Uma olhada por dentro: o processo de fabricação do disjuntor

Though disjuntores are found in homes, they are, of course, also utilized in industries, such as in manufacturing, healthcare facilities, data centers, mining, oil and gas, and agriculture, among various others. 

But, have you ever wondered what happens inside the circuit breaker manufacturing process? Learn the steps in this guide from professional baixa voltagem electrical manufacturer, TOSUN Electric: 

– Step 1: Welding

– Step 2: Assembly

– Step 3: Inspection

– Step 4: Electronics 

– Step 5: The OTS process

– Step 6: Tooling 

Atacadista de suprimentos elétricos

Descubra uma linha completa de produtos elétricos de um atacadista de suprimentos elétricos confiável. A TOSUNlux oferece disjuntores, contatores, interruptores e muito mais para mercados globais.

Ver produto

Step 1: Welding

The first step in the ever-complex circuit breaker manufacturing process is welding. Here, as how you know it, the metal components from frames to terminals are securely attached to each other. 

Also, precision welding techniques and skills – such as spot, laser, or arc welding – are implemented to provide joints with strength and reliability, so they can handle high electrical loads. There are times when automated welding systems are used.

Step 2: Assembly

Following the welding process, the components welded will be assembled. Thus, the mechanical parts, such as the springs, levers, and housings are fitted together. 

This process integrates both the structural and functional elements of the breaker, ensuring that the moving parts smoothly operate under different load conditions. There are times when this step may incorporate manual labor in large-scale industrial settings.

Step 3: Inspection

After assembly, each breaker undergoes the toughest and the most rigorous inspection process to detect defects and verify whether the device adheres to design specifications. 

The inspection process comprises dimensional checks, torque measurements, and visual evaluations for weld quality, assembly alignment, and surface defects. Sometimes, industries use methods like X-ray or ultrasonic inspections to detect flaws in detail. 

Step 4: Electronics

Especially in modern circuit breakers, this step plays a vital role in the monitoring, control, and protection phases. 

This particularly involves the installation of sensors, microprocessors, trip units, and control modules. However, remember that this step requires careful handling of sensitive components to avoid damage. 

Step 5: The OTS Process

Now, here is where things can get technical. OTS, or Operational Test Simulation, is performed in most circuit breakers to validate their performance under real-world conditions, but in simulation only. 

Here, breakers are put to problematic scenarios, like short-circuiting, to confirm how they’d respond. It verifies timing accuracy, current interruption capacity, and arc suppression performance. This step is necessary to ensure the breaker follows the industry standards.

Step 6: Tooling

Lastly, tooling. This ensures all parts and manufacturing equipment remain in the best conditions. This step is essential to maintain consistency across the production. 

Before concluding this discussion, note that the processes presented earlier are for general manufacturing processes for circuit breakers. For instance, in the case of the disjuntor miniatura manufacturing process steps, there might be additional or fewer steps.

Are you looking for circuit breaker manufacturing companies that make sure each of those necessary steps are carried out completely? Consider getting your industrial circuit breakers from TOSUN Elétrico. See the difference in terms of quality and enjoy the best customization opportunities. Submit your technical specifications today for a customized component solution.