Amcb (DIN-rail) Automatic Testing Line

2.General Design requirements:
· Output 900 poles per HR with 8 parallel thermal stations arrangement this testing line is suitable for 1P, current specification is from 6A to 63A. Magnetic trip type Is B &C.
· All the spare parts are deal with rust prevention, carbon steel plated nickel in the surface, aluminum parts Are oxygenation.
· Whole frame of each unit use aluminum alloy section, support foot can adjust height and with moving Castor, easy for moving. Color of the whole line is based on off-white;.
· This line transfer layout fluency, easy for manual operation and material transfer. Height of transfer line should be 950 mm
·  PC/PLC software must be in English User interface should toggle between English and Chinese.
· Measure meters (current meter, voltage meter, voltage withstand testing meter, manual inductor and soon) should supply the Measuring certificate by the third party from government (in English).
·  PC based Data acquisition capability required for Thermal Cold calibration, Thermal verification & Magnetic Testing and other production data.
· Provision to detect the product orientation and turn the product to orient it properly when inserted wrongly.

During the operations Running test, Calibration & Screw Assembly pressure must be on the breakers frame & cover to make sure good closing while testing
Calibration Offset page for Thermal & Magnetic stations for Quality (Touch screen software).
Reports from PC system we need it in Customer format will be given to ACA.


1) Data Base system for testing results
· Automatic Saving all testing data, Magnetic, Thermal & HV tests, and store it in database.

2) Inspection for Arc Chute and two Arc Accelerator
Check Arc Chute presence and reject breaker with missing arc chute.
Check 2 Arc Accelerator presence in both sides and reject breaker with missing arc accelerator.
Using magnetic sensor inspection.
Test one by one.

3) Bimetal screw assembly:
· This unit controlled by PLC and touch screen, set the assembly parameter ( product model, and so on) by touch screen. With 10 inch colorful touch screen, display techniques parameter, assembly result, indicate and alarm fault.
· Step motor screws is two sets. Two screw feeding system .
· The first assembly 1 and 3 positions of the product ; the second assembly 2 and 4 positions of the product .
· Failed breakers should be removed automatically.
· Rejection trey need to have 3-5 breakers for rejection.
· four product test together
· Bimetal screw need to Inner six angle screw.
· The need to control the gap with the product casing screw holes and screws .

4) 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.
·  AF will provide the flowchart of process, data acquisition. Statistical data easy to be shown on screen and could be printed. AF to give details about which reports & in which format.
· Rejection trey need to have 30 breakers for rejection.

5) Riveting Unit :
· Pole to be stripped adequately while Riveting.
· All 6 rivets to be inserted & riveted.
· Absence of Rivet to be detected.
· Various combinations can be achieved by riveting machine.
· One turntable, turntable with eight working station,

6) Generating Bar code (Ink Jet Unit):
· Bar code should be generated and printed on breaker using bar code printer. It shall 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.
· Barcode is 2D , 10x10 mm

7) Tripping Force test
· On testing station the first operation is to switch on/off product for one time to ensure tripping mechanism is in good condition.
· Cylinder will push breaker to on Position, and pin connected to stepper motor will trip breaker from side.
· Operation will happen 3 times, anytime breaker fail, we need to reject the breaker.
· Four parallel triping force stations

8) Unscrewing:
· Unscrewing of terminals
· fou product together ;
· screws is four sets

9) Magnetic Test:
· Power source: current capacity: 10~1000A accuracy ≤±5%; duration of input test current shall be 200ms maximum and should be settable in PC; Current should be multiple of breaker rating and it should 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.
· Six product test together

10) HV Test:
· Voltage source : 0~5000V adjustable testers of high leakage current Precision, Leakage Current capacity 100ma continuous, short in response time and very stability.
·  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.
· Testing will be for breaker in On Position on V shape between poles.
· Testing will be for breaker in Off Position between breaker terminals.
· four product test together

11) Thermal Test:
· Alfanar MCB is having predefined one current value for each MCB rating (2.5 In for the thermal) so Alfanar will provide the current value.
· 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
· 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
· eight parallel triping force stations


12) Pad Printing Unit:
· Machine will be suitable for 1P 63A 3 breakers in one shot
· Machine will be suitable for 2P 63A 1 breakers in one shot.
· Machine will be suitable for 3P 63A 1 breaker in one shot.
· Machine will have 3 color Pad printing stations will run Synchronized (with option to bypass any station).
· Printing Cups will be High quality (From KENT).
· Machine Printing Plates will be Thin Type of 0.25mm thickness made form Carbon Steel.
· Machine will come with 3 Plates which is suitable for 32A SP.
· For Each two stations two motors must carry big tape, so the pad can hit on tape for cleaning before taking ink from plate (The pads will be clean after adjustable number of printing)
· Machine PLC to be connected with main server in 63A Automatic line, and production reports can be taken from server.
· Cleaning device for the breakers using thinner added at the beginning of the line and air blow is available while breaker is running to make it dry.
· Will add 1 meter of conveyer after printing for one person sitting for visual inspection.
13) DInrail latch holder Assembly:
· This unit controlled by PLC and touch screen, set the assembly parameter ( product model, and so on) by touch screen. With 10 inch colorful touch screen, display techniques parameter, assembly result, indicate and alarm fault.
· One DInrail latch feeding system .
· Machine will be suitable for 1P 63A 3 breakers in one shot
· Machine will be suitable for 2P 63A 1 breakers in one shot.
· Machine will be suitable for 3P 63A 1 breaker in one shot.
· Failed breakers should be removed automatically.
Rejection trey need to have 3-5 breakers for rejection.


Equipment Layout: