Line end test systems

The flagship of our production are ‘end of line’ plants, developed starting from the specifications and in close collaboration with the customer, which incorporate finishing benches with assisted picking, product conveyors towards the test station, product sorting systems according to test results, product rework and packing benches.  Our test systems are designed to perform a very wide range of checks, from electrical functionality tests to electrical safety tests and stress tests, from checking the presence of components to visual inspection or the compliance of the product labels with the line currently in production.

Some examples of realized systems:



Molded-case circuit-breaker production line

The system carries out the testing and packaging phase of 400A to 630A LV molded-case circuit-breakers with dimensions of 255x185x125 mm and a maximum weight of 5.2 kg.

The system consists of:

  • Automatic station for circuit-breaker testing
  • Manual loading stations
  • Manual packing stations
  • Automatic marking stations
  • Manual device repair stations
  • Transport to the various stations

The system performs electrical tests and a presence check of piece components, the laser marking of the compliant pieces and the dispatch to the packaging bench, or the transfer of non-conforming items to the repair station.

Both packaging and repair stations are equipped with assisted picking systems for components required to complete the operations.

All the line stations and the supervisor are interconnected. The pallet exchange management is carried out starting from the information stored in the memories present on each pallet.

CT and VT automatic test line

The automatic test system TA and TV is divided into two separate sections, each specialized for a specific type of transformer and respectively, to the testing of the CT transformers and the testing of the VT transformers.

The automatic test system TA and TV is divided into two separate sections, each specialized for a specific type of transformer and respectively, to the testing of the CT transformers and the testing of the VT transformers.

The piece to be tested is initially mounted from the operator on a special pallet compatible with the automatic handling systems of the production plant. After this, the piece on the pallet is placed at the entrance of the system loading station, which takes it over and transfers it to the entrance of the respective testing station. A barcode reader checks the type of product to be tested and automatically configures the system for the specific testing cycle. The piece is transferred to the test station (protected by a suitable Faraday cage) and positioned precisely in the contracting position by an electro-pneumatic indexing system.

At the end of the test sequence, the piece is disconnected and conveyed to the unloading roller for later pick by the operator. The average cycle time for the CTs is about 12 minutes, while for the VTs it is about 10 minutes.

The system is equipped with two independent management systems in order to guarantee maximum flexibility. The system configuration is performed completely automatically starting from the reading of the bar code on the piece to reduce the “human” intervention in the test cycle and thus to guarantee the maximum objectivity of the test.

Both systems are interfaced to a supervisor PC for the exchange of test data with factory information systems.

Test line for differential blocks

The line allows customization, testing of tree-pole and four-pole type differential devices and possible rework.

The line includes three distinct modules:

  • Launch Form
  • End-line test module
  • PAM Form

connected to each other by a ring conveyor for rapid piece transfer.

The launching module, connected to the finishing line by a conveying belt, allows the assisted completion of the piece, the presence check of some components and the transfer of the completed piece to the End-line testing station. When the incoming piece arrives, a Data-matrix reader checks the type (3 or 4-pole) and the switch family to be processed so that the system can correctly load the finishing recipe and the specific testing cycle of the product.

At the end of the operations, the piece is transferred to the test station, which carries out the electrical tests and the presence of foreseen components for the product variant under test. At the end of the test, the system sorts the piece towards the packaging station in case of a positive result, or towards the PAM module (repair station) in case of non-conforming piece.

The PAM module – or repair station – allows the re-work of non-conforming piece and the re-sent for re-execution of the test cycle.

The system is connected to a concentrator PC, which collects the test data in a database, allowing search, analysis and exchange of information with the factory information system according to the Industry 4.0 approach.