Multi-Disciplinary Fabrication Processes Involved
Manufacturing switchgear, industrial relays, miniature circuit breakers (MCBs), and power distribution panels integrates several discrete disciplines under one roof:
- High-Speed Progressive Stamping: Stamping phosphor bronze, copper, and brass strips into intricate spring contacts and terminals at 400 strokes/min.
- Engineering Plastic Injection Moulding: Moulding polycarbonate (PC) and flame-retardant polyamide (Nylon 66) housings with sub-millimeter tolerances.
- Precision Surface Plating: Silver, tin, and nickel electroplating to guarantee electrical conductivity and corrosion resistance.
- Automated & Manual Sub-Assembly: High-speed staking, ultrasonic welding, and terminal rivet assembly.
- High-Voltage Dielectric Testing: 100% automated electrical testing checking contact resistance, insulation resistance, and trip curves.
Critical Operational Challenges in Electrical Manufacturing
With assemblies frequently containing 40+ miniature springs, screws, bimetal strips, and housings, missing a single screw halts assembly lines. Digital BOM management with phantom sub-assemblies and strict lot traceability ensures every manufactured breaker maps directly to its raw material heat lot and operator test log.
Production & Plant Control
Manage Operations with ERPrath ERP
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