Method for manufacturing alumina insulator resistant to 300kV direct current voltage

Abstract

The invention provides a method for manufacturing an aluminum oxide insulator resistant to 300kV direct-current voltage. The method comprises the following steps: step S1, performing isostatic pressing to form a cylindrical ceramic green body; s2, processing the shape of the green material, and turning an umbrella skirt; s3, sintering the processed green body material into ceramic to form a cooked body; s4, the size of the cooked blank is subjected to finish machining, upper and lower connecting end faces and hole sites are machined, and a ceramic insulation column is formed; s5, a metal top plate and a metal bottom corner are machined; s6, a metal top plate and a metal bottom corner are assembled at the upper end and the lower end of the ceramic insulation column respectively; and S7, spraying an insulating layer on the surface of the ceramic insulating column. By adopting the ceramic green body made of high-purity aluminum oxide, the whole ceramic insulation column is integrally sintered and formed, the bearing effect is better, the insulation performance is better, the total height design size is reduced, the bearing requirement is met, and meanwhile the machining and assembling cost is saved.

Description

Technical Field

[0001] The present invention relates to the technical field of insulators, and specifically, to a method for manufacturing an alumina insulator resistant to 300 kV DC voltage. Background Art

[0002] In the semiconductor manufacturing process, various production equipment is used. In the ion implantation equipment, the insulator serves as the supporting corner of the equipment. Due to conditions such as space, height, and withstand voltage of 300 kV DC voltage, and a load-bearing limit of one ton, the commonly used porcelain insulators cannot meet the requirements.

[0003] In the production of traditional porcelain insulators, the materials used are ceramics and glass. Ceramic insulators are made of raw materials such as clay, feldspar, and quartz, and have good insulation performance and mechanical strength. They can withstand harsh weather and environmental pollution and are widely used in high-voltage and extra-high-voltage transmission lines. Glass insulators are made of toughened glass, with a smooth surface and good self-cleaning properties. They can maintain good insulation performance in a polluted environment, and their characteristic of zero-value self-explosion facilitates the timely discovery of problems by operation and maintenance personnel, and they are also widely used in transmission lines.

[0004] In order to meet the requirements, traditional porcelain insulators need to be made very tall. Usually, the height of porcelain post insulators under a voltage level of 300 kV is between 2.2 meters and 2.8 meters. Large vertical lathes are required, the processing is complex, large sintering furnaces are needed, and the input cost is high. Moreover, the height is too high for transportation, the transportation cost increases, the assembly difficulty is large, and it is difficult to ensure the flatness of the upper and lower metal planes at a height between 2.2 meters and 2.8 meters. As the supporting corner of the equipment in the ion implantation equipment, the installation space cannot be given between 2.2 meters and 2.8 meters, which affects the overall height of the entire equipment.

[0005] The existing Chinese patent with the publication number CN110718343B discloses an alumina ceramic core rod composite insulator, including an alumina ceramic core rod and a skirt outer sleeve wrapped around the outside of the alumina ceramic core rod. The alumina ceramic core rod is cylindrical, and at least one groove is provided on the side surface of the alumina ceramic core rod; a reinforcing part is provided on the outer side wall of the alumina ceramic core rod; the reinforcing part includes grooves or protrusions, and the grooves or protrusions form a grid-like area on the outer surface of the alumina ceramic core rod; a number of triangular positioning blocks are arranged disorderly on the grid-like area. However, this patent still does not solve the problems existing in traditional insulators.

[0006] Therefore, a method for manufacturing an alumina insulator resistant to 300 kV DC voltage is needed, which can reduce the overall height while meeting various requirements, and can simplify the processes of manufacturing, processing, and assembly, thereby reducing costs. Summary of the Invention

[0007] Aiming at the defects in the prior art, the purpose of the present invention is to provide a manufacturing method for alumina insulators resistant to 300 kV DC voltage.

[0008] A manufacturing method for alumina insulators resistant to 300 kV DC voltage provided by the present invention includes the following steps:

[0009] Step S1, isostatically pressing a cylindrical ceramic green body;

[0010] Step S2, machining the outer shape of the green body and turning out the umbrella skirts;

[0011] Step S3, sintering the machined green body into porcelain to form a fired body;

[0012] Step S4, finely machining the dimensions of the fired body and machining out the upper and lower connection end faces and hole positions to form a ceramic insulating column;

[0013] Step S5, machining out a metal top plate and metal bottom corners;

[0014] Step S6, respectively assembling the metal top plate and metal bottom corners at the upper and lower ends of the ceramic insulating column;

[0015] Step S7, spraying an insulating layer on the surface of the ceramic insulating column.

[0016] Preferably, in step S1, the material of the ceramic green body is alumina ceramic powder with a purity of 95%. It is loaded into an isostatic pressing mold, vibrated and compacted by ultrasonic vibration, and then the green body is pressed out in the isostatic pressing mold.

[0017] Preferably, in step S1, the height of the green body is between 650 - 710 mm.

[0018] Preferably, in step S2, on an upright lathe, the lower end of the green body is clamped by a chuck, and the outer shape is turned according to the numerical control program, leaving allowances at the upper and lower ends. The number of umbrella skirts is 10 - 15, the umbrella skirts are arranged equidistantly in the vertical direction, the diameter range of the umbrella skirts is 270 - 332.2 mm, and the umbrella angle is 8 - 10 degrees.

[0019] Preferably, in step S3, the machined green body is fixed by a tooling and placed in a kiln for heating, heat preservation, and cooling, and sintered into porcelain in a high-temperature kiln at 1700 degrees.

[0020] Preferably, in step S4, after the green body is sintered into a fired body, it is finely machined. The upper step and plane of the ceramic insulating column are finely machined, the lower step large plane of the ceramic insulating column is finely machined, the outer circle of the ceramic insulating column is finely machined, and then the installation positions and screw hole positions matching the metal top plate and metal bottom corners are machined.

[0021] Preferably, in step S5, the installation positions and screw hole positions matching the ceramic insulating column are further machined on the metal top plate and metal bottom corners.

[0022] Preferably, in step S6, before assembly, measure whether the total height meets the requirements and record it with a dial indicator.

[0023] Preferably, in step S6, apply glue to the prepared metal top plate and paste it on the upper step of the ceramic insulating column. Apply glue to the metal bottom corners and bond them to the lower steps of the ceramic insulating column. When bonding, use a dial indicator to ensure that the flatness of the upper and lower metal surfaces is within 0.1.

[0024] Preferably, in step S7, spraying the insulating layer includes applying insulating paint or glazing.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] By using the ceramic green body made of high-purity alumina, the whole ceramic insulating column is integrally sintered and formed, avoiding segmented bonding, with better load-bearing effect and insulation performance, reducing the designed size of the total height, meeting the load-bearing requirements while saving machining and assembly costs; by changing the number and diameter of the umbrella skirts, various production requirements can be met, and the design theory that cannot be achieved by common electric porcelain insulators can be reached. While meeting various indicators, the overall height is reduced, and the production, processing, and assembly processes can be simplified, thereby reducing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] By reading the detailed description of the non-restrictive embodiments with reference to the following drawings, other features, objects, and advantages of the present invention will become more apparent:

[0028] Figure 1 It is a schematic structural diagram mainly showing the cylindrical ceramic green body of the present invention;

[0029] Figure 2 It is a schematic structural diagram mainly showing the ceramic insulating column of the present invention;

[0030] Figure 3 It is a schematic structural diagram mainly showing the metal top plate and the metal bottom corners of the present invention;

[0031] Figure 4 It is a schematic structural diagram mainly showing the 300 kV DC voltage-resistant alumina insulator of the present invention.

[0032] As shown in the figure:

[0033] Green body 1 Umbrella skirt 2 Ceramic insulating column 3

[0034] Metal top plate 4 Metal bottom corner 5 DETAILED DESCRIPTION OF THE EMBODIMENTS

[0035] The present invention will be described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but do not limit the present invention in any form. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several changes and improvements can still be made. These all belong to the protection scope of the present invention.

[0036] As Figures 1-4 shown, a method for manufacturing an alumina insulator resistant to 300 kV DC voltage according to the present invention includes the following steps:

[0037] Step S1, isostatically press a cylindrical ceramic green blank 1;

[0038] Step S2, machine the outer shape of the green blank 1 to turn out the umbrella skirts 2;

[0039] Step S3, sinter the machined green blank 1 into porcelain to form a fired blank;

[0040] Step S4, finely machine the dimensions of the fired blank and machine the upper and lower connecting end faces and hole positions to form a ceramic insulating column 3;

[0041] Step S5, machine out a metal top plate 4 and metal bottom corners 5;

[0042] Step S6, respectively assemble the metal top plate 4 and metal bottom corners 5 at the upper and lower ends of the ceramic insulating column 3;

[0043] Step S7, spray an insulating layer on the surface of the ceramic insulating column 3.

[0044] In step S1, the material of the ceramic green blank 1 is 95% pure alumina ceramic powder. It is loaded into an isostatic pressing mold, vibrated and compacted by ultrasonic vibration, and then the green blank 1 is pressed out in the isostatic pressing mold.

[0045] In step S1, 95% high-purity alumina ceramic powder is loaded into an isostatic pressing mold, vibrated and compacted by ultrasonic vibration, and then the green blank 1 is pressed out in the isostatic pressing mold. The height of the green blank 1 is between 650 - 710 mm, and the height of the finally formed product is greatly reduced. For example, a ceramic green blank 1 with a diameter of 409 mm and a height of 810 MM can be isostatically pressed.

[0046] In step S2, machine the outer shape of the green blank 1 obtained from the previous process. Use an upright lathe, clamp and fasten the lower end of the green blank 1 with a chuck, machine the outer shape according to the numerical control program, leave allowances at the upper and lower ends. The number of umbrella skirts 2 is 10 - 15, the umbrella skirts 2 are arranged equidistantly in the vertical direction, the diameter range of the umbrella skirts 2 is 270 - 332.2 mm, and the umbrella angle is 8 - 10 degrees.

[0047] In step S3, the processed green blank 1 is fixed by a tooling and placed in a kiln. After heating up, holding the temperature, and cooling down, it is sintered into porcelain under a high temperature of 1700 degrees in the kiln.

[0048] In step S4, after the green blank is sintered into a mature blank, finish machining is carried out. The upper step and plane of the ceramic insulating column 3 are finish machined, the lower step large plane of the ceramic insulating column 3 is finish machined, the outer circle of the ceramic insulating column 3 is finish machined, and then the installation positions and screw hole positions matching the metal top plate 4 and the metal bottom angle 5 are machined.

[0049] In step S5, a horizontal lathe and a machining center are used in cooperation for machining, and the installation positions and screw hole positions matching the ceramic insulating column 3 are further machined on the metal top plate 4 and the metal bottom angle 5.

[0050] In step S6, before assembly, first measure whether the total height meets the requirements and record it with a dial indicator.

[0051] In step S6, the prepared metal top plate 4 is coated with glue and pasted on the upper step of the ceramic insulating column 3. The metal bottom angle 5 is coated with glue and bonded to the lower step of the ceramic insulating column 3. When bonding, it is necessary to use a dial indicator to ensure that the flatness of the upper and lower metal surfaces is within 0.1.

[0052] In step S7, the metal is protected, and the surface of the ceramic is sprayed with insulating paint to increase the withstand voltage characteristics. The sprayed insulating layer includes applying insulating paint or glazing to achieve the characteristic of withstanding a DC voltage of 300 kV.

[0053] The ceramic material of this application is 95% pure alumina. The entire ceramic insulating column 3 is integrally sintered and formed, avoiding segmented bonding. It has a better load-bearing effect, can achieve a design effect of bearing 1 ton, and also saves machining and assembly costs. Further, because it is integrally sintered and formed of ceramic, it does not require segmented connection, does not require pasting, and there is no pasting glue. It is all made of high-temperature-resistant ceramic material. Alumina is sintered into porcelain at a high temperature of 1700 °C. Its withstand voltage performance is better than that of traditional ceramics made of raw materials such as clay, feldspar, and quartz, and its insulation performance is better, reducing the design size of the total height.

[0054] This application can meet various production requirements by changing the number of petticoats and the diameter of the petticoats, and can achieve a design theoretical withstand DC high voltage of 300 kV and a 1-ton load-bearing test that cannot be achieved by common electric porcelain insulators.

[0055] In the description of the present application, it should be understood that the orientation or positional relationship indicated by the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present application.

[0056] The specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Without conflict, the embodiments of the present application and the features in the embodiments can be combined with each other arbitrarily.

Claims

1. A method for manufacturing an alumina insulator capable of withstanding 300 kV DC voltage, characterized in that: The following steps are involved: Step S1, isostatically pressing a cylindrical ceramic green body (1); Step S2, processing the green material (1) to shape and machine out the shed (2); Step S3, sintering the processed green material (1) into porcelain to form a finished product; Step S4, fine-machining the size of the blank, and machining the upper and lower connecting end faces and holes to form a ceramic insulating column (3); Step S5, processing the metal top plate (4) and the metal bottom corner (5); Step S6, assembling the metal top plate (4) and the metal bottom corner (5) at the upper and lower ends of the ceramic insulating column (3) respectively; Step S7, spraying an insulating layer on the surface of the ceramic insulating column (3).

2. The method for manufacturing an alumina insulator capable of withstanding 300 kV DC voltage according to claim 1, characterized in that: In the step S1, the material of the ceramic green body (1) is alumina ceramic powder with a purity of 95%, which is placed in an isostatic pressing mold, compacted by ultrasonic vibration, and then the green body (1) is pressed in the isostatic pressing mold.

3. The method for manufacturing an alumina insulator capable of withstanding 300 kV DC voltage according to claim 1, characterized in that: In the step S1, the height of the green material (1) is between 650-710 mm.

4. The method for manufacturing alumina insulators capable of withstanding 300 kV DC voltage according to claim 1, characterized in that: In the step S2, a vertical lathe is used to clamp the lower end of the green material (1) with a chuck, and the shape is machined according to a numerical control program, leaving margins at the upper and lower ends. The number of sheds (2) is 10-15, and the sheds (2) are arranged equidistantly in the vertical direction. The diameter range of the sheds (2) is 270-332.2 mm, and the shed angle is 8-10 degrees.

5. The method for manufacturing alumina insulators capable of withstanding 300 kV DC voltage according to claim 1, characterized in that: In the step S3, the processed green material (1) is fixed in a kiln by a tool and subjected to heating, heat preservation and cooling, and is sintered into porcelain in a kiln at a high temperature of 1700 degrees.

6. The method for manufacturing alumina insulators capable of withstanding 300 kV DC voltage according to claim 1, characterized in that: In the step S4, the green body is sintered to form a cooked body and then finely processed. The upper step and plane of the ceramic insulating column (3) are finely processed, the large plane of the lower step of the ceramic insulating column (3) is finely processed, the outer circle of the ceramic insulating column (3) is finely processed, and then the mounting position and screw hole positions matching the metal top plate (4) and the metal bottom angle (5) are processed.

7. The method for manufacturing alumina insulators capable of withstanding 300 kV DC voltage according to claim 1, characterized in that: In the step S5, mounting positions and screw holes matching the ceramic insulating columns (3) are further processed on the metal top plate (4) and the metal bottom corners (5).

8. The method for manufacturing alumina insulators capable of withstanding 300 kV DC voltage according to claim 1, characterized in that: In step S6, before assembly, the total height is measured to see whether it meets the requirements, and recorded on a meter.

9. The method for manufacturing alumina insulators capable of withstanding 300 kV DC voltage according to claim 1, characterized in that: In step S6, the prepared metal top plate (4) is coated with glue and pasted on the upper step of the ceramic insulating column (3), and the metal bottom corner (5) is coated with glue and bonded to the lower step of the ceramic insulating column (3). During bonding, it is necessary to check to ensure that the flatness of the upper and lower metals is within 0.

1.

10. The method for manufacturing alumina insulators capable of withstanding 300 kV DC voltage according to claim 1, characterized in that: In the step S7, spraying the insulating layer includes applying insulating paint or glazing.

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