Extra-high voltage basin-type insulator manufacturing quality index evaluation method and system

Abstract

The invention relates to the technical field of insulator detection, in particular to an extra-high voltage basin-type insulator manufacturing quality index evaluation method and system. The method comprises the following steps: constructing a basin-type insulator sampling inspection damage data mathematical model; basic data and damage test data of each basin-type insulator are collected, and test parameters of each basin-type insulator are calculated; and obtaining a comprehensive score of each basin-type insulator based on the test parameters and the basin-type insulator sampling inspection damage data mathematical model. According to the method, plant-crossing / structure-crossing / batch-crossing rapid analysis of the manufacturing quality of the extra-high voltage basin-type insulator, accurate positioning of weak links and closed-loop optimization of process materials are realized, and the mechanical performance is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of insulator testing technology, specifically to a method and system for evaluating the manufacturing quality indicators of ultra-high voltage basin-type insulators. Background Technology

[0002] In the field of ultra-high voltage AC transmission, the 1100kV basin insulator, as a key component of the 1100kV combined electrical equipment (GIS), plays a crucial role in providing stable support and reliable fixation for the conductors, ensuring conductor-to-ground insulation, and separating gas chambers. Given its critical position, this insulator has extremely high requirements for electrical, thermal, and mechanical performance, posing significant challenges to its design and manufacturing. Manufacturing quality directly affects the long-term stable operation of the GIS. Due to the high internal electric field strength and high SF6 gas pressure of 1100kV GIS, the basin insulator is required to possess excellent electrical and mechanical properties, placing extremely high demands on its structural design. Experience has shown that simply enlarging the size of basin insulators at lower voltage levels is far from sufficient, especially in terms of mechanical performance.

[0003] Figure 1 This is a schematic diagram of a typical 1100kV basin-type insulator in the prior art. Figure 1 As shown, this basin-type insulator has an aluminum flange on the outside and a drum-shaped metal insert in the center. The structure is relatively simple, and shielding rings can be optionally added to both the conductor and the periphery. This structure is relatively easy to manufacture and control in terms of quality. During the process of curing the epoxy resin system at high temperature and cooling to room temperature, internal stress is generated due to volume shrinkage and other factors. The area around the center insert, due to the inhomogeneity of the interface, is where the internal stress is most concentrated. When an external water pressure load is applied, the external water pressure stress and the internal stress are superimposed. A properly designed insert structure that fits well with the resin body can avoid excessive concentration of interface stress, thereby improving the overall mechanical strength of the insulator. However, if the design is improper, the stress cannot be dissipated around the insert, and the strain around the metal insert will change abruptly, potentially causing microcracks around the insert. As the water pressure load increases, these microcracks propagate rapidly, first causing fracture at the root of the insert and ultimately leading to basin failure.

[0004] Currently, the production of 1100kV basin insulators involves a series of complex and rigorous production processes, encompassing multiple stages such as insert cleaning, interface treatment, mold assembly, mold pre-baking, casting, primary curing, demolding, secondary curing, gate removal, glass transition temperature measurement, and cleaning. In terms of quality control, existing technologies primarily focus on process control and improvement. For example, surface treatment of the central insert involves sandblasting to improve its surface cleanliness and roughness, thereby enhancing its contact with epoxy resin; uniformly coating the surface with an epoxy interface agent strengthens the interfacial adhesion and the mechanical strength of the basin insulator. Simultaneously, strict environmental control is maintained during mold assembly, with regular cleaning and sanitation measures implemented; during critical processes such as casting, curing, and demolding, a system for confirming the status of casting equipment and conducting regular equipment inspections and maintenance is established, employing a double confirmation system to ensure the equipment is in good condition before casting; during casting, various equipment parameters are monitored in real time, and products with abnormalities are scrapped; during mold preheating and drying, temperature curves and time are precisely monitored and controlled; the curing oven is regularly maintained, and the mold's status is reconfirmed before entering the oven.

[0005] However, existing technologies have significant objective shortcomings. Current quality control models for pot-type insulators are mostly limited to improving quality stability through process control and improvement, lacking in-depth analysis of pot-type insulator test data and research and analysis of the characteristics of the materials used. Furthermore, test data analysis methods and material performance testing methods are still imperfect, merely meeting the quality standards of pot-type tests, electrical tests, and sampling tests. In practice, destructive data from type tests and sampling tests are not fully utilized to deeply analyze the differences between different manufacturers, material structures, and processes. This makes it difficult to optimize the pot structure based on these in-depth analysis results, thus hindering the effective improvement of the mechanical and electrical performance of pot-type insulators and limiting further advancements in pot-type insulator manufacturing. Summary of the Invention

[0006] The purpose of this invention is to provide a method and system for evaluating the manufacturing quality indicators of ultra-high voltage basin insulators in order to solve at least one of the above-mentioned technical problems, and to provide a new and effective way to improve the quality of basin insulators.

[0007] The present invention achieves the above objectives through the following technical solutions: A method for evaluating the manufacturing quality indicators of ultra-high voltage basin insulators includes: Construct a mathematical model for the damage data of pot-type insulators during random inspections; Collect basic data and destructive test data for each pot insulator, and calculate the test parameters for each pot insulator; Based on the test parameters and the mathematical model of the sampled damage data of the basin insulators, the comprehensive score of each basin insulator is obtained.

[0008] Furthermore, a mathematical model for the sampling and testing damage data of basin-type insulators is constructed, including: Based on the mathematical analysis results of basic data and accumulated destructive test data of different types of pot insulators, and combined with expert experience, the key tests and quality indicators in the destructive test of pot insulators were identified. The test parameters of key tests are weighted according to the importance of each destructive test; Based on the mathematical analysis results and expert experience, standardized scoring criteria were set for each experimental parameter.

[0009] Furthermore, the basic data includes the materials used in the manufacture of the pot-type insulator and its structural parameters; the destructive test data includes various test results for the performance testing of the pot-type insulator.

[0010] Furthermore, the experimental parameters include: interfacial normal stress σ n Interfacial shear stress τ xy Elastic modulus of the first material E1, elastic modulus of the second material E2, stress concentration factor K at the failure initiation site t The stress coefficient σ at the final failure site P Maximum damage value, minimum damage value, average damage value, standard deviation of damage value, probability of damage P f .

[0011] Furthermore, the test parameters for each pot-type insulator are calculated, including: Based on material parameters and the interface stress transfer model, the interface normal stress σ is calculated. n Interfacial shear stress τ xy ; Based on the materials used in the manufacture of basin-type insulators, the first material elastic modulus E1 and the second material elastic modulus E2 are obtained. Based on the model of failure location and stress concentration factor, the stress concentration factor K at the failure initiation location is calculated. t The stress coefficient σ at the final failure site P ; Based on the structural parameters and failure value analysis model, the maximum failure value X is calculated. max Minimum value X min ,average value Standard deviation S; Based on the failure probability model of force distribution, the failure probability P is calculated. f .

[0012] Furthermore, the formula for calculating the comprehensive score of the mathematical model of the sampling and destructive data of basin-type insulators is as follows: Overall score = (s1 × w1) + (s2 × w2) + ... + (sm × w m ) Among them, s i w represents the standardized score of the i-th indicator, 1≤i≤m; i represents the weight of the i-th indicator; m represents the number of experimental parameters involved in the calculation.

[0013] Furthermore, the method also includes: evaluating the overall manufacturing quality of each basin insulator based on its comprehensive score, and providing reference directions for improving the manufacturing quality of basin insulators.

[0014] A quality evaluation system for ultra-high voltage basin-type insulators includes: The model building module is used to build mathematical models of the damage data from random inspections of basin-type insulators. The data acquisition module is used to collect basic data and destructive test data of each pot insulator, and to calculate the test parameters of each pot insulator; The comprehensive evaluation module is used to obtain the comprehensive score of each pot insulator based on the test parameters and the mathematical model of the sampled damage data of the pot insulator.

[0015] Furthermore, the system also includes: The evaluation and improvement module is used to evaluate the overall manufacturing quality of each pot insulator based on its comprehensive score, and to provide reference directions for improving the manufacturing quality of pot insulators.

[0016] An electronic device includes a processor, a memory, and a computer program stored in the memory and executable on the processor. When executed by the processor, the computer program implements the quality evaluation method for manufacturing ultra-high voltage basin insulators as described above.

[0017] The beneficial effects of this invention are as follows: This invention constructs a mathematical model for the sampling and destructive data of pot insulators, which includes key indicator screening, weighting, and standardized scoring. Combined with intelligent data acquisition and multi-dimensional parameter calculation, it achieves unified quantitative evaluation across manufacturers, batches, and structures. Based on the comprehensive score, it outputs quality ratings and process improvement directions, effectively improving the scientific nature and accuracy of pot insulator manufacturing quality control. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a typical 1100kV basin insulator in the prior art; Figure 2 This is a flowchart of a method for evaluating the manufacturing quality indicators of ultra-high voltage basin-type insulators according to one embodiment of the present invention. Figure 3This is a planar structural diagram of the center insert of the basin-type insulator of structure A; Figure 4 This is a plan view of the center insert of the basin-type insulator of structure B. Figure 5 This is a planar structural diagram of the center insert of a C-structure basin insulator. Figure 6 This is a schematic diagram of a quality evaluation structure for ultra-high voltage basin-type insulators according to one embodiment of the present invention. Detailed Implementation

[0019] The invention will now be discussed with reference to exemplary embodiments. It should be understood that the described embodiments are merely intended to enable those skilled in the art to better understand and thus implement the invention, and are not intended to imply any limitation on the scope of the invention.

[0020] As used herein, the term "comprising" and its variations are to be interpreted as open-ended terms meaning "including but not limited to". The term "based on" is to be interpreted as "at least partially based on". The terms "one embodiment" and "an embodiment" are to be interpreted as "at least one embodiment".

[0021] Example 1 Figure 2 This is a flowchart illustrating a method for evaluating the manufacturing quality indicators of ultra-high voltage basin-type insulators according to one embodiment of the present invention. Figure 2 As shown, according to one embodiment of the present invention, a method for evaluating the manufacturing quality indicators of ultra-high voltage basin-type insulators includes the following steps: Step S102: Construct a mathematical model of the damage data from random inspections of basin-type insulators; Step S104: Collect basic data and destructive test data for each pot insulator, and calculate the test parameters for each pot insulator; Step S106: Based on the test parameters and the mathematical model of the sampling failure data of the basin insulators, obtain the comprehensive score of each basin insulator.

[0022] In this embodiment, a method for evaluating the manufacturing quality of UHV pot-type insulators is established through the analysis of a large amount of test data from different manufacturers and with different structures. This provides a unified and quantifiable evaluation standard for the manufacturing quality of pot-type insulators of different materials, structures, manufacturers, and batches, enabling rapid analysis and judgment of pot-type insulator sampling data. By analyzing historical data on pot-type insulator failures, the manufacturing process and material selection of pot-type insulators can be optimized, thereby improving the mechanical strength and mechanical performance of pot-type insulators. By employing a three-step approach of "modeling-data collection-scoring," the scattered destructive water pressure values ​​from various factories are transformed into a unified metric. First, a mathematical model of the destructive data from random inspections of pot-type insulators is trained using historical big data and expert experience, incorporating 11 key test parameters and assigning statistical weights to each parameter. During random inspections, basic data and destructive test data (such as insert dimensions, material modulus, and peak water pressure) are automatically read. Various calculation models are invoked to calculate the test parameters in real time, mapping them to standardized scores (0-10 points) according to standardized scoring criteria before weighting to obtain a comprehensive score. The comprehensive score directly identifies the weakest link and feeds back to the casting mold temperature and insert stress relief groove dimensions, achieving a closed-loop process. This provides a unified and quantifiable evaluation standard for the manufacturing quality of pot-type insulators from different manufacturers, with different structures, materials, and batches. It enables rapid analysis and judgment of random inspection data and uses historical destructive data to guide the optimization of manufacturing processes and material selection, significantly improving the mechanical strength and performance of pot-type insulators.

[0023] This invention constructs a unified quantitative evaluation standard through a three-step method of "modeling-data collection-scoring," enabling rapid cross-factory / cross-structure / cross-batch analysis of the manufacturing quality of UHV pot insulators, precise location of weak links, and closed-loop optimization of processes and materials, thereby significantly improving mechanical performance.

[0024] According to one embodiment of the present invention, step S102 includes: Based on the mathematical analysis results of basic data and accumulated destructive test data of different types of pot insulators, and combined with expert experience, the key tests and quality indicators in the destructive test of pot insulators were identified. The test parameters of key tests are weighted according to the importance of each destructive test; Standardized scoring criteria for each experimental parameter were set based on mathematical analysis results and expert experience.

[0025] In this embodiment, step S102 is further defined. First, basic data (insertion dimensions, resin modulus, etc.) of pot-type insulators from different manufacturers, structures, materials, and batches are collected along with results from previous water pressure failure tests. Extreme value statistics, variance analysis, and regression fitting are used to obtain mathematical analysis results. Furthermore, experts in the field are invited to interpret the failure initiation point, propagation path, and critical load based on the failure mechanism, jointly selecting the interface normal stress σ.n Root stress concentration factor K t Probability of destruction P f Eleven key tests and quality indicators were conducted. Subsequently, the AHP-entropy weight combination method was adopted to combine statistical dispersion with engineering hazard degree, assigning objective-subjective integrated weights to each indicator to ensure that highly sensitive parameters have greater say. Then, based on the 90% confidence interval of historical data and combined with various standards and specifications, each indicator was mapped to a standardized score curve of 0-10 points, thereby establishing a quality judgment system covering the three axes of materials, structure and process, realizing multi-dimensional quality evaluation and analysis of pot insulators, and completing the construction of a mathematical model for the sampling and damage data of pot insulators.

[0026] This invention constructs a quality assessment system for basin insulators covering the three axes of materials, structure, and process by using a weight allocation method that combines multi-source data fusion analysis with subjective and objective factors, thereby achieving accurate evaluation of destructive testing in a multi-dimensional and quantifiable manner.

[0027] According to one embodiment of the present invention, the basic data includes the materials used in the manufacture of the basin insulator and its structural parameters; the destructive test data includes various test results for the performance testing of the basin insulator.

[0028] Preferably, the test parameters include: interfacial normal stress σ n Interfacial shear stress τ xy Elastic modulus of the first material E1, elastic modulus of the second material E2, stress concentration factor K at the failure initiation site t The stress coefficient σ at the final failure site P Maximum damage value, minimum damage value, average damage value, standard deviation of damage value, probability of damage P f .

[0029] Preferably, in step S104, the test parameters for each pot-type insulator are calculated, including: Based on material parameters and the interface stress transfer model, the interface normal stress σ is calculated. n Interfacial shear stress τ xy ; Based on the materials used in the manufacture of basin-type insulators, the first material elastic modulus E1 and the second material elastic modulus E2 are obtained. Based on the model of failure location and stress concentration factor, the stress concentration factor K at the failure initiation location is calculated. t The stress coefficient σ at the final failure site P ; Based on the structural parameters and failure value analysis model, the maximum failure value X is calculated. max Minimum value X min ,average value Standard deviation S; Based on the failure probability model of force distribution, the failure probability P is calculated. f .

[0030] In this embodiment, the overall architecture of the mathematical model for the sampling failure data of pot-type insulators includes a basic mechanism layer, a quantitative support layer, a standard output layer, and an application improvement layer. In the basic mechanism layer, the elastic modulus E1 of the first material, the elastic modulus E2 of the second material, the interface normal stress, and the interface shear stress are analyzed using a material parameter and interface stress transfer model; the stress at the final failure point (point P) and the concentrated stress Kt at the root of the insert are analyzed using a failure location and stress concentration factor model. In the quantitative support layer, the maximum, minimum, average, and standard deviation of the failure value are analyzed based on a structural parameter and failure value analysis model; the maximum stress, failure probability, and stress distribution standard deviation are analyzed based on a failure location and stress concentration factor model. In the standard output layer, based on the mathematical model for the sampling failure data of pot-type insulators, the scores of each sub-indicator are determined, and the scores of each test parameter are weighted and summed to obtain a comprehensive score. In the application improvement layer, based on the comprehensive score of each pot-type insulator, specific methods to improve the mechanical strength of pot-type insulators are analyzed, including: optimizing the structural design of the central insert, improving the stress at the interface between the insert and the resin, and ensuring process stability. The basic mechanism layer explains how stress is transmitted to vulnerable parts. The quantitative support layer calculates the probability of failure based on the basic mechanism support and data foundation. The standard output layer integrates the core indicators of the previous steps (material parameters, stress concentration threshold, and upper limit of failure probability) to form a quality evaluation standard. The application improvement layer proposes specific improvement suggestions such as material optimization and structural improvement based on the output of the standard output layer.

[0031] This invention constructs a multi-layered architecture model covering basic mechanisms, quantitative support, standard output, and application improvements to achieve stress transfer analysis, failure probability quantification, and closed-loop optimization of manufacturing quality for basin insulators, significantly improving the accuracy of mechanical performance evaluation and the effectiveness of process improvement.

[0032] According to one embodiment of the present invention, the comprehensive score calculation formula of the mathematical model of the sampling inspection destructive data of basin-type insulators is as follows: Overall score = (s1 × w1) + (s2 × w2) + ... + (s m × w m ) Among them, s i w represents the standardized score of the i-th indicator, 1≤i≤m; i represents the weight of the i-th indicator; m represents the number of experimental parameters involved in the calculation.

[0033] In this implementation, the model output layer uses a "weighted summation scoring method" to uniformly quantify the 11 key experimental parameters: first, based on the 90% confidence interval of historical data and expert experience, the 11 indicators are mapped to standardized scores s of 0-10. i Then according to the preset weight w i Linear superposition is used to calculate a comprehensive score, and a higher comprehensive score indicates better mechanical strength and consistency.

[0034] This invention uses a weighted summation scoring method to quantify various key test parameters, thereby achieving a precise quantitative evaluation of the mechanical strength and consistency of pot insulators.

[0035] According to one embodiment of the present invention, the method further includes: Step S108: Based on the comprehensive score of each pot insulator, evaluate the overall manufacturing quality of each pot insulator and provide reference directions for improving the manufacturing quality of pot insulators.

[0036] In this implementation, the system archives historical damage values ​​according to the manufacturer-structure-process dimensions. First, it checks and removes abnormal samples to ensure that the data from the same manufacturer is stable and reliable. Then, it selects benchmark basins with the dual objectives of "maximum damage value and minimum standard deviation". It calls the mechanism model to invert the stress relief groove size D / S, the protrusion length L1 / L2 and the curing temperature curve of the insert, quickly locks the optimal insert structure and the best process standard, and gives quantifiable improvement vectors to achieve targeted upgrades of low-scoring products. This closed-loop evaluation significantly shortens the trial and error cycle and comprehensively improves the mechanical strength and consistency of batches.

[0037] This invention achieves closed-loop evaluation and directional optimization of the manufacturing quality of basin insulators through dual-objective benchmark screening and mechanism model inversion, significantly shortening the trial-and-error cycle and improving the consistency of batch mechanical performance.

[0038] Example 2 According to one embodiment of the present invention, a method for evaluating the manufacturing quality indicators of ultra-high voltage basin insulators, based on sampling and water pressure destructive test data of basin insulators, analyzes destructive test data of basin insulators from different manufacturers, batches, and structures, and establishes multi-dimensional analysis methods such as a destructive data analysis model, a material parameter and interface stress transfer model, a destructive location and stress concentration factor model, and a destructive probability model based on stress distribution, to identify the basin insulator with the optimal structure and best mechanical strength, thereby improving the overall quality level of basin insulators; specifically including the following steps: Step S201: Obtain the failure values ​​and failure locations of pot-type insulators of different materials, structures, manufacturers, and batches, and construct a mathematical model of pot-type insulator sampling failure data. Based on the mathematical analysis results of basic data and accumulated destructive test data of different types of pot insulators, combined with expert experience, the key tests and quality indicators in the destructive test of pot insulators were identified; and the test parameters were weighted according to the importance of each destructive test, and a mathematical model of the destructive data of pot insulator sampling inspection was constructed.

[0039] The basic data includes: manufacturing materials and structural parameters; the destructive test data includes various test results for the performance testing of pot insulators (such as failure values ​​and failure locations).

[0040] In the process of identifying key tests and quality indicators, mathematical analysis was employed: calculating the maximum, minimum, standard (mean), standard deviation, and error range to form a data statistical distribution characteristic matrix. Box plots were used to display the differences in damage value distribution among different material groups, and heat maps were used to present the correlation strength between each parameter and the damage value, visually identifying data anomalies. The expert group then determined the final key tests and quality indicators based on the collected data and the results of the mathematical analysis.

[0041] The experimental parameters of the mathematical model for the random inspection failure data of basin-type insulators include: interface normal stress σ. n Interfacial shear stress τ xy Elastic modulus of the first material E1, elastic modulus of the second material E2, stress concentration factor K at the failure initiation site t The stress coefficient σ at the final failure site P Maximum damage value, minimum damage value, average damage value, standard deviation of damage value, probability of damage P f .

[0042] The formula for calculating the comprehensive score of the mathematical model of the random inspection damage data of basin-type insulators is as follows: Overall score = (s1 × w1) + (s2 × w2) + ... + (s m × w m ) Among them, s i w represents the standardized score of the i-th indicator; i represents the weight of the i-th indicator; m represents the number of experimental parameters involved in the calculation.

[0043] The standardized scoring criteria for each test parameter are pre-set based on mathematical analysis results and expert experience.

[0044] Step S202: Automatically collect the determined key tests and quality indicators using intelligent testing instruments; In the process of obtaining test parameters, various commonly used calculation models with existing technology can be used. Any model that can accurately obtain calculation results can be used. However, in order to ensure data consistency, the same model standard should be selected for testing different pot insulators.

[0045] Step S203: Input the data collected in step S202 into the mathematical model of the sampling and damage data of the basin insulator, and calculate the comprehensive score of each basin insulator.

[0046] Based on a pre-set standardized scoring standard, the scores of each test parameter of each pot insulator are obtained. The sum of the products of the scores of each test parameter and their weights is the comprehensive score of the pot insulator.

[0047] Step S204: Based on the comprehensive score of each pot insulator, evaluate the overall manufacturing quality of each pot insulator and provide reference directions for improving the manufacturing quality of pot insulators.

[0048] A higher overall score indicates higher manufacturing quality of the basin insulator, making it a preferred choice for subsequent applications.

[0049] Furthermore, based on the comprehensive score, we can further explore ways to improve the manufacturing quality of basin insulators.

[0050] This invention constructs a multi-dimensional analysis model, integrates mathematical statistics and expert experience to screen key indicators and assign weights, and uses intelligent instruments to automatically collect data and input it into the model to calculate a comprehensive score. This enables a unified quantitative evaluation of the manufacturing quality of pot insulators from different manufacturers, batches, and structures, providing a scientific basis for prioritizing the selection of high-quality products and optimizing manufacturing processes, and effectively improving the overall quality level of pot insulators.

[0051] Example 3 Figure 3 This is a plan view of the center insert of the basin-type insulator of structure A. Figure 4 This is a plan view of the center insert of the basin-type insulator of structure B. Figure 5 This is a planar structural diagram of the center insert of a C-structure basin insulator.

[0052] like Figure 3-5 As shown, in terms of design principles, a theoretical analysis is conducted on three types of basin-type insulators. In structure A, the upper and lower straight segments of the raised portion are L1 and L2, respectively. Structure B incorporates stress-relieving grooves with a width of D and a depth of S around the upper and lower edges of the insert in structure A. These grooves can buffer the force exerted by the resin on the insert during production and operation through their own deformation. Structure C, based on structure A, increases the length of the straight segments (L1′ and L2′) of the raised portion to enhance the radial support of the insert on the resin, thereby improving the overall mechanical strength.

[0053] Taking three different types of basin-type insulators—structure A, structure B, and structure C—as examples, the quality index evaluation method for UHV basin-type insulator manufacturing of this invention is used to evaluate the quality index of the three types of basin-type insulators. The specific process includes: Step S301: Collect basic data and test data for three types of basin insulators; Step S302: Based on material parameters and interface stress transfer model, calculate the interface normal stress and interface shear stress of the three types of pot insulators respectively. All three types of basin-type insulators are composed of an aluminum alloy central insert and cast resin. The mechanical parameters of the two materials are: aluminum alloy elastic modulus E1 = 70 GPa, Poisson's ratio μ1 = 0.34; resin elastic modulus E2 = 12 GPa, Poisson's ratio μ2 = 0.32. Based on linear elasticity mechanics, the interface stress transfer models constructed for the three types of basin-type insulators include: Assuming continuous normal displacement at the interface between the insert and the resin, and neglecting the influence of interface treatment processes, the interfacial normal stress σ of the three types of pot-type insulators is calculated using the following formula. n : Where, ε n (x) represents the interface normal strain, and x represents the position coordinate along the insert axis.

[0054] Compared to structure A, the stress relief groove in structure B reduces ε at the edges. n (x), such that ε n The maximum value of (x) decreases by approximately 15%.

[0055] The interfacial shear stress τ of the three types of basin insulators is calculated using the following formula. xy : Where, γ xy (x) represents the interfacial shear strain, G1 represents the first shear modulus, and G2 represents the second shear modulus; Shear stress is related to the material's shear modulus and shear strain. , Calculations show that the shear stress distribution in structure B is more uniform, and the amplitude of the negative shear stress ("compression effect") is reduced by approximately 3.2% compared to structure A.

[0056] Step S303: Based on the failure location and stress concentration factor model, calculate the stress concentration factor at the failure initiation location (root of insert) and the stress factor at the final failure location (point P) of the three types of pot insulators respectively. The stress concentration factor K at the failure initiation site (insert root) is calculated using the following formula. t : Kt =σ max根部 / σ 平均 Where, σ max根部 σ represents the maximum stress at the root of the insert. 平均 This indicates the average stress on the insert surface.

[0057] Failure of the pot-type insulator begins at the interface between the insert root and the resin. Calculations show that for structure A, K... t It is approximately 1.8 (maximum normal stress 5.492 MPa, average 3.0 MPa). Structure B has a stress relief groove that causes K to... t Reduced to 1.5 (maximum normal stress 6.865 MPa, average 4.5 MPa), K of structure C t It is approximately 1.6.

[0058] The stress coefficient σ at the final failure point (point P) is calculated using the following formula. P : (6) Where, σ 根部 The initial stress value at the crack root is represented by , e represents the natural constant, α represents the crack propagation coefficient, and L represents the distance from the crack root to point P.

[0059] The final fracture occurs at the point of maximum curvature on the convex surface (point P). The stress at this point is related to the crack propagation at the root of the insert. Simulations show that the σ of structure A... P Approximately 1.189 MPa, the stress at the root is reduced in structures B and C, σ P The pressures decreased to 1.056 MPa and 1.214 MPa, respectively.

[0060] Step S304: Based on the multi-dimensional mathematical model of damage value, calculate the difference in damage value of the three types of basin insulators respectively. The mathematical model includes calculating the maximum value X of the damage value. max Minimum value X min ,average value , standard deviation S; where: Maximum value X max =max{x1,x2,…,x n This reflects the highest level of mechanical strength in the sample; Minimum value X min =min{x1,x2,…,x n This reflects the lowest level of mechanical strength in the sample; average value = This reflects the overall mechanical strength level of the sample; Standard deviation S = This reflects the dispersion of the mechanical strength of the sample; the smaller the value, the better the consistency.

[0061] The experimental and computational analysis results are as follows: Among the eight sets of data for structure A, the maximum value was 3.4 MPa, the minimum value was 2.3 MPa, the average value was 2.75 MPa, and the standard deviation was 0.47 MPa, indicating that its mechanical strength was low and inconsistent.

[0062] Among the 10 sets of data for structure B, the maximum value was 4.3 MPa, the minimum value was 3.1 MPa, the average value was 3.80 MPa, and the standard deviation was 0.32 MPa. This indicates that structure B has a significantly improved mechanical strength compared to structure A, with less dispersion and better consistency.

[0063] Of the 10 sets of data for structure C, the maximum value was 4.38 MPa, the minimum value was 3.20 MPa, the average value was 4.00 MPa, and the standard deviation was 0.36 MPa. The mechanical strength improvement was the most significant, but the dispersion was slightly higher than that of structure B.

[0064] It is evident that, in terms of structural strength, the mechanical strength of both structure B and structure C basin insulators has been significantly improved, increasing the water pressure breaking strength while reducing dispersion. Structure C basin insulators achieve the highest water pressure breaking strength, while structure B basin insulators perform better in reducing dispersion.

[0065] Step S305: Based on the failure probability model of the force distribution, calculate the failure probability P of the three types of basin insulators. f ; The probability of destruction P is calculated using the following formula. f Where Φ represents the normal distribution function; σ 极限 This indicates the tensile strength of the material; resin is approximately 12 MPa, and aluminum alloy is approximately 200 MPa. max σ represents the maximum stress. 标准差 The standard deviation of stress distribution; Based on the differences in materials and the distribution of stress, calculations show that: Structure A: σ max =5.492MPa, σ 标准差 =0.47MPa, P f ≈0.2 (corresponding to a 50% pass rate); B structure: σ max =6.865MPa, σ 标准差 =0.32MPa, P f ≈0.05 (pass rate increased to 90%) C structure: σ 标准差=0.36MPa, P f ≈0.05.

[0066] Step S306: Calculate the comprehensive score of the three types of pot insulators based on the data obtained in steps S202-S205; The overall score is calculated using the following formula: Overall score = (s1×w1) + (s2×w2) + ... + (s 11 ×w 11 ) Among them, s i For the standardized score of the i-th indicator, w i Let be the weight of the i-th indicator.

[0067] The model parameter scores and weighting coefficients for the three types of basin insulators are shown in Table 1. Table 1: Model parameter scores and weighting coefficients for three types of pot-type insulators Step S307: Based on the comprehensive score of each pot insulator, evaluate the overall manufacturing quality of each pot insulator and provide reference directions for improving the manufacturing quality of pot insulators.

[0068] The detachment of the center insert is a major cause of failure in pot insulators during pressure tests. Generally, when the water pressure reaches a certain level, cracks will form in localized areas around the insert and it will first detach from the resin. Subsequently, the cracks will rapidly propagate to the point of maximum stress, leading to fracture. Therefore, attention should be paid to the stress condition at the interface between the insert and the resin.

[0069] The structural shape of the central insert affects the stress distribution at the interface between the insert and the resin, thus affecting the mechanical strength of the pot insulator. The stress relief groove can significantly reduce the stress at the edge of the insert, making the stress distribution on the insert surface more uniform and reducing the "compression effect" of the resin on the insert; increasing the length of the straight segment of the protrusion can move the stress towards the center of the insert and enhance the "supporting effect" of the resin on the insert.

[0070] The comprehensive scoring shows that, compared to structure A, both structures B and C of the pot-type insulator have significantly improved mechanical strength, with structure C showing a more pronounced improvement. However, structure B exhibits less dispersion in mechanical strength and a larger insulation margin. Considering all mechanical characteristics, structure B pot-type insulators are the preferred choice for engineering applications.

[0071] Analysis revealed that structure B incorporates stress-relieving grooves (D width, S depth) around the upper and lower edges of the insert in structure A. These grooves can buffer the forces exerted by the resin on the insert during production and operation through their own deformation, reducing stress at the insert edges and resulting in a more uniform stress distribution on the insert surface. This reduces the "compression effect" of the resin on the insert, thereby improving mechanical strength and consistency. Structure C increases the length of the straight segments (L1 and L2) of the insert's protrusions, enhancing the insert's radial support to the resin. This shifts stress towards the insert's center, delaying insert detachment or resin cracking, and further improving mechanical strength.

[0072] Reference directions for improving the manufacturing quality of pot-type insulators include: I. Improve the stress distribution at the interface between the insert and the resin During the curing and cooling process, the central insert and epoxy resin generate internal stress due to volume shrinkage, with the stress being most concentrated at the interface. The aforementioned structural optimization avoids excessive stress concentration at the interface, reduces the generation of microcracks around the insert, and thus improves overall mechanical strength. When subjected to external water pressure loads, the optimized structure allows for a more reasonable superposition of the external water pressure stress and internal stress, reducing the risk of crack propagation.

[0073] II. Ensure process stability The model analysis results show that structures B and C not only improved the water pressure failure strength but also reduced the standard deviation, indicating that structural optimization helps improve process consistency. During production, strict control over insert processing precision and resin casting processes is necessary to ensure product quality stability and further enhance the reliability of mechanical strength.

[0074] Example 4 Figure 6 This is a schematic diagram of a quality evaluation structure for ultra-high voltage basin-type insulators according to one embodiment of the present invention. Figure 6 As shown, according to one embodiment of the present invention, a quality evaluation system for ultra-high voltage basin-type insulators includes: Model building module 10 is used to build a mathematical model of the damage data of the basin insulator during random inspection; The data acquisition module 20 is used to collect basic data and destructive test data of each pot insulator and to calculate the test parameters of each pot insulator. The comprehensive evaluation module 30 is used to obtain the comprehensive score of each pot insulator based on the mathematical model of test parameters and random inspection damage data of pot insulators.

[0075] Preferably, the system further includes: Evaluation and improvement module 40 is used to evaluate the overall manufacturing quality of each pot insulator based on its comprehensive score, and to provide reference directions for improving the manufacturing quality of pot insulators.

[0076] This embodiment proposes a quality evaluation system for UHV pot-type insulator manufacturing. The system integrates mathematical analysis results of basic data and destructive test data with expert experience through a model building module 10, establishing a quantitative model containing multi-dimensional indicators such as stress parameters, failure value statistics, and failure probability. A data acquisition module 20 automatically acquires data on manufacturing materials, structural parameters, and performance tests, and calculates key test parameters such as interface stress and elastic modulus based on the mechanism model. A comprehensive evaluation module 30 uses a weighted summation algorithm to combine standardized scores with preset weights to generate a comprehensive score, enabling objective comparison of product quality across batches. An evaluation and improvement module 40 further identifies quality shortcomings based on the comprehensive score and outputs targeted improvement schemes such as insert structure optimization and process parameter adjustment, forming a complete closed loop from data modeling to quality optimization, significantly improving the standardization level and reliability of pot-type insulator manufacturing.

[0077] According to one embodiment of the present invention, an electronic device includes a processor, a memory, and a computer program stored in the memory and executable on the processor. When the computer program is executed by the processor, it implements the manufacturing quality index evaluation method for any UHV basin insulator of the present invention.

[0078] According to one embodiment of the present invention, a computer-readable storage medium is provided, on which a computer program is stored, and when the computer program is executed by a processor, it implements the method for evaluating the manufacturing quality indicators of any UHV basin insulator of the present invention.

[0079] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and media described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0080] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.

[0081] It should be understood that the sequence number of each step in the invention and embodiments of the present invention does not absolutely imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

Claims

1. A method for evaluating manufacturing quality indicators of an extra-high voltage pot-type insulator, characterized by, The method comprises the following steps: constructing a mathematical model of the sampling destruction data of the basin-type insulator; collecting basic data and destruction test data of each basin-type insulator, and calculating test parameters of each basin-type insulator; obtaining a comprehensive score of each basin-type insulator based on the test parameters and the mathematical model of the sampling destruction data of the basin-type insulator.

2. The manufacturing quality index evaluation method of the extra-high voltage pot-type insulator according to claim 1, characterized in that, The method of constructing the mathematical model of the sampling destruction data of the basin-type insulator comprises the following steps: combining expert experience, combing and determining key tests and quality indexes in the destruction test of the basin-type insulator based on mathematical analysis results of basic data and accumulated destruction test data of different types of basin-type insulators; performing weight assignment on test parameters of the key tests according to the importance of each destruction test; setting a standardization score standard of each test parameter based on the mathematical analysis results and expert experience.

3. The manufacturing quality index evaluation method of the extra-high voltage pot-type insulator according to claim 1, characterized in that: The basic data comprises manufacturing materials and structural parameters of the basin-type insulator, and the destruction test data comprises various test results for performance tests of the basin-type insulator.

4. The manufacturing quality index evaluation method of the extra-high voltage pot-type insulator according to claim 3, characterized in that, The test parameters include: interface normal stress σ n , interface shear stress τ xy , elastic modulus of the first material E1, elastic modulus of the second material E2, stress concentration coefficient K of the damage starting position t , stress coefficient σ of the final damage position P , maximum value of the damage value, minimum value of the damage value, average value of the damage value, standard deviation of the damage value, and damage probability P f .

5. The manufacturing quality index evaluation method of the extra-high voltage pot-type insulator according to claim 4, characterized in that, The method of calculating the test parameters of each basin-type insulator comprises the following steps: Based on the material parameters and the interface stress transfer model, the interface normal stress σ n , the interface shear stress τ xy ; obtaining a first material elastic modulus E1 and a second material elastic modulus E2 based on manufacturing materials of the basin-type insulator; Based on the damage site and stress concentration coefficient model, the stress concentration coefficient K of the damage starting site is calculated t , the stress coefficient σ of the final damage site P ; Based on the structural parameter and the damage value analysis model, the maximum value X of the damage value is calculated max , the minimum value X min , the average value , the standard deviation S; Based on the stress distribution of the damage probability model, the damage probability P is calculated f .

6. The manufacturing quality index evaluation method of the extra-high voltage pot-type insulator according to claim 1, characterized by, a comprehensive score calculation formula of the mathematical model of the sampling destruction data of the basin-type insulator is as follows: Summarized score = (s1 x w1) + (s2 x w2) +... + (s m x w m ) wherein s i denotes the standardized score of the i-th indicator, 1≤i≤m; w i denotes the weight of the i-th indicator; m denotes the number of trial parameters participating in the calculation.

7. The manufacturing quality index evaluation method of the extra-high voltage pot-type insulator according to claim 1, characterized by, The method further comprises the following steps: evaluating the comprehensive manufacturing quality of each basin-type insulator based on the comprehensive score of each basin-type insulator, and giving a reference direction for improving the manufacturing quality of the basin-type insulator.

8. An extra-high voltage pot-type insulator manufacturing quality index evaluation system, characterized by, The method comprises the following steps: a model construction module, configured to construct a mathematical model of the sampling destruction data of the basin-type insulator; a data collection module, configured to collect basic data and destruction test data of each basin-type insulator, and calculate test parameters of each basin-type insulator; a comprehensive evaluation module, configured to obtain a comprehensive score of each basin-type insulator based on the test parameters and the mathematical model of the sampling destruction data of the basin-type insulator.

9. The manufacturing quality index evaluation system for the extra-high voltage pot-type insulator according to claim 8, characterized by, The system further comprises: an evaluation improvement module, configured to evaluate the comprehensive manufacturing quality of each basin-type insulator based on the comprehensive score of each basin-type insulator, and give a reference direction for improving the manufacturing quality of the basin-type insulator.

10. An electronic device, comprising: The system comprises a processor, a memory, and a computer program stored in the memory and executable on the processor, and the computer program is executed by the processor to implement the manufacturing quality index evaluation method of the ultra-high voltage basin-type insulator according to any one of claims 1-7.

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