CN112592152A - Porcelain cross arm insulator and manufacturing method thereof - Google Patents
Porcelain cross arm insulator and manufacturing method thereof Download PDFInfo
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- CN112592152A CN112592152A CN202011304191.2A CN202011304191A CN112592152A CN 112592152 A CN112592152 A CN 112592152A CN 202011304191 A CN202011304191 A CN 202011304191A CN 112592152 A CN112592152 A CN 112592152A
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- 239000012212 insulator Substances 0.000 title claims abstract description 143
- 229910052573 porcelain Inorganic materials 0.000 title claims abstract description 29
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 16
- DSEKYWAQQVUQTP-XEWMWGOFSA-N (2r,4r,4as,6as,6as,6br,8ar,12ar,14as,14bs)-2-hydroxy-4,4a,6a,6b,8a,11,11,14a-octamethyl-2,4,5,6,6a,7,8,9,10,12,12a,13,14,14b-tetradecahydro-1h-picen-3-one Chemical compound C([C@H]1[C@]2(C)CC[C@@]34C)C(C)(C)CC[C@]1(C)CC[C@]2(C)[C@H]4CC[C@@]1(C)[C@H]3C[C@@H](O)C(=O)[C@@H]1C DSEKYWAQQVUQTP-XEWMWGOFSA-N 0.000 claims abstract description 24
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 24
- 229920002545 silicone oil Polymers 0.000 claims abstract description 24
- 229940099259 vaseline Drugs 0.000 claims abstract description 24
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims abstract description 24
- 239000005995 Aluminium silicate Substances 0.000 claims abstract description 22
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 22
- 239000010433 feldspar Substances 0.000 claims abstract description 22
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 22
- 229910052845 zircon Inorganic materials 0.000 claims abstract description 17
- 239000011248 coating agent Substances 0.000 claims description 43
- 238000000576 coating method Methods 0.000 claims description 43
- 238000003756 stirring Methods 0.000 claims description 35
- 238000004506 ultrasonic cleaning Methods 0.000 claims description 30
- 238000010438 heat treatment Methods 0.000 claims description 23
- 238000000034 method Methods 0.000 claims description 23
- 239000000945 filler Substances 0.000 claims description 21
- 239000000463 material Substances 0.000 claims description 21
- 238000001035 drying Methods 0.000 claims description 20
- 230000002209 hydrophobic effect Effects 0.000 claims description 20
- 239000006148 magnetic separator Substances 0.000 claims description 17
- 239000011268 mixed slurry Substances 0.000 claims description 17
- 230000003373 anti-fouling effect Effects 0.000 claims description 16
- 238000000498 ball milling Methods 0.000 claims description 15
- 238000003825 pressing Methods 0.000 claims description 15
- 239000002994 raw material Substances 0.000 claims description 15
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 14
- 239000002245 particle Substances 0.000 claims description 13
- 239000007787 solid Substances 0.000 claims description 10
- 238000009966 trimming Methods 0.000 claims description 10
- 238000001291 vacuum drying Methods 0.000 claims description 10
- 238000010304 firing Methods 0.000 claims description 8
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 7
- 229910052742 iron Inorganic materials 0.000 claims description 7
- 238000005303 weighing Methods 0.000 claims description 7
- 239000003973 paint Substances 0.000 claims description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- 239000000919 ceramic Substances 0.000 claims description 5
- 229910052802 copper Inorganic materials 0.000 claims description 5
- 239000010949 copper Substances 0.000 claims description 5
- 238000000227 grinding Methods 0.000 claims description 5
- 239000012535 impurity Substances 0.000 claims description 5
- 239000004615 ingredient Substances 0.000 claims description 5
- 238000007670 refining Methods 0.000 claims description 5
- 239000004576 sand Substances 0.000 claims description 5
- 238000012216 screening Methods 0.000 claims description 5
- 239000002002 slurry Substances 0.000 claims description 5
- 239000010959 steel Substances 0.000 claims description 5
- 239000000126 substance Substances 0.000 claims description 5
- 238000009864 tensile test Methods 0.000 claims description 5
- 238000007599 discharging Methods 0.000 claims description 2
- 238000005485 electric heating Methods 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- 239000000428 dust Substances 0.000 description 7
- 239000002519 antifouling agent Substances 0.000 description 5
- 230000009286 beneficial effect Effects 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000002156 mixing Methods 0.000 description 2
- 238000004381 surface treatment Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
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- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
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- C04B33/00—Clay-wares
- C04B33/24—Manufacture of porcelain or white ware
- C04B33/26—Manufacture of porcelain or white ware of porcelain for electrical insulation
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
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- C04B41/81—Coating or impregnation
- C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B17/00—Insulators or insulating bodies characterised by their form
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- H01B17/00—Insulators or insulating bodies characterised by their form
- H01B17/50—Insulators or insulating bodies characterised by their form with surfaces specially treated for preserving insulating properties, e.g. for protection against moisture, dirt, or the like
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- H—ELECTRICITY
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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- C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
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Abstract
The invention discloses a porcelain cross arm insulator and a manufacturing method thereof, and the formula comprises the following steps: kaolin, industrial alumina, feldspar, zirconite, ozokerite, silicone oil and vaseline, the parts by weight of each component are respectively: 100-120 parts of kaolin, 40-50 parts of industrial alumina, 5-15 parts of feldspar, 5-10 parts of zircon, 20-25 parts of ozokerite, 12-15 parts of silicone oil and 24-30 parts of vaseline.
Description
Technical Field
The invention relates to the technical field of electric power, in particular to a porcelain cross arm insulator and a manufacturing method thereof.
Background
Electric power is an energy source using electric energy as power, wherein during the use of electric power, an electric porcelain cross arm insulator is generally used, the electric porcelain cross arm insulator is a rod-shaped porcelain piece and is installed on an electric pole to support a lead, so that the electric porcelain cross arm insulator can play a role in insulating the lead from the ground and playing a role in a cross arm, and when the voltage level is higher, the requirement on the mechanical strength of the cross arm insulator is high.
The cross arm insulator can be divided into an electric porcelain, glass and a composite insulator according to different material types, wherein the electric porcelain cross arm insulator is most widely applied, but although the electric porcelain cross arm insulator is simple and easy to obtain, has low cost, strong brittleness, and is easy to be damaged when being stretched and collided by external force or has high voltage, so that the using strength of the insulator is greatly reduced, meanwhile, the cross arm insulator is exposed outside, and is exposed to the sun, a large amount of dust is easily accumulated on the surface, and a water film is formed on the surface of the insulator when raining, and dust particles attached to the water film easily cause the situations of short circuit and pollution flashover of a circuit, so that the insulator can be seriously or even punctured, the use safety is greatly reduced, therefore, the surface treatment of the insulator is required to prevent the formation of a water film, but the surface treatment effect is greatly reduced by slag and dust attached to the surface of the insulator during the treatment.
Disclosure of Invention
The invention aims to provide a porcelain cross arm insulator and a manufacturing method thereof, which aim to solve the problems in the background technology.
In order to solve the technical problems, the invention provides the following technical scheme: a porcelain cross arm insulator comprises the following components in formula: kaolin, industrial alumina, feldspar, zirconite, ozokerite, silicone oil and vaseline, the parts by weight of each component are respectively: 100-120 parts of kaolin, 40-50 parts of industrial alumina, 5-15 parts of feldspar, 5-10 parts of zircon, 20-25 parts of ozokerite, 12-15 parts of silicone oil and 24-30 parts of vaseline.
A method for manufacturing a porcelain cross arm insulator comprises the following steps of firstly, weighing raw materials; step two, ball milling and mud making; step three, preparing a base material; step four, preparing a filler; screening and pressing the mud; step six, vacuum mud refining; step seven, pressing and trimming; step eight, drying and dehydrating; step nine, glazing and sanding; step ten, firing and forming; step eleven, ultrasonic cleaning; step twelve, preparing the coating; thirteen, coating the surface; step fourteen, assembling and detecting;
in the first step, respectively weighing 120 parts of 100-120 parts of kaolin, 40-50 parts of industrial alumina, 5-15 parts of feldspar, 5-10 parts of zircon, 20-25 parts of ozokerite, 12-15 parts of silicone oil and 24-30 parts of vaseline according to the parts by weight of the components;
in the second step, the kaolin and the feldspar weighed in the first step are put into a ball mill, and the raw materials are ground into a base material with the size of 5-20 microns for later use by wet ball milling;
in the third step, putting the industrial alumina and the zircon weighed in the first step into a ball mill, and grinding the raw materials into a filler with the particle size of 5-20 microns by wet ball milling for later use;
in the fourth step, the base material prepared in the second step and the filler prepared in the third step are subjected to wet deferrization by a magnetic separator respectively, and then pumped into a stirrer to be stirred and mixed to prepare mixed slurry for later use;
in the fifth step, the mixed slurry prepared in the fourth step is respectively screened by screens of 180 meshes and 250 meshes to remove large particles, impurities and iron-containing substances in the mixed slurry, and then the screened slurry is transported to a mud press to be pressed into mud cakes for later use;
putting the mud cake prepared in the fifth step into a vacuum pug mill, and discharging air in the pug to prepare solid mud segments with uniform interior for later use;
placing the solid mud segment prepared in the step six into a mold, pressing the mud segment into the shape of the cross arm insulator, and then trimming redundant mud to leave an insulator mud blank meeting the shape requirement for later use;
in the eighth step, the insulator mud blank prepared in the seventh step is subjected to power frequency electric drying until the moisture content of the insulator mud blank is between 0.8 and 1.2 percent;
in the ninth step, a glaze layer is uniformly coated on the surface of the insulator mud blank subjected to power frequency electric drying in the eighth step, and then a layer of uniform sand grains is coated on the positions where hardware fittings are assembled at the two ends of the insulator mud blank;
in the tenth step, the insulator mud blank glazed and sanded in the ninth step is placed into a high-temperature electric kiln, slowly heated and fired, and is kept at the temperature of 1100-1150 ℃ for 10-12h, and then slowly cooled to room temperature to prepare an insulator main body for later use;
in the eleventh step, after the insulator body fired in the tenth step is washed twice by alcohol with the concentration of 95%, the insulator body is placed into an ultrasonic cleaning machine for ultrasonic cleaning, and after the insulator body is cleaned, the insulator body is placed into a vacuum drying oven, and after the insulator body is dried, the insulator body is cooled to the room temperature for later use;
in the twelfth step, an electric stirring pot is taken, the silicone oil selected in the first step is added into the stirring pot, the stirring is carried out while heating, and then the ozokerite and the vaseline are sequentially added into the stirring pot until the ingredients are completely molten, so as to prepare the hydrophobic antifouling paint for later use;
in the thirteenth step, the coating prepared in the twelfth step is uniformly coated on the insulator main body dried in the eleventh step by a brush, and after the coating is completely dried, the coating is coated again, and the coating is repeated for three times until a compact and uniform hydrophobic antifouling coating is formed on the surface of the insulator main body;
and in the fourteenth step, the steel caps and the copper pins at the two ends of the insulator main body coated with the hydrophobic antifouling coating in the thirteenth step are assembled, and then the insulator main body is checked one by one through a mechanical tensile test and an electrical test to ensure that all performances are good, so that the ceramic cross arm insulator is manufactured.
According to the technical scheme, in the fourth step, the magnetic separator is a permanent magnet drum magnetic separator, the rotating speed of the drum is 35-40r/min, the rotating speed of the stirrer is 350-450r/min, and the stirring time is 60-90 min.
According to the technical scheme, in the sixth step, the vacuum pugmill is a double-shaft vacuum pugmill, and the vacuum degree is 96-110 kPa.
According to the technical scheme, in the step ten, the temperature rise of the high-temperature electric kiln is divided into three stages, wherein the temperature of the first stage is 20-200 ℃, the temperature rise rate is 0.43 ℃/min, the temperature of the second stage is 200-,
according to the technical scheme, in the eleventh step, the ultrasonic cleaning machine is a three-tank type gas-phase ultrasonic cleaning machine, and the ultrasonic cleaning time is 5-10 min.
According to the technical scheme, in the eleventh step, the working temperature of the vacuum drying oven is 80-100 ℃, and the drying time is 5-7 min.
According to the technical scheme, in the twelfth step, the temperature of the electric heating stirring pot is 60-70 ℃, and the heating and stirring time is 10-20 min.
Compared with the prior art, the invention has the following beneficial effects:
1. according to the invention, the filler prepared by mixing the zircon and the industrial alumina is added into the formula, so that the brittleness of the insulator is reduced, the strength of the insulator is enhanced, and the probability of damage and breakdown damage is favorably reduced.
2. According to the invention, the silicone oil, the ozokerite and the vaseline are heated and mixed to prepare the hydrophobic antifouling agent, and then the hydrophobic antifouling agent is uniformly coated on the insulator main body for multiple times to form a compact and uniform coating, so that the adhesion of dust is reduced, a water film formed on the surface of the insulator main body by rainwater is avoided, the phenomena of pollution flashover and short circuit are avoided, and the use safety of the insulator is improved.
3. According to the invention, the base material, the filler and the mixed slurry are subjected to deferrization by the magnetic separator and the screen mesh respectively, so that the content of iron in the insulator is greatly reduced, the insulating capability of the insulator is improved, and meanwhile, before the hydrophobic antifouling agent is coated, the insulator main body is cleaned by using alcohol and an ultrasonic cleaner, so that dust and particles on the surface of the insulator main body are removed, and the coating effect of the hydrophobic antifouling agent is improved.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a flow chart of the method of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the present invention provides a technical solution:
example 1:
a porcelain cross arm insulator comprises the following components in formula: kaolin, industrial alumina, feldspar, zirconite, ozokerite, silicone oil and vaseline, the parts by weight of each component are respectively: 100-120 parts of kaolin, 40-50 parts of industrial alumina, 5-15 parts of feldspar, 5-10 parts of zircon, 20-25 parts of ozokerite, 12-15 parts of silicone oil and 24-30 parts of vaseline.
A method for manufacturing a porcelain cross arm insulator comprises the following steps of firstly, weighing raw materials; step two, ball milling and mud making; step three, preparing a base material; step four, preparing a filler; screening and pressing the mud; step six, vacuum mud refining; step seven, pressing and trimming; step eight, drying and dehydrating; step nine, glazing and sanding; step ten, firing and forming; step eleven, ultrasonic cleaning; step twelve, preparing the coating; thirteen, coating the surface; step fourteen, assembling and detecting;
in the first step, 100 parts of kaolin, 40 parts of industrial alumina, 5 parts of feldspar, 5 parts of zircon, 20 parts of ozokerite, 12 parts of silicone oil and 24 parts of vaseline are weighed according to the parts by weight of the components;
in the second step, the kaolin and the feldspar weighed in the first step are put into a ball mill, and the raw materials are ground into a base material with the size of 5-20 microns for later use by wet ball milling;
in the third step, putting the industrial alumina and the zircon weighed in the first step into a ball mill, and grinding the raw materials into a filler with the particle size of 5-20 microns by wet ball milling for later use;
in the fourth step, the base material prepared in the second step and the filler prepared in the third step are subjected to wet deferrization by a magnetic separator respectively, the magnetic separator is a permanent magnet drum type magnetic separator, the rotating speed of the drum body is 35-40r/min, then the base material and the filler are pumped into a stirrer to be stirred and mixed, the rotating speed of the stirrer is 350-450r/min, the stirring time is 60-90min, and mixed slurry is prepared for later use;
in the fifth step, the mixed slurry prepared in the fourth step is respectively screened by screens of 180 meshes and 250 meshes to remove large particles, impurities and iron-containing substances in the mixed slurry, and then the screened slurry is transported to a mud press to be pressed into mud cakes for later use;
in the sixth step, the mud cakes prepared in the fifth step are put into a vacuum pugmill, the vacuum pugmill is a double-shaft vacuum pugmill, the air in the pug is discharged under the vacuum degree of 96-110kPa, and solid pug sections with uniform inner parts are prepared for standby;
placing the solid mud segment prepared in the step six into a mold, pressing the mud segment into the shape of the cross arm insulator, and then trimming redundant mud to leave an insulator mud blank meeting the shape requirement for later use;
in the eighth step, the insulator mud blank prepared in the seventh step is subjected to power frequency electric drying until the moisture content of the insulator mud blank is between 0.8 and 1.2 percent;
in the ninth step, a glaze layer is uniformly coated on the surface of the insulator mud blank subjected to power frequency electric drying in the eighth step, and then a layer of uniform sand grains is coated on the positions where hardware fittings are assembled at the two ends of the insulator mud blank;
placing the insulator mud blank subjected to glazing and sanding in the ninth step into a high-temperature electric kiln, slowly heating and firing, wherein the temperature rise of the high-temperature electric kiln is divided into three stages, the temperature of the first stage is 20-200 ℃, the heating rate is 0.43 ℃/min, the temperature of the second stage is 200-600 ℃, the heating rate is 0.2 ℃/min, the temperature of the third stage is 600-1590 ℃, the heating rate is 0.42 ℃/min, preserving the heat for 10-12h at the temperature of 1100-1150 ℃, and then slowly cooling to room temperature to prepare an insulator main body for later use;
in the eleventh step, after the insulator body fired in the tenth step is washed twice by alcohol with the concentration of 95%, the insulator body is placed into an ultrasonic cleaning machine for ultrasonic cleaning, the ultrasonic cleaning machine is a three-groove type gas-phase ultrasonic cleaning machine, the ultrasonic cleaning time is 5-10min, the insulator body is placed into a vacuum drying box after being cleaned, the working temperature of the vacuum drying box is 80-100 ℃, the drying time is 5-7min, and the insulator body is cooled to the room temperature for later use after being dried;
in the twelfth step, an electric stirring pot is taken, the silicone oil selected in the first step is added into the stirring pot, the stirring is carried out while heating, the temperature of the electric stirring pot is 60-70 ℃, the heating and stirring time is 10-20min, then the ozokerite and the vaseline are sequentially added into the stirring pot until the ingredients are completely molten, and the hydrophobic antifouling paint is prepared for standby;
in the thirteenth step, the coating prepared in the twelfth step is uniformly coated on the insulator main body dried in the eleventh step by a brush, and after the coating is completely dried, the coating is coated again, and the coating is repeated for three times until a compact and uniform hydrophobic antifouling coating is formed on the surface of the insulator main body;
and in the fourteenth step, the steel caps and the copper pins at the two ends of the insulator main body coated with the hydrophobic antifouling coating in the thirteenth step are assembled, and then the insulator main body is checked one by one through a mechanical tensile test and an electrical test to ensure that all performances are good, so that the ceramic cross arm insulator is manufactured.
Example 2:
a porcelain cross arm insulator comprises the following components in formula: kaolin, industrial alumina, feldspar, zirconite, ozokerite, silicone oil and vaseline, the parts by weight of each component are respectively: 100-120 parts of kaolin, 40-50 parts of industrial alumina, 5-15 parts of feldspar, 5-10 parts of zircon, 20-25 parts of ozokerite, 12-15 parts of silicone oil and 24-30 parts of vaseline.
A method for manufacturing a porcelain cross arm insulator comprises the following steps of firstly, weighing raw materials; step two, ball milling and mud making; step three, preparing a base material; step four, preparing a filler; screening and pressing the mud; step six, vacuum mud refining; step seven, pressing and trimming; step eight, drying and dehydrating; step nine, glazing and sanding; step ten, firing and forming; step eleven, ultrasonic cleaning; step twelve, preparing the coating; thirteen, coating the surface; step fourteen, assembling and detecting;
in the first step, 120 parts of kaolin, 50 parts of industrial alumina, 15 parts of feldspar, 10 parts of zircon, 25 parts of ozokerite, 15 parts of silicone oil and 30 parts of vaseline are weighed according to the parts by weight of the components;
in the second step, the kaolin and the feldspar weighed in the first step are put into a ball mill, and the raw materials are ground into a base material with the size of 5-20 microns for later use by wet ball milling;
in the third step, putting the industrial alumina and the zircon weighed in the first step into a ball mill, and grinding the raw materials into a filler with the particle size of 5-20 microns by wet ball milling for later use;
in the fourth step, the base material prepared in the second step and the filler prepared in the third step are subjected to wet deferrization by a magnetic separator respectively, the magnetic separator is a permanent magnet drum type magnetic separator, the rotating speed of the drum body is 35-40r/min, then the base material and the filler are pumped into a stirrer to be stirred and mixed, the rotating speed of the stirrer is 350-450r/min, the stirring time is 60-90min, and mixed slurry is prepared for later use;
in the fifth step, the mixed slurry prepared in the fourth step is respectively screened by screens of 180 meshes and 250 meshes to remove large particles, impurities and iron-containing substances in the mixed slurry, and then the screened slurry is transported to a mud press to be pressed into mud cakes for later use;
in the sixth step, the mud cakes prepared in the fifth step are put into a vacuum pugmill, the vacuum pugmill is a double-shaft vacuum pugmill, the air in the pug is discharged under the vacuum degree of 96-110kPa, and solid pug sections with uniform inner parts are prepared for standby;
placing the solid mud segment prepared in the step six into a mold, pressing the mud segment into the shape of the cross arm insulator, and then trimming redundant mud to leave an insulator mud blank meeting the shape requirement for later use;
in the eighth step, the insulator mud blank prepared in the seventh step is subjected to power frequency electric drying until the moisture content of the insulator mud blank is between 0.8 and 1.2 percent;
in the ninth step, a glaze layer is uniformly coated on the surface of the insulator mud blank subjected to power frequency electric drying in the eighth step, and then a layer of uniform sand grains is coated on the positions where hardware fittings are assembled at the two ends of the insulator mud blank;
placing the insulator mud blank subjected to glazing and sanding in the ninth step into a high-temperature electric kiln, slowly heating and firing, wherein the temperature rise of the high-temperature electric kiln is divided into three stages, the temperature of the first stage is 20-200 ℃, the heating rate is 0.43 ℃/min, the temperature of the second stage is 200-600 ℃, the heating rate is 0.2 ℃/min, the temperature of the third stage is 600-1590 ℃, the heating rate is 0.42 ℃/min, preserving the heat for 10-12h at the temperature of 1100-1150 ℃, and then slowly cooling to room temperature to prepare an insulator main body for later use;
in the eleventh step, after the insulator body fired in the tenth step is washed twice by alcohol with the concentration of 95%, the insulator body is placed into an ultrasonic cleaning machine for ultrasonic cleaning, the ultrasonic cleaning machine is a three-groove type gas-phase ultrasonic cleaning machine, the ultrasonic cleaning time is 5-10min, the insulator body is placed into a vacuum drying box after being cleaned, the working temperature of the vacuum drying box is 80-100 ℃, the drying time is 5-7min, and the insulator body is cooled to the room temperature for later use after being dried;
in the twelfth step, an electric stirring pot is taken, the silicone oil selected in the first step is added into the stirring pot, the stirring is carried out while heating, the temperature of the electric stirring pot is 60-70 ℃, the heating and stirring time is 10-20min, then the ozokerite and the vaseline are sequentially added into the stirring pot until the ingredients are completely molten, and the hydrophobic antifouling paint is prepared for standby;
in the thirteenth step, the coating prepared in the twelfth step is uniformly coated on the insulator main body dried in the eleventh step by a brush, and after the coating is completely dried, the coating is coated again, and the coating is repeated for three times until a compact and uniform hydrophobic antifouling coating is formed on the surface of the insulator main body;
and in the fourteenth step, the steel caps and the copper pins at the two ends of the insulator main body coated with the hydrophobic antifouling coating in the thirteenth step are assembled, and then the insulator main body is checked one by one through a mechanical tensile test and an electrical test to ensure that all performances are good, so that the ceramic cross arm insulator is manufactured.
Example 3:
a porcelain cross arm insulator comprises the following components in formula: kaolin, industrial alumina, feldspar, zirconite, ozokerite, silicone oil and vaseline, the parts by weight of each component are respectively: 100-120 parts of kaolin, 40-50 parts of industrial alumina, 5-15 parts of feldspar, 5-10 parts of zircon, 20-25 parts of ozokerite, 12-15 parts of silicone oil and 24-30 parts of vaseline.
A method for manufacturing a porcelain cross arm insulator comprises the following steps of firstly, weighing raw materials; step two, ball milling and mud making; step three, preparing a base material; step four, preparing a filler; screening and pressing the mud; step six, vacuum mud refining; step seven, pressing and trimming; step eight, drying and dehydrating; step nine, glazing and sanding; step ten, firing and forming; step eleven, ultrasonic cleaning; step twelve, preparing the coating; thirteen, coating the surface; step fourteen, assembling and detecting;
in the first step, 110 parts of kaolin, 45 parts of industrial alumina, 10 parts of feldspar, 8 parts of zircon, 23 parts of ozokerite, 13 parts of silicone oil and 26 parts of vaseline are weighed according to the parts by weight of the components;
in the second step, the kaolin and the feldspar weighed in the first step are put into a ball mill, and the raw materials are ground into a base material with the size of 5-20 microns for later use by wet ball milling;
in the third step, putting the industrial alumina and the zircon weighed in the first step into a ball mill, and grinding the raw materials into a filler with the particle size of 5-20 microns by wet ball milling for later use;
in the fourth step, the base material prepared in the second step and the filler prepared in the third step are subjected to wet deferrization by a magnetic separator respectively, the magnetic separator is a permanent magnet drum type magnetic separator, the rotating speed of the drum body is 35-40r/min, then the base material and the filler are pumped into a stirrer to be stirred and mixed, the rotating speed of the stirrer is 350-450r/min, the stirring time is 60-90min, and mixed slurry is prepared for later use;
in the fifth step, the mixed slurry prepared in the fourth step is respectively screened by screens of 180 meshes and 250 meshes to remove large particles, impurities and iron-containing substances in the mixed slurry, and then the screened slurry is transported to a mud press to be pressed into mud cakes for later use;
in the sixth step, the mud cakes prepared in the fifth step are put into a vacuum pugmill, the vacuum pugmill is a double-shaft vacuum pugmill, the air in the pug is discharged under the vacuum degree of 96-110kPa, and solid pug sections with uniform inner parts are prepared for standby;
placing the solid mud segment prepared in the step six into a mold, pressing the mud segment into the shape of the cross arm insulator, and then trimming redundant mud to leave an insulator mud blank meeting the shape requirement for later use;
in the eighth step, the insulator mud blank prepared in the seventh step is subjected to power frequency electric drying until the moisture content of the insulator mud blank is between 0.8 and 1.2 percent;
in the ninth step, a glaze layer is uniformly coated on the surface of the insulator mud blank subjected to power frequency electric drying in the eighth step, and then a layer of uniform sand grains is coated on the positions where hardware fittings are assembled at the two ends of the insulator mud blank;
placing the insulator mud blank subjected to glazing and sanding in the ninth step into a high-temperature electric kiln, slowly heating and firing, wherein the temperature rise of the high-temperature electric kiln is divided into three stages, the temperature of the first stage is 20-200 ℃, the heating rate is 0.43 ℃/min, the temperature of the second stage is 200-600 ℃, the heating rate is 0.2 ℃/min, the temperature of the third stage is 600-1590 ℃, the heating rate is 0.42 ℃/min, preserving the heat for 10-12h at the temperature of 1100-1150 ℃, and then slowly cooling to room temperature to prepare an insulator main body for later use;
in the eleventh step, after the insulator body fired in the tenth step is washed twice by alcohol with the concentration of 95%, the insulator body is placed into an ultrasonic cleaning machine for ultrasonic cleaning, the ultrasonic cleaning machine is a three-groove type gas-phase ultrasonic cleaning machine, the ultrasonic cleaning time is 5-10min, the insulator body is placed into a vacuum drying box after being cleaned, the working temperature of the vacuum drying box is 80-100 ℃, the drying time is 5-7min, and the insulator body is cooled to the room temperature for later use after being dried;
in the twelfth step, an electric stirring pot is taken, the silicone oil selected in the first step is added into the stirring pot, the stirring is carried out while heating, the temperature of the electric stirring pot is 60-70 ℃, the heating and stirring time is 10-20min, then the ozokerite and the vaseline are sequentially added into the stirring pot until the ingredients are completely molten, and the hydrophobic antifouling paint is prepared for standby;
in the thirteenth step, the coating prepared in the twelfth step is uniformly coated on the insulator main body dried in the eleventh step by a brush, and after the coating is completely dried, the coating is coated again, and the coating is repeated for three times until a compact and uniform hydrophobic antifouling coating is formed on the surface of the insulator main body;
and in the fourteenth step, the steel caps and the copper pins at the two ends of the insulator main body coated with the hydrophobic antifouling coating in the thirteenth step are assembled, and then the insulator main body is checked one by one through a mechanical tensile test and an electrical test to ensure that all performances are good, so that the ceramic cross arm insulator is manufactured.
The porcelain cross arm insulators obtained in the above embodiments are compared, and the results are as follows:
| example 1 | Example 2 | Example 3 | Comparative example | |
| Drench artificial rain for five minutes | A small amount of water drops are attached to the surface | A small amount of water drops are attached to the surface | A small amount of water drops are attached to the surface | Form a water film |
| Tensile failure critical load/N | 385.5 | 390 | 410.2 | 301.4 |
Compared with the prior art, the invention has the following beneficial effects: the invention carries out primary deferrization on the base material and the filler by using a magnetic separator, and then carries out secondary deferrization on the mixed slurry by using a shaking sieving machine, thereby greatly reducing the content of iron in the insulator, being beneficial to improving the insulating property of the finished insulator, the industrial alumina and the zirconite are added in the formula, so that the brittleness of the insulator is reduced, the strength of the insulator is greatly improved, the surface of the insulator is coated with paint, the insulator main body is cleaned by alcohol and ultrasonic, dust and particles on the surface of the insulator main body are greatly reduced, the coating effect is improved, meanwhile, the hydrophobic antifouling agent prepared by heating and mixing the ozokerite, the silicone oil and the vaseline is coated on the insulator main body for three times to form a compact and uniform waterproof antifouling layer, so that rainwater and micro-dust can be prevented from forming a water film on the surface of the insulator, and the situations of short circuit and pollution flashover are avoided.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (8)
1. A porcelain cross arm insulator comprises the following components in formula: kaolin, industrial alumina, feldspar, zirconite, ozokerite, silicone oil and vaseline, its characterized in that: the weight parts of the components are respectively as follows: 100-120 parts of kaolin, 40-50 parts of industrial alumina, 5-15 parts of feldspar, 5-10 parts of zircon, 20-25 parts of ozokerite, 12-15 parts of silicone oil and 24-30 parts of vaseline.
2. A method for manufacturing a porcelain cross arm insulator comprises the following steps of firstly, weighing raw materials; step two, ball milling and mud making; step three, preparing a base material; step four, preparing a filler; screening and pressing the mud; step six, vacuum mud refining; step seven, pressing and trimming; step eight, drying and dehydrating; step nine, glazing and sanding; step ten, firing and forming; step eleven, ultrasonic cleaning; step twelve, preparing the coating; thirteen, coating the surface; step fourteen, assembling and detecting; the method is characterized in that:
in the first step, respectively weighing 120 parts of 100-120 parts of kaolin, 40-50 parts of industrial alumina, 5-15 parts of feldspar, 5-10 parts of zircon, 20-25 parts of ozokerite, 12-15 parts of silicone oil and 24-30 parts of vaseline according to the parts by weight of the components;
in the second step, the kaolin and the feldspar weighed in the first step are put into a ball mill, and the raw materials are ground into a base material with the size of 5-20 microns for later use by wet ball milling;
in the third step, putting the industrial alumina and the zircon weighed in the first step into a ball mill, and grinding the raw materials into a filler with the particle size of 5-20 microns by wet ball milling for later use;
in the fourth step, the base material prepared in the second step and the filler prepared in the third step are subjected to wet deferrization by a magnetic separator respectively, and then pumped into a stirrer to be stirred and mixed to prepare mixed slurry for later use;
in the fifth step, the mixed slurry prepared in the fourth step is respectively screened by screens of 180 meshes and 250 meshes to remove large particles, impurities and iron-containing substances in the mixed slurry, and then the screened slurry is transported to a mud press to be pressed into mud cakes for later use;
putting the mud cake prepared in the fifth step into a vacuum pug mill, and discharging air in the pug to prepare solid mud segments with uniform interior for later use;
placing the solid mud segment prepared in the step six into a mold, pressing the mud segment into the shape of the cross arm insulator, and then trimming redundant mud to leave an insulator mud blank meeting the shape requirement for later use;
in the eighth step, the insulator mud blank prepared in the seventh step is subjected to power frequency electric drying until the moisture content of the insulator mud blank is between 0.8 and 1.2 percent;
in the ninth step, a glaze layer is uniformly coated on the surface of the insulator mud blank subjected to power frequency electric drying in the eighth step, and then a layer of uniform sand grains is coated on the positions where hardware fittings are assembled at the two ends of the insulator mud blank;
in the tenth step, the insulator mud blank glazed and sanded in the ninth step is placed into a high-temperature electric kiln, slowly heated and fired, and is kept at the temperature of 1100-1150 ℃ for 10-12h, and then slowly cooled to room temperature to prepare an insulator main body for later use;
in the eleventh step, after the insulator body fired in the tenth step is washed twice by alcohol with the concentration of 95%, the insulator body is placed into an ultrasonic cleaning machine for ultrasonic cleaning, and after the insulator body is cleaned, the insulator body is placed into a vacuum drying oven, and after the insulator body is dried, the insulator body is cooled to the room temperature for later use;
in the twelfth step, an electric stirring pot is taken, the silicone oil selected in the first step is added into the stirring pot, the stirring is carried out while heating, and then the ozokerite and the vaseline are sequentially added into the stirring pot until the ingredients are completely molten, so as to prepare the hydrophobic antifouling paint for later use;
in the thirteenth step, the coating prepared in the twelfth step is uniformly coated on the insulator main body dried in the eleventh step by a brush, and after the coating is completely dried, the coating is coated again, and the coating is repeated for three times until a compact and uniform hydrophobic antifouling coating is formed on the surface of the insulator main body;
and in the fourteenth step, the steel caps and the copper pins at the two ends of the insulator main body coated with the hydrophobic antifouling coating in the thirteenth step are assembled, and then the insulator main body is checked one by one through a mechanical tensile test and an electrical test to ensure that all performances are good, so that the ceramic cross arm insulator is manufactured.
3. The method for manufacturing the porcelain cross arm insulator according to claim 2, wherein the method comprises the following steps: in the fourth step, the magnetic separator is a permanent magnetic drum type magnetic separator, the rotating speed of the drum body is 35-40r/min, the rotating speed of the stirrer is 350-450r/min, and the stirring time is 60-90 min.
4. The method for manufacturing the porcelain cross arm insulator according to claim 2, wherein the method comprises the following steps: in the sixth step, the vacuum pugmill is a double-shaft vacuum pugmill, and the vacuum degree is 96-110 kPa.
5. The method for manufacturing the porcelain cross arm insulator according to claim 2, wherein the method comprises the following steps: in the step ten, the temperature rise of the high-temperature electric kiln is divided into three stages, wherein the temperature of the first stage is 20-200 ℃, the temperature rise rate is 0.43 ℃/min, the temperature of the second stage is 200-.
6. The method for manufacturing the porcelain cross arm insulator according to claim 2, wherein the method comprises the following steps: in the eleventh step, the ultrasonic cleaning machine is a three-tank type gas phase ultrasonic cleaning machine, and the ultrasonic cleaning time is 5-10 min.
7. The method for manufacturing the porcelain cross arm insulator according to claim 2, wherein the method comprises the following steps: in the eleventh step, the working temperature of the vacuum drying oven is 80-100 ℃, and the drying time is 5-7 min.
8. The method for manufacturing the porcelain cross arm insulator according to claim 2, wherein the method comprises the following steps: in the twelfth step, the temperature of the electric heating stirring pot is 60-70 ℃, and the heating stirring time is 10-20 min.
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