1A-63A MCB Automatic Production-Testing Machine Line

This production line is used for MCB 63AMP product riveting, functional test, barcode generating and laser printing. The whole line use touch screen as human-computer interface and adopt PLC to control product parameters. Machine identify products by barcode to do test. Through computer remote monitoring system the production line realise intensive monitoring of process of all units and production technical parameters. Retrieve history report to be searched easily, unqualified products to be archived.
Production line work process
Running test, riveting, barcode printing&unscrewing, magnetic test, HV test, thermal test, dispensing, riveting, laser printing.


A   MCB On/Off Operation, Cold Calibration& Continuity Test:
·         Pole to be made "ON" from Dolly and to be made "OFF" from handle through mechanism. These operations to repeat 5 times.
·         Continuity to be tested across the pole in ON condition each time.
·         "No continuity" defect (no continuity in pole while Dolly is in "ON" condition) to be differentiated from "Not Latching" defect (pole not latching due to defective mechanism)
·         This unit controlled by PLC and touch screen, set the testing parameter ( product model, current grade, electric time and so on) by touch screen. With 10 inch colorful touch screen, display techniques parameter, testing result, indicate and alarm fault.
·         No of turns to be rotated for calibration should be settable with a resolution of 0.18 degree per step (That means 2000 steps for 1 full rotation of calibration screw). This should be settable manually during process on the PC screen.
·         In cold calibration, feedback from thermal verification test is required to modify backwards number of steps of rotation of calibration screw automatically as per inputs provided by Alfanar.
·         Failed breakers should be removed automatically.
·          Customer will provide the flowchart of process, data acquisition. Statistical data easy to be shown on screen and could be printed. Customer give details about which reports & in which format.
 
 
B    Riveting Unit:
 
·         Pole to be stripped adequately while Riveting.
·         All rivets to be inserted & Riveted.
·         Absence of Rivet to be detected.
·         various combinations can be achieved between two riveting machine.

 
C      Generating Bar code (Ink Jet Unit):
 
·         Bar code generated and printed on breaker using bar code printer. It will be 1st stage, so that individual breaker shall be traced in each testing stage for Data acquisition
·         When scanning the breaker with bar code scanner all test results should appear.
·         All breakers barcodes and results saved on PC database to maintain traceability at any time.
·         Should be possible to put individual barcode OR Batch code on product. Ability to set and change codes as per requested.  Code to appear at the bottom of breaker.

 
D     Unscrewing:
 
·         Lower Terminal Screw of Plugin MCB to be unscrewed
·         In case of New Design MCB, unscrewing can not be done before calibration hence to be done after calibration & Testing. Thus it should be possible to shift this station to suitable location for New Design
 
E    Magnetic Test:
 
·         Power source: current capacity: 10~1000A accuracy ≤±5%;duration of input test current shall be 200ms maximum and settable in PC; Current will be multiple of breaker rating and it will be settable.  , Waveform to be displayed on oscilloscope whenever required. Tripping time & Tripping current both to be displayed on suitable meters.
·         Electrode Contacts should be silver brazed.
·         Statistical data easy to be shown on screen and could be printed out.
 
F    H.V Test:
 
·         Voltage source : 0~5000V adjustable testers of high leakage current Precision, Leakage Current capacity 100ma continuous, short response and stable.
·          Dielectric test between two terminals in OFF condition and Terminal & Base bottom in ON condition to be tested each test for 1 sec. Leakage level for detection of fault shall be   at 2ma settable at different level on instrument.
·         Overall Accuracy better than 5%.
·         Statistical data easy to be shown on screen and could be printed.
 
G    Thermal Test & Sealing of Calibration Screw:
 
·         In Thermal test, Temperature sensor is required to change tripping band or current value as per room temperature
·         Technology parameter of constant power: D.C Source with following Specs
§  Overall Accuracy better than 0.2%
§  Repeatability better than 0.1%
§  Source Make: TDK Lamda 'GEN 20-250'
§  Digital type
·         Sealing thermal Screw Automatically to lock it.
·         Electrode Contacts should be silver brazed.
·         Statistical data easy to be shown on screen and could be printed.
·         Machine will take out automatically failed breakers and arrange them in different groups, 1 sec Low, 2 sec Low, 1 sec High, 2 sec High etc
 
 
 
H    Riveting Unit:
 
·         Pole to be stripped adequately while Riveting.
·         All rivets to be inserted & Riveted.
·         Absence of Rivet to be detected.

 
I    Laser Printing Unit:
 
·         Laser   "ON" & "OFF" with grey color on black dolly on two sides.
·         Toggling dolly from ON to OFF or OFF to ON as convenient
·         Printing Logo, Ratings, IEC standard, voltages, Ampere & curve type all in grey color over black breaker.