VCB RMU GIS PVB Switchgear Assembly lines / Production lines

• The structural characteristics assembly process and production line of MV switchgear

  Medium-voltage switchgear is designed with modular and metal-enclosed structures, featuring a three-compartment layout for enhanced safety and functionality. Its assembly process involves meticulous component preparation, precise cabinet and internal component installation, and rigorous inspection and testing. The production line includes material storage, sheet metal processing, assembly, testing, and packaging areas, ensuring high-quality output. Comprehensive testing covers design checks, resistance measurement, withstand voltage tests, mechanical operations, and insulation verification. This streamlined process guarantees reliability and safety, meeting industry standards for medium-voltage applications.

  

  Detailed Introduction of Medium-Voltage Switchgear

  I. Structural Characteristics

  Structural Table

  No.	Component Name	Function Description	Material	Notes
  1	Cabinet	The main structure of the switchgear, used for installing and fixing other components.	Zinc-aluminum alloy steel plate	The surface coating consists of 55% aluminum, 43.4% zinc, and 1.6% silicon, solidified at high temperature.
  2	Circuit Breaker Compartment	Installation of circuit breakers for circuit control.	–	–
  3	Busbar Compartment	Installation of busbars for power transmission.	–	–
  4	Cable Terminal Compartment	Connection of cables for power distribution.	–	–
  5	Low-Voltage Compartment	Installation of control and protection devices.	–	–
  6	Live Door	Isolation of high-voltage components to ensure operational safety.	–	–
  7	Circuit Breaker	Control of circuit connection and disconnection.	–	–
  8	Secondary Plug	Connection of the secondary circuit.	–	–
  9	Main Busbar	Power transmission.	–	–
  10	Busbar Insulator	Insulation and support of busbars.	–	–
  11	Ground Switch	Ground protection.	–	–
  12	Static Contact Box	Coordination with the moving contacts of the circuit breaker.	–	–
  13	Support Insulator	Support and insulation.	–	Optional with live display device.
  14	Insulating Partition	Isolation of different functional areas.	–	–
  15	Cable Connection Terminal	Connection of cables.	–	–
  16	Panel Heater	Prevention of condensation.	–	–
  17	Current Transformer	Measurement of current.	–	–
  18	Pressure Relief Panel	Pressure relief to ensure equipment safety.	–	–

  Detailed Description

  1. Modular Design

  • The medium-voltage switchgear adopts a modular structure, which can be flexibly configured according to different requirements and is convenient for expansion. Each functional unit, such as the circuit breaker compartment, busbar compartment, and cable compartment, is independently designed and can be easily combined to meet various requirements.
  • This modular design also facilitates the maintenance and replacement of individual components without affecting the entire system.

  1. Metal-Enclosed Structure

  • The switchgear is typically enclosed in a metal cabinet, which can effectively prevent interference from external factors such as dust, moisture, and small animals, ensuring the reliability and safety of the internal electrical components.
  • The cabinet is usually made of high-quality steel or aluminum alloy, with high mechanical strength and corrosion resistance.

  1. Three-Compartment Layout

  • The switchgear usually adopts a three-compartment layout, including the main switch compartment, busbar compartment, and cable compartment. This layout separates the high-voltage components and the control components, reducing the risk of electrical short circuits and improving the safety of operation and maintenance.
  • The compartments are interconnected through insulated busbars or connectors, ensuring reliable electrical connections while maintaining a clear separation of functions.

  1. Insulation and Arc Protection

  • The internal components of the switchgear are designed with high insulation performance to ensure safe operation at medium-voltage levels. Insulating materials such as epoxy resin, SF6 gas, or vacuum are commonly used to provide effective insulation between live parts.
  • Arc protection measures are also incorporated, such as arc shields and arc extinguishing devices, to prevent arc faults from causing damage to the equipment and personnel.

  II. Assembly Process

  Process Table

  No.	Process Name	Process Content	Equipment	Labor Hours Quota	Process Equipment
  1	Material Preparation	Preparation of all components.	Material transport vehicle	–	–
  2	Contact Box Assembly	Installation of contact boxes and related components.	Wiring rack	–	Elevating platform
  3	Cabinet Assembly	Assembly of cabinet components.	Cabinet assembly jig	–	Material placement table
  4	Electrical Connection	Connection of main and secondary circuits.	–	–	–
  5	Inspection and Adjustment	Inspection of assembly quality and adjustment of components.	–	–	–

  Detailed Description

  1. Component Preparation

  • All necessary components, including switchgear cabinets, circuit breakers, busbars, insulators, control devices, and accessories, are carefully inspected and prepared. Any damaged or defective parts are replaced to ensure the quality and reliability of the final product.
  • These components are usually pre-fabricated in a controlled environment to ensure precision and consistency.

  1. Cabinet Assembly

  • The metal enclosure of the switchgear is assembled first. The frame and panels are welded or bolted together to form a rigid structure. The enclosure is then painted or coated with a protective layer to enhance its corrosion resistance.
  • The compartments within the enclosure are partitioned using insulated panels or barriers to create separate spaces for different functions.

  1. Installation of Internal Components

  • The busbars are installed first, ensuring proper alignment and secure connections. The busbars are usually made of high-conductivity copper or aluminum and are insulated to prevent electrical leakage.
  • Circuit breakers and other switching devices are mounted in their designated compartments. These devices are carefully aligned and connected to the busbars through insulated connectors.
  • Control devices, such as relays, meters, and protection devices, are installed in the control compartment. Wiring is done according to the electrical schematics, ensuring correct connections and proper labeling.

  1. Inspection and Testing

  • After the assembly is complete, a thorough inspection is conducted to check for any loose connections, incorrect wiring, or misaligned components.
  • The switchgear is then subjected to various tests, including insulation resistance testing, dielectric withstand testing, and functional testing of the circuit breakers and control devices. These tests ensure that the switchgear meets the required safety and performance standards.

  III. Production Line

  Production Line Layout

  1. Material Storage and Preparation Area

  • This area is used for storing metal sheets, insulating materials, and components. The materials are organized and prepared for use in the production process.
  • Quality control checks are performed on incoming materials to ensure they meet the specified standards.

  1. Sheet Metal Processing Section

  • Metal sheets are cut, bent, and welded to form the enclosure and internal structures of the switchgear. Advanced sheet metal processing equipment, such as laser cutting machines and press brakes, are used to ensure precision and efficiency.
  • The processed metal parts are then sent to the painting or coating section for surface treatment.

  1. Component Assembly Line

  • This is the main area where the switchgear is assembled. The metal enclosures are placed on assembly stations, and components are installed in a sequential manner.
  • Assembly workers follow detailed work instructions and use specialized tools to ensure proper installation of each component.

  1. Testing and Inspection Station

  • After assembly, the switchgear is moved to the testing and inspection station. Here, technicians perform the necessary tests to verify the performance and safety of the equipment.
  • Any defects or issues identified during testing are corrected before the switchgear is approved for packaging and shipping.

  1. Packaging and Shipping Area

  • The final products are packaged in protective cases or crates to prevent damage during transportation. Shipping labels and documentation are attached, and the packaged switchgear is stored in a warehouse or loaded onto transport vehicles for delivery to customers.

  Assembly Testing Table

  No.	Test Item	Test Content	Testing Equipment	Testing Standard	Notes
  1	Design Inspection	Check whether the electrical circuit and mechanical structure design meet the requirements.	–	Complies with design drawings	–
  2	Main Circuit Resistance Measurement	Measure the resistance of the main circuit to ensure it meets the standard.	Resistance tester	Complies with standard	–
  3	Power Frequency Withstand Voltage Test	Conduct power frequency withstand voltage tests on the main and secondary circuits.	Withstand voltage tester	Complies with standard	–
  4	Mechanical Operation Test	Test the mechanical operation of circuit breakers and draw-out units.	–	Operation is smooth	–
  5	Secondary Circuit Inspection	Check the connections of the secondary circuit.	–	Connections are correct	–
  6	Insulation Test	Conduct insulation tests on the main cables and secondary circuits.	Insulation tester	Complies with insulation standards	–
  7	Five-Prevention Function Test	Test the five-prevention functions of the switchgear.	–	Complies with five-prevention requirements	–
  8	Mechanical Interlock Function Test	Test the mechanical interlock function.	–	Interlock is reliable	–

  The above content combines the detailed structural characteristics, assembly process, and production line of medium-voltage switchgear, as well as the structural table, process table, and assembly testing table, to comprehensively demonstrate the production process and quality control of medium-voltage switchgear.

• Vacuum Circuit Breaker Technology and Assembly Line

  Vacuum circuit breakers are advanced electrical devices that utilize vacuum as the arc-quenching medium, offering high efficiency and reliability. Their core components include the vacuum interrupter, operating mechanism, and secondary circuit. The assembly process involves meticulous steps such as material preparation, enclosure installation, vacuum interrupter fitting, and secondary circuit wiring. After assembly, rigorous testing is conducted, including mechanical characteristic tests, withstand voltage tests, and vacuum degree checks, to ensure the breaker’s performance and safety. Modern assembly lines are highly automated, equipped with PLC control and MES systems for real-time monitoring and data collection, ensuring high production efficiency and product quality. These breakers are known for their small size, long life, and environmental friendliness, making them ideal for modern power systems.

  

  I. Overview of Vacuum Circuit Breaker

  A vacuum circuit breaker (VCB) is a type of switching device that extinguishes arcs in a vacuum environment. The core principle is to use a high-vacuum environment as the arc-quenching medium. When the circuit is interrupted, an arc is generated as the contacts separate. Since there is no gas medium in the vacuum, the arc cannot be sustained and is quickly extinguished. This arc-quenching method is highly efficient and rapid, capable of interrupting high currents in a short time and reducing the risk of power system failures.

  The main components of a vacuum circuit breaker include the vacuum interrupter, the enclosure, the operating mechanism, and the secondary circuit. The vacuum interrupter is the core component, typically consisting of a high-vacuum glass or ceramic enclosure and high-temperature-resistant contact materials (such as copper-chromium alloy). The enclosure supports and protects the internal components, while the operating mechanism controls the opening and closing actions of the contacts.

  Vacuum circuit breakers are known for their small size, light weight, long operating life, and ease of maintenance. Since no oil or gas is required for arc quenching, they are more environmentally friendly and suitable for applications with frequent operations.

  II. Vacuum Circuit Breaker Structure Table

  No.	Component Name	Description
  1	Insulating Cylinder	Used for insulation and support of internal components
  2	Upper Bracket	Secures the upper terminal and other components
  3	Upper Terminal	Connects to the upper part of the external circuit
  4	Vacuum Interrupter	Core component for closing and breaking the circuit, and extinguishing arcs
  5	Flexible Connection	Provides electrical connection while allowing some movement
  6	Lower Bracket	Secures the lower terminal and other components
  7	Lower Terminal	Connects to the lower part of the external circuit
  8	Disc Spring	Provides operating force or holding force
  9	Insulating Rod	Transmits operating force, connecting the operating mechanism to the interrupter
  10	Four-Bar Linkage	Transmits the movement of the operating mechanism to the interrupter, enabling closing and opening operations
  11	Circuit Breaker Enclosure	Protects internal components from external interference and contamination
  12	Opening Spring	Provides the force for the opening operation
  13	Opening Electromagnet	Electromagnetic device for controlling the opening operation
  14	Closing Cam	Mechanical component for controlling the closing operation

  III. Vacuum Circuit Breaker Process Flow Table

  Process Name	Main Content
  Main Shaft Assembly	Install the main shaft components and buffers into the housing, ensuring correct assembly before moving to the next process
  Mechanism Assembly	Assemble the closing and opening operating mechanisms, and secure them after pre-assembly
  Housing and Spring Assembly	Complete the assembly of closing and opening springs
  Phase Column Pre-assembly	Perform pre-assembly of internal flexible connections, double-ended rods, and insulators in the phase column
  Phase Column Assembly	Install the pre-assembled phase column components onto the housing
  Base Assembly	Install the base and related components
  Contact Arm Assembly	Install the contact arm and related components
  Secondary Circuit Assembly	Complete the wiring and layout of the auxiliary control circuit
  Mechanical Run-in	Perform mechanical run-in on the assembled circuit breaker to ensure coordinated actions
  Characteristic Testing	Conduct mechanical characteristic testing, withstand voltage testing, and circuit resistance testing
  Final Inspection	Perform a comprehensive inspection of the product to ensure quality compliance
  Offline and Warehousing	Qualified products are taken offline and stored in the warehouse

  IV. Vacuum Circuit Breaker Assembly and Testing Table

  Test Item	Test Content
  Appearance Inspection	Inspect the appearance of the circuit breaker to ensure there are no defects or damage
  Mechanical Characteristic Testing	Test parameters such as contact gap, contact travel, synchronicity, and bounce
  Withstand Voltage Testing	Conduct AC withstand voltage and impulse withstand voltage tests
  Circuit Resistance Testing	Measure the connection quality of the conductive circuit
  Vacuum Degree Testing	Use a vacuum tester for qualitative testing
  Operating Characteristic Testing	Test the closing and opening speeds
  Low-Voltage Opening and Closing Test	Ensure the circuit breaker can reliably operate at low voltage
  Continuous No-Load Operation Test	Verify the stability of the equipment during continuous operation

  V. Vacuum Circuit Breaker Assembly Line

  A. Assembly Process

  1. Material Preparation and Verification
     Check the materials according to the assembly flow card to ensure that all components are present and meet the requirements.
  2. Enclosure and Auxiliary Unit Installation
     Assemble the outer frame and enclosure to support and protect the internal components.
  3. Closing and Opening Unit Assembly
     Install the closing and opening units to ensure coordinated actions.
  4. Vacuum Interrupter Installation
     Install the vacuum interrupter in place and seal it.
  5. Secondary Circuit Wiring
     Complete the wiring and layout of the auxiliary control circuit.

  B. Testing Process

  1. Appearance Inspection
     Inspect the assembled circuit breaker to ensure there are no defects.
  2. Mechanical Characteristic Testing
     Test parameters such as contact gap, contact travel, synchronicity, and bounce.
  3. Withstand Voltage Testing
     Conduct AC withstand voltage and impulse withstand voltage tests.
  4. Circuit Resistance Testing
     Measure the connection quality of the conductive circuit.
  5. Vacuum Degree Testing
     Use a vacuum tester for qualitative testing.
  6. Operating Characteristic Testing
     Test the closing and opening speeds.
  7. Low-Voltage Opening and Closing Test
     Ensure the circuit breaker can reliably operate at low voltage.
  8. Continuous No-Load Operation Test
     Verify the stability of the equipment during continuous operation.

  C. Automated Assembly Line

  Modern vacuum circuit breaker assembly lines typically feature highly automated designs, including modular design, automated assembly, online inspection, and intelligent logistics systems. Through PLC control and MES (Manufacturing Execution System), the production process is monitored in real-time and data is collected to improve production efficiency and product quality.

  D. Quality Assurance

  The assembly line is equipped with automatic withstand voltage equipment and dedicated internal pressure measurement processes to ensure the reliability and consistency of the products. In addition, the assembly process is conducted in a clean room environment to ensure the cleanliness of the products.

  Through the above structural design, process flow, and testing procedures, vacuum circuit breakers can be produced efficiently and with high quality, meeting the requirements of modern power systems for reliability and safety.

• Ring Main Units RMUs Switchgear Production lines Design

  The production line for Ring Main Units (RMUs) is a highly automated and efficient system designed to manufacture high-quality switchgear devices. It integrates advanced technologies such as automated assembly, performance testing, and helium leak detection to ensure product reliability and safety. The line features modular workstations for various assembly tasks, comprehensive testing systems for mechanical and electrical performance, and a control management system for real-time monitoring and data management. By combining flexibility with precision, the RMU production line meets diverse customer requirements while maintaining high efficiency and environmental sustainability.

  

  Types and Features of Ring Main Units (RMUs)

  Ring Main Units (RMUs) are high-voltage switchgear devices used in ring-type distribution networks. They can be classified into several types based on the insulation medium and structural form:

  Type	Features
  SF6 Gas-Insulated RMUs	Use SF6 gas as the insulation medium, offering excellent insulation and arc-quenching capabilities. They are highly reliable but have potential environmental impacts due to SF6 gas.
  Solid-Insulated RMUs	Use solid insulation materials (e.g., epoxy resin) to encapsulate the conductive circuits. They are environmentally friendly and highly safe, suitable for locations with strict environmental requirements.
  Air-Insulated RMUs	Use air as the insulation medium. They are cost-effective but have relatively lower insulation and safety performance.
  Vacuum RMUs	Use vacuum circuit breakers, known for their high safety and environmental friendliness. They can operate at voltage levels up to 24kV.
  Gas-Generating RMUs	Utilize solid gas-generating materials for arc quenching. The larger the current, the better the arc-quenching effect.
  Pressure-Gas RMUs	Use compressed air to blow out arcs, providing effective arc-quenching capabilities.

  Assembly and Production Process of Ring Main Units

  The assembly and production process of RMUs includes several key steps:

  Step	Content
  Metal Enclosure Manufacturing	Fabricate the sealed switch compartment using cold-rolled steel plates or stainless steel, ensuring strength and airtightness.
  Functional Circuit Assembly	Install load switches, grounding switches, and their contact systems, ensuring reliable electrical connections and insulation performance.
  Operating Mechanism Installation	Install spring-operated mechanisms with energy storage, ensuring mechanical interlocks with the switch compartment to prevent misoperation.
  Insulation Treatment	Apply insulation treatment to components to ensure sufficient insulation strength and safety.
  Performance Testing	Conduct mechanical characteristic tests, electrical performance tests, withstand voltage tests, and helium leak detection on gas compartments to ensure product quality.

  Automated Production Line for Ring Main Units

  The automated production line for RMUs integrates advanced automation and information management systems to achieve efficient, high-quality, and reliable production processes:

  Section	Content
  Production Line Body	Includes tracks and shuttle carts for transporting semi-finished and finished products.
  Workstation Modules	Located on both sides of the production line, used for specific assembly or testing processes.
  Performance Testing System	Includes comprehensive performance testing systems, helium leak detection systems, and withstand voltage testing systems to ensure product quality.
  Control and Management System	Enables real-time monitoring and information management, reducing manual intervention and improving production efficiency and reliability.
  Customized Design	Tailored to meet different models and production requirements, ensuring flexibility and adaptability.

  Structural Components of Ring Main Units

  RMUs typically consist of the following parts:

  Component	Content
  Switch Compartment	Includes load switches, grounding switches, and busbars, usually sealed within a metal enclosure.
  Fusible Link Compartment	Forms a protective circuit with the load switch for transformers, with high-voltage current-limiting fuses installed inside an insulated shell.
  Operating Mechanism Compartment	Equipped with manual or electric spring-operated mechanisms, located at the front of the RMU, featuring interlocking devices.
  Cable Compartment (Base Frame)	Forms the base of the RMU, used for cable connections.

  By implementing detailed production processes and automated production lines, the manufacturing of RMUs achieves high efficiency, quality, and environmental friendliness, meeting the needs of various application scenarios.

  Summary of Ring Main Unit (RMU) Production Processes and Equipment

  The production of Ring Main Units (RMUs) involves several key processes, each equipped with specialized devices to ensure production efficiency and product quality. Below is a detailed summary of the RMU production processes and equipment:

  Process	Content	Main Equipment
  1. Enclosure Manufacturing	Fabrication of the metal enclosure using cold-rolled steel sheets or stainless steel, ensuring strength and airtightness.	Pressing machines, welding robots, bending machines
  2. Component Machining	Machining of critical components such as switches, operating mechanisms, and insulating parts.	CNC machining centers, laser cutting machines, insulation treatment equipment
  3. Assembly	Assembling the enclosure, switches, operating mechanisms, and other components into a complete RMU.	Automated assembly line, robotic arms, torque wrenches
  4. Insulation Treatment	Insulating the interior of the RMU to ensure electrical performance.	Epoxy resin casting equipment, vacuum drying equipment
  5. Performance Testing	Conducting mechanical, electrical, and withstand voltage tests on the assembled RMU.	Comprehensive performance testing system, withstand voltage tester, helium leak detection equipment
  6. Quality Inspection	Checking the appearance, dimensions, and airtightness of the product to ensure compliance with standards.	Coordinate measuring machines, helium mass spectrometer leak detector
  7. Packaging and Storage	Packaging the qualified products and storing them in the warehouse.	Automatic packaging machines, forklifts, warehouse management system

  Summary

  The production of RMUs integrates automated production lines and advanced equipment to achieve full automation from enclosure manufacturing to finished product inspection. Each process is equipped with specialized devices to ensure production efficiency and product quality. This production model not only enhances efficiency but also ensures reliability and safety through strict testing procedures.

• Which switchgears are suitable for mass production on assembly lines?

  

  Adopting mass production of switchgear on assembly lines can significantly enhance production efficiency and reduce costs. Standardized operations on assembly lines ensure the stability and consistency of product quality, minimizing the defect rate caused by human factors. Moreover, mass production optimizes the procurement and management of raw materials, further lowering costs. This production mode also facilitates management and monitoring, enabling faster response to market demands and shorter delivery times. It not only boosts a company’s production capacity and market competitiveness but also better meets customer requirements for product quality and delivery time, driving sustainable development.

  Below is a summarized table of switchgear types, categorized by different criteria:

  Classification Basis	Type	Characteristics	Applications
  Voltage Level	Low-Voltage Switchgear	Voltage up to AC 1000V, simple structure, lower cost.	Suitable for residential, commercial buildings, and industrial low-voltage distribution systems.
  	Medium-Voltage Switchgear	Voltage typically around AC 10kV.	Suitable for medium-voltage distribution networks, such as urban power grids.
  	High-Voltage Switchgear	Voltage above AC 1000V, high safety and protection levels.	Suitable for high-voltage transmission, substations, and industrial high-voltage distribution.
  Internal Structure	Open-Type Switchgear	No enclosed shell, components exposed.	Suitable for applications with low protection requirements.
  	Metal-Enclosed Switchgear	Components enclosed in a metal shell, high protection level.	Suitable for general industrial and commercial distribution systems.
  	Metal-Clad Switchgear	High mechanical strength and protection level.	Suitable for high-demand distribution systems.
  Application	Infeed Cabinet	Receives electrical energy and introduces it to the busbar system, equipped with circuit breakers, CTs, and PTs.	Used at grid connection points.
  	Outfeed Cabinet	Distributes electrical energy, equipped with circuit breakers, CTs, and PTs.	Used for distributing electrical energy to various loads.
  	Bus Coupler Cabinet	Connects two busbars for switching operating modes.	Used for busbar connection and load distribution.
  	PT Cabinet	Equipped with voltage transformers for voltage monitoring and protection.	Used for voltage monitoring and protection.
  	Isolation Cabinet	Provides isolation for maintenance and inspection.	Used for equipment isolation and maintenance.
  	Capacitor Cabinet	Used for reactive power compensation to improve power factor.	Used for compensating reactive power in the grid.
  Installation Method	Fixed-Type Switchgear	Simple structure, low cost, but poor expandability.	Suitable for simple wiring and easy maintenance applications.
  	Drawer-Type Switchgear	Modular design, easy maintenance, high flexibility.	Suitable for applications requiring frequent maintenance and quick repairs.
  Protection Level	Fixed-Panel Switchgear	Lower protection level.	Suitable for environments with low protection requirements.
  	Protective Switchgear	Higher protection level.	Suitable for environments with high protection requirements.

  

  The advantages of using assembly-line manufacturing for switchgear can be summarized as follows:

  1. Increased Production Efficiency
     Assembly-line production achieves automation and standardization, with clear division of labor and unified production rhythms. This significantly shortens production cycles and greatly improves overall production efficiency.
  2. Ensured Quality Stability
     Strict quality control and standardized processes ensure the consistency and reliability of switchgear quality, reducing the defect rate caused by human factors and enhancing product safety.
  3. Reduced Production Costs
     Centralized management and optimized resource allocation minimize material waste and equipment idleness. Standardized production also lowers labor and management costs, improving the enterprise’s economic benefits.
  4. Enhanced Market Competitiveness
     Assembly-line production enables rapid response to market demands, supports large-scale manufacturing, and shortens product delivery times, thereby strengthening the company’s competitiveness in the market.
  5. Ease of Maintenance and Upgrades
     Standardized production processes make switchgear components more interchangeable and universal, facilitating subsequent maintenance and upgrades and reducing after-sales costs.
  6. Support for Large-Scale Development
     Assembly-line manufacturing lays the foundation for large-scale production, helping enterprises expand their capacity to meet the substantial market demand for switchgear and drive sustainable business growth.

• Custom production lines plant requirements of RMU VCB GIS

  

  Custom production lines are designed to meet specific product or production needs, and they can be individually adjusted according to the specific requirements of the enterprise. Here are some key points to consider when looking at custom production lines from different perspectives:

  1. Workshop Area:
     • Custom production lines need to be designed according to the actual area of the workshop to ensure that the layout of the production line is both rational and efficient.
     • The height, width, and length of the workshop will affect the layout of the production line and the selection of equipment.
  2. Planned Production Capacity:
     • The planned production capacity of a custom production line should match the production goals and market demand of the enterprise.
     • Capacity planning needs to consider factors such as production efficiency, equipment utilization rate, and production rhythm.
  3. Product Process Characteristics:
     • The custom production line should fully consider the special process requirements of the product, such as temperature, humidity, cleanliness, etc.
     • The design of the process flow should ensure product quality while meeting the requirements of production efficiency.
  4. Degree of Automation:
     • The degree of automation is a key factor in the design of custom production lines, which can significantly improve production efficiency and reduce labor costs.
     • The selection of automated equipment should be based on product characteristics, production scale, and budget.
  5. Flexibility and Scalability:
     • Custom production lines should have a certain degree of flexibility to adapt to changes in product updates or market demands.
     • Scalability refers to the ability of the production line to add equipment or adjust layouts in the future to meet larger production needs.
  6. System Integration:
     • The various components of a custom production line, such as robotic arms, conveyor belts, control systems, etc., need to be highly integrated to achieve a smooth production process.
     • System integration also includes the connection with enterprise resource planning (ERP), manufacturing execution system (MES), and other software.
  7. Maintenance and Support:
     • The design of a custom production line should consider the maintenance and support of equipment to ensure the long-term stable operation of the production line.
     • Choosing equipment and systems that are easy to maintain and upgrade can reduce long-term operating costs.
  8. Safety and Environmental Protection:
     • Safety is an indispensable factor in the design of production lines and should ensure that all operations comply with safety standards.
     • Environmental protection is also an important consideration in the design of modern production lines, and measures should be taken to reduce energy consumption and waste emissions.
  9. Cost-Benefit Analysis:
     • A comprehensive cost-benefit analysis should be conducted when designing a custom production line to ensure a reasonable return on investment.
     • Costs include equipment purchase, installation, operation, and maintenance.
  10. User Involvement:
      • The involvement of users or operators is crucial for the success of a custom production line, and their understanding and feedback on the production process can guide the optimization of the production line.

  The design of a custom production line is an interdisciplinary engineering project that requires knowledge and professional skills across various disciplines. It also requires continuous adjustment and optimization in response to market and technological developments.

  

  
  RMU (Ring Main Unit):

  • Structure: RMU is a compact type of switching equipment, commonly used in urban power distribution networks.
  • Process: It adopts a modular design, which is easy to install and maintain, and typically includes components such as circuit breakers, load switches, and grounding switches.

  VCB (Vacuum Circuit Breaker):

  • Structure: VCB uses vacuum as the insulating and arc-extinguishing medium, characterized by its small size and light weight.
  • Process: Its main advantages are long service life, low maintenance, and high reliability.

  GIS (Gas Insulated Switchgear):

  • Structure: GIS is a fully sealed metal enclosure filled with insulating gas (usually SF6).
  • Process: GIS offers high reliability and safety, suitable for high-voltage and high-current applications.
• Technical Key Points in the Production Process of RMUs (Ring Main Units)

  

  During the production process of RMUs (Ring Main Units), common technical challenges and their corresponding solutions are as follows:

  1. Environmental Control:
     • Challenge: Maintaining a clean and dry production environment to prevent moisture and dust.
     • Solution: Employ advanced environmental control technologies to ensure the temperature and humidity in the production area are within the appropriate range, reducing the impact on equipment insulation performance and mechanical parts.
  2. Intelligence and Automation:
     • Challenge: Achieving intelligent and automated production processes to improve efficiency and reduce human error.
     • Solution: Utilize Internet of Things (IoT) technology, combining online and offline services, to achieve deep integration of intelligent control and data services. Collect, analyze, and process data through intelligent gateways and store it on cloud platforms, using edge algorithms and big data analysis to determine the operation and “health” status of equipment.
  3. Material Selection and Processing:
     • Challenge: Choosing appropriate materials and processing them accurately to ensure the performance and reliability of the RMU.
     • Solution: Use solid insulating materials instead of SF6 gas to reduce environmental impact. Employ advanced material processing techniques such as ion implantation and molecular beam epitaxy for more precise material doping.
  4. Assembly Precision:
     • Challenge: Ensuring the precision of the RMU assembly to avoid performance issues due to improper assembly.
     • Solution: Use high-precision assembly equipment and tools, implement strict quality control measures, and ensure the assembly precision and consistency of each component.
  5. Safety and Protection:
     • Challenge: Ensuring the safety of operators during production and protecting equipment from external environmental impacts.
     • Solution: Design and use equipment with high protection levels, such as gas chambers welded by stainless steel laser, ensuring complete sealing to prevent gas leakage and sealing gasket issues.
  6. Testing and Verification:
     • Challenge: Conducting comprehensive testing and verification of the RMU after production to ensure it meets standards.
     • Solution: Perform visual inspections, main circuit resistance measurements, mechanical operation and mechanical characteristic measurement tests, insulation resistance tests, main circuit 1-minute power frequency voltage tests, and protective device tests to ensure the RMU’s performance meets requirements before use.
  7. Environmental Protection and Sustainability:
     • Challenge: Reducing the environmental impact during production and achieving sustainable development.
     • Solution: Use environmentally friendly materials and processes, such as solid insulation technology without SF6 gas, ensuring the product has eco-friendly characteristics throughout its lifecycle, and achieve recyclability of materials in product design, production, use, and recycling.
  8. Maintenance and Fault Handling:
     • Challenge: Effectively maintaining and handling faults during the RMU’s operation to ensure long-term stable operation.
     • Solution: Use intelligent sensing technology to monitor equipment status in real-time, identify and address potential issues promptly. Reduce inspection costs and improve maintenance efficiency through mobile operation and maintenance systems.

  By implementing these solutions, technical challenges in the RMU production process can be effectively addressed, ensuring the high quality and reliability of ring main units.

• The requirements for the assembly environment of RMU

  

  The requirements for the assembly production environment of RMU ring main units (RMUs) typically include the following aspects:

  1. Environmental Conditions: The assembly production environment should be kept clean and dry, avoiding humidity and dust to ensure the insulation performance and normal operation of the mechanical parts of the RMU.
  2. Temperature and Humidity: The temperature and humidity of the production environment should be controlled within an appropriate range to prevent material deformation or a reduction in the performance of electrical components.
  3. Operational Safety: Necessary safety measures should be taken during the assembly process, including personal protective equipment for operators and ensuring electrical safety during operations.
  4. Equipment and Tools: Professional equipment and tools suitable for the assembly of RMUs should be used to ensure assembly accuracy and product quality.
  5. Quality Control: Strict quality control measures should be implemented during the production process, including inspection of raw materials, semi-finished products, and finished products, to ensure the performance and reliability of the RMU.
  6. Technical Specifications: Assembly production should follow relevant technical specifications and standards, such as GB3906, to ensure that the RMU meets industry standards and safety requirements.
  7. Environmental Protection Requirements: With the increasing awareness of environmental protection, the production of RMUs should minimize the impact on the environment, such as using solid insulating materials without SF6 gas and ensuring the recyclability of materials.
  8. Intelligence and Automation: The production of modern RMUs may involve the application of intelligent and automated technologies to improve production efficiency and reduce human error.
  9. Maintenance and Testing: After assembly, RMUs should undergo necessary maintenance and testing, including visual inspection, main circuit resistance measurement, mechanical operation and mechanical characteristic measurement tests, insulation resistance tests, etc., to ensure their performance meets the requirements before being put into use.
  10. Training and Skills: Operators should receive professional training to master the assembly techniques and knowledge of RMUs to ensure the professionalism of the assembly process.

  These requirements ensure the quality and performance of RMUs during the production process, as well as the safety of operators and environmental protection.

• Ring main unit production line and mechanical property testing

  

  The ring main unit production line and mechanical property testing are crucial components in the manufacturing of electrical equipment, ensuring the quality and performance of the ring main units. Here is a detailed introduction to the ring main unit production line and mechanical property testing:

  1. Ring Main Unit Assembly Line: The ring main unit assembly line includes a main body, shuttle carts, workstations, etc., which use shuttle carts to move products through various workstations for preliminary welding, component assembly, and other steps. The production line utilizes automated equipment and information management systems to achieve full-process automation, with high adaptability and flexibility.
  2. Mechanical Property Testing: Mechanical property testing is a key step in ensuring the performance of the switching components within the ring main unit. The testing includes parameters such as the operating speed, simultaneity, opening distance, over-travel, contact bounce, and re-bounce of the circuit breaker. By using mechanical property testers, loop resistance testers, and potential transformer polarity testers, the performance of the switching components can be comprehensively evaluated.
  3. Ring Main Unit Comprehensive Performance Testing System: The comprehensive performance testing system includes wear-in tests, mechanical property tests, semi-finished product inspections, and finished product power tests. It communicates with the control management system via an Ethernet switch, enabling real-time data uploading and monitoring.
  4. Gas Chamber Helium Inspection System: The helium inspection system is used for dry leak detection of SF6 gas chambers, conducting helium mass spectrometry leak testing to determine the qualification of the gas chamber and allowing for the recycling of helium gas.
  5. Power Frequency Withstand Voltage Testing System: The power frequency withstand voltage testing system is used to verify the insulating strength of the ring main unit, including partial discharge tests and a shielding room for the test, ensuring the insulating performance of the ring main unit.
  6. Control Management System: The ring main unit assembly line control management system uses barcode guns, RFID, and other technologies to manage and trace products and materials, as well as to monitor the status of each workstation on the production line and track the status of the products.
  7. Environmental-friendly Design: Environmental-friendly ring main units use dry air or other environmentally friendly gases as insulating media, reducing greenhouse gas emissions, and include electrical five-prevention functions in the design to ensure operational safety.
  8. Customization and Flexible Production: The assembly line can be customized and adjusted according to different product requirements, with the ability for flexible production to quickly respond to market changes.

  Through the above processes, the ring main unit production line and mechanical property testing work together to ensure the high quality and performance of the ring main units, meeting the requirements of modern power systems for equipment.

• Ring main unit vacuum helium leak detection equipment Assembly line

  

  Ring main unit vacuum helium leak detection equipment and its assembly line are precision testing devices specifically used to detect whether there are any minute leaks in ring main units, widely applied in the manufacturing and maintenance of power equipment. Here is a detailed introduction to the equipment and assembly line:

  1. Function and Application of the Equipment: The equipment is mainly used to detect whether there are minute helium gas leaks in ring main units under vacuum conditions, ensuring the sealing and reliability of the ring main units. It is widely used across various industries including automotive, new energy, home appliances, industrial, aerospace, and military.
  2. Leak Detection Technology: Leak detection methods typically include water leak detection and helium leak detection. Helium leak detection uses the helium mass spectrometry method to detect very small leak rates. For example, by measuring the diameter and internal pressure of the bubbles, the leak rate of the leak hole can be calculated.
  3. Assembly Line Components: The assembly line may include a vacuum chamber, vacuum pumping unit, helium mass spectrometer leak detector, inflation and deflation mechanisms, and a PLC electrical control system. The vacuum chamber and pumping unit are responsible for creating and maintaining the vacuum environment, while the helium mass spectrometer leak detector analyzes the leakage of the workpiece and provides the final pass/fail results and leak rate.
  4. Process Flow: The process flow of the assembly line may include loading and unloading stations, vacuum pumping and helium charging stations, helium mass spectrometer leak detection stations, and helium gas recovery stations. The electrical control system displays the leak detection results on the equipment screen via PLC, ensuring the accuracy and convenience of operations.
  5. Technical Advantages: The equipment utilizes a low vacuum chamber system, which can determine minute leaks with a higher degree of precision compared to water detection or air pressure differential methods. The equipment can also be integrated with production line direct connection systems and robot handling systems to improve production efficiency and reduce operational errors.
  6. Market and Customers: The equipment and assembly line serve a wide range of customers, including automotive and parts manufacturing, home appliances, kitchen gas appliances, medical and aerospace fields.
  7. Services and Support: Comprehensive support from design to assembly adjustment is provided, ensuring that the workpiece inspection and control design of the operational machinery, as well as assembly adjustment, are all completed in-house by the company, offering customers a complete system solution.

  These high-end leak detection equipment and assembly lines are crucial for ensuring the quality and performance of ring main units, assisting manufacturers in promptly identifying and resolving potential leakage issues through precise detection technology.

• Ring main units RMUs Stud welding machine Assembly line

  

  The ring main unit stud welding machine is a specialized equipment for welding studs on the gas chamber of a ring main unit, playing a crucial role in the power supply system, especially in ring main power supply equipment that enhances the reliability of electricity supply. The ring main unit, as a core switching device, requires the front part of the gas chamber enclosure to be fixed by welding studs for the installation of insulating sleeves and operating mechanisms.

  There are various control methods for stud welding machines, including simple circuit control, circuit control with voltage detection, and more advanced microcontroller intelligent control. The microcontroller intelligent control offers a user-friendly interface, convenient operation, precise charging, and is unaffected by temperature, with automatic compensation for power loss.

  Energy storage stud welding does not require gas protection, is simple to operate, and is suitable for the requirements of automated production lines, widely used in automotive welding production lines. The production rate of this technology depends on the charging speed of the capacitor, with manual welding reaching 8/min and automatic welding reaching 40/min. There are two types of energy storage stud welding: lifting type and pressure type. The lifting type is suitable for welding aluminum studs and brass studs, with a welding time of about 1 millisecond; the pressure type is suitable for welding M10 and below stainless steel studs and low-carbon steel copper-plated studs, as well as M6 and below aluminum studs, and brass or copper studs, with a welding time of about 3 milliseconds.

  Additionally, there is an arc stud welding machine that completes the entire welding process by discharging the welding power supply and controlling the discharge time with thyristors, with a discharge time of 5-500 milliseconds. This welding method uses microcontroller intelligent control to set and control the parameters during the welding process more accurately.

  In the field of ring main unit preparation technology, there are also innovative stud welding fixtures, such as a ring main unit gas chamber stud welding fixture, which simplifies the welding process and improves work efficiency, solving the problems of high welding difficulty and low efficiency in existing technologies. This fixture includes components such as a stud positioning plate, pre-positioning pieces, and a gas chamber mounting panel, making the installation of the stud welding fixture simple, greatly improving welding efficiency, and making installation and disassembly more convenient.

  Furthermore, there is a gas-insulated ring main unit gas chamber stud welding fixture, which fixes the position of the gas-insulated ring main unit main body, then accurately adjusts the position of the gas chamber close to the welding position of the gas chamber on the main body, facilitating welding operations for workers, reducing labor, improving the accuracy of welding operations, and effectively improving the production and processing efficiency and quality of gas-insulated ring main units. This fixture includes a welding base, a gas chamber placement table, and a clamping plate base, etc., achieving precise position adjustment and efficient welding through the use of telescopic cylinders, a rotating worktable, and positioning rulers, etc.