Download our 2025 Product Catalog for detailed drawings and technical parameters of all switchgear components.
Get Catalog Download our 2025 Product Catalog for detailed drawings and technical parameters of all switchgear components.
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Switchgear Component manufacturing is the foundational industry that powers the assembly of Medium Voltage (MV) and High Voltage (HV) electrical panels. It involves the precision engineering of critical “passive” parts—such as epoxy insulation, earthing switches, and mechanical interlocks—that ensure the safety and functionality of KYN28, XGN, and Ring Main Units (RMU). As a dedicated Switchgear Component Manufacturer, XBRELE serves as the invisible backbone for panel builders worldwide. From 12kV contact boxes to 40.5kV wall bushings, we provide the essential building blocks that allow OEMs to assemble reliable, IEC-compliant switchgear with efficiency and confidence.
The manufacturing process for switchgear components is diverse, requiring expertise in both polymer chemistry and metal fabrication. At XBRELE, our production lines are segmented to handle these distinct disciplines while ensuring seamless integration in the final assembly.
Insulation Molding (APG Process): For Contact Boxes (Spouts) and Wall Bushings, we utilize the Automatic Pressure Gelation (APG) process. This involves pre-mixing epoxy resin with silica hardeners under vacuum to remove air bubbles, then injecting the mixture into heated steel molds. This technique ensures high dimensional accuracy and superior dielectric strength, essential for preventing partial discharge.
Metal Fabrication & Machining: Components like the JN15 Earthing Switch and VCB Chassis Trucks require robust mechanical structures. We process high-strength steel using CNC punching and bending machines to create frames that can withstand the electrodynamic forces of a short circuit (up to 40kA). Copper contacts are silver-plated to ensure low resistance.
Assembly & Integration: The final stage involves the assembly of multi-part mechanisms, such as the five-prevention mechanical interlocks. Technicians assemble springs, levers, and blocking magnets, testing the logic to ensure that a switchgear operator cannot make a dangerous mistake (e.g., closing the earthing switch on a live busbar).
The reliability of a switchgear panel starts with the raw materials of its smallest components. XBRELE sources only certified materials to guarantee longevity and safety.
Producing diverse switchgear components requires a versatile factory floor. XBRELE has invested in specialized machinery to control the quality of both insulation and mechanical parts.
APG Clamping Machines: Our insulation workshop is equipped with hydraulic APG clamping machines. These allow us to mold complex shapes like Post Insulators with embedded threaded inserts in a single cycle, ensuring high mechanical pull-out strength.
CNC Turret Punches & Lasers: For the earthing switches and chassis, precision is key to ensuring smooth rack-in/rack-out operations. Our CNC centers cut steel plates with 0.1mm tolerance, ensuring that every replacement part fits perfectly into the panel without filing or grinding.
Surface Treatment Lines: While often outsourced by smaller workshops, XBRELE maintains strict control over our silver-plating and zinc-plating partners to ensure the thickness and adhesion meet IEC standards for humid tropical environments.
Even a single defective insulator can cause a total switchgear failure. Therefore, XBRELE enforces a “Zero Defect” testing policy for all components compliant with IEC 60694 and IEC 62271-102.
| Test Name | Component Target | Purpose |
|---|---|---|
| X-Ray Flaw Detection | Insulators, Spouts | Scans internal structure to detect air voids or cracks inside the epoxy resin. |
| Power Frequency Withstand | Insulation Parts | Applies 42kV/1min to ensure dielectric strength meets 12kV requirements. |
| Loop Resistance Test | Earthing Switches | Ensures contact resistance is low enough to carry short-circuit currents. |
| Mechanical Endurance | Earthing Switches, Chassis | 2,000 operation cycles to verify spring life and mechanism durability. |
| Glass Transition (Tg) | Epoxy Material | Lab test to verify the thermal stability of the cured resin batch. |
For our JN15 Earthing Switches, we also conduct Short-Time Withstand Current tests (Type Test) to prove they can safely ground a 31.5kA or 40kA fault for 4 seconds without welding or disintegration.
Standard components do not always fit every project. Panel builders often face retrofitting challenges or specific utility requirements. A custom Switchgear Component manufacturer like XBRELE acts as your engineering partner.
We offer deep customization for Insulation Parts. If your busbar arrangement requires a non-standard bending load or a specific creepage distance for a coastal installation, we can modify the APG mold to produce a custom Post Insulator or Wall Bushing.
For Mechanical Parts, we can customize the width and stroke of the VCB Chassis Truck to fit non-standard cabinets (e.g., 650mm narrow panels). This flexibility allows OEMs to design compact switchgear without being limited by the rigid catalogs of large conglomerates.
Manufacturing components requires a different mindset than assembling whole panels. It requires a focus on material science and mass-production consistency. XBRELE brings decades of experience to this niche. We understand the “Five Prevention” interlock logic intimately because we manufacture the locks themselves.
Our experience extends to international standards. We know that a wall bushing for a project in Russia (GOST standard) may differ from one in Southeast Asia (IEC standard). Experienced manufacturers prioritize these nuances, ensuring that the components you buy will pass the final acceptance test of your complete switchgear assembly.
Sourcing switchgear components from a specialized manufacturer in China offers a significant cost advantage. By purchasing direct from XBRELE, panel builders bypass the markups of local distributors. Our location in Yueqing provides access to the world’s most efficient supply chain for copper and epoxy.
We also offer CKD (Complete Knock Down) and SKD kits. Instead of shipping bulky, fully assembled earthing switches, we can ship the parts in dense packaging for you to assemble locally. This drastically reduces ocean freight costs and import duties, making your final switchgear pricing much more competitive in your local tenders.
XBRELE demonstrates remarkable flexibility. We can handle high-mix, low-volume orders for repair and maintenance projects (e.g., 5 replacement contact boxes) just as efficiently as high-volume OEM orders (e.g., 5,000 post insulators for a factory production run).
Our product range covers the entire ecosystem of KYN28 and XGN cabinets. From the heavy-duty earthing switch at the bottom of the panel to the tiny heater and humidity controller in the low-voltage compartment, XBRELE offers a “One-Stop Shop” experience. This adaptability simplifies your procurement process, reducing the administrative burden of managing dozens of small vendors.
Sustainability in component manufacturing focuses on material efficiency and waste reduction. XBRELE utilizes advanced APG machines with optimized heating cycles to reduce energy consumption during the curing process.
We also implement strict recycling protocols for our metal scrap. The copper offcuts from our machining process are collected and recycled, ensuring minimal material waste. Furthermore, all our insulation materials and plating processes are RoHS compliant, ensuring that your final switchgear meets global environmental standards.
China is the global powerhouse for medium voltage components. Manufacturers here have achieved a scale of production that allows for unmatched quality-to-price ratios. XBRELE leverages this ecosystem to offer:
To select the best supplier for your switchgear assembly line, consider:
XBRELE checks all these boxes, positioning us as the ideal strategic partner for your supply chain.
Streamline your supply chain with factory-direct insulation and mechanical parts.
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