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PS 26029HARDWAREDisaster ManagementHidden GemFast Prototype (36h)

Automated High-Current Short-Circuit Test System for IEC 60898-1:2015 MCB Compliance.

Ministry of Consumer Affairs, Food & Public Distribution• Department of Consumer Affairs (DoCA)
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30-Second Plain English Summary

Testing Miniature Circuit Breakers (MCBs) under international standard IEC 60898-1:2015 requires dangerous high-current short-circuit tests (up to 10kA) with precise point-on-wave switching that manual laboratory setups struggle to capture accurately. Build an automated high-current short-circuit testing and data acquisition (DAQ) platform with microsecond synchronous point-on-wave firing, optical arc voltage monitoring, and automated test certificate generation for BIS laboratories.

5-Dimension Strategic ScorecardOverall Score: 3.8 / 5.0
Innovation
3.9 / 5
36h Feasibility
4 / 5
Uniqueness
3.5 / 5
Jury Appeal
3.8 / 5
Tech Depth
3.7 / 5
Recommended System Architecture Pipeline
High-Power Test Transformer + Rogowski Coils -> 1 MS/s Isolated DAQ -> FPGA Point-on-Wave Trigger -> FastAPI IEC Validation Engine -> Lab Test Console
Hardware Bill of Materials (BOM) & Cost BreakdownEstimated component unit economics in Indian Rupee (INR)
Prototype Unit Cost:₹2,78,500
ComponentSpecificationQtyEst. Cost
High-Current Pulse Test Transformer (up to 10,000A)Transformer-based short-circuit fault current source compliant with IEC 60898-11₹1,25,000
Automated R & XL Reactor Load BankSwitched high-power resistive and inductive banks for precise test power factor control (0.8-0.95)1₹48,000
High-Speed Point-on-Wave SCR Thyristor Closing Switch1200V / 2000A solid-state trigger synchronizing fault inception at precise voltage wave angles1₹32,000
LEM Wideband Rogowski / Hall-Effect Current TransducersCaptures peak let-through current (Ip) and I2t Joule integral waveforms up to 10kA2₹16,000
Industrial High-Speed DAQ & PLC Controller with 10-inch HMI1 MS/s multi-channel digitizer executing automated test report generation1₹38,000
Universal Pneumatic MCB Clamping Station & Blast Arc ChuteTransparent explosion-safe polycarbonate containment protecting test technicians1₹19,500
Power Input: 415V 3-Phase AC Industrial Laboratory Supply
Form Factor: Standard 19-inch Industrial Rack Panel with Pneumatic Blast Chamber
Architecture & Prototyping Strategy: Two-tier presentation strategy: (1) Hackathon Benchtop MVP (~₹8k–₹12k) with 50A transformer + shunt resistor + Arduino/STM32 fast ADC + relay; (2) Certification Lab Bench (~₹2.78L) with 10kA pulse transformer, automated R/XL load bank, SCR synchronous switch, and arc blast containment.
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Official Government Problem Description
Background: The safety of electrical installations hinges on reliable Miniature Circuit Breakers (MCBs). IEC 60898-1:2015 mandates rigorous short-circuit breaking capacity tests, crucial for ensuring MCBs perform correctly under severe fault conditions. Existing Problem: Current manual or semi-automated testing methods for MCBs introduce significant challenges. These include imprecise R (resistive) and XL (inductive) circuit configurations, increased test times, and elevated safety risks for personnel during high-energy fault current generation (up to 10,000A). This impacts test accuracy, repeatability, and overall safety in the MCB certification process. Detailed Description: This proposal outlines an automated machine to precisely control test currents, voltages, and circuit impedance, executing high-current short-circuit tests on single pole, SPN, DP, TP, and FP MCBs (0.5A-63A) per IEC 60898-1:2015. It features an Automated R and XL Circuit Combination Module with high-power, automatically switched banks for precise power factor control. A High-Current Power Source (transformer-based) delivers up to 10,000A. The Test Station includes universal MCB mounting and a critical arc chute for safety A sophisticated Control and Data Acquisition System (PLC/Industrial PC) manages tests captures high-speed waveforms, and analyzes data (Ip, I2t). A user-friendly HMI allows parameter input and automatic report generation. Comprehensive safety systems are integrated. Expected Solution: The automated machine will perform MCB breaking capacity tests with unprecedented accuracy and repeatability, fully adhering to IEC 60898-1:2015. This automation will ensure precise parameter control, significantly reduce test times, and enhance safety by minimizing human intervention during high-energy fault conditions. This state-of- he-art facility will provide a reliable platform for MCB certification, contributing directly to electrical safety and quality assurance.
AI & PPT Citation Format

Smart India Hackathon 2026 Problem Statement PS-26029: "Automated High-Current Short-Circuit Test System for IEC 60898-1:2015 MCB Compliance.", Ministry: Ministry of Consumer Affairs, Food & Public Distribution. Strategy & Architecture via SIH ONE (https://sihone.pages.dev/ps/26029)

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