VCB RMU GIS PVB Switchgear Assembly lines / Production lines
- VS1-12 vacuum circuit breaker characteristics and production processes
The VS1-12 vacuum circuit breaker is an indoor high-voltage switching device with the following characteristics and production processes:
1.Applicability: It is suitable for three-phase power systems with a rated voltage of 12kV and a frequency of 50Hz, serving as protective and control electrical equipment, especially suitable for places with frequent operations.
2.Mechanical Life: The mechanical life can reach up to 30,000 times, and the number of full-capacity short-circuit current breaking can reach 50 times.
3.Operational Reliability: It is suitable for reclosing operations and has extremely high operational reliability and service life.
4.Easy Maintenance: The VS1 vacuum circuit breaker (standard type) adopts a vertical insulating cylinder, and maintenance and upkeep usually only require occasional cleaning or lubrication of the operating mechanism.
5.Structural Advantages: The VS1 vacuum circuit breaker (pole type) adopts a solid insulating structure—integrated solid-sealed pole, achieving maintenance-free operation.
6.Installation Flexibility: The installation form in the switchgear can be either fixed or removable, and can also be installed on a frame for use.
7.Permanent Magnetic Operating Mechanism: It uses a permanent magnetic operating mechanism, combining the electromagnet with the permanent magnet in a special way to achieve all the functions of the traditional circuit breaker operating mechanism, enhancing the reliability of the circuit breaker.
8.Arc Extinguishing Chamber Technology: It uses a vacuum arc extinguishing chamber, with vacuum as the arc extinguishing and insulating medium, having an extremely high vacuum degree, and the medium insulation strength of the arc extinguishing chamber’s break is quickly restored, thus extinguishing the arc and achieving the purpose of breaking, as it uses magnetic field control of the vacuum arc, it has a strong and stable current breaking capability.
9.Testing Process: Includes appearance inspection, mechanical characteristic testing, withstand voltage testing, loop resistance testing, and vacuum degree testing to ensure that the assembled circuit breaker is defect-free and meets the standards.
10.Environmental Adaptability: It is suitable for various special environmental influences, including high ambient temperatures, low ambient temperatures, altitude, amplitude, and relative humidity.
11.Technical Parameters: The VS1-12 vacuum circuit breaker has detailed technical parameters, such as rated voltage, rated short-circuit breaking current, rated current, etc., to ensure its performance and safety under different working conditions.
12.Production Environment Requirements: The production environment should be free from fire, explosion hazards, severe pollution, chemical corrosion, and violent vibrations.
These characteristics and production processes ensure the high performance, high reliability, and long life of the VS1-12 vacuum circuit breaker, making it an ideal protective and control device in the power system.
- Gas Insulated Switchgear (GIS) Assembly Production line
Utilizing an assembly line and MES (Manufacturing Execution System) in the production and testing of Gas Insulated Switchgear (GIS) offers numerous advantages. The assembly line streamlines the manufacturing process, ensuring consistent quality and reducing the likelihood of human error. It allows for a clear division of labor, enhancing efficiency and throughput. The MES system provides real-time data collection and analysis, enabling better monitoring of production status and quality control. It facilitates just-in-time inventory management, reducing storage costs and material waste. Furthermore, MES supports traceability and compliance with industry standards, which is critical for high-voltage equipment like GIS. The integration of MES with the assembly line leads to a more flexible and adaptive production environment, capable of responding quickly to changes in demand or design specifications. Overall, the combination of an assembly line and MES system results in a more reliable, efficient, and cost-effective production process for GIS.
Gas Insulated Switchgear (GIS) structure and production testing process are key to ensuring its high performance and reliability. Here is the general information on GIS:
Structural Features
- Modular Design: GIS equipment adopts a modular design, which facilitates expansion and adaptation to different application requirements.
- Safe Encapsulation: All high-voltage components, such as circuit breakers, disconnectors, grounding switches, etc., are encapsulated within a metal housing, enhancing safety.
- High Gas Tightness: GIS equipment has good gas tightness, ensuring the stability of the internal SF6 gas, thereby safeguarding insulation and arc-extinguishing performance.
- Ease of Operation and Maintenance: The design takes into account the convenience of operation and ease of maintenance, including motor-operated mechanisms and the possibility of manual emergency operation.
- Independent Gas Compartments: Each gas compartment is independent, without gas connections, simplifying gas handling and maintenance.
Production Testing Process
- Factory Assembly: GIS equipment is assembled in the factory to ensure precise fitting of components and overall stability.
- Gas Filling and Testing: SF6 gas is filled in the enclosed gas compartments, and leakage tests are conducted to ensure the sealing and purity of the gas.
- Operating Mechanism Testing: The motor-operated operating mechanisms are tested to ensure reliable operation under normal and emergency conditions.
- Insulation Performance Testing: The insulation performance of GIS is tested, including partial discharge testing and insulation resistance testing.
- Functional Testing: All functions of GIS are tested, including the opening and closing operations of circuit breakers, operations of grounding switches, etc.
- Type Testing: Type testing is conducted according to International Electrotechnical Commission (IEC) standards to verify the performance of GIS equipment under extreme conditions.
- Pre-Delivery Testing: Comprehensive testing is carried out before delivery of GIS to ensure it meets customer requirements and standards.
Through these rigorous production testing processes, Gas Insulated Switchgear can ensure high performance, high reliability, and long service life.
- Air-Insulated Switchgear (AIS) Production line
Utilizing an assembly line for the production of Air-Insulated Switchgear (AIS) offers numerous significant benefits. Firstly, assembly line operations can significantly enhance production efficiency by automating and standardizing processes, reducing manual labor, and shortening production cycles. Secondly, the modular design of the assembly line allows for flexible adjustments to accommodate the production of different models and specifications of AIS equipment. Additionally, standardized quality control on the assembly line ensures that every product meets stringent quality standards, reducing the defect rate. At the same time, continuous operation on the assembly line minimizes material handling and storage time, reducing production costs. Lastly, assembly line production facilitates real-time monitoring and data collection, supporting continuous improvement and optimization of the production process. In summary, assembly line production not only improves production efficiency and product quality but also strengthens a company’s competitiveness in the market.
Air-insulated switchgear (AIS) structures and production testing processes are crucial to ensuring the quality and performance of the equipment. Here is the general information on air-insulated switchgear:
Structural Features
- Metal Enclosure: Air-insulated switchgear typically uses a metal-enclosed structure, which helps protect internal components from environmental influences and provides good electromagnetic compatibility.
- Air as Insulating Medium: The characteristic of air-insulated switchgear is the use of air as the insulating medium, which results in lower maintenance costs and environmental impact.
- Modular Design: Air-insulated switchgear adopts a modular design, allowing for flexible combinations of various functional units such as load switches, circuit breakers, and contactors, depending on different application requirements.
- Internal Arc Protection: Air-insulated switchgear is designed with internal arc protection features to safeguard operators in the event of an internal arc fault.
- Mechanical Interlocking Devices: The equipment is equipped with integrated central interlocking devices to ensure operational safety and prevent misoperation.
- Flexible Solutions: A variety of cabinet types are offered, including incoming and outgoing line cabinets, section cabinets, metering cabinets, and potential transformer (PT) cabinets, to meet different power grid configurations.
Production Testing Process
- Type Testing: A series of type tests are conducted during the design phase to verify the performance of the equipment under extreme conditions, including short-duration and peak withstand current tests, temperature rise tests, insulation tests, main switch opening and closing tests, and internal arc fault tests.
- Factory Testing: Each unit undergoes routine checks and tests before leaving the factory, including structural inspection, mechanical operation tests, power frequency withstand voltage tests, resistance measurement, and wiring correctness checks.
- Internal Arc Fault Protection Test: Internal arc fault protection tests are conducted to ensure that the equipment can protect the safety of operators in the event of an internal arc.
- Mechanical Operation Test: The main mechanical components of the equipment undergo operational life tests to ensure their reliability and durability.
- Temperature Rise and Main Circuit Resistance Measurement Test: Temperature rise tests ensure that the temperature rise of the equipment under rated current is within the specified range, while the main circuit resistance is measured to ensure compliance with standards.
- Gas Chamber Pressure Endurance Test: If the equipment includes gas chambers, pressure endurance tests are conducted to ensure the structural integrity.
- Seal Test: The sealing performance of the equipment is tested to ensure reliability under various environmental conditions.
Through these rigorous production testing processes, air-insulated switchgear can meet high standards of performance and safety requirements.
- SF6-insulated ring main unit Production assembly line
SF6-insulated ring main units (RMUs) are a type of medium-voltage electrical combination equipment, with SF6-insulated load switches as the core components, capable of switching, connecting, and protecting power systems. Here is detailed information on the structure, assembly and testing process, process layout, and production line of SF6-insulated ring main units:
Structure
The structure of SF6-insulated ring main units typically includes:
- High-quality stainless steel casing to ensure airtightness.
- SF6 gas filled inside to provide insulation and arc extinguishing functions.
- Load switches, grounding switches, fuse insulating cylinders, and other switch moving parts and busbars, all sealed within the SF6-insulated gas box.
- Modular design, with various module combinations to achieve different bus configurations, forming an SF6-insulated ring main unit system.
Assembly and Testing Process
The assembly and testing process usually includes the following steps:
- Component Preparation: Prepare the required parts and components.
- Assembly: Assemble the various parts of the SF6-insulated ring main unit in a predetermined order and method.
- Performance Testing: Conduct power frequency withstand voltage tests, lightning impulse voltage tests, etc., on the assembled SF6-insulated ring main unit to ensure its performance meets standards.
- Gas Filling and Detection: Fill the gas box with SF6 gas and perform vacuum leak detection to ensure the gas is sealed properly.
- Quality Control: Strict quality control is carried out during the production process to ensure that each part and the final product meet the specified standards and performance requirements.
Process Layout and Production Line
The design of the process layout and production line aims to ensure the production efficiency and product quality of SF6-insulated ring main units. The production line usually includes the following stages:
- Design Phase: Engineers design the structure and functionality of the SF6-insulated ring main unit based on requirements.
- Material Preparation: Prepare the necessary materials, including SF6 gas, stainless steel or other metal materials, insulating materials, etc.
- Manufacturing Process: Use either a common box type or modular manufacturing process for SF6-insulated components.
- Welding and Assembly: Use advanced welding techniques, such as laser cutting and automatic welding manipulators, to ensure the sealing and airtightness of the SF6-insulated gas box.
- Testing and Inspection: After assembly is complete, various tests are conducted on the SF6-insulated ring main unit, including withstand voltage tests, short-circuit current tests, operational life tests, etc.
- Automation Solutions: Provide automation solutions to facilitate the construction of smart distribution networks for customers.
- Final Inspection and Packaging: Conduct final inspections before the product leaves the factory to ensure the product is defect-free and package it appropriately to protect it during transportation.
- Shipping and Installation: Ship the completed product to the customer’s designated location and provide installation services.
With the development of technology, the production of SF6-insulated ring main units increasingly focuses on the reliability, safety, and environmental adaptability of the products.
- The vacuum chamber helium leak detection system for ring main units
The vacuum chamber helium leak detection system for ring main units (RMUs) is an automated testing system specifically designed for the high-voltage gas-insulated switchgear used in the power industry. This system utilizes the vacuum chamber method and helium mass spectrometry leak detection technology to create a pressure differential by simultaneously evacuating the vacuum chamber, and then conducting a leak test after injecting helium into the workpiece. The system is capable of determining large leaks, quantitatively detecting minor leaks, and can automatically recover and recycle the helium gas, improving the efficiency and environmental friendliness of the testing process. It is easy to operate, highly automated, meets the needs of continuous production, and ensures the safety and reliability of the testing.
The main components of the vacuum chamber helium leak detection system for ring main units include:
- Vacuum Chamber: Used to place the workpiece to be tested, perform vacuum operation, and create a pressure differential between the inside and outside of the workpiece for leak detection.
- Helium Mass Spectrometer Leak Detector: Detects the presence of helium and determines if there is a helium leak through mass spectrometry analysis technology.
- Main Vacuum Pump: Used for evacuating the vacuum chamber to ensure it reaches the required vacuum level.
- Control System: Controls the entire leak detection process, including evacuation, helium injection, testing, and recovery steps.
- Helium Gas Recovery Device: Recovers the helium gas used in the testing process for recycling.
Technical parameters of the vacuum chamber helium leak detection system for ring main units typically include:
- Vacuum chamber dimensions are customized based on the size of the workpiece.
- Helium gas pressure is adjustable up to 0.05Mpa.
- Working cycle is less than 40 minutes per piece.
- Helium gas recovery rate is between 95%-98%.
- Detectable leak rate is ≤2.8×10^-6 Pa m^3/S.
- System’s own leak rate is ≤10^-9 Pa m^3/s.
Overview of the operation method:
- Install the workpiece and close the vacuum chamber door.
- Evacuate the vacuum chamber while injecting high-pressure nitrogen gas into the workpiece for large leak and strength testing.
- If the test fails, the system will alarm and terminate the testing procedure.
- If the test passes, release the nitrogen gas and continue to evacuate the workpiece.
- Inject helium gas for vacuum mode micro-leak detection.
The application of the vacuum chamber helium leak detection system for ring main units not only improves the testing efficiency of power equipment but also reduces the testing costs, making it an indispensable testing tool in the modern power industry.
- RM6 Production line
The benefits of using a standardized production line to manufacture RM6 ring main units include increased efficiency, reduced costs, and consistent product quality assurance. Standardized production lines ensure that each product is manufactured according to the same standards and processes, reducing human errors and variations in the production process. Additionally, standardization helps to quickly respond to market demands and accelerate the time to market.
The structure of the RM6 ring main unit typically includes components such as load switches, grounding switches, and a front panel, which are equipped with mechanical interlocking devices to ensure operational safety. The RM6 switchgear also includes one to four integrated, compact functional units with fully sealed, fully insulated characteristics, including a stainless steel SF6 gas-insulated metal-enclosed chamber.
The assembly and testing process may include the following steps:
-Raw material preparation: Ensuring all components meet quality standards.
-Component assembly: Assembling various parts according to design drawings and process requirements.
-Welding: Using welding robots for precise welding to ensure the quality of the welds.
-Performance testing: Conducting various electrical performance tests on the assembled ring main unit.
-Quality inspection: Rigorous quality inspection of the product to ensure it meets standards.
-Packaging and shipping: Packaging qualified products for shipment.The application of welding robots in the manufacturing of RM6 ring main units can greatly improve welding efficiency and quality, achieving automated production. Welding robots ensure the consistency and quality of the welds by precisely controlling welding parameters such as welding speed and current.
Helium leak detection is a highly sensitive leak detection technique commonly used to detect tiny leaks in sealed containers. In the production of RM6 ring main units, helium leak detection can ensure the sealing of the SF6 gas-insulated environment, thereby ensuring the safety and reliability of the product.
The MES (Manufacturing Execution System) plays a key role in the production of RM6 ring main units, as it can monitor the production process in real time, collect and analyze production data, optimize production planning and scheduling, and improve production efficiency and product quality. The MES can also integrate with other information systems such as Enterprise Resource Planning (ERP) systems to achieve comprehensive management and control of the production process.
- Power Distribution Cabinet Production line
Manufacturers of Power Distribution Cabinets offer a variety of products to cater to the needs of different industries and applications. The types of products typically include but are not limited to:
1.High-voltage Switchgear: For control and protection in high-voltage power systems, often including circuit breakers, isolating switches, grounding switches, and other components.
2.Low-voltage Distribution Boards: For distribution in low-voltage power systems, which may contain circuit breakers, contactors, relays, etc., suitable for commercial and industrial environments.
3.Ring Main Units (RMUs): Special switching equipment used in ring distribution networks to provide higher reliability and flexibility of power supply.
4.Box Substations: Integrated substations that typically include transformers and related control equipment, suitable for outdoor or space-limited locations.
5.Intelligent Distribution Cabinets: Equipped with intelligent control and monitoring systems for remote monitoring and automated control capabilities.
Regarding production lines, manufacturers typically employ automated and informatized processes to enhance efficiency and product quality. Features of these production lines may include:
1.Automated Assembly Lines: Utilizing automated machinery and robots for assembling various components of the distribution cabinet, such as circuit breakers and contactors.
2.Intelligent Assembly Mode: Incorporating intelligent sensors and control systems to perform operations like automatic wire stripping, cutting, and crimping.
3.MES Systems: Manufacturing Execution Systems for real-time monitoring and management of the production process to ensure efficiency and quality.
4.Modular Design Assembly line: The production line is modular, allowing for quick reconfiguration to meet different product requirements.
5.Quality Control: Equipped with various testing and inspection equipment to ensure each distribution cabinet meets quality standards before shipment.
6.Customized Production: Some lines offer customization to meet specific customer requirements and application needs.
These manufacturers are continuously seeking technological innovation and improved production efficiency to meet market demands and are actively involved in promoting industry upgrades and transformations in the context of intelligent manufacturing and Industry 4.0.
- GIS Assembly Line Layout
The assembly line process for GIS can be summarized as follows: 1. Fabricate the gas chamber using 3.0mm thick stainless steel plates to ensure hermetic sealing; 2. Pre-install high-voltage components such as circuit breakers; 3. Assemble into a cabinet structure with stainless steel fasteners; 4. Conduct automatic gas filling and leak detection to ensure hermeticity; 5. Perform withstand voltage and lightning impulse tests to verify insulation performance; 6. Finally, conduct a functional and performance inspection before leaving the factory to ensure product compliance.
The structural, assembly, and testing process for an inflatable cabinet (also known as gas-insulated switchgear) can be summarized as follows:
Gas Chamber Fabrication: The gas chamber, made from 3.0mm thick stainless steel, is fabricated using high-precision robotic welding to ensure hermetic sealing.
Component Installation of gas-insulated switchgear: High-voltage components such as circuit breakers, current transformers, and other necessary equipment are pre-installed within the gas chamber.
Cabinet Assembly: The gas chamber is assembled into a cabinet structure, which includes the division of the cable chamber using stainless steel side panels and partitions, followed by the assembly of the cable chamber floor.
Fastening: All fasteners are made of stainless steel to ensure secure and stable connections.
Hermeticity Testing for gas-insulated switchgear: The gas chamber undergoes a hermeticity test using fully automatic inflation and leak detection equipment to ensure there are no leaks.
Withstand Voltage Testing: The cabinet is subjected to power frequency withstand tests to verify the insulation level and ensure it meets safety standards.
Lightning Impulse Testing: This test checks the insulation’s ability to withstand high-voltage surges, simulating lightning strikes.
Partial Discharge Testing: This test is conducted to detect any partial discharges within the insulation material, which could indicate potential failure points.
Final Inspection: Before leaving the factory, the cabinet undergoes a final inspection that includes checking the installation of all components and fasteners, verifying the functionality of the cabinet, and ensuring all operations are performed correctly and repeatedly.
The use of an assembly line for the production and testing of GIS offers numerous benefits, including streamlined workflow, enhanced efficiency, and reduced production time. It ensures consistent quality through standardized operations and facilitates easy identification of defects. Additionally, an assembly line allows for better utilization of resources, cost savings, and improved safety standards by separating hazardous operations. It also enables the implementation of advanced automation, contributing to higher precision and reliability in the final product.
- Environmental Protection Gas Insulated Switchgear Production Line Layout
The production process of an environmentally friendly inflatable cabinet, also known as gas-insulated switchgear, primarily includes the following steps: Precision welding of a gas chamber from 3.0mm thick stainless steel to ensure hermetic sealing, pre-installation of high-voltage components such as circuit breakers, assembly into a cabinet structure, fully automatic gas filling and leak testing to guarantee hermeticity, conducting power frequency withstand and lightning impulse tests to verify insulation performance, and finally, performing functional and performance inspections before leaving the factory to ensure the product meets environmental protection and safety standards.
Environmental protection gas-insulated switchgear, also known as an environmental protection inflatable cabinet, is a high-voltage switchgear that uses environmentally friendly gases such as dry air or nitrogen as the insulating medium, replacing the traditional SF6 gas. The structure, assembly, and testing process of the environmental protection inflatable cabinet are quite complex, involving precise engineering design and strict quality control. Here is a brief introduction to the structure, assembly, and testing process of the environmental protection inflatable cabinet:
Structural Design
-Gas Chamber Fabrication: The gas chamber is the core part of the inflatable cabinet, usually made from 3.0mm thick stainless-steel plates welded by high-precision robotic welding equipment to ensure good hermeticity.
-Insulating Medium: Since dry air or nitrogen is used as the insulating medium, its insulating performance is relatively weaker compared to SF6 gas. Therefore, it is necessary to improve the insulating performance through optimized structural design.
Assembly Process of environmental protection gas insulated switchgear production line
-Pre-installation of Components: Install switches, current transformers, operating mechanisms, and live indicators inside the gas chamber.
Cable Chamber Assembly: Divide the cable chamber using stainless steel side plates and partitions, and then assemble the cable chamber floor.
Fastener Installation: All fasteners are made of stainless steel to ensure stability and durability.
Testing Process
-Hermeticity Test: Use fully automatic inflation and leak detection equipment for vacuum inflation and leak detection to ensure the hermeticity of the gas chamber.
Power Frequency Withstand Test: Conduct the specified value of power frequency withstand test under zero-gauge pressure to verify the insulation level of the equipment.
-Lightning Impulse Test: Inspect whether the equipment insulation has the ability to withstand lightning impulse voltage.
-Partial Discharge Test: Detect internal discharge of insulating materials, surface discharge, and high-voltage electrode tip discharge to ensure that the maximum allowable partial discharge of the environmental protection cabinet complies with the standards.
Factory Inspection
-Functional Performance Check: Performed by professionals, including checking whether all components and fasteners are installed correctly and whether the inflatable cabinet has any functional defects.
-Repeatability of Operations Test: Repeat all operations more than 10 times to ensure the stability and reliability of the operations.
Withstand Voltage Test and Insulation Resistance Test: Finally, conduct a withstand voltage test and insulation resistance test to check whether the inflatable cabinet meets the relevant standards. - VCB Assembly lines Manufacturing production line
Indoor vacuum circuit breaker production lines are highly automated, featuring a structured assembly process that includes the integration of core components like vacuum interrupters and operating mechanisms. These lines are equipped with PLC-controlled systems for efficient operation, and they incorporate testing phases to ensure product quality. Advanced MES (Manufacturing Execution System) integration allows for real-time data collection, process monitoring, and seamless interaction with ERP and other systems, enhancing production efficiency and traceability.
Vacuum circuit breakers are a type of high-voltage switching equipment that utilizes vacuum as both the insulating and arc-extinguishing medium. The structure of indoor vacuum circuit breakers mainly includes the vacuum interrupter, operating mechanism, and supporting components. Here is information on the structure of indoor vacuum circuit breakers, assembly and testing process, automated production lines, and MES (Manufacturing Execution System):
Structure of Vacuum Circuit Breakers
- Vacuum Interrupter: The core component of the vacuum circuit breaker, responsible for extinguishing the arc when breaking the current. It typically consists of a hermetically sealed container made of ceramic, glass, or microcrystalline glass, with dynamic and static end plates, and a stainless steel bellows, ensuring hermeticity.
- Operating Mechanism: It can be a spring operating mechanism, electromagnetic operating mechanism, etc., responsible for the closing and tripping operations of the circuit breaker.
- Supporting Components: Including insulating supports and insulators, providing necessary mechanical support and insulation protection for the circuit breaker.
Assembly and Testing Process
- Main Shaft Assembly: Assemble the main shaft of the operating mechanism with other components.
- Mechanism Assembly: Assemble the rest of the operating mechanism to ensure its correct operation.
- Cabinet and Spring Assembly: Assemble the cabinet and springs to provide the necessary force for the operating mechanism.
- Phase Column Pre-assembly and Assembly: Pre-assemble and then officially assemble the phase columns into the circuit breaker.
- Chassis Assembly: Complete the assembly of the circuit breaker’s chassis.
- Characteristics Testing: Test various technical indicators of the circuit breaker, such as insulation level, contact bounce time, etc.
- Mechanical Run-in: Conduct mechanical run-in to ensure smooth operation of the operating mechanism.
Automated Production Line
Automated production lines, through the configuration of imported drive motors, PLC control systems, and sensors, achieve the automation of circuit breaker production. The production line includes automatic assembly, automatic testing, and automatic scheduling, reducing manual intervention and improving production efficiency.
MES System (Manufacturing Execution System)
The MES system is used to integrate factory control devices and processes to improve production efficiency and traceability. It can achieve production data collection, production instruction issuance, quality management, equipment management, report statistics, advanced automatic scheduling, and other functions. The MES system can also form a linkage with the ERP system, logistics system, inventory system, etc., to create a large closed-loop linkage system.