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(1) 40-year development history of manufacturing technology of insulator enterprises
In response to the common complaints that the existing low-voltage overhead line insulators of power grids are not firmly tied, the conductors bear the weight on non-metallic materials, the mechanical strength is poor, and the stability against wind and ice and snow is poor, which makes the poles easy to collapse. At present, all bare wires of low-voltage overhead conductors have been replaced by insulated wires. The insulated wires of the same wire diameter are larger than bare wires, and the weight is heavier, which is more likely to produce wind resistance (sail effect), increasing the swing torque of the wires. In snowy weather, insulated wires are more likely to freeze and increase in weight. Traditional aluminum wire and copper wire binding is no longer applicable, especially in windy areas, typhoon areas, ice and snow areas, and high-cold areas; the ability to resist natural disasters is weak. A low-voltage buckled polymer insulator has been developed.
This reinforced type of snap-on polymer insulator is more suitable for windy areas and high-cold frozen areas; the bearing of this insulator is on the metal parts and crossarms inside the product. Compared with traditional power insulators, it has good insulation performance, good stability, higher mechanical strength, will not be damaged during transportation, and does not require binding during installation, which is time-saving, labor-saving and convenient, and safer and more stable to use.
(2) Introduction to snap-on polymer insulator products
An organic polymer insulator consisting of an insulating part and a mounting bolt, the insulating part is made of polymer, adopts a two-petal buckled structure, and uses a snap-on method to install the insulated conductor.
Table 1 Electrical and mechanical properties of clamped polymer insulators
Insulator type
| Model
| Flame retardant level
| Water absorption rate
| Weathering requirements (UV aging test) | Nominal flashover voltage | Wind speed resistance
| Lateral tension
| Applicable conductor cross section mm² | |
Dry flash | Wet flash | ||||||||
Buckle | KYJJ-1/8 | V2 | ≤0.3% | Meet GB/T16422.2 standard requirements | 22 | 10 | 8KN | 35~70 | 35~70 |
KYJJ-2/10 | V2 | ≤0.3% |
| 22 | 10 | 10KN | 120~150 | 120~150 | |
KYJJ-3/10 | V2 | ≤0.3% | >1000h | 22 | 10 | 10KN | 185~240 | 185~240 | |
Table 2 Comparison of characteristics of traditional insulators and clamped polymer insulators
Features | Traditional insulators | Crimp-type polymer insulator |
Material | Ceramics | Modified polyolefin |
Production method | Making ingredients-refining mud - forming - firing | High temperature and high pressure injection molding (environmentally friendly) |
Mechanical strength | High mechanical strength but brittle, easy to break during transportation | High mechanical strength and certain toughness, not easy to be damaged during transportation |
Fixed method | Fixed with metal wires, easy to damage the insulation layer of the wire | Crimp-type fixation, no loss of insulated wire |
Wind speed resistance | (Local force is large, wear and even breakage may cause the wire) | (Large contact area at the fixed point, smooth design, not easy to wear the wire) |
Lateral tension | ≤35 m/s | ≥50m/sec |
Vibration force | 5kN | 8~10kN |
Operation time | The wire and the insulator are stressed, and the wire is easy to fall off and drop off when dancing | Mainly crossarms and bolts bear the force, not easy to fall off |
Weather resistance | (Poor wind resistance) | (Strong wind resistance) |
(1) 40 years of development and progress in digital manufacturing and process level
Five-axis manipulator embedded fully automatic production makes product performance more stable and the production process more environmentally friendly.
(2) Development plan for the next 5-10 years
Fully promote application and enhance the ability of insulators to resist wind, ice and snow, and natural disasters.