliability for high voltage meets both UL and IEC requirements. The line automates all processes involved in the manufacture of PV switches, including; housing feeding, terminal assembly, main contact assembly, rotary mechanism calibration, arc chute assembly, multi-pole stacking and complete testing.<\/p>\n

Automated systems – such as automatic housing and terminal module feeders, CCD guided copper busbar insertion, spring pressing, torque controlled screw tightening, contact pressure monitoring, knob, cam and shaft press\u00ad-fitting, stroke angle detection (ON \/ OFF), arc extinguisher plate placement, multiple pole riveting and Hi-Pot Testing (up to 5000 volts) – all contribute to increased productivity on the line. An integrated traceability system using laser marking, Datamatrix, and MES records all test results. The line is able to achieve an extremely high through\u00adput with only 3 to 4 operators per shift (material handler, maintenance, QC, and packaging). Products manufactured on this line are used in a variety of applications such as two, four, six, and eight pole DC isolators for Solar Combiner Boxes, inverters and battery storage systems.<\/p>\n

Standard delivery: 90-120 days | Customizable for 2P\u20118P | UL\/IEC compliant testing<\/span><\/p>\n<\/p><\/div>\n

\n \"DC<\/p>\n
PV switch assembly & test line (actual product)<\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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What is a DC Isolating Switch Automatic Production Line?<\/h2>\n

A complete automated production system that manufactures PV DC disconnect switches is known as a DC isolating switch production line (or DC isolators or load break switches). These switches are designed to assist in safely disconnecting solar arrays, inverters, and battery storage systems from each other. This production line automates the process from the assembly of the housing and terminals, the insertion of the copper busbars, the crimping of the spring, the tightening of the screws, the assembly of the contacts, the calibration of the rotary mechanisms (torque & stroke), the placement of the arc extinguishers, the stacking of the poles (2P through to 6P), and the final testing. The production line has been designed to meet the high standards demanded by the PV industry, e.g., even contact pressure to avoid arcing, knob torque being stable (ON\/OFF forces comply with UL 508I or IEC 60947-3), hi-voltage insulation (hi-pot tests up to 5 kV for 1000V\/1500V systems) and full traceability of components. This production line is non-standard\/custome made, according to your switch type\/design, current rating (16A through to 200A) and production quantities.<\/p>\n

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\n Automated terminal assembly<\/strong>
\n Copper busbar alignment, spring pressing, and torque\u2011controlled screw tightening with CCD verification.\n <\/div>\n
\n Rotary mechanism calibration<\/strong>
\n Knob\/cam\/shaft press\u2011fitting, torque curve recording, and ON\/OFF stroke angle detection.\n <\/div>\n
\n Arc\u2011chute & insulation assembly<\/strong>
\n Automatic feeding, insertion, and positioning of arc plates and insulating partitions with ultrasonic verification.\n <\/div>\n
\n Multi\u2011pole stacking & riveting<\/strong>
\n Automatic alignment, riveting, and CCD flatness inspection for 2P\u20118P modular stacks.\n <\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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Production Line Modules & Process<\/h2>\n
\n
\n \"Ak\u0131ll\u0131<\/p>\n
Zeka ve G\u00f6r\u00fcn\u00fcrl\u00fck<\/div>\n<\/p><\/div>\n
\n \"Verimlilik<\/p>\n
Verimlilik ve S\u00fcrd\u00fcr\u00fclebilirlik<\/div>\n<\/p><\/div>\n
\n \"Tasar\u0131m<\/p>\n
Tasar\u0131m ve Entegrasyon<\/div>\n<\/p><\/div>\n
\n \"G\u00fcvenlik<\/p>\n
G\u00fcvenlik ve G\u00fcvenilirlik<\/div>\n<\/p><\/div>\n<\/p><\/div>\n<\/p><\/div>\n

Teknik \u00d6zellikler<\/h2>\n
Fully automated DC isolator production line for PV applications. Terminal assembly, rotary mechanism, arc\u2011chute, multi\u2011pole stacking, hi\u2011pot test, torque\/stroke measurement, MES integration.<\/div>\n
\n\n\n\n\n\n\n <\/tr>\n\n\n\n\n\n\n\n
Supported pole configurations<\/th>\n2P, 4P, 6P, 8P (modular stacking)<\/td>\n<\/tr>\n
Switch current rating<\/th>\n16A \u2013 200A DC (customizable)<\/td>\n<\/tr>\n
Hi\u2011pot test voltage<\/th>\nUp to 5,000V AC\/DC, programmable, multi\u2011pole simultaneous<\/td>\n<\/tr>\n
Torque test range<\/th>\n0.5 \u2013 10 N\u00b7m, automatic curve recording, ON\/OFF force detection–\n <\/td>\n<\/tr>\n
Stroke angle detection<\/th>\n0\u2011180\u00b0, accuracy \u00b10.5\u00b0, OFF\u2011ON position verification–\n <\/td>\n<\/tr>\n
Contact pressure monitoring<\/th>\nLoad cell (10\u2011200N), real\u2011time data logging–\n <\/td>\n<\/tr>\n
Assembly modules<\/th>\nHousing feeder \u00b7 Terminal module feeder \u00b7 Spring insertion \u00b7 Copper busbar placement \u00b7 Screw tightening (torque controlled) \u00b7 Contact assembly \u00b7 Rotary mechanism press\u2011fit \u00b7 Arc\u2011chute feeder \u00b7 Multi\u2011pole riveting \u00b7 CCD inspection–\n <\/td>\n<\/tr>\n
CCD inspection<\/th>\nMissing parts, assembly position, label correctness, flatness–\n <\/td>\n<\/tr>\n
\u0130zlenebilirlik<\/th>\nLaser marking (model, batch, UL File No.) \u00b7 DataMatrix\/QR \u00b7 MES integration–\n <\/td>\n<\/tr>\n
Line personnel<\/th>\n3\u20114 operators per shift (material handler, maintenance, QC, packaging)–\n <\/td>\n<\/tr>\n<\/tbody>\n<\/table><\/div>\n

Temel Teknik Avantajlar<\/h2>\n
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Consistent contact pressure & torque<\/h4>\n

PV switches demand precise contact pressure to prevent arcing. The line uses servo\u2011controlled pressing with force monitoring and automatic screw tightening with torque feedback \u2013 eliminating manual variability.\n <\/p><\/div>\n

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High\u2011voltage insulation reliability<\/h4>\n

Every switch undergoes hi\u2011pot testing (up to 5kV) with automatic leakage current determination. Multi\u2011pole simultaneous testing ensures compliance with UL 508I or IEC 60947\u20113.\n <\/p><\/div>\n

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Complete rotary mechanism calibration<\/h4>\n

The knob\u2011drive mechanism (cam, shaft, handle) is automatically assembled, press\u2011fitted, and tested for operating torque and stroke angle (ON\/OFF position). Torque curves are recorded and must pass UL force limits.\n <\/p><\/div>\n

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Full MES integration for traceability<\/h4>\n

Each switch receives a laser\u2011marked DataMatrix code (model, batch, UL File No.). All test results (hi\u2011pot, torque, stroke, contact resistance) are bound to the serial number and uploaded to MES for full traceability and remote OEE monitoring.\n <\/p><\/div>\n<\/p><\/div>\n

<\/p>\n

\n Sekt\u00f6r liderlerinin g\u00fcvendi\u011fi<\/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 \"\u00c7AK\"\n <\/div>\n
\n \"Schneider\"\n <\/div>\n
\n \"IEK\n <\/div>\n
\n \"SUNIR\"\n <\/div>\n
\n \"Bevone\"\n <\/div>\n
\n \"Yol\"\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 PV Switch Manufacturer<\/h3>\n

A manufacturer of European PV combiner boxes required the automation of manufacturing for their 4P and 8P DC isolators (1000V\/32A). They were experiencing field failures due to inconsistent assembly processes resulting from manual handling with the incorrect amount of torque and contact pressure applied.
\nBenlong’s company was able to design and provide a custom-built DC isolating switch production line with eight total workstations (terminal assembly, rotary mechanism calibration, arc\u2011chute assembly, multi\u2011pole riveting, hi-pot testing, torque\/stroke measuring, laser marking and automatic packing). The results reported six months later:<\/p>\n

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98%<\/strong> First\u2011pass yield (up from 88%)<\/div>\n
2,400 units\/shift<\/strong> Throughput (8P equivalent)<\/div>\n
S\u0131f\u0131r<\/strong> field failures due to contact pressure or torque<\/div>\n<\/p><\/div>\n

The 14-month payback period for this line also aided this customer in obtaining UL 508I certification, as well as providing full traceability documentation.<\/p>\n<\/p><\/div>\n

Uygulamalar ve Entegrasyon<\/h2>\n
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PV combiner boxes<\/strong> \u2013 DC isolators for solar string protection<\/div>\n
Inverter DC disconnects<\/strong> \u2013 Integrated or standalone switches<\/div>\n
Battery energy storage systems<\/strong> \u2013 DC isolation for racks<\/div>\n
EV charging stations<\/strong> \u2013 DC load break switches<\/div>\n<\/p><\/div>\n<\/p><\/div>\n

\u00d6zel M\u00fchendislik ve Teslimat<\/h2>\n
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1. Product & process design<\/strong> 20-40 days \u00b7 switch samples, pole config, UL\/IEC requirements<\/div>\n
2. Module & line layout<\/strong> 20-30 days \u00b7 3D simulation, station definition<\/div>\n
3. \u00dcretim<\/strong> 90-120 g\u00fcn<\/div>\n
4. Pre\u2011FAT<\/strong> Benlong fabrikas\u0131nda<\/div>\n
5. Installation & commissioning<\/strong> On-site 15\u201120 days<\/div>\n
6. Son SAT s\u0131nav\u0131 ve e\u011fitim<\/strong> 7\u201110 days \u00b7 acceptance report<\/div>\n<\/p><\/div>\n
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Request a Custom DC Isolator Line Quote<\/h2>\n

Provide us with your drawings of the switch, the pole configuration (2p-8p), as well as the current ratings and intended output. Our engineering team will create a fully loaded line that includes terminal assembly, torque\/stroke testing, hi-pot testing, and MES. Each proposal will also include a complete ROI analysis.<\/p>\n

\u015eimdi bilgi al\u0131n<\/a><\/p>\n

WhatsApp: +86 150 5837 0007 | E-posta: xsb@benlongkj.cn | \u0130ngilizce ve \u00c7ince destek<\/p>\n<\/p><\/div>\n

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