Forming and tempering production process of disc-shaped suspension type glass insulator

Abstract

The invention discloses a forming and tempering production process of a disc-shaped suspension type glass insulator, and relates to the technical field of glass insulator manufacturing, and the forming and tempering production process comprises the following steps: step S1, preparing materials; s2, high-temperature melting is carried out; s3, preliminary forming is carried out; s4, temperature equalization treatment; step S5: carrying out toughening treatment; s6, stress detection; step S7, fitting installation; the temperature difference gradient between the surface and the interior of the insulator is reduced, the surface compressive stress distribution uniformity is improved, the impact resistance is improved, and the risk of internal cracks is reduced.

Description

Technical Field

[0001] This invention relates to the field of glass insulator manufacturing technology, specifically to the molding and tempering production process of disc suspension glass insulators. Background Technology

[0002] Disc-type suspension glass insulators are core components of transmission lines, and their performance directly affects the safety of power grid operation.

[0003] In the traditional tempering process, due to the low heat transfer coefficient of the cooling medium and the uneven curved surface of the insulator, the temperature gradient between the surface and the interior of the insulator is too large, the surface compressive stress distribution is uneven, the compressive stress layer depth is small, the impact resistance is insufficient, and local thermal stress is easily generated, increasing the risk of internal cracks. Summary of the Invention

[0004] The purpose of this invention is to provide a molding and tempering process for disc suspension glass insulators, so as to reduce the temperature gradient between the surface and the interior of the insulator, improve the uniformity of surface compressive stress distribution, improve impact resistance, and reduce the risk of internal cracks.

[0005] The optimized structure of the present invention is achieved through the following technical solution: The molding and tempering production process of the disc-shaped suspension glass insulator includes the following steps: Step S1: Ingredient preparation; A small amount of clarifying agent and fluxing agent are added to high-purity quartz sand, soda ash, and limestone, and then mixed evenly through a precise batching system. Step S2: High-temperature melting; The raw materials are put into a horseshoe flame furnace or an electric melting furnace and melted into a uniform glass liquid at a high temperature of 1480~1550℃. Impurities are discharged through the liquid flow hole and the flow rate of the glass liquid is controlled to ensure the uniformity of composition. Step S3: Preliminary Forming: A high-precision electronic servo feeder is used to cut the molten glass into regular droplets by a robotic arm, which then fall into the forming mold for preliminary forming. Step S4: Temperature equalization treatment; The formed glass parts are placed in a homogenizing furnace and held at 670~780℃ for 2 minutes; Step S5: Tempering treatment; After being uniformly heated, the insulators are transferred to a tempering station for tempering treatment, which forms a compressive stress layer on the surface and a tensile stress layer inside. Step S6: Stress detection; The compressive stress value and stress layer depth of the insulator surface were tested using measuring instruments to determine whether they met the production standards. Step S7: Install hardware: Install fittings on insulators that meet production standards.

[0006] In some embodiments, step S3 includes the following steps: Step S31: One-time molding; The material drips into the lower mold, and the upper mold presses down quickly to initially form the insulator head and skirt, ensuring the accuracy of the umbrella ribs and internal thread structure; Step S32: Secondary trimming; The local temperature of the insulator is controlled, and a fine-tuning mold adapted to the shape of the insulator is used to correct edge defects and optimize the skirt curvature.

[0007] In some embodiments, in step S4, the uniform heating furnace adopts segmented heating control, with the first segment holding the temperature for 1 minute at a temperature of 700~780℃, and the second segment holding the temperature for 1 minute at a temperature of 670~700℃.

[0008] In some embodiments, a heating gun is provided between step S3 and step S4, which can heat the insulator to 700~780°C.

[0009] In some embodiments, step S5 includes the following steps: Step S51: High-temperature heating; The insulators, after being heated to uniform temperature, are subjected to a heat treatment to reach a high temperature of 1100-1300℃. Step S52: Rapid cooling treatment; Rapid cooling treatment is applied to high-temperature insulators; Step S53: Slow cooling treatment; The insulators that have been rapidly cooled are subjected to a slow cooling treatment.

[0010] In some embodiments, in step S52, an annular circulating conveyor frame is used. The conveyor frame is provided with rotatable claws, and high-temperature insulators are provided on the claws. The top of the conveyor frame is provided with multiple upper spray heads, which spray mist-like coolant onto the top surface of the high-temperature insulators on the claws. The bottom of the conveyor frame is provided with multiple lower spray heads, which spray mist-like coolant onto the bottom surface of the high-temperature insulators on the claws.

[0011] In some embodiments, the conveyor frame is further provided with a transverse air outlet, the air blowing direction of the transverse air outlet is the same as the movement direction of the high-temperature insulator, and the air blowing range of the transverse air outlet covers the height of the high-temperature insulator.

[0012] In some embodiments, in step S53, a conveyor network is used to slowly cool the insulators after rapid cooling. The conveyor network can realize V-shaped transportation of the insulators. A cooling pool is provided in the middle of the conveyor network, and a slow cooling liquid is provided in the cooling pool. A nozzle is provided at the inlet of the cooling pool. The nozzle is located at the bottom of the conveyor network, and the spraying direction of the nozzle is perpendicular to the conveying direction of the conveyor network.

[0013] In some embodiments, in step S53, a ventilation assembly is provided in the cooling pool, and the exhaust port of the ventilation assembly is located on the inner walls on both sides of the cooling pool.

[0014] In some embodiments, step S8 is also included: maintenance; After the insulators are fitted with hardware, they are transferred to a constant temperature and humidity curing chamber for curing. The temperature in the curing chamber is controlled at 20-25℃, and the humidity is maintained at 60%-70%. The environment of the curing chamber is monitored in real time by temperature and humidity sensors and automatically adjusted.

[0015] The above-described technical solutions in the embodiments of the present invention have at least the following technical effects or advantages: This invention optimizes the molding and tempering process, reduces stress concentration, lowers the temperature gradient between the surface and interior of the insulator, improves the uniformity of surface compressive stress distribution, enhances impact resistance, reduces the risk of internal cracks, eliminates edge defects, reduces residual stress, lowers the spontaneous explosion rate, improves product qualification rate, and reduces raw material waste and rework costs. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the process of the present invention. Detailed Implementation

[0018] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0019] In the description of this invention, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0020] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0021] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0022] refer to Figure 1 The molding and tempering process of disc suspension glass insulators includes the following steps: Step S1: Ingredients Quartz sand with a purity ≥99.5%, soda ash with a purity ≥99%, and limestone with a purity ≥98% can be used as the main raw materials. A small amount of clarifying agent and fluxing agent are added. The clarifying agent can be sodium sulfate (Na2SO4), added at 0.5%-1% of the total raw material mass; the fluxing agent can be boric acid (H3BO3), added at 1%-2% of the total raw material mass. The raw materials are added to the storage silo of the precision batching system according to the specified proportions. A loss-in-weight weighing scale weighs each raw material sequentially with an accuracy of ±0.3% according to the preset formula. The weighed raw materials enter a dynamic mixing device, where they are three-dimensionally stirred by blades rotating at 1500-2000 r / min for 3-5 minutes to achieve a mixing uniformity of over 99%. The mixed raw materials are then transported to the kiln feed inlet through a conveying pipeline. The precision batching system ensures a high-precision ratio of raw materials, providing a stable foundation for subsequent melting.

[0023] Step S2: High-temperature melting Raw materials are fed into a horseshoe-flame furnace or an electric melting furnace and melted into a homogeneous molten glass at a high temperature of 1480-1550℃. A horseshoe-flame furnace can be used for melting, equipped with temperature sensors and flow control valves. Temperature is monitored in real time by temperature sensors distributed at different locations within the furnace. The flow control valve, based on the required discharge rate of the molten glass (15-25 kg / min), uses a PID control algorithm to adjust the burner power and the opening size of the flow channel in real time, stabilizing the discharge rate of the molten glass at 15-25 kg / min and controlling temperature fluctuations within ±10℃. This ensures the uniformity of the molten glass composition and its fluidity, reduces the generation of impurities and bubbles, and provides high-quality raw materials for the forming process. After the raw materials enter the furnace, they gradually melt into molten glass at high temperatures. The melting time is 4-6 hours, during which impurities and air bubbles are discharged from the molten glass through the flow channel. Once the molten glass reaches a uniform state free of obvious impurities, it flows through the flow channel into the subsequent forming process.

[0024] Step S3: Initial shaping A high-precision electronic servo feeder is used to cut molten glass into regular droplets by a robotic arm, which then fall into the molding die to achieve the initial forming of the insulator.

[0025] Specifically, it includes the following steps: Step S31: One-time molding The high-precision electronic servo feeder's robotic arm cuts molten glass into regular droplets with a movement accuracy of ±0.1mm, with a weight error controlled within ±1%. The droplets fall into the lower mold, where the upper mold rapidly presses down at a speed of 80-120mm / s, applying a pressure of 5-8MPa for 2-3 seconds, thus initially shaping the insulator head and skirt. The mold can be manufactured using precision machining technology to ensure that the accuracy of complex structures such as umbrella ribs and internal threads reaches ±0.1mm.

[0026] Step S32: Secondary trimming After one-time molding, the insulator moves to the finishing station along with the mold. Heating wires on the mold surface provide localized temperature control of the insulator, with a temperature adjustment range of ±10℃. Simultaneously, a fine-tuning mold adapted to the insulator's shape is used to precisely finish the insulator's edges. A mechanical fine-tuning device adjusts the curvature of the sheds, eliminating sharp edges and unevenness. A heated threaded rod ensures the precision of the insulator's internal threads, achieving a surface smoothness of Ra≤0.8μm, reducing the risk of stress concentration during subsequent tempering. Precise edge processing using the fine-tuning mold eliminates stress concentration points caused by one-time molding, improving the insulator's mechanical properties.

[0027] Step S4: Temperature equalization treatment After molding, the glass insulators are conveyed into a uniform heating furnace, which employs segmented heating control. The first segment involves holding the insulator at 700-780℃ for 1 minute, ensuring a uniform temperature rise and eliminating surface stress. The second segment involves holding the insulator at 670-700℃ for 1 minute, further eliminating internal thermal stress and improving the uniformity of the internal structure. A heating gun is installed between steps S3 and S4 to rapidly heat the insulator to 700-780℃, ensuring uniform temperature before entering the furnace, reducing internal thermal stress, and minimizing the temperature difference between the insulator and the furnace, thus ensuring effective temperature uniformity. Step S5: Tempering After being homogenized, the insulators are transferred to the tempering station for tempering treatment to improve their strength.

[0028] Specifically, it includes the following steps: Step S51: High-temperature heating: After being uniformly heated, the insulators are conveyed into a tunnel-type heating furnace. The furnace is divided into multiple heating zones, with different heating temperatures and times set according to the thickness and shape of different parts of the insulator. For example, the heating temperature for the insulator head is set to 1300℃ for 5 minutes, while the heating temperature for the skirt section is set to 1100℃ for 3 minutes. This ensures that the entire insulator is uniformly heated to 1100-1300℃. Step S52: Rapid cooling treatment: A circular conveyor system can be used to transfer heated insulators to the system, where they move in a circular motion. The conveyor system is equipped with rotatable claws to hold the high-temperature insulators in place. These claws can rotate at a speed of 0.5-1 r / s to ensure uniform cooling of the insulator surface. Multiple upper spray nozzles are located at the top of the conveyor system, and multiple lower spray nozzles are located at the bottom, simultaneously spraying a mist of coolant onto the top and bottom surfaces of the insulators. The coolant can be a mixture of deionized water and ethylene glycol (volume ratio 7:3), with a spray pressure of 0.3-0.5 MPa and droplet size controlled at 50-100 μm. The conveyor system also features transverse air vents, with the airflow direction matching the movement direction of the high-temperature insulators and covering their entire height. The airflow speed is 10-15 m / s, accelerating surface heat dissipation and achieving uniform and rapid cooling of the insulator surface, forming a surface compressive stress layer. The rapid cooling time can be controlled within 30-60 seconds, causing the surface temperature of the insulator to drop rapidly and forming a surface compressive stress layer.

[0029] During the rapid cooling process, the mist-like coolant comes into contact with the high-temperature insulator surface. Through forced convection and coolant evaporation, a large amount of heat is carried away, achieving rapid cooling. The transverse air vents further enhance air convection heat transfer, ensuring a uniform temperature drop on the insulator surface. By controlling the coolant spray pressure, droplet size, and airflow velocity, the cooling rate can be precisely controlled, resulting in a uniform compressive stress layer on the insulator surface.

[0030] Step S53: Slow cooling treatment: After rapid cooling, the insulators enter the slow cooling stage via a conveyor network that allows for V-shaped transport. A cooling pool is located in the middle of the conveyor network, containing a slow-cooling liquid (with the same composition as the standard coolant). The temperature of the slow-cooling liquid in the cooling pool is maintained at 20-30℃. Through contact between the insulators and the slow-cooling liquid, the residual stress inside the insulators after rapid cooling is slowly released. Sprayers are installed at the inlet of the cooling pool, located at the bottom of the conveyor network, with the spray direction perpendicular to the transport direction. The spray speed can be 0.2-0.3 m / s. The spray from the nozzles fills the gaps in the insulators when they come into contact with the slow-cooling liquid, achieving complete coverage of the portion entering the cooling pool. This ensures uniform cooling of the insulators, preventing internal stress differences caused by uneven cooling and improving the mechanical strength and stability of the insulators.

[0031] A ventilation system can be installed inside the cooling pool. The exhaust ports of the ventilation system are located on the inner walls on both sides of the cooling pool, allowing compressed air (pressure 0.1 - 0.2 MPa) to be blown into the cooling pool. This creates slight fluctuations in the cooling liquid within the pool, promoting a uniform decrease in the surface temperature of the insulators, effectively releasing and reducing residual stress inside the insulators. Simultaneously, the introduced compressed air exchanges heat with the cooling liquid, achieving uniform heat exchange between the cooling liquid and the external environment, thus improving the cooling efficiency of the cooling liquid.

[0032] In some embodiments, thermal shock is also included, whereby the tempered insulator is immediately subjected to thermal and cold shocks to simulate performance under extreme conditions, eliminating products with internal inclusions or poor tempering. High-temperature (approximately 600°C) heat treatment can cause potential NiS impurities in the insulator to expand and spontaneously burst prematurely, thereby reducing the spontaneous breakage rate during operation and improving the quality of tempered glass insulators.

[0033] Step S6: Stress Testing The tempered insulators are tested using a critical angle polarizer or a surface stress meter.

[0034] Place the insulator on the worktable of the testing instrument, adjust the instrument parameters, and ensure that the light is incident perpendicularly onto it. Insulator surface. By analyzing the interference fringes of polarized light, the compressive stress value at different locations on the insulator surface is measured, and the stress layer depth is calculated using the instrument's built-in algorithm. The compressive stress value on the insulator surface must be ≥600MPa, and the stress layer depth ≥2mm. If the test results do not meet the standards, the insulator is marked as a defective product and isolated. Defective products can be remelted and reintroduced into the production process, reducing raw material waste. Step S7: Install hardware Install fittings on insulators that meet production standards. First, apply high-temperature cement adhesive to the installation area of ​​the insulator, ensuring a thickness of 2-3 mm and even application. Then, accurately place the fitting at the adhesive-coated location and apply 5-8 kN of pressure using a specialized clamp to ensure a tight fit between the fitting and the insulator. Finally, place the insulator with the fitting installed in a curing oven and cure at 80-100℃ for 2-3 hours to allow the adhesive to fully harden and form a strong connection.

[0035] Step S8: Maintenance After the insulators with the fittings installed are placed in a constant temperature and humidity curing chamber, the temperature is controlled at 20-25℃ and the humidity at 60%-70%, and the environment is automatically adjusted in real time using temperature and humidity sensors. During the curing process, the cement adhesive continues to undergo a hydration reaction, further enhancing the connection strength between the fittings and the insulator. The curing time is 24-48 hours. After curing, a shear strength test is performed on the joint, requiring a shear strength of ≥15MPa to ensure that the insulator can withstand mechanical loads in actual use.

[0036] The specific working principle is as follows: Quartz sand with a purity of 99.6%, soda ash with a purity of 99.2%, and limestone with a purity of 98.5% were selected as the main raw materials; sodium sulfate (Na2SO4) was selected as the clarifying agent, and boric acid (H3BO3) was selected as the fluxing agent.

[0037] Based on the glass formula, calculate the raw material usage for each batch (based on the production of 1000 insulators): 3000 kg of quartz sand, 800 kg of soda ash, 500 kg of limestone, 20 kg of sodium sulfate, and 45 kg of boric acid. Input the raw materials sequentially into the storage silo of the precision batching system.

[0038] The loss-in-weight weighing scale is started, and each raw material is weighed sequentially. After weighing, the raw materials enter the dynamic mixing device for three-dimensional stirring, which continues for 4 minutes. The mixed raw materials are then conveyed to the feed inlet of the horseshoe flame furnace through a closed conveying pipeline at a stable flow rate. The horseshoe flame furnace is started and preheated, with the melting temperature set to 1500-1530℃ and the glass melt discharge rate set to 20 kg / min.

[0039] After the raw materials enter the kiln, they gradually melt under high temperature. The kiln control system automatically adjusts the burner power and the opening size of the flow channel based on feedback data from temperature sensors. When the temperature of the upper layer reaches 1510℃, the middle layer 1520℃, and the lower layer 1505℃, the system maintains stable operation with these parameters. After 5 hours of melting, the molten glass reaches a uniform state, free of visible impurities and bubbles. At this point, the molten glass flows through the flow channel at a stable rate of 20 kg / min into the subsequent forming process.

[0040] The high-precision electronic servo feeder starts, with the upper mold pressing speed set to 100mm / s, the pressing pressure set to 6MPa, and the pressing duration set to 2.5 seconds. The robotic arm cuts the molten glass into regular droplets, which fall precisely into the lower mold. The upper mold quickly presses down, initially forming the insulator head and skirt. After each forming operation, the robotic arm quickly resets, ready for the next droplet grabbing and delivery.

[0041] The heating wire on the mold surface is activated, raising the temperature of the area requiring adjustment to 750℃, while maintaining the temperature of other areas at 620℃. The fine-tuning mold, adapted to the shape of the insulator, is installed in place, and the mechanical fine-tuning device is debugged. The insulator, after being formed in one piece, moves to the adjustment station with the mold. The fine-tuning mold begins its work, precisely adjusting the edges of the insulator, while simultaneously using a heated threaded rod to calibrate and adjust the precision of the insulator's internal threads. The mechanical fine-tuning device meticulously adjusts the curvature of the skirts, eliminating sharp edges and unevenness.

[0042] Between steps S3 and S4, the heating gun is preheated to a temperature of 750℃. After the insulator emerges from the secondary finishing station, the heating gun rapidly heats it, quickly raising its temperature to 750℃. The heated insulator then enters the isothermal equalization furnace via a conveyor. The furnace employs segmented heating control. The first segment maintains the temperature at 750℃ for 1 minute, ensuring a uniform temperature rise throughout the insulator and eliminating surface stress. The second segment maintains the temperature at 680℃ for 1 minute, further eliminating internal thermal stress in the insulator.

[0043] After being homogenized, the insulators are conveyed into a tunnel-type heating furnace. The insulator head is heated at 1300℃ for 5 minutes in the head heating zone; the skirt section is heated at 1100℃ for 3 minutes in the skirt heating zone; then, a brief transition heating zone is applied to ensure the insulator is uniformly heated to 1200℃. The annular circulating conveyor is activated, with the gripper rotation speed set to 0.8 r / s; the upper and lower spray heads are ready, and the coolant (deionized water to ethylene glycol volume ratio 7:3) has been injected into the storage tank. The spray pressure is set to 0.4 MPa, and the droplet size is controlled at approximately 80 μm; the lateral airflow velocity is set to 12 m / s. The heated insulators are transferred to the annular circulating conveyor, where the grippers firmly secure them. During the annular movement, the upper and lower spray heads simultaneously spray atomized coolant onto the top and bottom surfaces of the insulators, while the lateral airflow continues to blow air. The rapid cooling process lasts for 45 seconds, causing the surface temperature of the insulator to drop rapidly and forming a surface compressive stress layer. The insulators are transferred to the conveyor network, which then initiates a V-shaped transport process. The temperature of the slow-cooling liquid (with the same composition as the coolant) in the cooling tank is maintained at 25°C. The spray speed from the nozzles at the cooling tank inlet is set to 0.25 m / s. The ventilation system is ready, the exhaust port is open, and the compressed air pressure is set to 0.15 MPa. After rapid cooling, the insulators enter the slow-cooling stage via the conveyor network, gradually coming into contact with the slow-cooling liquid in the cooling tank during the V-shaped transport. The slow-cooling liquid sprayed from the nozzles evenly covers the insulators, and the compressed air blown in by the ventilation system causes slight ripples in the liquid. The slow-cooling process lasts for 90 minutes, effectively releasing residual stress inside the insulators.

[0044] The tempered insulators were tested using a critical angle polarimeter. The insulators were placed on the instrument's worktable, and the instrument parameters were adjusted to ensure the light was incident perpendicularly onto the insulator surface. The compressive stress values ​​at different locations on the insulator surface were measured by analyzing the interference fringes of the polarized light, and the stress layer depth was calculated using the instrument's built-in algorithm. The test results showed that the compressive stress values ​​on the surface of this batch of insulators were all between 650 and 750 MPa, and the stress layer depth was ≥2.2 mm, all meeting production standards. Insulators that failed the test were immediately marked and isolated for subsequent remelting. At the standard insulator installation location, apply high-temperature cement adhesive evenly using a specialized applicator, ensuring the adhesive thickness is controlled to 2.5mm. Accurately place the fitting at the adhesive-coated location and apply 6kN of pressure using a specialized clamp to ensure a tight fit between the fitting and the insulator. Then, place the insulator with the fitting installed in a curing oven and cure at 90℃ for 2.5 hours to allow the adhesive to fully harden and form a strong connection.

[0045] After the insulators were fitted with hardware, they were transferred to a constant temperature and humidity curing room. The temperature in the curing room was controlled at 22℃, and the humidity was maintained at 65%. The temperature and humidity sensors monitored the environment in real time and automatically adjusted the curing room environment. After 36 hours of curing, the shear strength of the insulator hardware joints was tested. The test results showed that the shear strength of all insulators reached 18MPa, meeting the requirement of ≥15MPa. This batch of insulators was considered complete and ready for packaging and warehousing, awaiting shipment.

[0046] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. The molding and tempering production process of disc-shaped suspension glass insulators, characterized in that: Includes the following steps: Step S1: Ingredient preparation; A small amount of clarifying agent and fluxing agent are added to high-purity quartz sand, soda ash, and limestone, and then mixed evenly through a precise batching system. Step S2: High-temperature melting; The raw materials are put into a horseshoe flame furnace or an electric melting furnace and melted into a uniform glass liquid at a high temperature of 1480~1550℃. Impurities are discharged through the liquid flow hole and the flow rate of the glass liquid is controlled to ensure the uniformity of composition. Step S3: Preliminary shaping: A high-precision electronic servo feeder is used to cut the molten glass into regular droplets by a robotic arm, which then fall into the forming mold for preliminary shaping; Step S4: Temperature equalization treatment; The formed glass parts are placed in a homogenizing furnace and held at 670~780℃ for 2 minutes; Step S5: Tempering treatment; After being uniformly heated, the insulators are transferred to a tempering station for tempering treatment, which forms a compressive stress layer on the surface and a tensile stress layer inside. Step S6: Stress detection; The compressive stress value and stress layer depth of the insulator surface were tested using measuring instruments to determine whether they met the production standards. Step S7: Install hardware: Install fittings on insulators that meet production standards.

2. The molding and tempering production process of the disc-shaped suspension glass insulator according to claim 1, characterized in that: Step S3 includes the following steps: Step S31: One-time molding; The material drips into the lower mold, and the upper mold presses down quickly to initially form the insulator head and skirt, ensuring the accuracy of the umbrella ribs and internal thread structure; Step S32: Secondary trimming; The local temperature of the insulator is controlled, and a fine-tuning mold adapted to the shape of the insulator is used to correct edge defects and optimize the skirt curvature.

3. The molding and tempering production process of the disc-shaped suspension glass insulator according to claim 1, characterized in that: In step S4, the uniform temperature furnace adopts segmented heating control. The first segment maintains the uniform temperature for 1 minute, with a holding temperature of 700~780℃. The second segment maintains the uniform temperature for 1 minute, with a holding temperature of 670~700℃.

4. The molding and tempering production process of the disc-shaped suspension glass insulator according to claim 3, characterized in that: A heating gun is provided between step S3 and step S4, which can heat the insulator to 700~780℃.

5. The molding and tempering production process of the disc-shaped suspension glass insulator according to claim 1, characterized in that: Step S5 includes the following steps: Step S51: High-temperature heating; The insulators, after being heated to uniform temperature, are subjected to a heat treatment to reach a high temperature of 1100-1300℃. Step S52: Rapid cooling treatment; Rapid cooling treatment is applied to high-temperature insulators; Step S53: Slow cooling treatment; The insulators that have been rapidly cooled are subjected to a slow cooling treatment.

6. The molding and tempering production process of the disc-shaped suspension glass insulator according to claim 1, characterized in that: In step S52, an annular circulating conveyor frame is used. The conveyor frame is equipped with rotatable claws, and high-temperature insulators are mounted on the claws. The top of the conveyor frame is equipped with multiple upper spray heads, which spray mist-like coolant onto the top surface of the high-temperature insulators on the claws. The bottom of the conveyor frame is equipped with multiple lower spray heads, which spray mist-like coolant onto the bottom surface of the high-temperature insulators on the claws.

7. The molding and tempering production process of the disc-shaped suspension glass insulator according to claim 6, characterized in that: The conveyor frame is also equipped with a transverse air blowing port. The air blowing direction of the transverse air blowing port is the same as the movement direction of the high-temperature insulator, and the air blowing range of the transverse air blowing port covers the height of the high-temperature insulator.

8. The molding and tempering production process of the disc-shaped suspension glass insulator according to claim 5, characterized in that: In step S53, a conveyor network is used to slowly cool the insulators after rapid cooling. The conveyor network can realize V-shaped transportation of the insulators. A cooling pool is provided in the middle of the conveyor network. The cooling pool contains slow cooling liquid. A nozzle is provided at the inlet of the cooling pool. The nozzle is located at the bottom of the conveyor network, and the spraying direction of the nozzle is perpendicular to the conveying direction of the conveyor network.

9. The molding and tempering production process of the disc-shaped suspension glass insulator according to claim 8, characterized in that: In step S53, a ventilation assembly is provided in the cooling pool, and the exhaust port of the ventilation assembly is located on the inner walls on both sides of the cooling pool.

10. The molding and tempering production process of the disc-shaped suspension glass insulator according to claim 1, characterized in that: It also includes step S8: maintenance; After the insulators are fitted with hardware, they are transferred to a constant temperature and humidity curing chamber for curing. The temperature in the curing chamber is controlled at 20-25℃, and the humidity is maintained at 60%-70%. The environment of the curing chamber is monitored in real time by temperature and humidity sensors and automatically adjusted.

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