CN111341507A - Tough column type porcelain insulator for high-voltage line - Google Patents
Tough column type porcelain insulator for high-voltage line Download PDFInfo
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Abstract
The invention discloses a tough column porcelain insulator for a high-voltage line, which comprises an insulator body, an upper steel cap and a lower steel cap, the insulator body is provided with a bone column body, an upper core head and a lower core head which are integrally connected with two ends of the bone column body, a large umbrella skirt and a small umbrella skirt are arranged on the bone column body at intervals, an annular groove and an inserting groove are arranged on the upper core head, annular bosses are arranged on the inner side surface of an upper steel cap at intervals, a plug connector is arranged between the upper steel cap and the upper core head, the invention has the advantages of high mechanical strength, excellent electrical performance, stable and reliable quality, high mechanical impact resistance, strong pollution resistance, small maintenance workload and lower cost, and can completely meet the technical requirements of the column type porcelain insulator for the 110-plus-330 KV high-voltage transmission line.
Description
Technical Field
The invention relates to a porcelain insulator, in particular to a tough column type porcelain insulator for a high-voltage line.
Background
Along with the influence of the environment including severe ice and frost climate, earthquake destructive power and the like, the high-voltage transmission line has higher and higher requirements on the electrical performance and the mechanical performance of the post porcelain insulator, in the 110KV-330KV transmission line, the mechanical strength grade of the post porcelain insulator is required to be more than 15KN, the tensile strength is required to be more than 180-200MPa, and the impact toughness is also high. Most of the existing common column-type porcelain insulators are made of bauxite, kaolin and feldspar as main raw materials, and are fired at high temperature, and although more corundum and mullite exist in phase groups in the tissues, the phase group microcrystals are not distributed uniformly, crystal grains are thick, the sizes are different, and the contents of air holes and glass phases are more, so that the existing common column-type porcelain insulator has the porcelain strength grade below 15KV, the tensile strength is only 80-120 MPa generally, the best tensile strength is only 150 MPa, and the requirement on impact toughness is not high, so that the common column-type porcelain insulator has low mechanical strength and heavy quality and cannot completely meet the technical requirement on the use of 110KV-330KV high-voltage lines. The 110KV-330KV column type porcelain insulator is also made of special ceramics (such as silicon carbide ceramics, boron nitride ceramics, zirconia ceramics and the like), but the special ceramics are made of the special ceramics, the raw material consumption is large, the energy consumption is high, the manufacturing cost is high, the manufacturing process is complex, the special ceramics are suitable for small tools, cutters, blades, wear-resistant parts, engine components and the like, the special ceramics are not suitable for batch production of porcelain insulators with heavy mass and larger volume, and the special ceramics are used for manufacturing the porcelain insulators, so that the strength problem of the insulator body can be only solved, and the connection strength between the insulator body and the steel cap cannot be still solved. The existing rod-shaped post porcelain insulator product has low tensile strength, and also has the reason that the porcelain insulator body and the steel cap are connected and fixed in a common cement cementing mode, the bending moment resistance of a connecting body part is poor, in addition, the 110KV-330KV high-voltage line bears the external reasons of self gravity, wire pulling force, wind power and vibration, particularly the increase of earthquake acting force and the like, and the connection of the porcelain insulator body and the steel cap is easy to be damaged by torsional fracture, so that the AC power gasification conductive contact line supporting system has a residual fault, and the operation reliability and the safety of a high-voltage transmission line are influenced.
Disclosure of Invention
Aiming at the problems of the common column type porcelain insulator in the prior art, the invention provides the strong column type porcelain insulator for the high-voltage line, which has high mechanical strength grade, high tensile strength, strong impact toughness capability, firm and reliable connection, strong durability and is suitable for stable and safe operation of a 110-plus-330 high-voltage power grid.
The technical scheme adopted by the technical problem to be solved by the invention is as follows: a high-strength column porcelain insulator for high-voltage line comprises an insulator body, an upper steel cap and a lower steel cap, the insulator body is provided with a bone column body, an upper core head and a lower core head which are integrally connected with the two ends of the bone column body, the skeleton column body is provided with a large umbrella skirt and a small umbrella skirt at intervals, glaze layers are arranged on the skeleton column body and the umbrella skirt, the upper core head is provided with annular grooves at intervals along the axial direction and splicing grooves at intervals along the radial direction, the inner side surface of the upper steel cap is provided with annular bosses at intervals, a plug connector is arranged between the upper steel cap and the upper core head, the plug connector comprises a pressure plate arranged on the upper core print and a plug board with the upper end fixedly connected with the pressure plate at intervals, the splicing plate is provided with an opening and is positioned in the splicing groove, an upper gluing layer is arranged in an upper cavity between the upper steel cap and the upper core head, and the upper gluing layer can be closed and opened with the outside through an upper plugging head in the middle of the upper steel cap; annular clamping grooves are formed in the lower core head at intervals along the axial direction of the lower core head, annular grooves are formed in the inner side surface of the lower steel cap at intervals, a clamping piece is arranged between the lower steel cap and the lower core head and comprises a clamping head with a fan-shaped lower end, a clamping plate integrally connected with the upper end of the clamping head and a screw integrally connected with the upper end of the clamping plate, the screw extends out of the lower steel cap, the cross section of the clamping head is matched with the annular clamping grooves and can be embedded into the annular clamping grooves, a lower gluing layer is arranged in a lower cavity between the lower steel cap and the lower core head, and the lower gluing layer can be closed and opened with the outside through a lower sealing head in the middle of the lower steel cap; the insulator body consists of 20-40wt% of calcined bauxite, 10-30wt% of kaolin, 10-20wt% of quartz powder, 10-20wt% of Luxi china clay, 5-10wt% of Yichun Gaoan china clay and 10-20wt% of feldspar, the calcined bauxite, the high clay, the quartz powder, the Luxi china clay, the Yichun Gaoan china clay and the feldspar are mixed with appropriate amount of water and ball-milled uniformly, then mud is prepared by mud pressing, decaying and vacuum pugging, then the mud is prepared into blanks, sprayed and fired at high temperature, and then the blanks are cut, cemented and cured to obtain the insulator, wherein the glaze consists of 10-20wt% of kaolin, 10-20wt% of talc, 20-40wt% of bauxite, 10-15wt% of porcelain powder, 5-10wt% of feldspar, 1-3wt% of opacifier, 5-10wt% of water glass and 3-5wt% of coloring materials, tantalum carbide powder with the weight of 0.1-0.5wt% of the raw material is added into the raw material.
The Luxi annual porcelain clay is produced in Luxi annual pond village in Nuxi City of Nuanxi province, and comprises the following chemical components: al (Al)2O3:35.2-42.7wt%,SiO2:44.2-47.1wt%,Fe2O3:0.6-1.2wt%,TiO2：0.32 to 0.98 weight percent, 3.2 to 5.1 weight percent of CaO, 2.5 to 3.1 weight percent of MgO, and the balance of impurities, and has high content of alumina, good fluidity and plasticity.
The Yichun Gao 'an porcelain clay is produced in the Yichun Gao' an city of Jiangxi province and comprises the following chemical components: al (Al)2O3:40.2-46.7wt%,SiO2:35.2-38.1wt%,Fe2O30.2 to 0.5 weight percent, 4.7 to 5.1 weight percent of CaO, 3.5 to 5.1 weight percent of MgO, and the balance of impurities, and the content of alumina is high.
The tantalum carbide powder is cubic crystal powder and belongs to a sodium chloride type cubic crystal system. The alloy is insoluble in water, has strong oxidation resistance and obvious effect of inhibiting the growth of crystal grains, is mainly used as an additive for powder metallurgy, cutting tools, fine ceramics, chemical vapor deposition, hard wear-resistant alloy cutters, tools, dies and wear-resistant and corrosion-resistant structural parts, and improves the impact toughness of the alloy.
The invention discloses a tough column type porcelain insulator for a high-voltage line, which comprises the following technical indexes:
tensile failure load is more than or equal to 200KN, bending failure load is more than or equal to 15KN, creepage distance: the main diameter is more than or equal to 3200mm,
the impact withstand voltage (standard lightning peak value) is more than or equal to 550KV, and the power frequency voltage withstand voltage (effective value) is more than or equal to 275KV
Cold and hot shock property/K is more than or equal to 150, tensile strength is more than or equal to 180MPa, and impact toughness (AKV +/-20 ℃ and more than or equal to 6J/cm)2）。
The invention adopts some technical means to produce the porcelain insulator which is suitable for a 110-plus-330 KV power transmission line network and is between a common porcelain insulator and a special porcelain insulator according to the technical requirements of the porcelain insulator for a high-voltage line, and the invention aims to realize the invention by adopting the following technical measures:
1. firstly, through improving the connection structure at steel cap and column type insulator both ends, make the adhesive slurry colloid, make whole with steel cap and core through the flow and the solidification of slurry adhesive, improve the tensile and torsional strength of being connected of steel cap and porcelain insulator body, prevent to take place the separation between steel cap and the porcelain insulator body and drop and the fracture. The specific technical measures are as follows: the steel plug connectors capable of being integrated with the adhesive are arranged in the adhesive layer between the existing insulator body and the upper steel cap, and the plug boards which are axially and annularly distributed on the plug connectors, the annular grooves and the annular bosses which are radially distributed can effectively prevent the upper steel cap and the upper core head from relative radial rotation and axial movement, so that the connection strength and the impact toughness between the insulator body and the upper steel cap are improved; the steel clamping piece which is integrated with the adhesive is arranged in the cementing layer between the existing insulator body and the lower steel cap, and the lower core head and the lower steel cap can not radially rotate and axially move relatively by utilizing the fan-shaped clamping head, the screw rod and the nut on the clamping piece, so that the tensile strength and the torsional strength (impact toughness) of the connection between the steel cap and the porcelain insulator body can be greatly improved under the condition of keeping the porcelain insulator body from increasing weight.
2. Secondly, by changing the raw material composition of the insulator body and adding the porcelain clay produced in a place with better performance, the content of alumina is ensured to be not less than 35-40%, which is beneficial to improving the product quality, improving the tensile strength of the insulator body, particularly the connection part of the umbrella skirt and the bone column on the insulator body, preventing the connection part of the umbrella skirt and the bone column from being broken, and correspondingly reducing the manufacturing cost of the insulator body by utilizing the advantage of lower price of the porcelain clay in the place.
3. Thirdly, a small amount of tantalum carbide is added into the glaze, and the tantalum carbide can form a crystal grain growth inhibitor with metal elements (aluminum, iron, magnesium and the like) in the insulator body in high-temperature sintering, so that the crystal grains on the surface layer of the insulator body are refined, the contact interface of the glaze and the insulator body is purified, and the compactness of the contact interface is improved, thereby improving the mechanical strength and the impact toughness of the insulator.
The invention solves the problems of low strength of the column porcelain insulator body from the blank formula, high-aluminum strength porcelain is taken as a matrix of the porcelain body, high-aluminum mullite is taken as a main crystal phase, and the series products take high-aluminum low-silicon as a basic formula and take the high-aluminum mullite as a main crystal phase after being sintered; by utilizing the strengthening mechanism of pre-stress and grain refinement, the mullite main crystal phase is evenly dispersed, the grain size is below 0.2-0.5 mu m, the content of the glass phase is less than 10 percent, and the content of air holes is below 8 percent, thereby improving the mechanical strength and the physical and chemical properties of the porcelain insulator.
The oxidizing atmosphere is a flame atmosphere generated under the conditions that air is fully supplied in the kiln and fuel is completely combusted during kiln burning (at high temperature), the flame atmosphere is smokeless and transparent, and the main components of combustion products are carbon dioxide and excess oxygen, and the combustion products contain no combustible substances or little combustible substances, so that the electric porcelain products can be fully oxidized without overburning.
On the basis of the manufacturing technology of the common ceramic column insulator, the manufacturing cost of the common ceramic column insulator is kept equivalent to that of the common ceramic column insulator through the technical measures, the problem that the conventional common ceramic column insulator cannot be applied to a 110-plus-330 KV high-voltage line due to low mechanical strength is solved, and the problems of complex technical process control and high cost caused by manufacturing the column insulator by adopting special ceramic materials are also avoided.
Through actual production and accounting, the manufacturing cost of the column type porcelain insulator is 1-1.1 times of the production cost of the common ceramic column type insulator, while the cost of the column type porcelain insulator manufactured by special ceramics is 1.6-2 times of the production cost of the common ceramic rod type column insulator,
the invention has the advantages of high mechanical strength, excellent electrical performance, stable and reliable quality, high mechanical strength grade up to the technical requirement of more than 16KN, high mechanical impact resistance, high pollution resistance, small maintenance workload and lower cost, and can completely meet various technical requirements of the porcelain insulator for the 110-plus-330 KV high-voltage transmission line.
Drawings
Figure 1 is a schematic view of a half-section structure of the present invention,
figure 2 is a schematic cross-sectional view a-a of figure 1,
fig. 3 is a schematic sectional structure view of B-B of fig. 1.
In the figure, 1, a lower flange 2, a nut 3, a lower cementing layer 4, a lower plugging head 5, a lower core head 6, an annular clamping groove 7, an insertion plate 8, a clamping plate 9, a clamping head 10, a screw 11, a lower steel cap 12, a small umbrella skirt 13, a large umbrella skirt 14, an upper steel cap 15, a supporting plate 16, a wire groove 17, an upper core head 18, a clamping opening 19, an upper plugging head 20, a pressing plate 21, an upper cementing layer 22, a connecting hole 23, an insertion groove 24, an opening 25, an annular boss 26, an annular groove 27, a bone column 28 and an annular groove.
Detailed Description
Example 1, in fig. 1, 2 and 3, the tough column porcelain insulator for high voltage lines is of L160B1180 (1100) type, has a structural height of 1180mm and a weight of 26Kg (similar to the original type), and includes an insulator body, an upper steel cap 14 and a lower steel cap 11, the top of the upper steel cap has a supporting plate 15, the supporting plate has a wire slot 16 and a connecting hole 22, the insulator body is composed of 30wt% of calcined bauxite, 20wt% of kaolin, 15wt% of quartz powder, 15wt% of luxi niao china clay, 5wt% of yichun high-safety china clay and 15wt% of feldspar, the insulator body has a bone column 27, an upper core 17 and a lower core 5 integrally connected to both ends of the bone column, the bone column is provided with a large umbrella skirt 13 and a small umbrella skirt 12 at intervals, the bone column and the umbrella skirt are provided with a glaze layer having a thickness of 0.2-0.3 mm on the surface or by spraying, the upper core head is provided with three annular grooves 26 with square cross sections at intervals along the axial direction, four inserting grooves 23 with the thickness of 2 mm and the width of one third to one half of the radius of the upper core head are arranged at intervals along the radial direction, the inner side surface of the upper steel cap is provided with three annular bosses 25 with square cross sections at intervals, the annular bosses and the annular grooves are arranged in a vertically staggered mode, an upper cavity is formed between the upper steel cap and the upper core head, a steel inserting piece is arranged in the upper cavity, the inserting piece comprises a pressing plate 20 arranged on the upper core head and four inserting plates 7 which are fixedly connected with the pressing plate at intervals and are distributed annularly, the upper ends of the four inserting plates are 1.5 mm thick, the lower ends and the outer sides of the inserting plates are in free shapes, and the width of the inserting plates is limited to ensure that the distance between the outer side surfaces of the inserting plates and the inner side surfaces of the upper steel cap is larger than the width of a convex tip, the upper steel cap is inserted into the upper core head smoothly, the insertion plate is provided with an opening 24 (the diameter of the opening is 3-5 mm and the adhesive flows between the insertion plates), the insertion plate is fixed in the insertion groove by glue, an upper adhesive layer 21 is arranged in a cavity between the upper steel cap and the upper core head, the upper adhesive layer can be sealed and opened with the outside through an upper sealing plug 19 in the middle of the upper steel cap, the upper sealing plug is provided with a clamping and detaching opening 18 and can be fixed with the support plate through threads, and the upper sealing plug is fixed on the end face of the upper steel cap through threads. The lower end of the lower steel cap is connected with a circular lower flange 1, the lower core head is provided with annular clamping grooves 6 along the axial direction at intervals, annular grooves 28 are arranged on the inner side surface of the lower steel cap at intervals, a lower cavity is formed between the lower steel cap and the lower core head, three clamping pieces are arranged in the lower cavity at intervals, each clamping piece comprises a clamping head 9 with a fan-shaped lower end, a clamping plate 8 integrally connected with the upper end of the clamping head and a screw rod 10 integrally connected with the upper end of the clamping plate, the screw rod extends out of the lower steel cap, a nut 2 is arranged on the screw rod, the cross section shape of the clamping head is matched with the annular clamping grooves and can be embedded into the annular clamping grooves, the arc width of the clamping head is 1/8-1/5 of the circumferential length of the annular clamping grooves, the thickness of the clamping head and the clamping plate is smaller than the minimum distance between the inner side surface of the steel cap and the outer side surface of the lower core head (namely, the distance between, the core is overhead under inserting with not influencing down the steel cap, be provided with lower cementing layer 3 down in the cavity between steel cap and the core head down, cementing layer can seal with the external world and open down through lower shutoff head 4 in the middle of the lower steel cap.
The upper steel cap and the lower steel cap are respectively connected with the insulator body by gluing with an upper gluing layer 21 and a lower gluing layer 3 in cavities at two ends of the insulator body, the gluing agent is a flowable slurry (glue) body (similar to a toothpaste shape) formed by mixing steel grit and cementing cement, or a flowable slurry (glue) body formed by mixing magnetic grit and cement or a high-strength gluing agent, the upper steel cap and the lower steel cap are respectively gummy on a production line, when the upper steel cap is glued, the plug connector is fixed on the upper core head by the gluing agent (the plug board on the plug connector is inserted into the plug flower connecting groove, the pressing board is contacted with the end face of the upper core head, then the upper steel cap is sleeved, the contact part of the lower end of the upper steel cap and the upper core head is sealed by the gluing agent to prevent the gluing agent from flowing out, then the gluing agent is squeezed in, and then the gluing port is sealed by the upper seal.
The invention relates to a method for manufacturing a tough column type porcelain insulator for a high-voltage line, which comprises the following steps:
1. grinding slurry by using raw material mixed balls: uniformly mixing the raw materials in percentage by weight, feeding the mixture into a ball mill, and mixing the raw materials in a ratio of 1: 0.4-0.5, adding water into the ball mill, ball milling for more than 12 hours to prepare slurry with the fineness of 100 plus 200 meshes, filtering the slurry by using a vibrating sieving machine, and removing impurities such as particles, hard blocks, residues and the like to obtain clean slurry;
2. filtering and dehydrating to obtain mud cakes, and standing the mud cakes in a sealed chamber with the temperature of more than 15 ℃ and the humidity of not more than 25% for 10-15 hours;
3. performing vacuum pugging: putting the aged mud cakes into a horizontal vacuum pugging machine, performing spiral extrusion, pumping out air to obtain long rod-shaped mud sections, and then putting the mud sections in a warehouse for drying and shaping in the shade;
4. manufacturing a blank body: placing the mud segment on a rotating disc-shaped die frame body, and processing an inner cavity formed by a bone column body and a core head and an annular groove on the inner end surface of the core head step by using a vertical fettling knife;
5. placing the green body prepared in the step 4 on a moulding bed which can rotate at a constant speed and has a shape matched with that of the inner cavity, respectively processing an annular groove and a cross groove on the end surface of a core head, the outer side surface of the core head and the outer surface of an upper umbrella skirt by utilizing forming cutters with different shapes fixed on the same vertical shaft from top to bottom, processing umbrella skirt grooves by utilizing a forming cutter which is fixed on the vertical shaft and can randomly adjust the height upwards to form the inner surface of the upper umbrella skirt and the outer surface of the lower umbrella skirt, and processing the inner surface of the lower umbrella skirt by utilizing a forming cutter which is fixed on the vertical shaft and can randomly adjust the height upwards;
6. respectively finishing the outer surface of the upper umbrella skirt and the outer surface of the lower umbrella skirt by using a forming cutter, putting the upper umbrella skirt and the lower umbrella skirt into a natural ventilation position for drying, and after the surface of a blank body is whitened, sending the blank body into a microwave oven for drying at the temperature of 80-100 ℃ until the moisture content is below 0.05%;
7. putting the dried blank body on a horizontal rotating glazing machine for dip-coating and glazing, wherein the glaze is composed of 15wt% of kaolin, 15wt% of talc, 35wt% of bauxite, 10wt% of porcelain powder, 10wt% of feldspar, 3wt% of zirconium silicate (opacifier), 8wt% of water glass and 4wt% of coloring material, and the raw material is added with 0.3wt% of tantalum carbide powder (granularity is 200 meshes and 300 meshes).
8. Putting the glazed green body into a natural gas kiln, heating to 300 ℃, preserving heat for 1-2 hours, heating to 700 ℃, preserving heat for 8-12 hours, heating to 1050 ℃, preserving heat for 10-12 hours, opening a furnace door, naturally cooling to normal temperature, and discharging;
9. and (4) flattening and polishing, gluing an upper steel cap and a lower steel cap on the primary qualified product after inspection, then performing anti-bending, water pressure and microwave flaw detection, and packaging and warehousing the qualified product.
The technical indexes of the tough column type porcelain insulator for the high-voltage line in the embodiment I are detected as follows:
tensile breaking load of 175KN, bending breaking load of 15.3KN, creepage distance: 3315mm main
560KV of impact tolerance voltage (standard lightning peak value) and 288KV of power frequency voltage tolerance voltage (effective value)
165 cold and hot sudden change/K, 40.90KV tolerance voltage of artificial pollution
Tensile strength: 208MPa, impact toughness (AKV +/-20 ℃, 8.2J/cm)2）。
Example 2, in fig. 1, 2 and 3, the tough post porcelain insulator for high voltage lines is of L160B1170 (1300) type, has a structural height of 1100mm, and a weight of 24Kg (similar to the original type), and includes an insulator body, an upper steel cap 14 and a lower steel cap 11, the top of the upper steel cap has a supporting plate 15, the supporting plate has a wire slot 16 and a connecting hole 22, the insulator body is composed of 40wt% of calcined bauxite, 10wt% of kaolin, 20wt% of quartz powder, 10wt% of luxi niao china clay, 8wt% of yichun high-safety china clay and 12wt% of feldspar, the insulator body has a bone cylinder 27, an upper core 17 and a lower core 5 integrally connected to both ends of the bone cylinder, the bone cylinder is provided with a large umbrella skirt 13 and a small umbrella skirt 12 at intervals, the bone cylinder and the umbrella skirt are coated or sprayed with a glaze layer having a thickness of 0.2-0.3 mm, four annular grooves 26 with square cross sections are arranged on the upper core head along the axial direction at intervals, four insertion grooves 23 are arranged on the inner side surface of the upper steel cap at intervals along the radial direction, the thickness of each insertion groove is 2 mm, the width of each insertion groove is one third to one half of the radius of the upper core head, three annular bosses 25 with square cross sections are arranged on the inner side surface of the upper steel cap at intervals, the annular bosses and the annular grooves are arranged in a vertically staggered mode, an upper cavity is formed between the upper steel cap and the upper core head, a steel insertion part is arranged in the upper cavity, the insertion part comprises a pressing plate 20 arranged on the upper core head and an insertion plate 27 fixedly connected with the pressing plate at intervals, the width of the insertion plate is limited to ensure that the distance between the outer side surface of the insertion plate and the inner side surface of the upper steel cap is larger than the width of a convex tip (or a bevel, which is not marked in the drawing) at the lower end, the splicing plate is provided with an opening 24 (the diameter of the opening is 4-5 mm and is used for flowing of an adhesive between the splicing plates), the splicing plate is fixed in the splicing groove by using the adhesive, an upper adhesive layer 21 is arranged in a cavity between the upper steel cap and the upper core head, the upper adhesive layer can be closed and opened with the outside through an upper plugging head 19 in the middle of the upper steel cap, and the upper plugging head is fixed on the upper steel cap by using threads; the lower core head is provided with annular clamping grooves 6 at intervals along the axial direction, the inner side surface of the lower steel cap is provided with annular grooves 28 at intervals, the upper plugging head is provided with hexagonal bayonets 18 (used for dismounting the upper plugging head and the lower plugging head) and can be fixed with the supporting plate through threads, the lower end of the lower steel cap is connected with a circular lower flange 1, a lower cavity is formed between the lower steel cap and the lower core head, three clamping pieces are arranged in the lower cavity at intervals, each clamping piece comprises a clamping head 9 with a fan-shaped lower end, a clamping plate 8 integrally connected with the upper end of the clamping head and a screw rod 10 integrally connected with the upper end of the clamping plate, the thickness of the clamping head and the thickness of the upper clamping plate are smaller than the minimum distance between the inner side surface of the lower steel cap and the outer side surface of the lower core head, (namely, the distance between the outer side surface of the clamping head and the inner side surface of the lower steel cap is, the screw rod 10 stretches out down outside the steel cap, is equipped with nut 2 on the screw rod, chucking head cross sectional shape matches and can imbed the ring groove in with ring groove, be provided with lower cementing layer 3 down in the cavity between steel cap and the lower core head, lower cementing layer can seal and open with the external world through lower shutoff head 4 in the middle of the steel cap down.
The upper steel cap and the lower steel cap are respectively connected with the insulator body in a gluing way through an upper gluing layer 21 and a lower gluing layer 3 in cavities at two ends of the insulator body, the gluing layers are made into a flowable slurry (glue) body (similar to a toothpaste shape) formed by mixing steel grit and cementing cement, or made into a flowable slurry (glue) body by mixing magnetic grit and cement or a high-strength gluing agent, the upper steel cap and the lower steel cap are respectively gummy on a production line, when the upper steel cap is glued, the plug-in connector is fixed on the upper core head by using the glue (a plug-in board on the plug-in connector is inserted into a plug-in groove, a pressing plate is contacted with the end face of the upper core head, the upper steel cap is sleeved, the contact part of the lower end of the upper steel cap and the upper core head is sealed by using the glue, the glue is prevented from flowing out from the place, then the glue is squeezed into the glue, and the upper seal seals a glue injection opening, when the lower, the cementing of the lower steel cap can be finished by the cementing method in the same way.
The invention relates to a method for manufacturing a tough column type porcelain insulator for a high-voltage line, which comprises the following steps:
1. grinding slurry by using raw material mixed balls: uniformly mixing the raw materials in percentage by weight, feeding the mixture into a ball mill, and mixing the raw materials in a ratio of 1: 0.4-0.5, adding water into the ball mill, ball milling for more than 12 hours to prepare slurry with the fineness of 100 plus 200 meshes, filtering the slurry by using a vibrating sieving machine, and removing impurities such as particles, hard blocks, residues and the like to obtain clean slurry;
2. filtering and dehydrating the mud slurry to obtain mud cakes, and standing the mud cakes in a sealed chamber with the temperature of more than 15 ℃ and the humidity of not more than 25% for 10-15 hours;
3. performing vacuum pugging: putting the aged mud cakes into a horizontal vacuum pugging machine, performing spiral extrusion, pumping out air to obtain long rod-shaped mud sections, and then putting the mud sections in a warehouse for drying and shaping in the shade;
4. manufacturing a blank body: placing the mud segment on a rotating disc-shaped die frame body, and processing an inner cavity formed by a bone column body and a core head and an annular groove on the inner end surface of the core head step by using a vertical fettling knife;
5. placing the green body prepared in the step 4 on a moulding bed which can rotate at a constant speed and has a shape matched with that of the inner cavity, respectively processing an annular groove and a cross groove on the end surface of a core head, the outer side surface of the core head and the outer surface of an upper umbrella skirt by utilizing forming cutters with different shapes fixed on the same vertical shaft from top to bottom, processing umbrella skirt grooves by utilizing a forming cutter which is fixed on the vertical shaft and can randomly adjust the height upwards to form the inner surface of the upper umbrella skirt and the outer surface of the lower umbrella skirt, and processing the inner surface of the lower umbrella skirt by utilizing a forming cutter which is fixed on the vertical shaft and can randomly adjust the height upwards;
6. respectively finishing the outer surface of the upper umbrella skirt and the outer surface of the lower umbrella skirt by using a forming cutter, putting the upper umbrella skirt and the lower umbrella skirt into a natural ventilation position for drying, and after the surface of a blank body is whitened, sending the blank body into a microwave oven for drying at the temperature of 80-100 ℃ until the moisture content is below 0.05%;
7. and putting the dried blank body on a horizontal rotating glazing machine for dip-coating glaze, wherein the glaze is prepared from 20wt% of kaolin, 15wt% of talc, 30wt% of bauxite, 15wt% of porcelain powder, 8wt% of feldspar, 2wt% of zinc oxide (opacifier), 7wt% of water glass and 3wt% of coloring material, and tantalum carbide powder (with the particle size of 200-300 meshes) accounting for 0.4wt% of the weight of the raw materials is added into the raw materials.
8. Putting the glazed green body into a natural gas kiln, heating to 300 ℃, preserving heat for 1-2 hours, heating to 700 ℃, preserving heat for 8-12 hours, heating to 1050 ℃, preserving heat for 10-12 hours, opening a furnace door, naturally cooling to normal temperature, and discharging;
9. and (4) flattening and polishing, gluing an upper steel cap and a lower steel cap on the primary qualified product after inspection, then performing anti-bending, water pressure and microwave flaw detection, and packaging and warehousing the qualified product.
The opacifier is zirconium silicate or zinc oxide, and the coloring materials are respectively as follows: milky white, brownish yellow, blue-gray, or coffee.
In the second embodiment, the tough column type porcelain insulator for the high-voltage line is detected to have the following technical indexes:
tensile breaking load was 168KN, bending breaking load was 15.3KN, creepage distance: main 3316.7mm
550KV of impact tolerance voltage (standard lightning peak value) and 280KV of power frequency voltage tolerance voltage (effective value)
Cold and hot rapid denaturation/K160, artificial pollution withstand voltage 4.2KV
The tensile strength is 188.6MPa, and the impact toughness (AKV +/-20 ℃, 7.68J/cm)2）。
Claims (3)
1. The utility model provides a strong column type porcelain insulator of strengthening and toughening for high-voltage line, it includes the insulator body, goes up steel cap (14) and lower steel cap (11), the insulator body has bone cylinder (27) and the whole last core head (17) and lower core head (5) that link to each other with bone cylinder both ends, the interval is provided with big full skirt (13) and little full skirt (12) on the bone cylinder, bone cylinder and full skirt are provided with glaze layer, characterized by in appearance: the upper core head is provided with annular grooves (26) at intervals along the axial direction thereof, splicing grooves (23) at intervals along the radial direction thereof, annular bosses (25) are arranged at intervals on the inner side surface of the upper steel cap, a splicing component is arranged between the upper steel cap and the upper core head, the splicing component comprises a pressing plate (20) arranged on the upper core head and a splicing plate (7) the upper end of which is fixedly connected with the pressing plate at intervals, the splicing plate is provided with openings (24), the splicing plate is positioned in the splicing grooves, an upper bonding layer (21) is arranged in an upper cavity between the upper steel cap and the upper core head, and the upper bonding layer can be closed and opened with the outside through an upper sealing plug head (19) in the middle of the upper steel cap; annular clamping grooves (6) are arranged on the lower core head at intervals along the axial direction of the lower core head, annular grooves (28) are arranged on the inner side surface of the lower steel cap at intervals, a clamping piece is arranged between the lower steel cap and the lower core head, the clamping piece comprises a clamping head (9) with a fan-shaped lower end, a clamping plate (8) integrally connected with the upper end of the clamping head and a screw rod (10) integrally connected with the upper end of the clamping plate, the screw rod extends out of the lower steel cap, the insulator body consists of 20-40wt% of calcined bauxite, 10-30wt% of kaolin, 10-20wt% of quartz powder, 10-20wt% of Luxi porcelain clay, 5-10wt% of Yichun high-security porcelain clay and 10-20wt% of feldspar, and is manufactured according to the following steps:
A. grinding slurry by using raw material mixed balls: uniformly mixing the raw materials in percentage by weight, feeding the mixture into a ball mill, and mixing the raw materials in a ratio of 1: 0.8-1, adding water into the ball mill, ball milling for more than 12 hours to prepare slurry with the fineness of 100 plus 200 meshes, filtering the slurry by using a vibrating sieving machine, and removing impurities such as particles, hard blocks, residues and the like to obtain clean slurry;
B. filtering and dehydrating the mud material to obtain mud cakes, and standing the mud cakes in a sealed chamber with the temperature of more than 15 ℃ and the humidity of not more than 25 percent for 10-15 hours;
C. performing vacuum pugging: putting the aged mud cakes into a horizontal vacuum pugging machine, performing spiral extrusion, pumping out air to obtain long rod-shaped mud sections, and then putting the mud sections in a warehouse for drying and shaping in the shade;
D. manufacturing a blank body: placing the mud segment on a rotating disc-shaped die frame body, and processing an inner cavity formed by a bone column body and a core head and an annular groove on the inner end surface of the core head step by using a vertical fettling knife;
E. d, placing the green body prepared in the step D on a forming die which can rotate at a constant speed and has a shape matched with that of the inner cavity, respectively machining an annular groove on the end surface of the core head, the outer side surface of the core head and the outer surface of the upper umbrella skirt by utilizing forming cutters with different shapes fixed on the same vertical shaft from top to bottom, machining umbrella skirt grooves by utilizing the forming cutters with different heights which are fixed on the vertical shaft and can be randomly adjusted upwards to form the inner surface of the upper umbrella skirt and the outer surface of the lower umbrella skirt, and machining the inner surface of the lower umbrella skirt by utilizing the forming cutters with different heights which are fixed on the vertical shaft and can;
F. respectively finishing the outer surface of the upper umbrella skirt and the outer surface of the lower umbrella skirt by using a forming cutter, putting the upper umbrella skirt and the lower umbrella skirt into a natural ventilation position for drying, and after the surface of a blank body is whitened, sending the blank body into a microwave oven for drying at the temperature of 80-100 ℃ until the moisture content is below 0.05%;
G. putting the dried blank body on a horizontal rotating glazing machine for dip-coating glaze, wherein the glaze is composed of raw materials of 10-20wt% of kaolin, 10-20wt% of talc, 20-40wt% of bauxite, 10-15wt% of porcelain powder, 5-10wt% of feldspar, 1-3wt% of opacifier, 5-10wt% of water glass and 3-5wt% of coloring material, the raw materials are added with tantalum carbide powder accounting for 0.3-0.5wt% of the weight of the raw materials,
H. putting the glazed green body into a natural gas kiln, heating to 300 ℃, preserving heat for 1-2 hours, heating to 700 ℃, preserving heat for 8-12 hours, heating to 1050 ℃, preserving heat for 10-12 hours, opening a furnace door, naturally cooling to normal temperature, and discharging;
I. and (4) flattening and polishing, gluing an upper steel cap and a lower steel cap on the primary qualified product after inspection, then performing anti-bending, water pressure and microwave flaw detection, and packaging and warehousing the qualified product.
2. The strong column porcelain insulator for the high-voltage line according to claim 1, which is characterized in that: the tough post porcelain insulator for the extra-high voltage line has the following technical indexes:
tensile failure load is more than or equal to 160KN, bending failure load is more than or equal to 12KN, creepage distance: the main diameter is more than or equal to 3200mm,
the impact withstand voltage (standard lightning peak value) is more than or equal to 550KV, the power frequency voltage withstand voltage (effective value) is more than or equal to 275KV,
the cold and hot shock property/K is more than or equal to 150, the tensile strength is more than or equal to 180MPa, and the impact toughness (AKV +/-20 ℃ and more than or equal to 6J/cm)2）。
3. The strong column porcelain insulator for the high-voltage line according to claim 1, which is characterized in that: the glaze material consists of 20wt% of kaolin, 15wt% of talc, 30wt% of bauxite, 15wt% of porcelain powder, 8wt% of feldspar, 2wt% of zinc oxide, 7wt% of water glass and 3wt% of coloring material, wherein the raw materials are added with tantalum carbide powder with the weight of 0.4wt% and the particle size of 200-300 meshes).
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116813308A (en) * | 2023-06-27 | 2023-09-29 | 萍乡市中源瓷业有限公司 | High-strength light column porcelain insulator and preparation method thereof |
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Effective date of registration: 20210203 Address after: 337000 Fu Tian Village, Gao Keng Town, Anyuan District, Pingxiang, Jiangxi Applicant after: JIANGXI PROVINCE PINGXIANG BO PORCELAIN HIGH VOLTAGE INSULATOR Co.,Ltd. Address before: 337200 Yuquanshan Avenue, Zhangjiafang street, Zhangjiafang Township, Luxi County, Pingxiang City, Jiangxi Province Applicant before: Jiangxi Shanggao electric porcelain Co.,Ltd. |
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