Assembly line of the new RCCB EFI-P

One of the main requirements in the development of the new Residual Current Circuit Breakers (RCCBs) EFI-P was that the design must be suitable for the highest possible level of automation of component fabrication and final assembly. Therefore, the appropriate design solutions were taken into consideration as early as the product development phase.

Miran Dolinšek R&D

The concept of the assembly line was made according to our requirements, which we coordinated with the selected contractor before implementation. The basic requirement was the highest possible level of automation and control of the entire assembly process from start to finish. The assembly line consists of 15 machines, which are interconnected by appropriate manipulators or conveyor belts. The RCCB assembly process is almost entirely automated.

When planning the line, it had to be taken into account that all standard RCCBs were to be composed on it. Currently, there are 71 technical types, which differ in the number of poles (EFI-P2 and EFI-P4), type of mechanisms, rated currents, residual currents… The product and its subassemblies undergo 21 measurements, tests and video inspections during the production process, and if the results deviate from the prescribed ones, the disputed subassembly is automatically eliminated. All important data on installation and performed measurements and tests are recorded in a database, which ensures traceability via a 2D code printed on the housing of the EFI-P RCCB.

Materials are inserted on the line or into individual machines via vibrators (bulk material) or dosing strips (material packed in trays) and manipulated by robots. Both the presence and suitability of the material are checked before removing the use. If the material does not conform to the type of RCCB being assembled, the material is removed to an appropriate place on the machine. During assembly, we also check the suitability of the assembly, the presence and position of the elements in the subassemblies, electrical conductivity, the suitability of welding parameters, we perform a high-voltage test and finally the residual current test. If any of the results deviates from the prescribed, the product is automatically removed from the line. All important assembly data is recorded in a database that ensures traceability via a 2D code printed on the housing of the product.

Once the RCCB has been assembled and the electrical tripping test performed on the assembly line, the RCCB is then magnetically adjusted, and subjected to various tests, required by IEC standard. When all tests are positive, the screws are sealed and we add a QR code on the housing, which leads the user to the product's website, where all technical data, sketches and diagrams, certificates and instructions for use are available.