Product Overview
The ground rail trolley type withdrawable switchgear assembly line is a custom non-standard automated production line developed for the electrical complete equipment industry. It is designed according to the structural features and manufacturing process of KYN28A-12 armored removable AC metal-enclosed withdrawable switchgear. It meets the assembly requirements of withdrawable truck, compartment layout and layered cabinet structure, supporting mass standardized production of 10kV withdrawable switchgear. It can also be flexibly used for assembly and testing of KYN61-40.5 high voltage switchgear, medium and low voltage distribution cabinets. It serves as the main production line equipment for high voltage electrical manufacturers to realize station-based continuous manufacturing of heavy cabinets.
KYN28A-12 withdrawable switchgear is core power distribution equipment used in industrial and mining plants, municipal power distribution and substation systems. It has good insulation performance, compact layout, high safety and convenient maintenance, widely adopted in medium and high voltage power distribution systems. The assembly line sets workstations based on the layered structure of withdrawable switchgear including busbar compartment, circuit breaker compartment, cable compartment and instrument compartment. It can complete all processes in one continuous workflow: cabinet pre-assembly, frame assembly, primary component installation, busbar connection, secondary circuit wiring, truck commissioning, cabinet cleaning and calibration, power frequency withstand voltage test, partial discharge test, air tightness test, finished product inspection and offloading.
This switchgear production line solves common problems of discrete stand-alone production: disconnected working procedures, cabinet deformation and paint damage caused by frequent crane lifting, difficult high-position assembly, separate testing stations, unstable production takt and inconsistent product quality. It fits mass production of 10kV/35kV electrical workshops. It supports continuous mass production of KYN28A-12 withdrawable switchgear, and also small-batch trial production of KYN61 high voltage switchgear and various medium & low voltage distribution cabinets. It is a versatile automated production line for high voltage cabinets.
System Composition and Technical Parameters
1. Ground Rail Trolley Conveying System
The core conveying unit adopts ground embedded rails and independent driven trolleys, designed for heavy high voltage cabinets such as KYN28A-12 withdrawable switchgear and KYN61 high voltage switchgear. Rated load capacity of each trolley ≥2500kg, capable of transporting fully assembled cabinets with components, busbars and truck units. The trolley frame is welded with thick rectangular tubes. The trolley surface is covered with wear-resistant protective plates to prevent deformation and paint scratches on the bottom of switchgear and distribution cabinets.
The line is equipped with variable speed drive. Trolley speed range: 0.05~0.25m/min. Low speed for precision assembly and commissioning, constant speed for mass production. The assembly line is equipped with mechanical positioning locks and infrared position sensors. The trolley will be locked automatically once it reaches the workstation to avoid cabinet movement during assembly and wiring, ensuring assembly accuracy. The whole line adopts linear modular layout with reserved interfaces for buffer stations and transfer stations. The number of workstations can be adjusted according to cabinet dimensions and production capacity to meet upgrading demands of electrical manufacturers of different scales.
2. Dual-side Open Assembly Workstations (Matching for Withdrawable Switchgear Line)
Spacious open working areas are reserved on both sides of the ground rail assembly line. Modular elevated platforms can be selected to solve limited operating space for upper busbar compartment and instrument compartment of KYN28A-12 switchgear. The elevated platform is welded with Q235B carbon steel profiles. The platform surface adopts 3mm anti-slip patterned steel plate, rated uniform load ≥200kg/㎡, which can carry multiple operators, assembly tools and testing instruments.
The line is fitted with 1.2m safety guardrails and anti-slip steel ladders complying with mechanical safety regulations. The platform height matches the layered structure of KYN28A-12 withdrawable switchgear, and also adapts to high-position assembly of tall KYN61-40.5 high voltage switchgear and large distribution cabinets. Operators can complete busbar connection, insulator installation, secondary cable routing, instrument wiring and truck calibration efficiently. The platform adopts modular assembly with adjustable opening width and working spacing. It is treated by sand blasting and electrostatic powder coating for corrosion resistance and wear resistance, supporting 24-hour continuous operation.
3. Integrated High Voltage Test Workstation
This withdrawable switchgear assembly line integrates a closed high voltage test chamber, realizing in-line assembly, commissioning and testing instead of separated processes. The test chamber is built with thick steel plates with internal insulation structure, reserved high voltage test ports and explosion-proof observation windows for test status monitoring.
The chamber is equipped with intelligent safety interlock door system. The high voltage circuit cannot be energized unless the door is fully closed, eliminating safety risks during high voltage tests. This workstation covers all factory acceptance tests of KYN28A-12 withdrawable switchgear, KYN61 high voltage switchgear and medium & low voltage distribution cabinets: power frequency withstand voltage test, partial discharge test and air tightness test. Cabinets are transported into the chamber directly by trolleys without secondary hoisting, reducing cabinet deformation, paint damage and insulation damage, improving testing efficiency and pass rate.
4. PLC Intelligent Control System (Central Control of Assembly Line)
The whole switchgear production line adopts industrial PLC for centralized control. Each trolley and workstation has independent control circuits, with industrial touch screen for human-machine interaction. The system supports manual / automatic modes, which can be switched according to production takt and cabinet types (KYN28A-12 withdrawable switchgear, KYN61 high voltage cabinet, medium & low voltage distribution cabinet).
The control system has overload protection, emergency stop interlock, photoelectric protection, workstation status feedback and fault alarm. It reserves communication interface for MES system to realize data collection, capacity statistics, process traceability and equipment monitoring for intelligent workshop upgrade. All motors, sensors and contactors are industrial grade for long time continuous operation. Control circuit: AC220V; power circuit: AC380V, stable operation and low failure rate.
Core Technical Features
- Optimized for withdrawable switchgear process, multi-cabinet flexibility: The assembly line follows the layered assembly process of KYN28A-12 armored withdrawable switchgear, meeting precision assembly requirements of circuit breaker truck, busbar system and secondary circuit. It also supports full-process production of KYN61-40.5 high voltage switchgear and various medium & low voltage distribution cabinets. It serves as main production line for high voltage workshops for mass production and small-batch trial manufacturing.
- Heavy load design with good cabinet protection: The ground rail trolley system runs stably. Protective plates on trolley surface protect cabinet structure and coating, reducing collision and deformation during transportation and assembly.
- Ergonomic workstation design improves efficiency: Dual-side open stations with modular elevated platforms solve insufficient operating space for high-position assembly of withdrawable switchgear. Standardized layout simplifies assembly work with full safety protection complying with workshop safety requirements.
- Integrated assembly and testing shortens production cycle: Cabinet assembly, component installation, busbar wiring, withstand voltage test and partial discharge test are completed on one line. Repeated crane handling is eliminated, cutting production cycle of withdrawable switchgear and distribution cabinets by more than 30%.
- Modular custom design for wide adaptability: The whole line adopts modular structure. Total length, workstation quantity, trolley quantity and test modules can be adjusted according to workshop space, production capacity and cabinet specifications to meet customized requirements of electrical manufacturers.
- Multi safety interlock for stable operation: The line is equipped with emergency stop interlock, chamber door lock, photoelectric protection, overload power-off and fault alarm. It protects equipment, cabinets and operators, complying with national mechanical safety standards and high voltage electrical manufacturing specifications.
Application Fields
This withdrawable switchgear assembly line is widely used by high voltage electrical equipment manufacturers. It is mainly used for KYN28A-12 armored removable AC metal-enclosed withdrawable switchgear and KYN61-40.5 high voltage switchgear. It covers cabinet assembly, primary component installation, busbar assembly, secondary circuit wiring, truck commissioning, insulation withstand voltage test, partial discharge test, air tightness test and finished product inspection. It also supports batch production and prototype test of various medium & low voltage distribution cabinets and metal-enclosed switchgear of similar dimensions. It is core production line equipment for high voltage workshops to realize standardized, automated and intelligent manufacturing.
