Method for assembling end face hardware of insulator

Abstract

This invention discloses a method for assembling end face fittings on insulators, specifically for assembling end face fittings on post insulators. The insulator is a porcelain post insulator with non-closed upper and lower end faces, each pre-installed with a cylindrical end face fitting assembly portion. The end face fitting includes an upper connecting flange and a lower connecting flange, assembled onto the upper and lower end face assembly portions of the insulator. The end face fitting features include: an assembly through hole with a first and second conical beveled portion, the opening side facing outwards, an annular connecting portion, and an adhesive flow channel; it also includes a compensation insert. The method includes preparation, pre-assembly, pressing, and adhesive injection steps to obtain a finished porcelain post insulator with the end face fittings assembled. This invention solves the problems of low assembly efficiency, unstable quality, and high assembly complexity in existing insulator end face fittings, improving assembly efficiency and quality while reducing production costs and waste for enterprises.

Description

Technical Field

[0001] This invention relates to the field of insulator assembly technology, and more particularly to a method for assembling end face fittings of insulators. Background Art

[0002] Porcelain insulators, as unique insulation control elements, play a crucial role between conductors of various potentials or between conductors and ground potential components. They are primarily used to support and fix conductors, prevent current from returning to ground, and possess the characteristics of withstanding voltage and mechanical stress. In overhead transmission lines, their high insulation strength ensures excellent insulation performance, effectively preventing current leakage and electric shock accidents. Ceramic post insulators hold a pivotal position in power systems.

[0003] Commercially available insulators come in a wide variety of types and shapes. Although the structures and shapes of different types of insulators vary considerably, they all consist of two parts: the insulating component and the end-face fittings. Porcelain insulators use ceramic insulators to increase creepage distance. To ensure that the insulators are not affected by various electromechanical stresses caused by changes in environmental and electrical load conditions, and to guarantee the service life and operational life of the entire line, the end-face fittings are responsible for fixing and connecting the insulators, ensuring their structural and connection stability and safety within the power system. During manufacturing, adhesives are used to bond the end-face fittings to both ends of the insulating component, forming a single unit and the final product.

[0004] The interface between the end face fittings and the insulating components is crucial for ensuring the parallelism and coaxiality of post insulators. Due to the diverse materials and high electric field strength at this interface, air is easily ionized, potentially inducing dendritic discharge loads. Therefore, the sealing condition of the interface has a significant impact on the performance of composite insulators. However, existing insulator end face fittings are mostly assembled using epoxy resin bonding. This method requires a large gap between the insulator and the end face fitting to facilitate epoxy resin injection, but this gap significantly affects the dimensional and positional tolerances of the assembled product. During the injection process, manual operation with simple clamps is used, resulting in a simplistic clamping structure and poor positioning stability, easily leading to voids in the gap. This will cause deviations in the coaxiality of the end face fittings and insulating components of individual products, affecting the consistency of batch products, increasing dispersion, and in severe cases, potentially leading to batch defects and scrapping, causing significant waste and losses for the enterprise. Summary of the Invention

[0005] The technical problem solved by this invention is to provide a method for assembling end face fittings of insulators, which can be used to solve the problems of low assembly efficiency, unstable quality and high assembly complexity of insulator end face fittings mentioned in the background art.

[0006] The technical problem solved by this invention is achieved by the following technical solution:

[0007] A method for assembling end face fittings on an insulator, used for assembling end face fittings on a post insulator, wherein the insulator of the post porcelain insulator is a porcelain post insulator, the upper and lower end faces of the insulator are non-closed end faces, and cylindrical end face fitting assembly parts are reserved on the upper and lower end faces of the insulator respectively.

[0008] The end face fitting includes an upper connecting flange and a lower connecting flange. The upper connecting flange is assembled at the upper end face fitting assembly position of the insulating component; the lower end face fitting assembly position of the insulating component is also assembled thereon. The end face fitting has the following structural features:

[0009] The upper connecting flange and the lower connecting flange both have a first tapered bevel and a second tapered bevel formed on their assembly through holes. The first tapered bevel is located on the back side of the insulating part insertion side, and the second tapered bevel is located on the back side of the insulating part insertion side. The opening sides of the first tapered bevel and the second tapered bevel face outward. The assembly through holes of the upper connecting flange and the lower connecting flange have an annular connecting portion between the first tapered bevel and the second tapered bevel. The annular connecting portion is attached to the glazed sand layer surface of the insulating part on its inner side, and multiple adhesive flow channels are uniformly formed on its own annular surface.

[0010] The upper connecting flange and the lower connecting flange also include a compensation insert, which is an annular structure of the same material as the upper connecting flange / lower connecting flange and matches the corresponding first conical inclined surface on the upper connecting flange / lower connecting flange;

[0011] The method specifically includes the following steps:

[0012] S1. Prepare the insulating parts and end face fittings. Confirm that the surface of the insulating parts is clean and undamaged, and that the end face fitting assembly part of the insulating parts has been formed and coated with a glazed sand layer. Confirm that the size and shape of the end face fittings match the insulating parts.

[0013] S2. Use the fixture to vertically clamp the insulating component and pre-assemble it in the vertical clamping state of the fixture. During pre-assembly, sequentially install the sealing component and the corresponding compensation insert on the side of the insulating component to be assembled. Then, use the auxiliary fixture to position the end face hardware on the end face of the insulating component to ensure that the position of the end face hardware is accurate and without deviation.

[0014] S3. Using a pressure tool, under the guidance of the inclined surface of the first cone-shaped inclined section, press the end face hardware into the corresponding end face hardware assembly position of the insulating part. Then, press the compensation insert into the first cone-shaped inclined section from the bottom and use the lower sealing part to fix the position of the compensation insert and seal the lower end assembly gap.

[0015] S4. Install a sealing element on the annular surface of the second cone-shaped inclined section. Use multiple pressure nozzles on the annular surface of the upper sealing element to apply pressure adhesive to the second cone-shaped inclined section and the gap between the end face hardware and the insulating element. After the adhesive is applied, cure and shape it to obtain the finished product of the post porcelain insulator equipped with the end face hardware.

[0016] As a further limitation, when the clamping fixture is used to vertically clamp the insulating component, the corresponding clamping fixture has multiple sets to perform multi-point clamping in the height direction of the insulating component.

[0017] When multiple clamping fixtures are used to vertically clamp and assemble the corresponding insulating parts, clamping positions are set at the lower end and at least one clamping position is set in the middle section of the insulating parts; during assembly, end face fittings are assembled at the upper end.

[0018] The clamping fixture uses a rigid clamping method to clamp and fix the insulating component.

[0019] As a further limitation, the angle between the inclined surface on the first conical inclined surface and the axis of the insulating component is 7~15°, and the height of the first conical inclined surface is 25~35% of the height of the end face hardware.

[0020] As a further limitation, the angle between the inclined surface on the second conical inclined surface and the axis of the insulating component is 45~60°; and the height of the second conical inclined surface is 5~15% of the height of the end face hardware.

[0021] As a further limitation, multiple side channels are formed on both sides of the adhesive flow channel, and the cross-sectional area of ​​a single side channel is 1 / 10 to 1 / 5 of the cross-sectional area of ​​the adhesive flow channel. The two adhesive flow channels at the two ends of the single side channel are adjacent.

[0022] As a further limitation, in order to improve the stable assembly performance of the insulating components, when assembling end face fittings on the insulating components, the upper connecting flange is assembled first, and then the lower connecting flange is assembled.

[0023] As a further limitation, the upper seal and the lower closure are fixed in position using a fixed bracket and an external structure set on the fixed bracket, and the fixed position is ensured to be firm and not loose.

[0024] Beneficial Effects: The end-face fitting assembly method for insulators of the present invention achieves efficient, stable, and precise assembly, reducing assembly costs while ensuring assembly quality and efficiency. The method employs a first conical bevel design between the insulator and the end-face fitting, allowing the end-face fitting to be more easily pressed into the end-face fitting assembly position of the insulator during assembly. This enables pressure assembly of the end-face fitting with minimal assembly gaps, ensuring coaxiality between the end-face fitting and the insulator. The second conical bevel, combined with an annular connecting portion with multiple adhesive flow channels, allows for better penetration of adhesive into all corners of the assembly gap, resulting in more uniform and thorough adhesive application and improved sealing performance of the annular connecting portion and after assembly. Furthermore, this method is applicable to various types and shapes of cylindrical support insulators, exhibiting strong versatility and flexibility. Attached Figure Description

[0025] Figure 1 This is an assembly diagram of a preferred embodiment of the present invention.

[0026] Figure 2 for Figure 1 A detailed enlarged diagram of part A in the middle.

[0027] Figure 3 This is a cross-sectional view of the end face fitting on the inner side in a preferred embodiment of the present invention.

[0028] The components are: 1. Inner hole; 2. Pressure injection seat; 3. Upper seal; 4. End face fitting; 5. Lower seal; 6. Insulating component; 7. Glazed sand layer; 8. Second cone inclined section; 9. Adhesive flow channel; 10. Compensating insert; 11. Side support channel; 12. First cone inclined section; 13. Annular connecting part. Detailed Implementation

[0029] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below with reference to specific illustrations.

[0030] In the following embodiments, those skilled in the art will understand that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have a meaning consistent with their meaning in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless defined as herein.

[0031] In this embodiment, the end face fitting assembly method for insulators is used to achieve the following: Figure 1 , Figure 2The shown pattern is used to assemble the end face fittings 4 onto the insulating component 6 on the post porcelain insulator. In this embodiment, the insulating component 6 and the end face fittings 4 are independently formed but configured as a set for easy assembly.

[0032] In this embodiment, the insulating component 6 is a typical post insulator structure made of commercially available electrical porcelain material used to manufacture porcelain insulators. It is a pre-formed ceramic sintered structure. This type of high-strength, high-density ceramic material has excellent compressive strength and wear resistance, can withstand certain end face pressure, and also has good insulation performance and chemical stability, which can ensure that the insulator operates stably in harsh environments such as high voltage and high humidity.

[0033] The insulating component 6 includes a cylindrical structure with non-closed upper and lower end faces. Multiple umbrella groups are distributed on the outer surface of the middle section of the cylindrical structure to form a specific umbrella group structure. This umbrella group structure effectively increases the creepage distance of the insulator and improves its electrical performance. The shape and size of the corresponding umbrella groups in the umbrella group structure can be designed according to actual conditions. The insulating component 6 has pre-reserved end-face hardware assembly parts at both the upper and lower ends of the cylindrical structure. These end-face hardware assembly parts are used for assembling the end-face hardware 4. The insulating component 6 has an inner hole 1 at the central axis of the cylindrical structure, which penetrates the entire insulating component 6 for installing wires or other conductive parts.

[0034] The end face fitting 4 includes an upper connecting flange mounted on the upper end face of the insulating component 6 and an upper connecting flange mounted on the lower end face of the insulating component 6. The upper connecting flange has a similar structure and assembly method to the upper connecting flange. In this embodiment, the upper connecting flange is used as the end face fitting 4 to describe the assembly method.

[0035] It is worth noting that, given that some post insulators have a tapered structure (smaller at the top and larger at the bottom) for their insulating components 6, to ensure stability during vertical clamping, we prioritize installing the upper connecting flange first to improve the stable assembly performance of the insulating components. After the upper connecting flange is installed, the lower connecting flange is then assembled after flipping the insulator, utilizing the fit between the upper connecting flange and the top of the small section.

[0036] In this embodiment, the upper connecting flange of the end face fitting 4 has a mounting through hole that matches the end face fitting assembly portion on the upper end face of the insulating member 6, allowing the end face fitting 4 to pass through the mounting through hole as follows: Figure 1 , Figure 2 The end face fitting 4 is mounted on the upper end face of the insulating component in the manner shown. The end face fitting 4 has a second tapered bevel portion 8 formed on the upper inner side of the mounting through hole, and a first tapered bevel portion 12 formed on the lower inner side of the mounting through hole. The bevel opening sides of both the first tapered bevel portion 12 and the second tapered bevel portion 8 face outward.

[0037] In this embodiment, the design of the first tapered inclined surface 12 takes into account both ease of assembly and stability. The angle between its inclined surface and the axis of the insulating component 6 is controlled between 7 and 15°. This angle is neither too large, which would cause assembly difficulties and excessive adhesive application, nor too small, which would affect assembly stability. At the same time, the height of the first tapered inclined surface is set to 25% to 35% of the height of the end face hardware. This height meets the assembly requirements without affecting the overall strength of the structure.

[0038] The design of the second conical bevel section prioritizes sealing performance. The angle between its bevel and the axis of the insulating component is 45-60°. This angle, combined with the multi-pressure injection seat 2 on the annular structure, facilitates pressurized re-injection of the adhesive, allowing for pressure-bearing filling of the gap between the end face hardware 4 and the glazed sand layer 7, forming a uniformly distributed, dense, and non-porous adhesive layer. The height of the second conical bevel section is 5-15% of the height of the end face hardware. This design ensures sufficient injection pressure while avoiding excessive thickness that could lead to localized material waste.

[0039] The end face fitting 4 uses the first conical inclined portion 12 side as the insertion side of the insulating component 6 and the second conical inclined portion 8 side as the glue injection side. At the same time, the end face fitting 4 is designed with an annular connecting portion 13 between the first conical inclined portion 12 and the second conical inclined portion 8. The inner diameter of the annular connecting portion 13 matches the end face fitting assembly portion of the insulating component, so that the assembled end face fitting 4 can abut against the surface of the glazed sand layer 7 of the insulating component 6 from the inside of the annular connecting portion 13. The annular connecting portion 13 also has multiple adhesive flow channels 9 uniformly formed on the annular surface of the inner diameter side. The adhesive flow channels 9 are blind groove structures that run vertically through the bottom. The open surface of the blind groove faces inward, so as to connect the two conical inclined portions at the top and bottom. This provides a channel for the glue injection process after the end face fitting 4 is assembled, so that the glue can flow smoothly into each part and achieve a complete seal. This ensures the stability of the structure and facilitates the subsequent glue injection operation.

[0040] In this embodiment, to further ensure the efficiency and effect of adhesive injection, the end face fitting 4 has multiple side support channels 11 formed on both sides of the adhesive flow channel 9, and their structural style is as follows: Figure 3 As shown, the cross-sectional area of ​​a single side channel 11 is 1 / 10 to 1 / 5 of the cross-sectional area of ​​the adhesive flow channel 9, and each side channel 11 is connected to two adjacent adhesive flow channels 9 at both ends. These side channels 11 can further increase the flow range of the adhesive, allowing the adhesive to better penetrate into all corners and form a more robust sealing structure. The combination of the adhesive flow channel 9 and the side channel 11 not only improves the efficiency of adhesive injection, but also ensures the uniformity and integrity of the adhesive injection, ensuring that the adhesive can be evenly distributed and form a good cross-linking structure, thereby improving the overall sealing and insulation performance of the insulator's adhesive joint.

[0041] In this embodiment, the end face fitting 4 is used in conjunction with the compensation insert 10, the upper seal 3, and the lower closure 5 during assembly, and specifically includes the following operation steps:

[0042] Step 1: First, prepare the insulating component 6 and the end face fitting 4. Ensure that the surface of the insulating component 6 is clean and undamaged. If necessary, use a cleaning agent to clean the surface. At the same time, ensure that the end face fitting assembly part of the insulating component 6 has been formed and coated with a glazed sand layer. Verify that the size and shape of the end face fitting 4 and the corresponding compensation insert 10 are consistent with the insulating component 6.

[0043] Step 2: Use tooling to vertically fix the insulating component 6. During fixing, use multiple points along the height of the insulating component 6 to ensure that it remains vertical during assembly, avoiding tilting or misalignment, thereby improving assembly accuracy and stability. During assembly, first set a clamping position at the lower end of the insulating component 6, and at least one clamping position in the middle section of the insulating component 6. Use a clamping tooling that matches the size of the corresponding clamping position of the insulating component 6 to rigidly clamp and fix the insulating component 6, and perform pre-assembly in the vertical fixed state of the tooling. During pre-assembly, sequentially put on the sealing component 5 and the corresponding compensation insert 10. Then use an auxiliary positioning tooling to position the end face hardware 4 to the upper end face of the insulating component 6 to ensure accurate positioning without deviation.

[0044] Step 3: Using a pressure tool, press the end face fitting 4 into the corresponding end face fitting assembly position on the insulating component 6. During this process, the first conical beveled part of the insulating component acts as a guide, making the assembly process smoother. Then, press the compensation insert into the gap position of the first conical beveled part 12 from below using the lower sealing part 5 to compensate for the assembly gap of the first conical beveled part 12, improving the tightness and stability of the assembly. At the same time, the lower sealing part 5 is fixed in position and closes the lower assembly gap. If necessary, use an external fixing bracket and the external structure on the bracket to fix the lower sealing part 5, ensuring stable position during assembly and glue injection, and avoiding possible errors and deviations during the assembly process.

[0045] Step 4: After the end face fitting 4 is installed, the sealing element 3 is installed on the corresponding annular surface of the upper surface of the second conical inclined part 8; at the same time, six pressure injection seats 2 are evenly arranged on the upper annular surface of the upper sealing element 3. The pressure injection seats 2 are connected to the second conical inclined part 8 on the inside, so that under the condition that the upper sealing element 3 is fixed and sealed, the gap between the second conical inclined part 8, the end face fitting 4 and the insulating element 6 can be injected with circumferential multi-point pressure through the multiple pressure injection seats 2 arranged in the ring.

[0046] Step 5: After the glue is applied, the assembly of the single-end face hardware 4 is completed. After the glue has cured, the insulation part 6 can be flipped over, and the assembly of the other end face hardware 4 can be carried out in the same way. After the insulation part 6 is completed and the two end face hardware 4 are assembled, they are cured and shaped to obtain the finished post porcelain insulator with assembled end face hardware.

[0047] The assembly method in this embodiment is simple, easy to implement, and convenient to operate. It can effectively improve the assembly accuracy and stability of the post porcelain insulator. Through the assembly method in this embodiment, the end face hardware of the post porcelain insulator can be assembled efficiently and stably, thereby improving the overall performance and reliability of the insulator.

[0048] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A method for assembling end face fittings on an insulator, used for assembling end face fittings on a post insulator, characterized in that, The insulating component of the post insulator is a porcelain post insulator. The upper and lower end faces of the insulating component are non-closed end faces. Cylindrical end face hardware assembly parts are reserved at the upper and lower end faces of the insulating component respectively. The end face fitting includes an upper connecting flange and a lower connecting flange. The upper connecting flange is assembled at the upper end face fitting assembly position of the insulating component; the lower end face fitting assembly position of the insulating component is also assembled thereon. The end face fitting has the following structural features: The upper connecting flange and the lower connecting flange both have a first tapered bevel and a second tapered bevel formed on their assembly through holes. The first tapered bevel is located on the back side of the insulating part insertion side, and the second tapered bevel is located on the back side of the insulating part insertion side. The opening sides of the first tapered bevel and the second tapered bevel face outward. The assembly through holes of the upper connecting flange and the lower connecting flange have an annular connecting portion between the first tapered bevel and the second tapered bevel. The annular connecting portion is attached to the glazed sand layer surface of the insulating part on its inner side, and multiple adhesive flow channels are uniformly formed on its own annular surface. The upper connecting flange and the lower connecting flange also include a compensation insert, which is an annular structure of the same material as the upper connecting flange / lower connecting flange and matches the corresponding first conical inclined surface on the upper connecting flange / lower connecting flange; The method specifically includes the following steps: S1. Prepare the insulating parts and end face fittings. Confirm that the surface of the insulating parts is clean and undamaged, and that the end face fitting assembly part of the insulating parts has been formed and coated with a glazed sand layer. Confirm that the size and shape of the end face fittings match the insulating parts. S2. Use the fixture to vertically clamp the insulating component and pre-assemble it in the vertical clamping state of the fixture. During pre-assembly, sequentially install the sealing component and the corresponding compensation insert on the side of the insulating component to be assembled. Then, use the auxiliary fixture to position the end face hardware on the end face of the insulating component to ensure that the position of the end face hardware is accurate and without deviation. S3. Using a pressure tool, under the guidance of the inclined surface of the first cone-shaped inclined section, press the end face hardware into the corresponding end face hardware assembly position of the insulating part. Then, press the compensation insert into the first cone-shaped inclined section from the bottom and use the lower sealing part to fix the position of the compensation insert and seal the lower end assembly gap. S4. Install a sealing element on the annular surface of the second cone-shaped inclined section. Use multiple pressure nozzles on the annular surface of the upper sealing element to apply pressure adhesive to the second cone-shaped inclined section and the gap between the end face hardware and the insulating element. After the adhesive is applied, cure and shape it to obtain the finished post insulator equipped with the end face hardware.

2. The method for assembling end face fittings of an insulator according to claim 1, characterized in that, When using the clamping fixture to vertically clamp the insulating component, the corresponding clamping fixture has multiple sets to perform multi-point clamping in the height direction of the insulating component. When multiple clamping fixtures are used to vertically clamp and assemble the corresponding insulating parts, clamping positions are set at the lower end and at least one clamping position is set in the middle section of the insulating part; during assembly, end face fittings are assembled at the upper end.

3. The method for assembling end face fittings of an insulator according to claim 2, characterized in that, The clamping fixture uses a rigid clamping method to clamp and fix the insulating component.

4. The method for assembling end face fittings of an insulator according to claim 1, characterized in that, The angle between the inclined surface on the first conical inclined surface and the axis of the insulating component is 7~15°, and the height of the first conical inclined surface is 25~35% of the height of the end face hardware.

5. The method for assembling end face fittings of an insulator according to claim 1, characterized in that, The angle between the inclined surface on the second conical inclined surface and the axis of the insulating component is 45~60°; and the height of the second conical inclined surface is 5~15% of the height of the end face hardware.

6. The method for assembling end face fittings of an insulator according to claim 1, characterized in that, Multiple side channels are formed on both sides of the adhesive flow channel. The cross-sectional area of ​​a single side channel is 1 / 10 to 1 / 5 of the cross-sectional area of ​​the adhesive flow channel. Two adhesive flow channels are adjacent at the two ends of a single side channel.

7. The method for assembling end face fittings of an insulator according to claim 1, characterized in that, To improve the stable assembly performance of the insulating components, the method involves assembling the upper connecting flange first and then assembling the lower connecting flange when assembling the end face fittings on the insulating components.

8. The method for assembling end face fittings of an insulator according to claim 1, characterized in that, The upper and lower sealing components are fixed in position using a fixed bracket and an external structure set on the fixed bracket, ensuring that the fixed position is firm and does not loosen.

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