A modular stacked high-voltage base insulator system and its assembly method

Abstract

This invention provides a modular stacked high-voltage base insulator system and its assembly method, belonging to the field of high-voltage electrical insulation technology and structural engineering technology. It includes: a base for fixed connection to a ground foundation structure; a top cover for fixed connection to the bottom of an antenna mast; at least two layers of insulator units disposed between the base and the top cover, each insulator unit layer consisting of multiple independent insulator units arranged in a circumferential array; multiple metal equalizing bearing rings, layered between adjacent insulator unit layers, between the bottommost insulator unit layer and the base, and between the topmost insulator unit layer and the top cover; the system also includes a pre-tightening mechanism for applying axial pre-tightening force to the entire stacked structure, compressing it into a stable whole. This invention provides a modular stacked high-voltage base insulator system with superior performance and its matching assembly method.

Description

Technical Field

[0001] This invention relates to the fields of high-voltage electrical insulation technology and structural engineering technology, and in particular to a modular stacked high-voltage base insulator system and its assembly method. Background Technology

[0002] Very Long Wave (VLF / LF) radio signals are characterized by low propagation loss and strong penetration (especially through seawater), making them a key technology for global communication, particularly for timing and underwater communication. To effectively transmit VLF / LF signals, the antenna system typically requires a very large physical size, often employing a massive grounded mast or guyed tower structure. For example, the antenna mast can exceed 350 meters in height, and the total weight of a single mast, including the guy wires and other accessories, can reach hundreds or even thousands of tons. To effectively feed radio frequency energy into the antenna, the entire massive metal mast needs to be highly insulated from the ground. This necessitates the installation of a base insulator at the mast's base that can withstand the immense weight of the mast (thousands of tons), wind loads, and other mechanical stresses, while also being able to withstand high voltage.

[0003] These antenna masts are themselves part of the antenna radiator, and when in operation, their bases carry extremely high voltages relative to the ground (e.g., up to 250kV or higher). Therefore, a special base insulator must be installed between the mast base and the ground foundation. This insulator must simultaneously meet two extremely demanding conditions:

[0004] 1. Extremely high mechanical load-bearing capacity: It must be able to support the enormous weight of the mast above, as well as additional environmental loads such as wind, snow, and ice, for a long period of time and stably.

[0005] 2. Extremely high electrical insulation performance: It must be able to reliably isolate high voltage on the mast and prevent flashover or breakdown to ground.

[0006] Currently, a common technical solution in the industry is to use large, integral ceramic insulators. However, this type of integral insulator solution has the following inherent technical bottlenecks and drawbacks:

[0007] (1) Manufacturing process limits: As the size and weight of the antenna continue to increase, the requirements for the size and strength of the insulator also increase dramatically. Manufacturing such a huge single ceramic component is extremely prone to micro-cracks or even explosions due to internal stress during the forming, sintering, and cooling processes, resulting in a very low yield and high cost.

[0008] (2) Risk of single point failure: The integral structure is a "single point failure" system. Once the insulator body develops a through crack due to material fatigue, accidental impact or lightning strike, the entire insulator will instantly lose its load-bearing and insulation capabilities, causing the antenna mast to collapse and resulting in catastrophic consequences.

[0009] (3) Uneven stress distribution: Under enormous axial pressure, it is very difficult to ensure that the stress is completely and uniformly distributed inside the large and irregular single ceramic unit. Stress concentration points will become the source of structural failure.

[0010] (4) Difficulty in transportation, maintenance and replacement: A huge precision ceramic component weighing several tons is extremely risky to transport and hoist on site. Any minor bump may cause it to be scrapped. Once it needs to be replaced, the entire antenna mast must be lifted, the old insulator weighing several tons must be removed and the new one installed. The process is extremely complicated, time-consuming and costly. Moreover, the replacement operation requires a long interruption of the launch mission, which is very costly.

[0011] (5) Lack of flexibility: Once the size and performance of the integral insulator are determined, they cannot be changed, making it impossible to adapt to the antenna requirements of different heights and voltage levels, and lacking design flexibility and scalability.

[0012] Therefore, a completely new design concept is urgently needed to avoid the inherent risks of the above-mentioned monolithic solution and to provide a safer, more reliable and engineering-feasible high-voltage, high-load-bearing antenna base insulator solution. Summary of the Invention

[0013] This invention provides a modular stacked high-voltage base insulator system and its assembly method, which overcomes a series of problems existing in the prior art, such as high manufacturing difficulty, low reliability, risk of single-point failure, and high maintenance cost of large integral ceramic insulators. It provides a modular stacked high-voltage base insulator system with a completely different structure and superior performance, as well as its matching assembly method.

[0014] In a first aspect, the present invention provides a modular stacked high-voltage base insulator system, comprising:

[0015] The base is used for fixed connection with the ground foundation structure;

[0016] Top cover, used for fixed connection to the bottom of the antenna mast;

[0017] At least two layers of insulator units are disposed between the base and the top cover, and each layer of insulator units consists of multiple independent insulator units arranged in a circumferential array.

[0018] Multiple metal pressure-equalizing bearing rings are arranged in layers between adjacent insulator unit layers, between the bottommost insulator unit layer and the base, and between the topmost insulator unit layer and the top cover.

[0019] The system also includes a pre-tightening mechanism for applying axial pre-tightening force to the entire stacked structure, compressing it into a stable whole.

[0020] According to the present invention, a modular stacked high-voltage base insulator system is provided, wherein the independent insulator unit is a solid cylinder, a hollow cylinder, or a cylinder structure with multi-stage sheds.

[0021] According to the present invention, a modular stacked high-voltage base insulator system is provided, wherein the insulator unit is made of ceramic.

[0022] According to the modular stacked high-voltage base insulator system provided by the present invention, the metal equalizing bearing ring is provided with positioning grooves corresponding to the positions of the insulator units.

[0023] According to the present invention, a modular stacked high-voltage base insulator system is provided, wherein the outer edge of the metal equalizing bearing ring has a smooth, rounded structure to improve the electric field distribution and suppress corona discharge.

[0024] According to the present invention, a modular stacked high-voltage base insulator system is provided, wherein the pre-tightening mechanism consists of multiple tie rods evenly distributed along the circumference. The tie rods pass through reserved holes on the multi-layer metal equalizing bearing rings, and pre-tightening force is applied through nuts at both ends of the tie rods.

[0025] According to the present invention, a modular stacked high-voltage base insulator system is provided, wherein the tie rod is made of alloy steel.

[0026] According to the present invention, a modular stacked high-voltage base insulator system is provided, wherein the insulator unit layer has two layers and the metal equalizing bearing ring has three layers.

[0027] Secondly, the present invention provides an assembly method for any of the above-mentioned modular stacked high-voltage base insulator systems, the method comprising the following steps: fixing the base; installing a first layer of metal equalizing bearing rings and placing multiple ceramic insulator units of the first layer on it; sequentially installing subsequent metal equalizing bearing rings and ceramic insulator units of corresponding layers until the top cover is installed; installing a pre-tightening mechanism and applying pre-tightening force according to a preset procedure to compress the entire stacked structure.

[0028] The assembly method provided by the present invention further includes: monitoring the stress state of the insulator unit in real time by means of strain sensors disposed on the insulator unit, and ensuring that the stress value deviation of all insulator units is controlled within a certain range.

[0029] The modular stacked high-voltage base insulator system and its assembly method provided by this invention have the following advantages compared with the prior art:

[0030] (1) Breaking through manufacturing bottlenecks and achieving unlimited expansion: This invention decomposes a huge, difficult-to-manufacture monolithic insulator into multiple small, easy-to-manufacture, and quality-controlled standardized ceramic insulator units. This makes it possible to carry out large-scale, high-quality production using existing mature processes, significantly improving the yield and reducing costs. Theoretically, by increasing or decreasing the number of units and layers, systems with arbitrary load-bearing capacity and insulation class can be constructed, exhibiting excellent scalability.

[0031] (2) Extremely high system reliability and safety (redundant design): This system is highly redundant. Even if a single insulator unit breaks, its load will be immediately redistributed to other units in the same layer and the equalizing bearing rings in the upper and lower layers. The overall structure and insulation performance of the system will not fail immediately, but will only decrease slightly, which will buy valuable time for detection and replacement and avoid the catastrophic consequences caused by the "single point failure" of the integral insulator.

[0032] (3) Optimized stress and electric field distribution: The structural connecting parts (flanges) and functional parts (equalizing rings / corona rings) are cleverly integrated into one, which effectively improves the voltage distribution of the entire insulator column and avoids stress concentration. Through the rigid conduction of the equalizing bearing ring and the adaptive compensation of the flexible pad, it can be ensured that the huge load of thousands of tons can be distributed extremely evenly on each independent insulator unit. At the same time, the metal ring plays a role in voltage division and shielding in electrical terms, making the electric field distribution more ideal and greatly improving the insulation reliability of the system.

[0033] (4) Simplified transportation, convenient maintenance and low life cycle cost: The individual modules are lightweight and small in size, making them easy to package, transport and hoist on site, reducing operational risks and costs; if maintenance is required, the failed individual insulator unit can be easily pulled out and replaced by slightly unloading the preload, and the entire process does not require hoisting the antenna mast, making the operation simple and fast, greatly reducing maintenance difficulty and operating costs.

[0034] (5) It achieves design flexibility and scalability: By increasing or decreasing the number of standardized insulator units, the total height and total insulation level of the insulator can be easily adjusted to meet the needs of antenna projects with different voltage levels and different mechanical loads, thus realizing "customization" and "serialization". Attached Figure Description

[0035] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the overall structure of the modular stacked high-voltage base insulator system provided by the present invention;

[0037] Figure 2 This is a cross-sectional structural diagram of the modular stacked high-voltage base insulator system provided by the present invention;

[0038] Figure 3 This is a top view of the structure of a single insulator unit layer provided by the present invention;

[0039] Figure 4 This is a three-dimensional schematic diagram of a single independent ceramic insulator unit provided by the present invention. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0041] It should be noted that in the description of the embodiments of the present invention, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. The terms "upper," "lower," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present 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, and therefore should not be construed as a limitation of the present invention. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly, for example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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 elements. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0042] The modular stacked high-voltage base insulator system provided by this invention includes:

[0043] (1) Base, used for fixed connection with the ground foundation structure.

[0044] The base (base) serves as the bottom support of the entire system, fixed to the ground or concrete foundation, providing mechanical anchoring points, and serving as the foundation of the entire stacked structure. It can be a metal base (base).

[0045] (2) Top cover, used for fixed connection with the bottom of the antenna mast.

[0046] The top cover is attached to the top of the system and is used to secure the antenna mast or other high-potential equipment. It can be a metal top cover.

[0047] (3) At least two layers of insulator units are disposed between the base and the top cover, and each layer of insulator units consists of multiple independent insulator units arranged in a circumferential array.

[0048] Each layer consists of multiple independent insulator units arranged in a circular array (i.e., a ring around a central axis). "Independent" means that each insulator unit is manufactured and replaceable individually, without relying on adjacent units to form the overall structure. "At least two layers" indicates that the system can be stacked and expanded in the height direction, increasing the insulation height (and thus improving the withstand voltage rating) by adding layers.

[0049] Alternatively, the independent insulator unit can be a solid cylinder, a hollow cylinder, or a cylindrical structure with multi-stage sheds.

[0050] The insulator unit can be made of ceramic, i.e., a ceramic insulator unit.

[0051] (4) Multiple metal pressure-bearing rings are arranged in layers between adjacent insulator unit layers, between the bottom insulator unit layer and the base, and between the top insulator unit layer and the top cover.

[0052] Metal equalizing load-bearing rings have dual functions: 1) Load bearing: As a rigid support surface, they uniformly transfer the load of the top cover to the lower insulator unit; 2) Voltage equalization: The conductive metal rings can improve the electric field distribution and avoid corona discharge or flashover caused by local electric field concentration.

[0053] Optionally, the metal equalizing bearing ring is provided with a positioning groove corresponding to the position of the insulator unit.

[0054] The grooves provide mechanical restraint for each layer of insulator units, preventing radial offset or rotation during installation or operation and ensuring uniform axial load distribution. In multi-layer stacked structures, misalignment of insulator units can lead to stress concentration or even localized crushing. The positioning grooves force upper and lower layers of units to align coaxially, improving overall structural stability. During on-site installation, workers simply "embed" the insulator units into the grooves for automatic alignment, eliminating the need for additional measurements or adjustments and improving assembly efficiency and consistency.

[0055] Optionally, the outer edge of the metal equalizing bearing ring has a smooth, rounded structure to improve the electric field distribution and suppress corona discharge.

[0056] (5) The system also includes a pre-tightening mechanism for applying axial pre-tightening force to the entire stacked structure, so as to compress it into a stable whole. That is, axial pre-tightening force is applied to the entire stacked structure to compress the base, multilayer insulator unit, equalizing ring and top cover into a whole.

[0057] Optionally, the pre-tightening mechanism consists of multiple tie rods evenly distributed along the circumference. The tie rods pass through reserved holes on the multi-layered metal pressure-equalizing bearing rings, and a pre-tightening force is applied through nuts at both ends of the tie rods.

[0058] The number of pull rods can be set according to requirements, and the material of the pull rods can be alloy steel.

[0059] It should be noted that the number of the above-mentioned insulator unit layers and metal equalizing bearing rings can be set according to requirements; in one embodiment, the insulator unit layers are two layers and the metal equalizing bearing rings are three layers.

[0060] Based on the above-described modular stacked high-voltage base insulator system, the present invention also provides an assembly method applicable to any of the above-described modular stacked high-voltage base insulator systems, the method comprising the following steps:

[0061] (1) Fixed base;

[0062] Securely connect the base to the concrete foundation or steel structure platform using anchor bolts, welding, or embedded parts; ensure that the upper surface of the base is level, clean, and free from deformation to guarantee the coaxiality and load uniformity of subsequent stacking.

[0063] (2) Install the first layer of metal equalizing bearing ring and place multiple ceramic insulator units of the first layer on it.

[0064] First, place the metal equalizing bearing ring, then place the insulator unit. The metal equalizing bearing ring serves as a bearing platform, and the positioning groove on its upper surface can guide the insulator unit into precise position.

[0065] (3) Install the subsequent metal equalizing bearing rings and the corresponding ceramic insulator units in sequence until the top cover is installed.

[0066] Stack the insulators upwards in an alternating sequence of “metal equalizing bearing ring → insulator unit → metal equalizing bearing ring → insulator unit…”; install a top cover (instead of adding another metal ring) on ​​top of the last layer of insulator units, and press the top cover directly onto the top metal equalizing bearing ring.

[0067] (4) Install the pre-tightening mechanism and apply the pre-tightening force according to the preset procedure to compress the entire stacked structure.

[0068] Install a pre-tightening mechanism: for example, insert multiple circumferentially distributed tie rods and apply pre-tightening force through the nuts at both ends of the tie rods to achieve the compression of the entire stacked structure.

[0069] "Preset procedure": refers to a tightening strategy determined based on engineering experience or experiments, which usually includes: step loading: such as applying force gradually in 3 to 5 levels to avoid instantaneous overload; synchronous application: using diagonal tightening and cyclic force application (similar to flange bolt tightening) to ensure that each tie rod is subjected to balanced force.

[0070] Optionally, the assembly method provided by the present invention further includes:

[0071] The stress state of the insulator unit is monitored in real time by strain sensors installed on the insulator unit, and the stress value deviation of all insulator units is controlled within a certain range.

[0072] The modular stacked high-voltage base insulator system and its assembly method provided by this invention have the following advantages compared with the prior art:

[0073] (1) Breaking through manufacturing bottlenecks and achieving unlimited expansion: This invention decomposes a huge, difficult-to-manufacture monolithic insulator into multiple small, easy-to-manufacture, and quality-controlled standardized ceramic insulator units. This makes it possible to carry out large-scale, high-quality production using existing mature processes, significantly improving the yield and reducing costs. Theoretically, by increasing or decreasing the number of units and layers, systems with arbitrary load-bearing capacity and insulation class can be constructed, exhibiting excellent scalability.

[0074] (2) Extremely high system reliability and safety (redundant design): This system is highly redundant. Even if a single insulator unit breaks, its load will be immediately redistributed to other units in the same layer and the equalizing bearing rings in the upper and lower layers. The overall structure and insulation performance of the system will not fail immediately, but will only decrease slightly, which will buy valuable time for detection and replacement and avoid the catastrophic consequences caused by the "single point failure" of the integral insulator.

[0075] (3) Optimized stress and electric field distribution: The structural connecting parts (flanges) and functional parts (equalizing rings / corona rings) are cleverly integrated into one, which effectively improves the voltage distribution of the entire insulator column and avoids stress concentration. Through the rigid conduction of the equalizing bearing ring and the adaptive compensation of the flexible pad, it can be ensured that the huge load of thousands of tons can be distributed extremely evenly on each independent insulator unit. At the same time, the metal ring plays a role in voltage division and shielding in electrical terms, making the electric field distribution more ideal and greatly improving the insulation reliability of the system.

[0076] (4) Simplified transportation, convenient maintenance and low life cycle cost: The individual modules are lightweight and small in size, making them easy to package, transport and hoist on site, reducing operational risks and costs; if maintenance is required, the failed individual insulator unit can be easily pulled out and replaced by slightly unloading the preload, and the entire process does not require hoisting the antenna mast, making the operation simple and fast, greatly reducing maintenance difficulty and operating costs.

[0077] (5) It achieves design flexibility and scalability: By increasing or decreasing the number of standardized insulator units, the total height and total insulation level of the insulator can be easily adjusted to meet the needs of antenna projects with different voltage levels and different mechanical loads, thus realizing "customization" and "serialization".

[0078] Furthermore, in order to provide a clearer explanation of the technical solution of the present invention, the following description is provided in conjunction with... Figures 1 to 4 An embodiment with two layers of insulator unit and three layers of metal equalizing bearing ring will be described.

[0079] A modular stacked high-voltage base insulator system for very long wave / long wave antenna masts includes a metal base connected to the ground foundation, a metal top cover connected to the bottom of the antenna mast, and at least two layers of insulator units disposed between the two. The core innovation of this invention lies in the at least two layers of insulator units, each of which is not a single unit but rather composed of multiple independent ceramic insulator units arranged in a circumferential array. These circumferentially distributed, independent, and replaceable ceramic insulator units collectively form a "cage"-like structure, primarily bearing the vertical compressive load of the tower. The modular design not only distributes manufacturing complexity but also provides for failure redundancy and convenient maintenance. Metal equalizing rings are layered and graded between adjacent insulator unit layers, and between the insulator layers and the base and top cover.

[0080] Furthermore, in order to optimize performance and structural stability:

[0081] (1)The independent ceramic insulator unit is preferably a solid cylinder, a hollow cylinder, or a cylinder with multiple skirts (insulating umbrella skirts for increasing the creepage distance and improving the rain flash performance). The material is high-strength engineering ceramics (such as alumina ceramics with 95% or more alumina) to ensure the compressive strength and insulation performance of a single module. Since it is a standardized unit, its size is relatively small (for example, the height is 0.5 - 1.0 meters), and mature ceramic manufacturing processes (such as isostatic pressing) can be used for mass production, thus ensuring high quality and high yield.

[0082] (2)The multi-layer metal grading and stress-bearing rings play multiple roles. Through the hierarchical structure and the setting of grading rings, the electric field distribution can be more effectively controlled, enabling the voltage to be evenly distributed among each layer, improving the insulation margin, and effectively suppressing corona discharge:

[0083] a) Stress-bearing: evenly distribute the load transmitted from the upper layer (or the top cover) to each independent ceramic insulator unit in the lower layer;

[0084] b) Grading: as an equipotential surface, evenly distribute the total voltage electrically to each insulator unit layer to avoid a certain layer from bearing too high voltage;

[0085] c) Electric field shaping: its smooth and large-rounded outer edge contour can serve as a corona ring, effectively improving the electric field distribution at the outer edge of the insulator system, suppressing tip discharge, and increasing the withstand voltage level.

[0086] (3)The system can apply a pre-tightening force through a set of central or external pre-tightening mechanisms to compress all loose modules (insulator units, grading rings) into a stable integral structure with prestress, improving the system's anti-lateral force and anti-vibration capabilities.

[0087] The core idea of the assembly method配套 with this system is "layer-by-layer construction, real-time monitoring, and precise pressure application". By installing insulator units and grading rings layer by layer, and finally using the pre-tightening mechanism, under the monitoring of strain sensors, symmetrically and stepwise apply the pre-tightening force until the stress values of each ceramic stress-bearing unit are in an ideal and uniform distribution state.

[0088] Refer to Figures 1 to 4 , this embodiment discloses a modular stacked ultra-high voltage base insulator system for supporting a very long wave / long wave antenna mast with a load of 4000 tons, a height of 350 meters, and a working voltage of 250 kV.

[0089] This system sequentially includes from bottom to top: a metal base 101, a first-layer metal grading and stress-bearing ring 104a, a first insulator unit layer, a second-layer metal grading and stress-bearing ring 104b, a second insulator unit layer, and a third-layer metal grading and stress-bearing ring 104c (this ring also serves as the bottom plate of the top cover 102). It should be noted that there is an unclear expression "配套" in the original text. I have translated it as "配套" in the translation for now. You may need to clarify its specific meaning for a more accurate translation.

[0090] Metal base 101: Made of high-strength cast steel, it is firmly fixed to the reinforced concrete foundation with anchor bolts. Its upper surface is precision machined to ensure flatness.

[0091] Independent ceramic insulator unit 103: such as Figure 4 As shown, this embodiment employs a solid cylindrical structure, formed by hot-pressing and sintering 99.5% high-purity alumina ceramic. Each unit has a diameter of 250 mm and a height of 1200 mm. It possesses a compressive strength exceeding 1500 MPa.

[0092] Insulator unit layer: This embodiment includes two insulator unit layers. For example... Figure 3 As shown, each layer consists of 8 independent ceramic insulator units 103 arranged in a uniform array along a circle with a diameter of 2.5 meters.

[0093] Metal equalizing bearing ring 104: such as Figure 1 As shown, there are three pieces: 104a, 104b, and 104c. They are forged from high-strength aluminum alloy or stainless steel, and the surface is polished to reduce corona discharge.

[0094] Its outer diameter is 3.2 meters, which is larger than the 2.5-meter diameter of the insulator layer, and its outer edge is a smooth circular tube with a radius of 50 mm. The upper and lower surfaces of the ring are machined with positioning grooves with a depth of 10 mm according to the layout of the ceramic insulator units to ensure that each ceramic insulator unit can be accurately positioned.

[0095] It should be noted that the specific appearance of the metal equalizing and bearing rings in different layers can be changed according to their applicability, but they all serve the functions of equalizing pressure and bearing force.

[0096] Metal top cover 102: connected to the bottom of the mast via a flange, and fixed below it to the uppermost pressure equalizing bearing ring 104c.

[0097] Pre-tightening mechanism 105: such as Figure 1 As shown, this embodiment employs an external preload design. Eight high-strength alloy steel tie rods, each 80mm in diameter, are evenly distributed around the circumference of the system, passing through pre-drilled holes in the three-layer equalizing bearing ring 104. By applying torque to the specially designed nuts at both ends of the tie rods, approximately 800 tons of preload force is provided to the entire system.

[0098] Assembly method:

[0099] Reference Figure 1 The assembly process in this embodiment is as follows:

[0100] S01: Foundation preparation: Clean the concrete foundation, hoist and fix the metal base 101.

[0101] S02: Constructing the first layer: Hoist the first layer equalizing bearing ring 104a onto the base 101. Then, place the eight independent ceramic insulator units 103 one by one into the positioning grooves of 104a.

[0102] S03: Constructing the Second Layer: Hoist the second-layer equalizing bearing ring 104b, aligning its positioning groove with the eight ceramic insulator units of the first layer, and lower it down. Then, install the eight ceramic insulator units 103 of the second layer into place.

[0103] S04: Install the top cover: hoist the topmost equalizing bearing ring 104c and the metal top cover 102.

[0104] S05: Applying Preload: Install 8 external tie rods as the preload mechanism 105. Using a hydraulic torque wrench, tighten the nuts gradually and synchronously in 5 levels, following a diagonal sequence. Strain gauges attached to the bottom of each ceramic insulator unit transmit real-time data to the monitoring center. Monitoring personnel ensure that the stress value deviation of all 16 units remains within 5% during loading. Finally, when the total preload reaches 800 tons, lock all nuts.

[0105] S06: Completion: Install the antenna mast and complete the connection.

[0106] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; 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; and these 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.

[0107] For example, individual ceramic insulator units can have skirts to increase creepage distance; the pre-tightening mechanism can also adopt a center-through tie rod; the number of insulator layers and the quantity per layer can be adjusted according to actual load and voltage requirements. All these variations and modifications should fall within the scope of protection defined by the appended claims.

Claims

1. A modular stacked high-voltage base insulator system, characterized in that, include: The base is used for fixed connection with the ground foundation structure; Top cover, used for fixed connection to the bottom of the antenna mast; At least two layers of insulator units are disposed between the base and the top cover, and each layer of insulator units consists of multiple independent insulator units arranged in a circumferential array. Multiple metal pressure-equalizing bearing rings are arranged in layers between adjacent insulator unit layers, between the bottommost insulator unit layer and the base, and between the topmost insulator unit layer and the top cover. The system also includes a pre-tightening mechanism for applying axial pre-tightening force to the entire stacked structure, compressing it into a stable whole; The metal equalizing bearing ring is provided with a positioning groove corresponding to the position of the insulator unit, and the positioning groove forces the upper and lower units to be coaxially aligned. The outer edge of the metal equalizing bearing ring has a smooth, rounded structure to improve the electric field distribution and suppress corona discharge. The pre-tightening mechanism consists of multiple tie rods evenly distributed along the circumference. The tie rods pass through pre-drilled holes on the multi-layered metal pressure-equalizing bearing rings, and pre-tightening force is applied through nuts at both ends of the tie rods.

2. The modular stacked high-voltage base insulator system according to claim 1, characterized in that, Independent insulator units are solid cylinders, hollow cylinders, or cylindrical structures with multi-stage sheds.

3. The modular stacked high-voltage base insulator system according to claim 2, characterized in that, The insulator unit is made of ceramic.

4. The modular stacked high-voltage base insulator system according to claim 1, characterized in that, The tie rod is made of alloy steel.

5. The modular stacked high-voltage base insulator system according to claim 1, characterized in that, The insulator unit layer has two layers, and the metal equalizing bearing ring has three layers.

6. An assembly method for a modular stacked high-voltage base insulator system as described in any one of claims 1 to 5, characterized in that, The method includes the following steps: Fixed base; Install the first layer of metal equalizing bearing ring, and place multiple ceramic insulator units of the first layer on it; Install the subsequent metal equalizing bearing rings and the corresponding ceramic insulator units in sequence until the top cover is installed; Install the pre-tightening mechanism and apply pre-tightening force according to the preset procedure to compress the entire stacked structure.

7. The assembly method according to claim 6, characterized in that, Also includes: The stress state of the insulator unit is monitored in real time by strain sensors installed on the insulator unit, and the stress value deviation of all insulator units is controlled within a certain range.

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