Download our 2025 Product Catalog for detailed drawings and technical parameters of all switchgear components.
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Vacuum Circuit Breaker manufacturing is a specialized high-voltage engineering discipline that involves the production of critical protection devices used to safeguard electrical distribution networks ranging from 12kV to 40.5kV. The process encompasses multiple intricate stages, from the electromagnetic design of the operating mechanism and material selection of the contacts to precision machining, insulation embedding, and rigorous testing according to IEC 62271-100 standards. As a leading Vacuum Circuit Breaker Manufacturer, XBRELE ensures the production of high-quality, high-endurance components that meet the stringent requirements of utilities, mining operations, and industrial switchgear panel builders worldwide.
The manufacturing process for vacuum circuit breakers involves several key stages, beginning with detailed design specifications based on client requirements (such as altitude, rated current, and short-circuit capacity).
Mechanism Assembly: The first physical stage is the sub-assembly of the operating mechanism. At XBRELE, we manufacture both modular spring-charged mechanisms optimized for the VS1 Indoor Vacuum Circuit Breaker and permanent magnet mechanisms. This involves the precise installation of closing springs, opening springs, cams, and latches onto a CNC-machined steel chassis. Unlike stamped parts used by budget manufacturers, our machined components ensure smoother mechanical operation and reduced wear over time.
Vacuum Interrupter Integration: The core of the process is the integration of the Vacuum Interrupter (VI). We utilize an advanced embedding process where the VI is cast directly into epoxy resin poles. This “Solid Insulation” technique protects the vacuum bottle from external environmental factors like dust, humidity, and condensation, which are common causes of flashover in older air-insulated designs.
Final Assembly & Calibration: The embedded poles are then mounted to the operating mechanism chassis. Technicians perform critical adjustments to the “Three-Phase Synchronism” and “Contact Over-travel.” These parameters are vital; if the contacts do not open simultaneously within 2ms, it can cause unbalanced arcing and premature failure. throughout the manufacturing process, precision and expertise are essential to ensure the final product meets the necessary standards for arc quenching and dielectric strength.
The quality of a finished Vacuum Circuit Breaker is directly dependent on the purity of the raw materials used. XBRELE maintains strict supplier protocols to ensure material excellence.
The production of Vacuum Circuit Breakers relies on a range of specialized equipment to ensure precision and quality. Key tools include design software for 3D modeling (CAD/CAM), which is essential for creating accurate chassis specifications and simulating mechanical stress before production begins.
The manufacturing process utilizes CNC Machining Centers and Laser Cutting Machines for shaping the steel frames and operating linkages with micron-level tolerance. For insulation, we employ Automatic Pressure Gelation (APG) Clamping Machines. These machines inject epoxy resin into molds under high pressure and vacuum, ensuring a void-free insulation structure that eliminates the risk of Partial Discharge.
To maintain high standards, manufacturers employ various testing equipment for electrical and mechanical verification. These tools are vital for conducting performance tests, including loop resistance testers, mechanical characteristic analyzers, and X-Ray imaging systems to inspect the internal integrity of the embedded poles. The use of cutting-edge technology in VCB production contributes to the creation of high-quality, reliable products that meet industry standards and customer requirements.
Testing procedures for Vacuum Circuit Breakers are rigorous and comprehensive, ensuring the products meet stringent safety and performance standards defined by IEC 62271. These evaluations are not optional; they are a mandatory gateway for every unit leaving the XBRELE factory.
| Test Name | Standard / Limit | Purpose |
|---|---|---|
| Power Frequency Withstand Voltage | 42kV / 1min (for 12kV VCB) | Verifies insulation integrity between phases and to ground. |
| Main Circuit Resistance Test | < 40μΩ (Typical) | Ensures low contact resistance to prevent overheating at rated current. |
| Mechanical Characteristic Test | Bounce < 2ms; Sync < 2ms | Checks opening/closing speed, synchronism, and bounce duration. |
| Vacuum Degree Check | < 1.33 x 10^-3 Pa | Uses magnetron discharge to ensure no micro-leaks in the interrupter. |
Additionally, Type Tests (Design Verification) include Short-Circuit Breaking Capacity tests to confirm the breaker can interrupt fault currents (e.g., 31.5kA) without failure, and Lightning Impulse Voltage tests (75kV/125kV BIL) to guarantee safety during storm surges. These tests are crucial for maintaining the reliability and effectiveness of VCBs in protecting electrical connections and equipment across diverse applications.
Working with a custom Vacuum Circuit Breaker manufacturer offers several key advantages for businesses seeking tailored solutions for their electrical installations. Switchgear cabinets vary significantly between manufacturers (e.g., ABB UniGear, Schneider MVnex, or local KYN28 designs). Custom manufacturers can provide VCBs that precisely match specific installation dimensions, including the Phase Center Distance (150mm, 210mm, 275mm) and the contact arm length, ensuring seamless integration into existing systems.
This customization extends to factors such as Rated Voltage (12kV vs 24kV), Control Voltage (DC 220V, DC 110V, or AC 220V), and specialized Altitude Corrections. For projects in high-altitude regions (above 2000m), standard air insulation is insufficient. XBRELE custom manufactures “High-Altitude” VCBs with reinforced external insulation and extended creepage distances to prevent flashover in thin air.
Additionally, custom manufacturers can provide expert technical support and guidance throughout the selection, installation, and maintenance processes, ensuring that clients receive the most suitable and efficient solutions for their unique needs, rather than being forced to adapt their project to a rigid standard catalog.
Vacuum Circuit Breaker manufacturers bring extensive experience and expertise to their craft, honed over decades of industry involvement. XBRELE has been deeply involved in the medium voltage sector, evolving from component manufacturing to complete VCB assembly. This long-standing experience translates into deep industry knowledge, allowing manufacturers to develop specialized solutions for diverse sectors including oil and gas, mining, petrochemicals, and renewable energy grids.
Experienced manufacturers prioritize quality control, innovation, and adherence to international standards. We understand the specific arc-quenching physics required for different loads—for example, switching a capacitor bank requires different breaker characteristics (low restrike probability, Class C2) compared to switching a short-circuit fault. This expertise enables manufacturers to provide valuable technical support to clients, helping them select the most appropriate VCB class (M2, E2, C2) for specific applications and ensuring optimal performance and longevity of electrical installations.
Vacuum Circuit Breaker manufacturers, particularly those based in countries like China, offer cost-effective solutions without compromising on quality. These manufacturers leverage economies of scale, efficient production processes, and comprehensive local supply chains to keep prices competitive. For instance, XBRELE produces critical components like the switchgear insulation parts and contact arms in-house, reducing the markup layering typically seen with assemblers who buy all parts externally.
Companies in the Yueqing electrical hub have established themselves as global suppliers of high-quality, cost-effective medium voltage equipment. This cost-effectiveness extends to customized solutions, allowing businesses to access tailored VCB designs without incurring excessive expenses. The ability to provide low-cost, high-quality products has positioned these manufacturers as preferred suppliers for OEM panel builders in cost-sensitive markets like Southeast Asia, South America, and Africa.
Vacuum Circuit Breaker manufacturers demonstrate remarkable flexibility in meeting diverse industry needs. They offer a wide range of products, from standard Indoor Draw-out Type (VS1) breakers to Fixed Type Side-Mounted (ZN85 series) units. This flexibility extends to the operating mechanism choice, with options including the traditional Spring Mechanism for standard reliability or the Permanent Magnet Mechanism for high-frequency switching applications.
Manufacturers like XBRELE showcase this adaptability by producing VCBs that accommodate different busbar alignments and interlock logics. This versatility is particularly valuable in industries such as mining retrofit projects, where a modern VCB must fit into a switchgear cabinet designed 20 years ago. Additionally, many manufacturers offer private labeling (OEM) services, allowing clients to brand the breakers as their own.
Sustainable Vacuum Circuit Breaker manufacturers are increasingly focusing on eco-friendly practices and high-quality materials to meet growing environmental concerns. Unlike SF6 (Sulfur Hexafluoride) breakers, which use a potent greenhouse gas, Vacuum Circuit Breakers are inherently more environmentally friendly as the arc quenching occurs in a vacuum bottle with no emissions.
To further enhance sustainability, manufacturers are adopting innovative production techniques. We utilize recyclable thermoplastic materials where possible and ensure that our epoxy resin curing processes are optimized for energy efficiency. XBRELE is committed to reducing the carbon footprint of the grid by providing low-resistance breakers that reduce energy loss (I²R losses) during operation.
Chinese electric manufacturers have emerged as significant players in the global medium voltage market, offering competitive advantages in cost, technology, and production capabilities. These manufacturers leverage China’s robust manufacturing infrastructure—specifically the complete industrial cluster in Wenzhou—to produce high-quality VCBs at lower costs. Companies like XBRELE provide a wide range of VCB solutions, catering to diverse utility and industrial needs.
Key benefits of considering Chinese manufacturers include:
To find the perfect Vacuum Circuit Breaker manufacturer, consider the following key factors:
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