IEC 60898‑1 · High‑volume assembly

MCB Automatic Production Line
2,500+ units/hour | 1P‑4P assembly

An automated assembly line that makes MCBs is capable of performing many tasks. The assembly line welds the bimetal, welds the magnetic trip, assembles multiple poles, and performs electrical and mechanical endurance testing. The assembly line runs continuously and produces MCBs at a high volume.

2,500+
Units/hour
1P‑4P
Pole configuration
100%
Inline testing
15+
Integrated stations
Core advantages

Why a fully automatic MCB production line?

By utilizing automatic assembly lines, manufacturers of large volumes of miniature circuit breakers are able to ensure consistent torque, accurate bimetal placement (position), and have conducted 100% in-line mechanical and electrical testing in compliance with IEC 60898-1 standards .

Multi‑pole automatic assembly
CCD vision‑guided conversion from 1P to 2P/3P/4P. Servo riveting with real‑time force monitoring. Tool‑less changeover between pole configurations.
Precision welding stations
Automatic welding for bimetal support frames (±0.05mm) and magnetic trip set coil leads. Micro‑resistance or laser welding with post‑weld verification.
Integrated endurance testing
Mechanical life test (ON/OFF cycling) and electrical endurance test with programmable L‑R load, contact voltage drop monitoring, auto‑shutdown on welding.
MES & full traceability
Each unit’s welding parameters, torque values, and endurance results linked to serial number. Real‑time SPC and reject sorting.
Integrated line modules

Our MCB automatic production line components

All necessary elements for assembling and testing micro circuit breakers. These include parts feeding systems all the way through endurance benchmarks.

Each module can be ordered separately or as a fully integrated line. Custom configurations for 1P‑4P MCBs available.
Field results

Real impact from automatic MCB lines

Global MCB brand – China
Deployed full assembly line for 1P‑4P MCBs. Output increased from 1,200 to 2,600 units/hour. Welding consistency improved by 90% with vision‑guided stations.
Indian electrical manufacturer
Integrated multi‑pole assembly and electrical endurance test. Reduced field failures due to contact welding by 70%. Payback period 11 months.
Middle East distributor
Custom line for B/C/D curve MCBs. Achieved 100% inline mechanical life verification. Passed major utility audit with full traceability.
European OEM
Added automatic bimetal welding and magnetic trip assembly. Labor cost reduced by 65%, first‑pass yield 99.4%.
Technical specs

Traditional semi‑auto line vs. our fully automatic MCB line

Gain awareness of the variations between testing coverage, throughput and packaging accuracy while producing compact circuit breakers.

Parameter Traditional semi‑auto line Benlong fully automatic line
Output (units/hour)800‑1,2002,500‑3,500
Pole assembly methodManual clip + hand screwCCD vision + servo riveting
Welding accuracy (bimetal)±0.2mm (operator)±0.05mm (vision guided)
Magnetic trip weldingManual solderingMicro‑resistance/laser, post‑weld check
Mechanical endurance testSample‑based, external100% inline, programmable cycles
Electrical endurance testSample‑based100% inline, L‑R load, contact monitoring
Traceability levelPaper logSerialized barcode, MES upload
Typical investment$200k – $500k$800k – $2.2M+

If an MCB line is fully automated, then its payback period is 12-18 months with a capacity of at least 5 million units annually. Determine your return on investment (ROI).

Design guide

How to specify an MCB automatic production line – 5 steps

Plan your miniature circuit breaker assembly line for maximum efficiency and IEC compliance.

Step 1: Define pole mix & output volume
Specify ratio of 1P, 2P, 3P, 4P MCBs and daily target. This determines multi‑pole assembly station design and changeover frequency.
Step 2: Select welding technologies
Bimetal support frame → resistance welding; magnetic trip coil leads → micro‑resistance or laser welding. Both with integrated verification.
Step 3: Decide endurance test scope
Mechanical only (ON/OFF cycles) or electrical with L‑R load (PF 0.85). For IEC 60898‑1 Clause 9.11 compliance, electrical endurance is required.
Step 4: Plan for quick changeover
Tool‑less changeover between pole configurations (15‑20 minutes). For frequent changes, add a second set of fixtures.
Step 5: Specify MES & data logging
Each unit’s welding parameters (current, time, force), torque values, and test results linked to serial number. Real‑time SPC dashboards.

If you’re interested in a full MCB Production solution, just send us your Pole Combination and what you need to produce (Output) and we can provide you with a complete production line. Please contact our line integration team →

HỒ SƠ CÔNG TY

Tích hợp hệ thống tự động hóa là cốt lõi

Benlong Automation Technology Co., Ltd. is a proudly recognized national high-tech enterprise engaged in developing state-of-the-art digital intelligent manufacture equipment. Established in 2008 in Wenzhou, China, we specialize as a manufacturer-focused provider of MCB automatic assembly and testing solutions to low-voltage electrical manufacturers globally.

We design our automated MCB manufacturing lines for mass production by combining multi-pole manufacturing, accurate welding, mechanical/electrical endurance testing, and MES connection.

We specialize in providing assembly equipment and services for manufacturers who produce miniature circuit breakers as they transition to Industry 4.0.

MCB production line assembly workshop
Doanh nghiệp công nghệ cao quốc giaMCB Assembly & Test
2008Được thành lập
50,88 triệuVốn điều lệ RMB
160+Bằng sáng chế quốc gia
26Bản quyền phần mềm
300+Hồ sơ trình độ chuyên môn
1200+Khách hàng được phục vụ
MCB production line engineering
ENGINEERING & INTEGRATION

From components to full MCB assembly line

Benlong manufactures and designs fully automatic MCB production lines, comprising all essential processes, such as multi-pole assembly, bimetal welding, magnetic trip welding, cycling for mechanical endurance, electrical endurance testing, and packaging. In addition, we also provide turnkey installations, PLC programming, and MES handshake.

Multi‑pole automatic assembly machine – CCD vision, servo riveting, tool‑less changeover
Bimetal support frame welding machine – ±0.05mm accuracy, 1,400‑2,400 pcs/hour
Magnetic trip set welding machine – micro‑resistance or laser, post‑weld verification
Electrical endurance test bench – L‑R load, contact welding detection, auto shutdown
Request a custom MCB line quote
MÔI TRƯỜNG NHÀ MÁY

Built for reliable MCB production lines

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

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

Trusted by MCB manufacturers worldwide

From China to Europe, our automatic production lines are improving quality and throughput for miniature circuit breakers.

Algeria MCB 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

GIẤY CHỨNG NHẬN & DANH HIỆU

Công nghệ, bằng sáng chế và sự công nhận chất lượng

Benlong đã đạt được chứng nhận doanh nghiệp công nghệ cao quốc gia, nhiều bằng sáng chế, bản quyền phần mềm và các giải thưởng trong ngành, phản ánh sự đầu tư liên tục vào phát triển công nghệ và đổi mới sản xuất thông minh.

ISO9001 Certificate

Chứng chỉ ISO9001

ISO14001 Certificate

Chứng chỉ ISO14001

ISO14001 Certificate

Chứng chỉ ISO14001

ISO9001 Certificate

Chứng chỉ ISO9001

ISO 45001 Certificate

Chứng chỉ ISO 45001

TUV Certificate

Chứng chỉ TUV

Got Questions?

MCB Automatic Production Line – FAQs

What is MCB in automation?

MCB means miniature circuit breaker. MCBs protect electrical circuits from overloads or short-circuiting in automation solutions. MCBs protect wiring for homes, businesses and factories and MCBs are tested and assembled on our automatic production line with bimetals, coils, contacts, and housings to create finished MCBs.

What is an automated production line?

An automated production line is an automated series of machines with work stations interconnected by a material handling system for assembling components and performing tests with minimal human involvement. Our MCB production line utilizes part feeding, assembly of multiple poles, welding, mechanical and electrical endurance testing, and MES data collection. The entire production line operates under one PLC.

What are the three types of MCB?

There are three categories of MCBs based on the tripping curve. The MCB classifications are: B (3 to 5 times In for residential and general-purpose usage), C (5 to 10 times In for moderate commercial and industrial loads with an inrush), and D (10 to 20 times In for large inrush loads such as transformers and motors). The automatic production line can easily produce all three styles of products by using adjustable magnetic trip calibration stations.

What is the full automatic production line?

Our complete automatic production line refers to the fact that every single process in the production of circuit breakers occurs automatically by machines without the use of any human labour. For example, when producing MCBs (Miniature Circuit Breakers), the following steps will each take place automatically and in sequence:
1) Bimetal welding
2) Assembling of the magnetic trip
3) Riveting of the contacts
4) Assembling of the multiple poles
5) Conducting a mechanical endurance test on all of the circuits
6) Conducting an electrical endurance test on all of the circuits
7) Marking the MCBs with a laser
8) Packaging of the MCBs on one conveyor. The operator is only required to monitor the entire production process and load component magazines.

What is the typical uptime of your MCB automatic line?

Our MCB Automatic Line achieves up to 95% Overall Equipment Effectiveness (OEE) with planned maintenance. The average time before a machine failure happens is in excess of 1,000 operational hours. Remote diagnostics via a VPN accounts for a reduction in downtime of 60%.

Can the line handle both thermal‑magnetic and electronic MCBs?

Yes. For Thermal‑Magnetic (dual breaking mechanism) MCBs, the MCB Automatic Line contains the bimetal welding and magnetic trip assembly processes. For Electronic RCBOs (Residual Current Breakers with overcurrent protection), the line has the capacity to add an earth leakage current test station. The MCB Automatic Line configuration is both modular and expandable.
Bắt đầu dự án của bạn

Need a Turnkey MCB Automatic Production Line?

Tell us your pole configuration (1P‑4P), target output, and required curves (B/C/D). Our engineers will design a custom assembly line with welding, endurance testing, and full MES integration.

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