MCB (MINIATURE CIRCUIT BREAKER)
AND DB (DISTRIBUTION BOARD)
[CODE NO.4063]
(1) MCB
An MCB or miniature circuit breaker is an electromagnetic device that embodies complete enclosure in a molded insulating material. The main function of an MCB is to switch the circuit, i.e., to open the circuit (which has been connected to it) automatically when the current passing through it (MCB) exceeds the value for which it is set. It can be manually switched ON and OFF as similar to normal switch if necessary.
A Miniature Circuit Breaker (MCB) is an automatically operated electrical switch used to protect low voltage electrical circuits from damage caused by excess current from an overload or short circuit. MCBs are typically rated up to a current up to 125 A, do not have adjustable trip characteristics, and can be thermal or thermal-magnetic in operation.
All fuses need to be replaced with MCB for better safety and control when they have done their job in the past. Unlike a fuse, an MCB operates as automatic switch that opens in the event of excessive current flowing through the circuit and once the circuit returns to normal, it can be reclosed without any manual replacement. MCBs are used primarily as an alternative to the fuse switch in most of the circuits. A wide variety of MCBs have been in use nowadays with breaking capacity of 10KA to 16 KA, in all areas of domestic, commercial and industrial applications as a reliable means of protection.
A typical external appearance of an MCB is shown in figure. MCBs are manufactured in different pole versions such as single, double, triple and four pole structures with different fault current levels. Mostly, MCBs are linked to give two and three-pole versions such that a fault in one line will break the complete circuit and hence complete circuit isolation are provided. This feature will be helpful in case of single phasing in three phase motor protection.
These are rated at 220V for DC supply and 240/415 for AC supply (single and three-phase) with different short circuit current capacity. Typically, single phase devices have load current range of up to 100 A. Some MCBs have facility to adjust its tripping current capacity while some devices are fixed for some load current and short circuit rating.
Working Principle Miniature Circuit Breaker
There is two arrangement of operation of a miniature circuit breaker. One due to the thermal effect of over current and other due to electromagnetic effect of over current. The thermal operation of the miniature circuit breaker is achieved with a bimetallic strip whenever continuous over current flows through MCB, the bimetallic strip is heated and deflects by bending.
This deflection of the bimetallic strip releases a mechanical latch. As this mechanical latch is attached to the operating mechanism, it causes to open the miniature circuit breaker contacts. But during short circuit conditions, the sudden rising of current causes electromechanical displacement of plunger associated with tripping coil or solenoid of MCB. The plunger strikes the trip lever causing the immediate release of the latch mechanism consequently open the circuit breaker contacts. This was a simple explanation of the miniature circuit breaker working principle.
COST ESTIMATION
Plant Capacity 20,000 Nos/Day
Land & Building (5000 sq.mt.) Rs. 5.77 Cr
Plant & Machinery Rs. 3.29 Cr
Working Capital for 2 Months Rs. 6.38 Cr
Total Capital Investment Rs. 16.81 Cr
Rate of Return 70%
Break Even Point 36%
INTRODUCTION
(1) MCB
WORKING PRINCIPLE MINIATURE CIRCUIT BREAKER
MINIATURE CIRCUIT BREAKER CONSTRUCTION
CONSTRUCTION OF MCB
FRAME OF MINIATURE CIRCUIT BREAKER
OPERATING MECHANISM OF MINIATURE CIRCUIT BREAKER
TRIP UNIT OF MINIATURE CIRCUIT BREAKER
OPERATION OF MINIATURE CIRCUIT BREAKER
TYPES OF MINIATURE CIRCUIT BREAKERS (MCB’S)
TYPE B MCB
TYPE C MCB
TYPE D MCB
(2) DISTRIBUTION BOX
TYPES OF ELECTRICAL DISTRIBUTION BOARDS
FUSE BOXES:
MAIN BREAKER PANEL:
MAIN LUG PANEL:
SUBPANELS:
TRANSFER SWITCHES:
USAGE AND APPLICATION
1. HOME ELECTRICAL PANELS
2. LIGHTS
3. INDUSTRIAL APPLICATIONS
4. HEATERS
5. GROUND FAULT TRIP MECHANISM
B.I.S. SPECIFICATION
PROCESS FLOW CHART
PROCESS FLOW CHART (MCB)
PROCESS FLOW CHART DISTRIBUTION BOX
PRODUCTION PROCESS
(A) FOR MCB
(1) SPOT WELDING:-
PROCESSING AND EQUIPMENT
COMPONENTS USED IN SPOT WELDING ARE:
SPOT WELDING IS THE INITIAL STAGE OF AUTOMATED MCB PRODUCTION
HERE IT INCORPORATES FOLLOWING STAGES:
THE ABOVE MENTIONED STAGES ARE BETTER EXPLAINED THROUGH
FOLLOWING BLOCK DIAGRAMS:
STAGE 1
STAGE 2
STAGE 3
STAGE 4
STAGE 5
KNOB ASSEMBLY:-
STEPS OF KNOB ASSEMBLY:-
STAGE 1
STAGE 2
TOOLS USED:-
THE PROCESS FLOW DIAGRAM FOR KNOB ASSEMBLY IS SHOWN BELOW
MCB ASSEMBLY:-
THERMAL OPERATION:-
MAGNETIC OPERATION:-
QUALITY CONTROL
SCHEME OF INSPECTION AND TESTING:
(B) FOR DB
PROCESS OF MANUFACTURE
IN BRIEF THE MANUFACTURING PROCESS CONSISTS OF:
QUALITY CONTROL AND STANDARDS
MARKET POSITION
CHINA CIRCUIT BREAKER MARKET, BY RATED VOLTAGE (USD MILLION)
EUROPE CIRCUIT BREAKER MARKET, BY COUNTRY, 2024 (UNITS)
INCREASING RURAL ELECTRIFICATION, TO DRIVE THE GLOBAL MCB
AND MCCB MARKET
MARKET OVERVIEW
MARKET SEGMENTATION
NORTH AMERICA DISTRIBUTION PANEL MARKET, BY END USE,
2016 & 2024 (USD BILLION)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
PLANT LAYOUT
SUPPLIERS OF MCB
SUPPLIERS OF DB
RAW MATERIAL SUPPLIERS
SUPPLIERS OF PRODUCTION LINES
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF EXHAUST FAN
SUPPLIERS OF TESTING EQUIPMENTS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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