CN115008657A - Novel epoxy resin pouring method for basin-type insulator - Google Patents
Novel epoxy resin pouring method for basin-type insulator Download PDFInfo
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- CN115008657A CN115008657A CN202210671227.3A CN202210671227A CN115008657A CN 115008657 A CN115008657 A CN 115008657A CN 202210671227 A CN202210671227 A CN 202210671227A CN 115008657 A CN115008657 A CN 115008657A
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- 239000000843 powder Substances 0.000 claims abstract description 18
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/071—Preforms or parisons characterised by their configuration, e.g. geometry, dimensions or physical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/30—Mounting, exchanging or centering
- B29C33/305—Mounting of moulds or mould support plates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/70—Maintenance
- B29C33/72—Cleaning
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/02—Deburring or deflashing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/22—Component parts, details or accessories; Auxiliary operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/22—Component parts, details or accessories; Auxiliary operations
- B29C39/44—Measuring, controlling or regulating
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/10—Process efficiency
Abstract
The invention provides a novel epoxy resin pouring method for a basin-type insulator, which specifically comprises the following steps: s100, cleaning the surface of the insert conductor; s200, airing: placing the cleaned insert conductor on a tool rack, airing for 30min, and waiting for the solvent to completely volatilize; s300, drying: placing the insert conductor into an oven for baking, and opening an oven door to cool to room temperature along with the oven after baking; s400, coating conductive rubber-polyimide: coating conductive rubber-polyimide with the thickness of 0.5mm on the surface of the insert conductor needing to be painted; the viscosity value is controlled between 1400cP and 1450 cP; s500, pouring, wherein the pouring material comprises epoxy resin, a liquid curing agent and alumina powder in a mass ratio of 5:2:15, and a tamping-assisted pouring method is adopted during pouring; s600, cleaning a casting piece; s700, packaging and warehousing the casting after inspection and test.
Description
Technical Field
The invention relates to the technical field of high-voltage insulation, in particular to a novel epoxy resin pouring method for a basin-type insulator.
Background
Basin-type insulators, as important devices in the field of high-voltage switchgear, are generally cast from epoxy resin materials. The epoxy resin is a thermosetting plastic resin, and is injected into a mold and then maintained at a certain temperature for a certain period of time to perform a crosslinking reaction, thereby finally completing the curing, and the curing is generally faster as the temperature is higher. Taking an epoxy resin material which is currently used as an example, the temperature of the injected epoxy resin material is about 130 ℃, and the injection temperature is kept for about 12 hours after the injection of the epoxy resin material into a mold, so that the mold release state can be achieved. Of course, the temperature parameter and the time parameter adopted by the epoxy resin curing process are different, and meanwhile, due to the difference of the structures of the conductors of the inserts and the surface smoothness, the performance and the quality of the basin-type insulator can be directly influenced by the difference of the combination degree of the conductors of the inserts and the epoxy resin. In the traditional technology, the poured basin-type insulator has the defects of more bubbles, serious cracking and poor internal cleanliness, so that the basin-type insulator has poor through-flow capacity, is not high-temperature resistant and is easy to discharge, and serious safety accidents are caused.
Disclosure of Invention
In order to solve the problems and make up the defects of the prior art, the invention provides a novel epoxy resin pouring method for a basin-type insulator.
The invention is realized by the following technical scheme:
a novel epoxy resin pouring method for a basin-type insulator specifically comprises the following steps.
S100, cleaning the surface of the insert conductor: firstly, processing an insert conductor into a thread shape, cleaning burrs by using ultrasonic waves, and then absolutely smoothing concave-convex grooves on the surface of the insert conductor by using a micro-arc oxidation method; the micro-arc oxidation method is to place the insert conductor in an electrolyte solution and generate a ceramic surface film layer by applying high voltage.
S200, air drying treatment: placing the cleaned insert conductor on a tool rack for airing, wherein the airing time of the insert conductor is 30min, and waiting for the solvent to be completely volatilized;
s300, drying: placing the insert conductor into an oven for baking, controlling the temperature of the oven at 145-155 ℃ and the baking time to be more than 30 minutes, then closing a heat source, opening a furnace door and cooling to the room temperature along with the furnace;
s400, coating an adhesive: coating conductive rubber-polyimide with the thickness of 0.5mm on the surface of the insert conductor needing to be painted; the viscosity value of the polyimide must be controlled between 1400cP and 1450 cP;
s500, pouring, wherein the pouring material comprises epoxy resin, a liquid curing agent and alumina powder, and the mass ratio of the epoxy resin to the liquid curing agent to the alumina powder is 5:2: 15;
s600, cleaning a casting piece;
s700, packaging and warehousing the casting after inspection and test.
Further, the step S400 of applying the adhesive conductive rubber-polyimide includes the steps of:
s401, mixing, namely uniformly stirring the conductive rubber, filtering the conductive rubber by using a 40-mesh stainless steel filter screen, adding dimethylbenzene for dilution, adjusting the viscosity value to be 1400-1450 cP, then putting the conductive rubber into a clean original conductive rubber barrel, and sealing, refrigerating and storing the conductive rubber;
s402, the viscosity of the conductive rubber must be tested before the coating operation is started, and the viscosity is measured once every two hours during the operation period so as to ensure that the viscosity value is controlled between 1400cP and 1450cP, otherwise, the viscosity value is adjusted to be qualified; when greater than 1450cP, adding xylene to reduce its viscosity value; when the viscosity is less than 1400cP, adding the original conductive rubber glue solution to improve the viscosity value;
and S403, coating, namely coating the surface of all the conductors of the insert to be painted with conductive rubber with the thickness of 0.5mm, and immediately transferring to the next process, wherein the clearance time is not more than 20 minutes.
Further, the S500 pouring process includes the following steps:
s501, determining the proportion of the castable, wherein the proportion of the castable is as follows: epoxy resin: liquid curing agent: the ratio of alumina powder to alumina powder is 5:2: 15;
s502, filling a mold;
(1) cleaning a mold: before each pouring, the surfaces of the mould, the insert, the fastener and the positioning piece must be cleaned by a scraper knife, white cotton cloth or napkin paper or hairless paper according to the process; cleaning the residual release agent in the die forming hole, the insert positioning reference surface, the die sealing groove and the like; spraying a release agent on the inner surface of the mold in contact with the epoxy resin, and removing the redundant release agent by using napkin paper or hairless paper after spraying;
(2) assembling a mold: the insert conductor coated with the conductive rubber is taken by wearing a clean special cloth glove, the insert conductor is fixed on a die by using a related bolt and a positioning pin, and the die fixing bolt is fastened after die assembly, so that tight die assembly is ensured; after the die is installed, a release agent is required to be wiped on the outer surface of the die and the part of the castable which is easy to flow near a pouring gate, so that the die is convenient to clean after pouring; the top thread hole on the upper template is blocked by napkin coated with release agent or no fluff paper, so as to prevent the pouring material from flowing in; a cover cap is added on the opening of the cooling water tank and is fastened by bolts; the appearance of the whole die is neat; wrapping the mold gate with plastic cloth, and tightening with a string to prevent foreign matters from falling into the cavity; placing the primarily used mold into a box-type furnace to be preheated to 90-97 ℃, and pouring the mold for recycling without preheating treatment;
(3) setting the technical parameters of the pouring equipment: according to the requirements of the epoxy resin pouring process, the following parameters are respectively set: setting the preheating treatment temperature of the epoxy resin to be 125 ℃; setting the preheating treatment temperature of the alumina powder filler to be 125 ℃; setting the preheating treatment temperature of the liquid curing agent to be 40 ℃; setting the heating treatment temperature of the premixing tank to 125 ℃; setting the holding temperature and the stirring time of the static mixer to be 108 ℃/1.5 h; the mold preheating temperature in a box type curing furnace is 90-97 ℃; setting the heating temperature of the casting tank and the vacuum degree of the vacuum pumping as 140 ℃/2 hPa-5 hPa; setting the vacuumizing time and the vacuum degree of the mold after the mold is put into a furnace to be 15min/10 hPa-15 hPa; setting the proportion of epoxy resin and filler conveyed by a hydraulic metering pump into a premixing tank at a weight ratio of 100: 300; setting the proportion of the mixture and the curing agent in the hydraulic metering pump conveying premixing tank into the static mixer, wherein the weight ratio is 400: 40; setting the weight of the automatic casting material according to the size of the mould; one set of mould is provided with an automatic pouring number, and after the technical parameters are designed once, if the used materials and the pouring process are not changed, repeated design is not needed; if the materials or the mixture ratio is changed, the set value of the mixing ratio is adjusted in time;
s503, respectively filling the epoxy resin, the alumina powder and the liquid curing agent which meet the requirements and are qualified through inspection into a resin dissolving tank, a filling bag-unpacking box or a drying tank and a material preparation tank, and carrying out power-on heating;
s504, when the cycloresin and the alumina powder filler are respectively heated for 4 hours at the temperature of 120-140 ℃, starting a hydraulic metering pump, and feeding the two materials into a premixing tank which is heated to 120-130 ℃ according to a required proportion to mix; heating, stirring and vacuumizing the mixture in the mixing tank for 5 hours until the vacuum degree reaches 10 hPa-15 hPa for later use;
s505, placing the mold fixed with the insert conductor into a box-type furnace, heating to 90-97 ℃, removing plastic cloth wrapping a mold gate, moving the mold into a square pouring tank, sealing, vacuumizing for 15min, wherein the vacuum degree reaches 10 hPa-15 hPa, and when the temperature reaches 85-95 ℃, starting a hydraulic metering pump to feed the mixture and the curing agent into a static mixer heated to 105-110 ℃ according to the proportion of 10:1 for pouring;
s506, when the temperature of the pouring furnace reaches 85-95 ℃ and the temperature in the static mixer reaches 105-110 ℃, pouring can be carried out; before pouring, firstly, two strokes are taken to a material receiving barrel, then a pouring pipe is adjusted to be aligned to a pouring gate of a mold, and the 'automatic pouring number' of the poured mold is started for pouring according to a pre-designed program;
s507, before pouring and feeding, starting a vibrator below the mold, adjusting the vibrator to 200HZ until feeding is completed, and closing the vibrator;
and S508, sequentially pouring the molds, waiting for 10-15 min, breaking vacuum, and discharging the molds. The mix cannot remain in the static mixer and the pipes following it for too long a time, or it can solidify and clog. Therefore, after the pouring is finished, the pouring mixer and the inner wall of the pouring pipeline must be cleaned in time;
s509, curing: after water is added into a water cooling port of the mold, the mold is sent into a curing furnace and cured for 10 hours at the temperature of 120-130 ℃;
s510, demolding: the demoulding operation is finished within 20min after the mould is taken out of the furnace, the surface of the mould is poured, overflowed and cleaned by a shovel blade quickly, a pouring gate, an insert fixing bolt and a mould fixing bolt are removed, an upper template is jacked open evenly by a jackscrew diagonal angle or a multifunctional hydraulic puller, and the upper template is lifted away from an upper mould;
s511, leveling, namely secondary curing: checking whether the leveling tool accessories are complete, cleaning the inner cavity and the joint surface of the leveling tool accessories, and cleaning a sprue and external burrs of the insulating part to be leveled after demolding; loading the cleaned insulating part into a leveling tool, fixing the insulating part by using a bolt, and then loading the insulating part into a curing furnace; the bolts are not screwed too tightly to prevent fracturing, and are fastened once again when the furnace temperature rises and is stabilized at 120-130 ℃, and the temperature is kept and cured for 10-14 h; after the leveling is finished, turning off a power supply to cool along with the furnace, discharging the furnace when the furnace temperature is reduced to below 60 ℃, and cooling at room temperature; and measuring the flatness of the leveled insulating part on a special tool, and turning to the next procedure when the flatness of the part is less than 0.3mm, or re-leveling.
Further, the cleaning of the casting piece in the step S600 comprises the following steps: placing the numbered parts on a workbench, removing large burrs on the periphery of the parts by using a tool, and polishing by using an angle grinder; cleaning burrs around the conductor of the central insert of the part by using a cutter, and polishing by using 400# gauze; when the through hole is cleaned, the burr at the through hole part is cleaned up by a straight grinding machine; the resin in the threads of the insert is removed by a screw tap; polishing the concave and convex uneven part of the sealing groove by using 400# abrasive cloth, and polishing by using scouring pad; polishing the pouring gate according to the radian of the part by using an angle grinder, and polishing the pouring gate smoothly by using No. 400 abrasive paper and scouring pad; polishing high points on the insulating surface by using an angle grinder, and polishing the high points smoothly by using No. 400 abrasive paper and scouring pad; the resin at the root of the joint between the insert and the insulating part is cleaned during cleaning.
The invention has the following technical effects:
1. the embedded part of the insert conductor is processed into a thread shape, and the concave-convex surface of the thread on the surface of the insert conductor is absolutely smooth, so that the influence of burrs on the insulating property and the bubbles caused by the uneven surface are reduced.
2. The conductive rubber-polyimide is coated on the surface of the embedded part of the conductor to increase the adhesion, reduce bubbles, form a protective film on the surface of the embedded part of the conductor, improve the corrosion resistance of the embedded part of the conductor, and simultaneously have higher insulativity to effectively prevent discharge.
3. And (3) adopting auxiliary secondary vibration to completely inlay the filler and remove internal bubbles.
Drawings
FIG. 1 is a schematic diagram of the process steps of the present invention.
FIG. 2 is a schematic view of a micro-arc oxidation apparatus according to the present invention.
Detailed Description
The following describes the method for pouring the novel epoxy resin for the basin-type insulator in detail with reference to specific embodiments.
A novel epoxy resin pouring method for a basin-type insulator specifically comprises the following method steps as shown in attached figure 1.
S100, cleaning the surface of the insert conductor: the insert conductor is previously processed into a thread shape, burrs are cleaned by ultrasonic waves, and then the concave-convex grooves on the surface of the insert conductor are absolutely smoothed by a micro-arc oxidation method.
The micro-arc oxidation method comprises the following steps, see fig. 2:
s101, placing the conductor inserts into a device arranging frame in a micro-oxidation treatment box, strictly prohibiting stacking and arranging, wherein the device interval is more than 200mm, so that each insert can form an independent reaction site, and mutual influence is avoided;
s102, preparing an oxidizing solution according to the mixture ratio of 800kg of hydrogen peroxide, 50kg of 2-ethyl anthraquinone, 90kg of tetrahydro-2-ethyl anthraquinone and 160kg of phosphoric acid, and pouring the oxidizing solution into a micro-oxidation treatment box. The top layer insert is ensured to be submerged below 200 mm;
s103, closing a power knife switch in the power box, inputting the AC380V power into a rectifier bridge part of the alternating current-direct current voltage conversion and regulation box, adopting A, B, C and 3 paths of independent rectification for voltage division rectification, converting the AC380V power into 3 paths of DC220V power, and passing through a voltage regulator part;
s104, inputting the converted direct-current voltage into a micro-arc oxidation treatment box by adopting a step-by-step boosting mode through a conduction switch of the alternating-current/direct-current voltage conversion and regulation box, starting to switch on the first DC220V voltage, generating red glimmer around the conductor insert after 3 minutes, starting to oxidize, switching on the second DC220V voltage, generating red-yellow flame around the conductor insert after 1 minute, reacting strongly, switching on the third DC220V voltage, generating blue flame around the conductor insert after 1 minute, reacting violently, starting to reduce after 5 minutes, reacting basically disappearing after 10 minutes, forming porcelainization on the surface of the conductor insert, and finishing micro-arc oxidation treatment.
When the workpiece is treated by micro-arc oxidation, the treatment solution should be kept in a well-stirred state to exert the maximum effect of surface oxidation. Under the special condition of over high water hardness, sodium tripolyphosphate can be added before the tank is prepared to adjust the water quality, 200-500 g of sodium tripolyphosphate (namely 0.2-0.5 per mill) is added into every 1000Kg of water, but the sodium tripolyphosphate is not used excessively or is added normally, and is only used when a new tank is prepared.
Adopting a micro-arc oxidation method: the process of generating a ceramic surface film layer by applying a high voltage, which is the result of the synergy of physical discharge and electrochemical oxidation. The insert conductor surface concave-convex groove is absolutely smoothened by the micro-arc oxidation method, and the obtained insert conductor surface concave-convex groove has ceramic texture, dull appearance, no highlight product, fine hand feeling and wide applicable base material: al, Ti, Zn, Zr, Mg, Nb and alloys thereof, etc.; the micro-arc oxidation method is simple in pretreatment, and the obtained product is excellent in corrosion resistance, weather resistance and heat dissipation performance.
S200, drying: and placing the cleaned insert conductor on a tool rack for airing, wherein the airing time of the insert conductor is 30min until the solvent is volatilized.
S300, drying treatment: and placing the insert conductor into an oven for baking, controlling the temperature of the oven at 145-155 ℃ for more than 30 minutes, then closing a heat source, and opening the oven door to reduce the temperature to room temperature along with the oven.
S400, coating an adhesive: firstly, the materials are proportioned, (1) the unpacked conductive rubber-polyimide is stirred uniformly, then filtered by a 40-mesh stainless steel filter screen, diluted by adding dimethylbenzene, the viscosity value is adjusted to be 1400-1450 cP, and then the conductive rubber-polyimide is put into a clean original conductive rubber barrel and is sealed, refrigerated and stored.
(2) The viscosity of the conductive rubber was measured using a model NDJ-1 rotational viscometer. The viscosity of the conductive rubber must be measured every day before the coating operation begins, every two hours during the operation. The viscosity value of the modified polyvinyl alcohol must be controlled between 1400cP and 1450cP, otherwise, the modified polyvinyl alcohol is qualified. When greater than 1450cP, adding xylene to reduce its viscosity value; when the viscosity is less than 1400cP, adding the original glue solution to improve the viscosity value. The viscosity value is too high, the slight aging is easy to generate on the outer side of the body, and the cleaning effect is poor due to the too low viscosity value.
(3) Then coating is carried out, all the surfaces of the conductors of the inserts to be painted are coated with conductive rubber with the thickness of 0.5mm, and the next procedure is immediately carried out, wherein the gap time is not more than 20 minutes. If the thickness of the conductive rubber exceeds 0.5mm, the conductor insert and the insulating resin cannot be completely attached, and if the thickness of the conductive rubber is less than 0.5mm, the insert falls off due to insufficient adhesion.
The polyimide is analyzed by thermogravimetry, and the initial decomposition temperature of the polyimide is generally about 500 ℃. Polyimide prepared from pyromellitic dianhydride and p-phenylenediamine has a thermal decomposition temperature of 600 ℃, and is one of the highest heat-stable varieties in the polymers so far.
The polyimide has good dielectric property, the dielectric constant is about 3.4, fluorine is introduced, or air is dispersed in the polyimide in a nanometer size, and the dielectric constant can be reduced to about 2.5. The dielectric loss is 10, the dielectric strength is 100-300 kV/mm, and the volume resistance is 10170-cm. These properties can be maintained at a high level over a wide temperature range and frequency range.
And S500, pouring. The pouring process specifically comprises the following steps:
s501, determining the proportion of the castable, wherein the quality and the type of the material in the embodiment are shown in the following table;
and S502, filling the mold.
(1) Cleaning a mold: before each pouring, the surfaces of the mould, the insert, the fastener and the positioning piece must be cleaned by a scraper knife, white cotton cloth or napkin paper or hairless paper according to the process. Special attention should be paid to cleaning up the residual release agent in the die forming hole, the insert positioning reference surface, the die sealing groove and the like. The inner surface of the mold contacting with the epoxy resin is sprayed with a release agent, and then the excess release agent is removed by using napkin paper or hairless paper after spraying.
(2) Assembling a mold: the insert conductor coated with the conductive rubber is taken by wearing the clean special cloth glove, the insert conductor is fixed on a die by using a related bolt and a positioning pin, and the die fixing bolt is fastened after die assembly. Tight die assembly should be ensured. After the mold is installed, a release agent must be wiped on the outside of the mold and the position of the castable which is easy to flow near a pouring gate, so that the mold is convenient to clean after pouring; the top thread hole on the upper template is blocked by napkin coated with release agent or no fluff paper, so as to prevent the pouring material from flowing in; a cover cap is added on the opening of the cooling water tank and is fastened by bolts; the appearance of the whole die is neat. The pouring gate of the mold is wrapped up by plastic cloth and tied by a string, so as to prevent foreign matters from falling into the cavity. The mould used for the first time is placed into a box-type furnace to be preheated to 90-97 ℃, and preheating treatment is not needed for casting recycling.
(3) Setting the technical parameters of the pouring equipment: according to the requirements of the epoxy resin pouring process, the following parameters are respectively set: the epoxy resin preheating temperature was set to 125 ℃. The preheating temperature of the alumina powder filler is set to be 125 ℃. The preheating temperature of the liquid curing agent was set to 40 ℃. The heat treatment temperature of the premixing tank was set to 125 ℃. The temperature of the static mixer is set and the stirring time is set to be 108 ℃/1.5 h. The preheating temperature of the mould in the box type curing furnace is 90-97 ℃. The heating temperature of the casting pot and the vacuum degree of the vacuum pumping are set to be 140 ℃/2 hPa-5 hPa. Setting the vacuumizing time and the vacuum degree of the mold after the mold is put into the furnace to be 15min/10 hPa-15 hPa. And setting the proportion of the epoxy resin and the filler conveyed by the hydraulic metering pump into the premixing tank at a weight ratio of 100: 300. And setting the proportion of the mixture and the curing agent in the premixing tank conveyed by the hydraulic metering pump into the static mixer, wherein the weight ratio is 400: 40. And setting the weight of the automatic casting material according to the size of the mould. One set of mould is provided with an automatic pouring number so as to be distinguished during pouring. After the technical parameters are designed once, if the used materials and the pouring process are not changed, repeated design is not needed; if the materials or the mixture ratio is changed, the set value of the mixing ratio is adjusted in time.
S503, respectively filling the epoxy resin, the alumina powder and the liquid curing agent which meet the requirements and are qualified through inspection into a resin dissolving tank, a filling bag-unpacking box (drying tank) and a material preparation tank, and carrying out power-on heating.
S504, after the cyclo-resin and the alumina powder filler are respectively heated at the temperature of 120-140 ℃ for 4 hours, a hydraulic metering pump is started, and the two materials are fed into a premixing tank which is heated to 120-130 ℃ according to the required proportion to be mixed. The mixture in the mixing tank is heated, stirred and vacuumized for 5 hours, and the vacuum degree reaches 10 hPa-15 hPa for later use.
S505, placing the mold fixed with the insert conductor into a box type furnace, heating to 90-97 ℃, removing plastic cloth wrapping a mold pouring gate, moving the mold into a square pouring tank, sealing, vacuumizing for 15min until the vacuum degree reaches 10-15 hPa, and when the temperature reaches 85-95 ℃, starting a hydraulic metering pump to feed the mixture and the curing agent into a static mixer heated to 105-110 ℃ according to the proportion of 10:1, and pouring.
S506, when the temperature of the pouring furnace reaches 85-95 ℃ and the temperature in the static mixer reaches 105-110 ℃, pouring can be carried out. Before pouring, two strokes are firstly taken to the material receiving barrel, then the pouring pipe is adjusted to be aligned with the pouring gate of the mold, and the 'automatic pouring number' of the poured mold is started for pouring according to a pre-designed program.
And S507, before pouring and feeding, starting a vibrator below the mold, adjusting the vibrator to 200HZ until feeding is completed, and closing the vibrator.
And S508, sequentially pouring the molds, waiting for 10-15 min, breaking vacuum, and discharging the molds. The mix cannot remain in the static mixer and the pipes following it for too long a time, or it can solidify and clog. Therefore, after the pouring is finished, the pouring mixer and the inner wall of the pouring pipeline must be cleaned in time.
S509, curing: after water is added into the water cooling port of the mold, the mold is sent into a curing furnace and cured for 10 hours at the temperature of 120-130 ℃.
S510, demolding: the demoulding operation is finished within 20min after the mould is taken out of the furnace. And after the die is discharged from the furnace, quickly using a scraper knife to clean the pouring overflow on the surface of the die. And detaching the pouring gate, the insert fixing bolt and the mold fixing bolt. And (4) uniformly jacking the upper template by using a jackscrew diagonal or a multifunctional hydraulic puller, and lifting the upper template away from the upper die.
The multifunctional hydraulic puller operation procedure is as follows: carefully checking each part of a puller before use, and strictly avoiding use due to defects; before use, the hydraulic puller with the corresponding tonnage, such as a 5T or 3T hydraulic puller, is selected according to the outer diameter, the pull distance and the load force of the casting mold, so that overload use is avoided, and damage is avoided. (2) When in use: firstly, the oil return rotary handle is rotated by hand and screwed to the ON position in the clockwise direction. And secondly, adjusting the hook claw seat to a proper position, so that the upper surface of the hook claw seat and the top end of the piston starting rod are placed in a fixing plate welded with the upper template and the lower template, the fixing plate is provided with an opening, and the size of the opening is larger than that of the thread of the hook claw seat. The upper and lower templates are welded face to face, and the total number of the fixing plates is two. The jackscrew is level with the lower side fixed plate plane, and the stroke is mastered. And thirdly, two ends of the casting mold are respectively provided, two persons insert the handles into the lifting hand holes to lift the pistons back and forth at the same time, at the moment, the starting rod moves forwards stably, the hook claw seats correspondingly move backwards, and the upper template is ejected out. And fourthly, standing on the side surface of the puller to operate when in use. (3) The effective distance of a piston starting rod of the hydraulic puller is only 50mm, so the depth distance is not more than 50mm when the hydraulic puller is used, the hydraulic puller is stopped when the hydraulic puller is not pulled out, an oil return valve is loosened to retract the piston starting rod, and the steps of the first step, the second step and the third step are repeated for the second time after the hydraulic puller is adjusted to be pulled out. (4) To retract the piston actuating lever, the oil return valve lever is manually turned counterclockwise to the OFF position, slightly unscrewed, and the piston actuating lever is gradually retracted under the action of the spring. (5) The new or long-placed hydraulic puller has more air in the oil cylinder, so that when the hydraulic puller is used, a piston rod possibly has a micro sudden jump phenomenon, and the hydraulic puller can reciprocate 2-3 times without load to remove air in a cavity. The puller which is idle for a long time is free from work for a long time, so that the hardening of the sealing piece is caused, the service life of the puller is influenced, and the puller does not carry out reciprocating motion for 2-3 times every month when not used. The puller is frequently checked and regularly maintained, after the puller is used, the puller is subjected to pressure relief and is placed in a dry and clean place without corrosion, so that the use safety and reliability are ensured. Carefully knocking the small end of the casting by a wooden hammer to loosen the small end, and carefully taking out the casting. Carefully cleaning the die face and the casting material at the rest part by using a scraper knife, and blowing clean by using a compressed air spray gun.
S511, leveling, namely secondary curing: checking whether the leveling tool accessories are complete, cleaning the inner cavity and the joint surface of the leveling tool accessories, and cleaning a sprue and external burrs of the insulating part to be leveled after demolding; loading the cleaned insulating part into a leveling tool, fixing the insulating part by using a bolt, and then loading the insulating part into a curing furnace; the bolts are not screwed too tightly to prevent fracturing, and when the furnace temperature rises and is stabilized at 120-130 ℃, the bolts are fastened again and are cured for 10-14 h; after the leveling is finished, turning off a power supply to cool along with the furnace, discharging the furnace when the furnace temperature is reduced to below 60 ℃, and cooling at room temperature; and measuring the flatness of the leveled insulating part on a special tool, and turning to the next procedure when the flatness of the part is less than 0.3mm, or re-leveling.
S600, cleaning a casting part, namely placing the numbered part on a workbench, removing peripheral large burrs by using a tool, and then polishing by using an angle grinder. The part was deburred around the center insert conductor with a cutter and polished with 400# gauze. When the through hole is cleaned, the burr at the through hole part is cleaned up by a straight grinding machine. If resin exists in the threads of the insert, the resin can be removed by tapping with a screw tap. And (3) polishing the concave and convex uneven part of the sealing groove by using 400# abrasive cloth, and polishing by using scouring pad to ensure the roughness of the sealing groove. And (5) polishing the pouring gate according to the radian of the part by using an angle grinder, and polishing the pouring gate smoothly by using No. 400 abrasive paper and scouring pad. The high points on the insulating surface were polished with an angle grinder and smoothed with 400# sandpaper and scouring pad. The resin at the root of the joint between the insert and the insulating part is cleaned during cleaning.
And S700, packaging and warehousing the casting after inspection and test.
Claims (7)
1. A novel epoxy resin pouring method for a basin-type insulator is characterized by comprising the following steps: the method specifically comprises the following steps:
s100, cleaning the surface of the insert conductor: firstly, processing an insert conductor into a thread shape, cleaning burrs by using ultrasonic waves, and then absolutely smoothing concave-convex grooves on the surface of the insert conductor by using a micro-arc oxidation method;
s200, air drying treatment: placing the cleaned insert conductor on a tool rack for airing, wherein the airing time of the insert conductor is 30min, and waiting for the solvent to be completely volatilized;
s300, drying: placing the insert conductor into an oven for baking, controlling the temperature of the oven at 145-155 ℃ and the baking time to be more than 30 minutes, then closing a heat source, opening a furnace door and cooling to the room temperature along with the furnace;
s400, coating conductive rubber-polyimide: coating conductive rubber-polyimide with the thickness of 0.5mm on the surface of the insert conductor needing to be painted; the viscosity value of the polyimide must be controlled between 1400cP and 1450 cP;
s500, pouring, namely pouring, wherein the pouring material comprises epoxy resin, a liquid curing agent and alumina powder, the mass ratio of the epoxy resin to the liquid curing agent to the alumina powder is 5:2:15, and feeding and tamping assistance are adopted during pouring to reduce bubbles;
s600, cleaning a casting piece;
s700, packaging and warehousing the casting after inspection and test.
2. The novel epoxy resin pouring method for the basin-shaped insulator according to claim 1, characterized in that: the micro-arc oxidation method comprises the following steps:
s101, placing the conductor inserts into a device arranging frame in a micro-oxidation treatment box, strictly prohibiting stacking and arranging, wherein the device interval is more than 200mm, so that each insert can form an independent reaction site, and mutual influence is avoided;
s102, preparing an oxidizing solution according to the mixture ratio of 800kg of hydrogen peroxide, 50kg of 2-ethyl anthraquinone, 90kg of tetrahydro-2-ethyl anthraquinone and 160kg of phosphoric acid, and pouring the oxidizing solution into a micro-oxidation treatment box;
s103, closing a power knife switch in the power box, inputting the AC380V power into a rectifier bridge part of the alternating current-direct current voltage conversion and regulation box, adopting A, B, C and 3 paths of independent rectification for voltage division rectification, converting the AC380V power into 3 paths of DC220V power, and passing through a voltage regulator part;
s104, inputting the converted direct-current voltage into a micro-arc oxidation treatment box by adopting a step-by-step boosting mode through a conduction switch of the alternating-current/direct-current voltage conversion and regulation box, starting to switch on the first DC220V voltage, generating red glimmer around the conductor insert after 3 minutes, starting to oxidize, switching on the second DC220V voltage, generating red-yellow flame around the conductor insert after 1 minute, reacting strongly, switching on the third DC220V voltage, generating blue flame around the conductor insert after 1 minute, reacting violently, starting to reduce after 5 minutes, reacting basically disappearing after 10 minutes, forming porcelainization on the surface of the conductor insert, and finishing micro-arc oxidation treatment.
3. The novel epoxy resin pouring method for the basin-type insulator according to claim 2, characterized in that: when the workpiece is subjected to micro-arc oxidation treatment, the treatment solution is kept in a good stirring state to exert the maximum effect of surface oxidation; under the special condition of over high water hardness, sodium tripolyphosphate can be added before the tank is prepared to adjust the water quality, 200-500 g of sodium tripolyphosphate is added into every 1000Kg of water, namely 0.2-0.5 per mill, but the sodium tripolyphosphate is not used excessively or is added at ordinary times, and is only used when a new tank is prepared.
4. The novel epoxy resin pouring method for the basin-type insulator according to claim 1, characterized in that: the step S400 of applying the adhesive conductive rubber-polyimide includes the steps of:
s401, mixing, namely uniformly stirring the conductive rubber, filtering the conductive rubber by using a 40-mesh stainless steel filter screen, adding dimethylbenzene for dilution, adjusting the viscosity value to be 1400-1450 cP, then putting the conductive rubber into a clean original conductive rubber barrel, and sealing, refrigerating and storing the conductive rubber;
s402, the viscosity of the conductive rubber must be tested before the coating operation is started, and the viscosity is measured once every two hours during the operation period so as to ensure that the viscosity value is controlled between 1400cP and 1450cP, otherwise, the viscosity value is adjusted to be qualified; when the viscosity is larger than 1450cP, adding dimethylbenzene to reduce the viscosity value; when the viscosity is less than 1400cP, adding the original conductive rubber glue solution to improve the viscosity value;
and S403, coating, namely coating the surface of all the conductors of the insert to be painted with conductive rubber with the thickness of 0.5mm, and immediately transferring to the next process, wherein the clearance time is not more than 20 minutes.
5. The novel epoxy resin pouring method for the basin-shaped insulator according to claim 1, characterized in that: the S500 pouring treatment comprises the following steps:
s501, determining the proportion of the castable, wherein the proportion of the castable is as follows: epoxy resin: liquid curing agent: the ratio of alumina powder to alumina powder is 5:2: 15;
s502, filling a mold;
s503, respectively filling the epoxy resin, the alumina powder and the liquid curing agent which meet the requirements and are qualified through inspection into a resin dissolving tank, a filling bag-unpacking box or a drying tank and a material preparation tank, and carrying out power-on heating;
s504, after the cyclo-resin and the alumina powder filler are respectively heated at the temperature of 120-140 ℃ for 4 hours, starting a hydraulic metering pump, and feeding the two materials into a premixing tank which is heated to 120-130 ℃ according to a required proportion to mix; heating, stirring and vacuumizing the mixture in the mixing tank for 5 hours until the vacuum degree reaches 10 hPa-15 hPa for later use;
s505, placing the mold fixed with the insert conductor into a box-type furnace, heating to 90-97 ℃, removing plastic cloth wrapping a mold gate, moving the mold into a square pouring tank, sealing, vacuumizing for 15min, wherein the vacuum degree reaches 10 hPa-15 hPa, and when the temperature reaches 85-95 ℃, starting a hydraulic metering pump to feed the mixture and the curing agent into a static mixer heated to 105-110 ℃ according to the proportion of 10:1 for pouring;
s506, when the temperature of the pouring furnace reaches 85-95 ℃ and the temperature in the static mixer reaches 105-110 ℃, pouring can be carried out; before pouring, two strokes are firstly made to the material receiving barrel, then the pouring pipe is adjusted to be aligned to a pouring gate of the mold, and the automatic pouring number of the poured mold is started for pouring according to a pre-designed program;
s507, before pouring and feeding, starting a vibrator below the mold, adjusting the vibrator to 200HZ until feeding is completed, and closing the vibrator;
s508, sequentially pouring the molds, waiting for 10-15 min, breaking vacuum, and discharging the molds from the furnace;
the mixture can not be kept in the static mixer and the pipeline behind the static mixer for too long time, or the mixture can be solidified and blocked; therefore, after the pouring is finished, the pouring mixer and the inner wall of the pouring pipeline must be cleaned in time;
s509, curing: after water is added into a water cooling port of the mold, the mold is sent into a curing furnace and cured for 10 hours at the temperature of 120-130 ℃;
s510, demolding: the demoulding operation is finished within 20min after the mould is taken out of the furnace, the surface of the mould is poured, overflowed and cleaned by a shovel blade quickly, a pouring gate, an insert fixing bolt and a mould fixing bolt are removed, an upper template is jacked open evenly by a jackscrew diagonal angle or a multifunctional hydraulic puller, and the upper template is lifted away from an upper mould;
s511, leveling, namely secondary curing: checking whether the leveling tool accessories are complete, cleaning the inner cavity and the joint surface of the leveling tool accessories, and cleaning a sprue and external burrs of the insulating part to be leveled after demolding; loading the cleaned insulating part into a leveling tool, fixing the insulating part by using a bolt, and then loading the insulating part into a curing furnace; the bolts are not screwed too tightly to prevent fracturing, and when the furnace temperature rises and is stabilized at 120-130 ℃, the bolts are fastened again and are cured for 10-14 h; after the leveling is finished, turning off a power supply to cool along with the furnace, discharging the furnace when the furnace temperature is reduced to below 60 ℃, and cooling at room temperature; and measuring the flatness of the leveled insulating part on a special tool, and turning to the next procedure when the flatness of the part is less than 0.3mm, or re-leveling.
6. The novel epoxy resin pouring method for the basin-shaped insulator according to claim 5, characterized in that: the S502 and the die filling comprise the following steps:
(1) cleaning a mold: before each pouring, the surfaces of the mould, the insert, the fastener and the positioning piece must be cleaned by a scraper knife, white cotton cloth or napkin paper or hairless paper according to the process; cleaning the residual release agent in the die forming hole, the insert positioning reference surface, the die sealing groove and the like; spraying a release agent on the inner surface of the mold in contact with the epoxy resin, and removing the redundant release agent by using napkin paper or hairless paper after spraying;
(2) assembling a mold: the insert conductor coated with the conductive rubber is taken by wearing a clean special cloth glove, the insert conductor is fixed on a die by using a related bolt and a positioning pin, and the die fixing bolt is fastened after die assembly, so that tight die assembly is ensured; after the die is installed, a release agent is required to be wiped on the outer surface of the die and the part of the castable which is easy to flow near a pouring gate, so that the die is convenient to clean after pouring; the top thread hole on the upper template is blocked by napkin coated with release agent or no fluff paper, so as to prevent the pouring material from flowing in; a cover cap is added on the opening of the cooling water tank and is fastened by bolts; the appearance of the whole die is neat; wrapping the mold gate with plastic cloth, and tightening with a string to prevent foreign matters from falling into the cavity; placing the primarily used mold into a box-type furnace to be preheated to 90-97 ℃, and pouring the mold for recycling without preheating treatment;
(3) setting the technical parameters of the pouring equipment: according to the requirements of the epoxy resin pouring process, the following parameters are respectively set: setting the preheating treatment temperature of the epoxy resin to be 125 ℃; setting the preheating treatment temperature of the alumina powder filler to be 125 ℃; setting the preheating treatment temperature of the liquid curing agent to be 40 ℃; setting the heating treatment temperature of the premixing tank to 125 ℃; setting the holding temperature and the stirring time of the static mixer to be 108 ℃/1.5 h; the mold preheating temperature in a box type curing furnace is 90-97 ℃; setting the heating temperature of the casting tank and the vacuum degree of vacuum pumping as 140 ℃/2 hPa-5 hPa; setting the vacuumizing time and the vacuum degree of the mold after the mold is put into a furnace to be 15min/10 hPa-15 hPa; setting the proportion of conveying the epoxy resin and the filler into the premixing tank by the hydraulic metering pump, wherein the weight ratio is 100: 300; setting the proportion of the mixture and the curing agent in the hydraulic metering pump conveying premixing tank into the static mixer, wherein the weight ratio is 400: 40; setting the weight of the automatic castable according to the size of the mould; one set of mould is provided with an automatic pouring number, and after the technical parameters are designed once, if the used materials and the pouring process are not changed, repeated design is not needed; if the materials or the mixture ratio is changed, the set value of the mixing ratio is adjusted in time.
7. The novel epoxy resin pouring method for the basin-shaped insulator according to claim 1, characterized in that: s600, cleaning the casting piece comprises the following steps: placing the numbered parts on a workbench, removing large burrs on the periphery by using a tool, and then polishing by using an angle grinder; cleaning burrs around the conductor of the central insert of the part by using a cutter, and polishing by using 400# gauze; when the through hole is cleaned, the burr at the through hole part is cleaned up by a straight grinding machine; removing the resin in the threads of the insert by using a screw tap; polishing the concave and convex uneven part of the sealing groove by using 400# abrasive cloth, and polishing by using scouring pad; polishing the pouring gate according to the radian of the part by using an angle grinder, and polishing the pouring gate smoothly by using No. 400 abrasive paper and scouring pad; polishing high points on the insulating surface by using an angle grinder, and polishing the high points smoothly by using No. 400 abrasive paper and scouring pad; the resin at the root of the joint between the insert and the insulating part is cleaned up during cleaning.
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| CN112847999A (en) * | 2021-01-07 | 2021-05-28 | 迈杰科输配电设备江苏有限公司 | Dynamic pouring process of epoxy resin basin-type insulator |
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