A production method for disc-shaped porcelain or glass insulator surface molded or injection coated with high-temperature vulcanized silicone rubber

Abstract

The present invention relates to a production method for a disc-shaped porcelain or glass insulator whose surface is molded or injected with high-temperature vulcanized silicone rubber, comprising: (1) using a three-dimensional scanner to collect three-dimensional data of the appearance structure; (2) analyzing and processing the data, and determining a three-dimensional digital model of the product under the condition that the set shape and position tolerances are met and the highest qualified rate is achieved; (3) scanning the insulators one by one to obtain three-dimensional data, comparing the deviation with the three-dimensional digital model, and removing those that do not meet the set shape and position tolerances; (4) designing a mold based on the three-dimensional digital model and the required silicone rubber thickness, and selecting a molding or injection process to obtain a disc-shaped porcelain or glass insulator with a high-temperature vulcanized silicone rubber molded on the surface in one step. The method of the present invention removes insulators that do not meet the shape and position tolerance requirements, avoids production stoppage and damage to the mold caused by insulator cracking due to mismatching during the molding or injection process, improves production efficiency, reduces production costs, and achieves industrialized production of products.

Description

Technical Field

[0001] The present invention relates to the technical field of insulators for power transmission lines, and in particular to a production method for a disc-shaped porcelain or glass insulator whose surface is molded or injection-coated with high-temperature vulcanized silicone rubber. Background Art

[0002] Insulators come in a wide variety of shapes and types. While their structure and appearance vary significantly, they all consist of two main components: the insulating element and the connecting fittings. Insulators are specialized insulating components that play a vital role in overhead transmission lines. Insulators are categorized by installation method as suspension insulators and post insulators. Based on the insulating material used, they can be divided into porcelain insulators, glass insulators, and composite insulators (also known as synthetic insulators).

[0003] Porcelain and glass insulators have good mechanical properties and aging properties, but their anti-pollution flashover performance is poor. A layer of high-temperature vulcanized silicone rubber is compounded on the outside of disc-shaped porcelain and glass insulators, which not only retains the excellent mechanical properties and aging properties of porcelain and glass insulators, but also greatly improves the anti-pollution flashover performance.

[0004] For example, Chinese Patent Authorization Publication No. CN113270236 discloses a method for manufacturing a disc-shaped suspension composite insulator. The method involves applying a coupling agent to the surface of the core disc, then drying it naturally or in an oven. The product is then placed in a vulcanization mold and molded with silicone rubber sheds in one step using a molding or injection process. The main disadvantage of this solution is that the silicone rubber sheds have low mechanical strength and are prone to aging.

[0005] In addition to the above implementation methods, a layer of high-temperature vulcanized silicone rubber sheet can be pasted on the surface of the core disk of the disc-shaped porcelain or glass insulator, and room-temperature vulcanized silicone rubber can be coated on the parts that cannot be covered on the surface. Due to the non-mechanized one-time molding or injection molding, the consistency of the product and some electrical performance will be reduced.

[0006] The technical difficulty in coating the core disk of disc-shaped porcelain and glass insulators with a layer of high-temperature vulcanized silicone rubber using a molding or injection molding process lies in the individual differences in the core disk size of porcelain and glass insulators. During the production process, factors such as the production process, the environment, and external forces can lead to certain deviations between the finished porcelain and glass parts and the design drawings, and these differences vary from one individual to another. The contradiction between the individual differences in the external structure of the core disks of porcelain and glass insulators and the relatively single-sized molds is one of the issues that must be resolved. Furthermore, the core disks of porcelain and glass insulators can crack during the molding or injection molding process due to high temperature, high pressure, and drastic changes in airflow and pressure. The cracked porcelain, glass, and high-temperature vulcanized silicone rubber mix together and adhere to the mold cavity, causing production stoppages and mold damage, severely impacting production efficiency and profitability, and making industrial mass production impossible. Summary of the Invention

[0007] In response to the shortcomings of the existing technology, the present invention provides a production method for molding or injection-coating high-temperature vulcanized silicone rubber on the surface of disc-shaped porcelain or glass insulators. The composite insulators produced according to the processing method of the present invention have good product consistency, excellent electrical properties, mechanical properties and aging properties, and can be industrialized and mass-produced.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] A method for producing a disc-shaped porcelain or glass insulator by molding or injection coating the surface of a high-temperature vulcanized silicone rubber, characterized by comprising the following steps:

[0010] (1) Use a 3D scanner to collect the appearance and structure 3D data of a certain number of randomly sampled disc-shaped porcelain or glass insulators of the same model;

[0011] (2) Analyze and process all sample data, and determine the three-dimensional digital model of the product under the conditions of meeting the set geometric tolerances and having the highest pass rate;

[0012] (3) Use a 3D scanner to scan the disc-shaped porcelain or glass insulators to be coated with high-temperature vulcanized silicone rubber one by one to obtain the 3D data of their appearance structure, and compare the deviation with the 3D digital model of the product. If the measurement results can meet the set shape and position tolerances, the insulator is suitable for the next processing step, otherwise it will be discarded;

[0013] (4) The insulators that meet the requirements are processed by molding or injection technology to obtain disc-shaped porcelain or glass insulators with high-temperature vulcanized silicone rubber molded on the surface in one step.

[0014] The sample data in step (2) is analyzed and processed as follows:

[0015] ① Take the outer contour edge data of the sample core disk and easily get the disk diameter D;

[0016] ② Take the average value u of the disk diameter D of each sample;

[0017] ③ Set the outer contour edge diameter tolerance h of the core disk, and obtain samples with disk diameter D in the interval [uh,u+h] through screening;

[0018] ④ Take the three-dimensional point cloud data of all samples that satisfy the disk diameter D in the interval [uh,u+h] and calculate the average value to obtain the optimized data;

[0019] ⑤ Perform data conversion, feature extraction, and model reconstruction on the data optimized in step ④ to obtain a three-dimensional digital model of the insulator.

[0020] As described above, in the production method of a disc-shaped porcelain or glass insulator surface molded or injection coated with high-temperature vulcanized silicone rubber, in step (4), the mold required for the molding or injection process is designed based on the three-dimensional digital model and the required thickness of the coated high-temperature vulcanized silicone rubber.

[0021] The above-mentioned method for producing a disc-shaped porcelain or glass insulator surface molded or injection coated with high-temperature vulcanized silicone rubber, wherein the molding process:

[0022] a. The high-temperature vulcanized silicone rubber compound is pressurized, heated, molded, and vulcanized in a metal mold at a pressure of 5 MPa, a temperature of 120-130°C, and a time of 10-30 minutes to form a blank suitable for the shape of the inner and outer layers of the insulator core disk.

[0023] b. Place the inner and outer layer blanks of the insulator to be processed into the molding die, and then move the mold into the vulcanization molding machine.

[0024] c. Close the mold and heat it at 160℃-250℃, pressurize it for 4-8 hours to form and vulcanize it, then cool it and demould it to obtain the product.

[0025] The above-mentioned method for producing a disc-shaped porcelain or glass insulator surface molded or injection coated with high-temperature vulcanized silicone rubber, wherein the injection process:

[0026] Ⅰ. Using platinum-catalyzed insulating liquid silicone rubber material, place the insulator to be processed into the injection mold, and after the mold is closed, add liquid vulcanized silicone rubber through the mold pouring system;

[0027] Ⅱ. Keep heating at 80℃-160℃ and pressurize at 5-15MPa for 5-30 minutes to vulcanize. After cooling, demould to obtain the product.

[0028] Compared with the existing technology, the technical solution of this application has the following beneficial effects:

[0029] 1. The pioneering use of 3D scanning technology establishes a three-dimensional digital model of the same type of disc-shaped porcelain or glass insulators through sampling, scanning, analysis and calculation. The disc-shaped porcelain insulators to be coated with high-temperature vulcanized silicone rubber are then 3D scanned one by one and compared with the three-dimensional digital model. The form and position tolerances of the insulators are measured, and insulators that do not meet the processing requirements are eliminated. The above screening method solves the contradiction between the external structure of individual core discs and the relatively single-sized mold in the existing technology, and realizes a stable and reliable processing technology for the integral coating of the core disc of disc-shaped porcelain and glass insulators with high-temperature vulcanized silicone rubber, thereby realizing the industrialized mass production of disc-shaped composite insulators.

[0030] 2. Process and analyze the three-dimensional data of the collected samples to determine the three-dimensional digital model of the insulator product. Then, based on the three-dimensional digital model and the required thickness of the high-temperature vulcanized silicone rubber coating, design the mold cavity size. This allows a single-size mold to allow more insulators of the same model to enter the molding or injection process, ensuring the highest pass rate for insulators of the same model, thereby improving insulator utilization.

[0031] 3. The insulator adopts a one-time molded or injected high-temperature vulcanized silicone rubber composite layer, with good product consistency, excellent electrical properties, mechanical properties and aging properties. DETAILED DESCRIPTION

[0032] A production method for a disc-shaped porcelain or glass insulator is provided, wherein the surface of the core disc is coated with a certain thickness of high-temperature vulcanized silicone rubber, characterized by comprising the following steps:

[0033] (1) Use a 3D scanner to collect the appearance and structure 3D data of a certain number of randomly sampled disc-shaped porcelain or glass insulators of the same model;

[0034] For example, from 1,000 ordinary disc-shaped porcelain or glass insulators of the same model and the same production process, a 3D scanner is used to collect the appearance and structural 3D data of 100 randomly sampled ordinary disc-shaped porcelain or glass insulator samples of the same model (for example, height 170mm, core disk diameter 320mm).

[0035] (2) Analyze and process all sample data, and determine the three-dimensional digital model of the insulator product under the conditions of meeting the set shape and position tolerances and having the highest pass rate;

[0036] The sample data in step (2) is analyzed and processed as follows:

[0037] ① Take the outer contour edge data of the sample core disk and easily get the core disk diameter D;

[0038] ② Take the average value u of the scanning disk diameter D of each sample;

[0039] ③ Set the core disk diameter tolerance h, and through screening, obtain samples with a disk diameter D in the interval [uh, u+h]. For example, set the core disk outer contour edge diameter tolerance h to ±2mm, and through screening, obtain samples with a disk diameter D in the interval [u-2, u+2].

[0040] ④ Take the three-dimensional point cloud data of all samples that satisfy the disk diameter D in the interval [uh,u+h] and calculate the average value to obtain the optimized data;

[0041] ⑤ With the help of engineering software (Geomagic), the optimized data in step ④ is converted, features are extracted, and the model is reconstructed to obtain the three-dimensional digital model of this type of insulator.

[0042] (3) Use a 3D scanner to scan the disc-shaped porcelain or glass insulators to be coated with high-temperature vulcanized silicone rubber one by one to obtain the 3D data of their appearance structure, and compare the deviation with the 3D digital model of the product to obtain the specific deviation value. If the measurement results can meet the set shape and position tolerances, the insulator is suitable for the mold, otherwise it is rejected;

[0043] The deviation comparison is as follows:

[0044] The specific form and position deviation values ​​are compared with the set form and position tolerances. If the form and position deviation values ​​are within the set form and position tolerances, the measured results meet the set form and position tolerances, and the insulator proceeds to the next molding or injection molding process. Otherwise, the insulator is rejected and does not proceed to the next molding or injection molding process. The form and position tolerances are set tolerances and vary depending on the insulator model.

[0045] For example, for 1,000 ordinary disc-shaped porcelain or glass insulators of the same model and the same production process, a 3D scanner is used to scan each of the above insulators, and the collected 3D data is compared with the 3D digital model by a computer to obtain the deviation chromatogram and specific deviation values.

[0046] In this embodiment, the 3D scanner utilizes an existing 3D laser scanner. The 3D laser scanner system utilizes a reverse positioning scanning mode, resulting in high system accuracy. This helps improve the accuracy of virtual comparisons and effectively safeguards subsequent molding or injection molding. The 3D laser scanner is a necessary means for data collection; its specific design is not the focus of this application's technical innovation. The selection of a 3D laser scanner does not affect the scope of protection of this application.

[0047] (4) Design the mold required for the molding or injection process based on the three-dimensional digital model of the insulator product and the required thickness of the high-temperature vulcanized silicone rubber coating; use the molding or injection process to process the insulator that meets the requirements to obtain a disc-shaped porcelain or glass insulator with a high-temperature vulcanized silicone rubber molded on the surface in one step.

[0048] In this application, the molding or injection process uses existing technologies (e.g., Chinese patents CN203406100, CN103943288, and CN113270236). Molding or injection is necessary to achieve the coating of high-temperature vulcanized silicone rubber, but it is not the focus of the technical innovation of this application. The molding or injection process does not affect the scope of protection of this application.

[0049] Molding or injection molding process description:

[0050] Molding process:

[0051] a. The high-temperature vulcanized silicone rubber compound is pressurized, heated, molded, and vulcanized in a metal mold at a pressure of 5 MPa, a temperature of 120-130°C, and a time of 10-30 minutes to form a blank suitable for the shape of the inner and outer layers of the insulator core disk.

[0052] b. Place the inner and outer layer blanks of the insulator to be processed into the molding die, and then move the mold into the vulcanization molding machine.

[0053] c. Close the mold and heat it at 160℃-250℃, pressurize it for 4-8 hours to form and vulcanize it, then cool it and demould it to obtain the product.

[0054] Injection process:

[0055] Ⅰ. Using platinum-catalyzed insulating liquid silicone rubber material, place the insulator to be processed into the injection mold, and after the mold is closed, add liquid vulcanized silicone rubber through the mold pouring system;

[0056] Ⅱ. Keep heating at 80℃-160℃ and pressurize at 5-15MPa for 5-30 minutes to vulcanize. After cooling, demould to obtain the product.

[0057] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A method for producing a disc-shaped porcelain or glass insulator surface molded or injection coated with high-temperature vulcanized silicone rubber, characterized in that The steps include: (1) Use a 3D scanner to collect the appearance and structure 3D data of a certain number of randomly sampled disc-shaped porcelain or glass insulators of the same model; (2) Analyze and process all sample data, and determine the three-dimensional digital model of the product under the conditions of meeting the set geometric tolerances and having the highest pass rate; (3) Use a 3D scanner to scan the disc-shaped porcelain or glass insulators to be coated with high-temperature vulcanized silicone rubber one by one to obtain the 3D data of their appearance structure, and compare the deviation with the 3D digital model of the product. If the measurement results can meet the set shape and position tolerances, the insulator is suitable for the next process, otherwise it is discarded; (4) Processing the insulators that meet the requirements by molding or injection molding to obtain disc-shaped porcelain or glass insulators with high-temperature vulcanized silicone rubber molded on the surface in one step; The sample data in step (2) is analyzed and processed as follows: ① Take the outer contour edge data of the sample core disk and obtain the disk diameter D; ② Take the average value u of the disk diameter D of each sample; ③ Set the outer contour edge diameter tolerance h of the core disk, and obtain samples with disk diameter D in the interval [uh,u+h] through screening; ④ Take the three-dimensional point cloud data of all samples that satisfy the disk diameter D in the interval [uh,u+h] and calculate the average value to obtain the optimized data; ⑤ Perform data conversion, feature extraction, and model reconstruction on the data optimized in step ④ to obtain a three-dimensional digital model of the insulator; In step (4), the mold required for the molding or injection process is designed based on the three-dimensional digital model and the required thickness of the coated high-temperature vulcanized silicone rubber.

2. The method for producing a disc-shaped porcelain or glass insulator by molding or injection coating the surface with high-temperature vulcanized silicone rubber according to claim 1, characterized in that: The molding process: a. Pressurize and heat the high-temperature vulcanized silicone rubber mixture in a metal mold to form and vulcanize it at a pressure of 5 MPa and a temperature of 120-130°C for 10-30 minutes to form a blank suitable for the shape of the inner and outer layers of the insulator core disk; b. Place the inner and outer layers of the insulator to be processed into a molding die, and then move the mold into a vulcanizing molding machine; c. Close the mold and heat it at 160℃-250℃, pressurize it for 4-8 hours to form and vulcanize it, then cool it and demould it to obtain the product.

3. The method for producing a disc-shaped porcelain or glass insulator by molding or injection coating the surface with high-temperature vulcanized silicone rubber according to claim 1, characterized in that: The injection process: Ⅰ. Using platinum-catalyzed insulating liquid silicone rubber material, place the insulator to be processed into the injection mold, and after the mold is closed, add liquid vulcanized silicone rubber through the mold pouring system; Ⅱ. Keep heating at 80℃-160℃ and pressurize at 5-15MPa for 5-30 minutes to vulcanize. After cooling, demould to obtain the product.