Insulator and production process thereof

Abstract

The invention belongs to the field of insulator production, and particularly relates to an insulator and a production process thereof, and the method comprises the following steps: 1, preparing a silica gel material; 2, installing fittings at the two ends of the core tube; 3, wrapping the core tube by using the silica gel material in the step 1, and exposing the hardware fittings at the two ends to the outside; 4, placing the core tube wrapped with the silica gel material into a production device; step 5, extruding the silica gel material through a production device, so that the silica gel material is molded into an umbrella skirt to coat the core tube, and a semi-finished product of the composite insulator is obtained; 6, waste materials overflowing in the extrusion process are removed through a production device; and 7, controlling the semi-finished product of the composite insulator to rotate by using a production device, and removing the silica gel material adhered between the umbrella skirts to obtain a finished product of the composite insulator. According to the method, the silica gel material adhered between the umbrella skirts can be automatically removed, manual removal is not needed, and the production efficiency of the composite insulator is further improved.

Description

Technical Field

[0001] This invention belongs to the field of insulator manufacturing, and particularly relates to an insulator and its manufacturing process. Background Technology

[0002] Insulators are devices installed between conductors at different potentials or between a conductor and a component at ground potential, capable of withstanding voltage and mechanical stress. Composite insulators, also known as synthetic insulators, consist of a glass fiber resin core rod, an organic material sheath, and skirts. They are characterized by their small size, light weight, high tensile strength, and excellent resistance to pollution flashover, but their aging resistance is not as good as that of porcelain and glass insulators. In the production of composite insulators, silicone material needs to be wrapped around the core tube and then extruded into a skirt shape. However, in conventional molding equipment, excess silicone material is squeezed out after extrusion, causing silicone material to stick between the skirts. After the insulator is removed manually, the excess silicone material needs to be removed manually, resulting in increased operation steps and wasted manpower. Therefore, the production efficiency of composite insulators needs to be further improved. Summary of the Invention

[0003] In view of this, the technical problem to be solved by the present invention is to provide an insulator and its manufacturing process, which can automatically remove the silicone material adhering between the sheds without manual removal, thereby further improving the production efficiency of composite insulators.

[0004] This invention provides an insulator and its manufacturing process, the method comprising the following steps:

[0005] Step 1: Prepare silicone material;

[0006] Step 2: Install fittings at both ends of the core tube;

[0007] Step 3: Use the silicone material from Step 1 to wrap the core tube, exposing the hardware at both ends;

[0008] Step 4: Place the core tube wrapped with silicone material into the production device;

[0009] Step 5: The silicone material is extruded through the production device to form a skirt that covers the core tube, thus obtaining a composite insulator semi-finished product.

[0010] Step Six: Use the production equipment to remove the waste material that overflows during the extrusion process;

[0011] Step 7: Use the production equipment to control the rotation of the composite insulator semi-finished product, so as to remove the silicone material adhering between the skirts, thus obtaining the finished composite insulator.

[0012] The silicone material contains aluminum hydroxide powder.

[0013] The core tube is a glass fiber resin core rod.

[0014] The production device includes a molding table and a snap-fit ​​mold. The snap-fit ​​mold is located above the molding table. Both the molding table and the snap-fit ​​mold are provided with recesses for molding silicone material. A core tube is placed inside the molding table. Multiple umbrella skirts are formed on the core tube. Fittings are fixedly connected to both ends of the core tube. A friction wheel is fixedly connected to the fitting at one end. The surface of the friction wheel is provided with friction patterns. A drive wheel is rotatably connected to the molding table and contacts the friction wheel.

[0015] Two rotating rods are rotatably connected to the forming platform, and positioning rollers are rotatably connected to both rotating rods. Torsion springs are fixedly connected between the two rotating rods and the forming platform.

[0016] The molding table is fixedly connected to guard plates at both ends.

[0017] Two cutting rollers are rotatably connected to the forming platform.

[0018] The insulator consists of a core tube, silicone material, fittings, and a friction wheel. Attached Figure Description

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and specific implementation methods.

[0020] Figure 1 and Figure 2 A flowchart of an insulator and its manufacturing process;

[0021] Figure 3 and Figure 4 This is a schematic diagram of the overall structure of the production unit;

[0022] Figure 5 This is a schematic diagram of the collection box structure;

[0023] Figure 6 This is a cross-sectional view of the pulley structure;

[0024] Figure 7 This is a schematic diagram of the snap-fit ​​mold structure;

[0025] Figure 8 This is a schematic diagram of the cutting roller structure;

[0026] Figure 9 This is a schematic diagram of the drive wheel structure;

[0027] Figure 10 This is a schematic diagram of the forming stage. Detailed Implementation

[0028] The present invention will be described in detail with reference to the accompanying drawings in the embodiments of the present invention.

[0029] An insulator and its manufacturing process, comprising the following steps:

[0030] Step 1: Prepare silicone material;

[0031] Step 2: Install fittings at both ends of the core tube;

[0032] Step 3: Use the silicone material from Step 1 to wrap the core tube, exposing the hardware at both ends;

[0033] Step 4: Place the core tube wrapped with silicone material into the production device;

[0034] Step 5: The silicone material is extruded through the production device to form a skirt that covers the core tube, thus obtaining a composite insulator semi-finished product.

[0035] Step Six: Use the production equipment to remove the waste material that overflows during the extrusion process;

[0036] Step 7: Use the production equipment to control the rotation of the composite insulator semi-finished product, so as to remove the silicone material adhering between the skirts, thus obtaining the finished composite insulator.

[0037] The silicone material contains aluminum hydroxide powder.

[0038] The core tube is a glass fiber resin core rod.

[0039] See Figure 7-10 The diagram illustrates how the silicone material adhering between the umbrella skirts 302 can be removed according to the present invention without manual removal. Further,

[0040] The production apparatus includes a molding table 101 and a snap-fit ​​mold 405. The snap-fit ​​mold 405 is located above the molding table 101. Both the molding table 101 and the snap-fit ​​mold 405 are provided with recesses for molding silicone material. A core tube 301 is placed inside the molding table 101. Multiple umbrella skirts 302 are formed on the core tube 301. Fittings 303 are fixedly connected to both ends of the core tube 301. A friction wheel 304 is welded and fixedly connected to one end of the fitting 303. The surface of the friction wheel 304 is provided with friction texture. A drive wheel 204 is rotatably connected to the molding table 101 through a bearing. The drive wheel 204 is in contact with the friction wheel 304.

[0041] When using the production device, the operator first fixes two fittings 303 to the left and right ends of the core tube 301 respectively. Then, the core tube 301 is wrapped with silicone material and placed in the recess of the forming table 101. At this time, the friction wheel 304 contacts the drive wheel 204. By controlling the snap-fit ​​mold 405 to move downward and snap-fit ​​with the forming table 101, the silicone material is formed into the umbrella skirt 302 under the squeezing action between the snap-fit ​​mold 405 and the forming table 101. At the same time, the excess silicone material will be discharged through the gap between the snap-fit ​​mold 405 and the forming table 101. After the umbrella skirt 302 is formed, the snap-fit ​​mold 405 is controlled to move upward, so that the snap-fit ​​mold 405 is separated from the forming table 101 and the formed composite insulator.

[0042] Because excess silicone material tends to adhere between the skirts 302 when discharged, it is necessary to manually remove the composite insulator and remove the adhered silicone material by hand. However, this device controls the rotation of the drive wheel 204 to drive the friction wheel 304, which in turn drives the composite insulator to rotate as a whole. When the composite insulator rotates, it cooperates with the forming table 101 to remove the silicone material adhering between the skirts 302 without manual removal. This saves production time and operation steps, improves production efficiency, and the removed silicone material remains on the forming table 101. During the next extrusion molding, it will overflow along with other silicone material and does not need to be handled separately.

[0043] See Figure 8-9 A schematic diagram of an embodiment of the invention capable of positioning the friction wheel 304 is shown, further...

[0044] Two rotating rods 205 are rotatably connected to the forming table 101 via bearings. Each rotating rod 205 is rotatably connected to a positioning roller 207 via bearings. Torsion springs 206 are welded and fixedly connected to the forming table 101 for each rotating rod 205.

[0045] When placing the core tube 301, the two rotating rods 205 are pried apart. At this time, the friction wheel 304 comes into contact with the drive wheel 204. Under the action of the torsion spring 206, the two rotating rods 205 automatically move closer to the center, and then the two positioning rollers 207 clamp the friction wheel 304. The function of the two positioning rollers 207 is to position the friction wheel 304, which can ensure that the friction wheel 304 is in close contact with the drive wheel 204, prevent the drive wheel 204 from slipping with the friction wheel 304 when it rotates, and prevent the adhesive from lifting the composite insulator when the fastening mold 405 is detached from the composite insulator, thereby increasing the stability of the composite insulator.

[0046] See Figure 8 The diagram shows an embodiment of the invention in which silicone material can be discharged through the front and rear ends of the molding stage 101. Further,

[0047] The forming table 101 has protective plates 202 welded and fixed to both ends.

[0048] The function of the protective plate 202 is to prevent the silicone material from being discharged through the left and right ends of the molding table 101, so that the silicone material can be discharged through the front and rear ends of the molding table 101.

[0049] See Figure 8 A schematic diagram of an embodiment of the invention capable of cutting off discharged silicone material is shown, further...

[0050] Two cutting rollers 203 are rotatably connected to the forming table 101 via bearings.

[0051] When the silicone material is squeezed and overflows, the two cutting rollers 203 are controlled to rotate outward. The cutting rollers 203 can cut off the discharged silicone material, thereby preventing the silicone material from accumulating on the molding table 101.

[0052] See Figure 6 The diagram illustrates an embodiment of the invention in which cut silicone material can be collected and discharged. Further,

[0053] A collection box 101 is bolted to the lower end of the forming table 101. A screw 102 is rotatably connected to the collection box 101 via a bearing. A discharge port 103 is provided inside the collection box 101. Pulleys 105 are fixedly connected to the screw 102 and the drive wheel 204 via keys. The two pulleys 105 are connected by a synchronous belt. A drive motor 104 is bolted to the collection box 101. The screw 102 is fixedly connected to the output shaft of the drive motor 104 via a coupling.

[0054] The cut silicone material automatically falls into the collection box 101. At this time, the drive motor 104 drives the screw 102 to rotate. The screw 102 can convey the cut silicone material to the discharge port 103 on the left side and finally discharge it through the discharge port 103. At the same time, the screw 102 also drives the drive wheel 204 to rotate through the cooperation of the pulley 105 and the timing belt, so as to remove the adhesive silicone material. This makes the drive wheel 204 and the screw 102 controlled synchronously, avoiding the accumulation of silicone material in the collection box 101.

[0055] See Figure 6 and Figure 9 A schematic diagram of an embodiment of the present invention that implements the function of cutting off the silicone material when it automatically overflows is shown. Further,

[0056] Two hydraulic cylinders 401 are bolted to the collection box 101. The moving ends of the two hydraulic cylinders 401 are bolted to the lifting plate 402. Two limit rods 404 are slidably connected to the lifting plate 402. The snap-fit ​​mold 405 is bolted to the lower end of the two limit rods 404. Springs 403 are fitted on both limit rods 404. The springs 403 are located between the lifting plate 402 and the snap-fit ​​mold 405. Two racks 406 are bolted to the lower end of the snap-fit ​​mold 405. Gears 407 are keyed to both cutting rollers 203. The racks 406 are located inside the gears 407.

[0057] By controlling the retraction of the moving ends of the two hydraulic cylinders 401, the lifting plate 402 moves downward. The lifting plate 402 drives the snap-fit ​​mold 405 to move downward. After the snap-fit ​​mold 405 contacts the molding table 101, the silicone material automatically overflows. The lifting plate 402 continues to move downward. At this time, the two springs 403 are compressed by force, and the two racks 406 mesh with the two gears 407 respectively. When the racks 406 move downward, they drive the gears 407 to rotate, thereby driving the cutting roller 203 to rotate outward, realizing the function of cutting the silicone material when it automatically overflows.

[0058] The insulator consists of a core tube, silicone material, fittings, and a friction wheel.

Claims

1. A process for the production of an insulator, characterized in that, Includes the following steps: Step 1: Prepare silicone material; Step 2: Install fittings at both ends of the core tube; Step 3: Use the silicone material from Step 1 to wrap the core tube, exposing the hardware at both ends; Step 4: Place the core tube wrapped with silicone material into the production device; Step 5: The silicone material is extruded through the production device to form a skirt that covers the core tube, thus obtaining a composite insulator semi-finished product. Step Six: Use the production equipment to remove the waste material that overflows during the extrusion process; Step 7: Use the production equipment to control the rotation of the composite insulator semi-finished product, so as to remove the silicone material adhering between the skirts, thus obtaining the finished composite insulator.

2. The insulator manufacturing process according to claim 1, characterized in that: The silicone material contains aluminum hydroxide powder.

3. The insulator manufacturing process according to claim 2, characterized in that: The core tube is a glass fiber resin core rod.

4. The insulator manufacturing process according to claim 3, characterized in that: The production device includes a molding table (101) and a snap-fit ​​mold (405). The snap-fit ​​mold (405) is located above the molding table (101). Both the molding table (101) and the snap-fit ​​mold (405) are provided with recesses for molding silicone material. A core tube (301) is placed inside the molding table (101). Multiple umbrella skirts (302) are formed on the core tube (301). Fittings (303) are fixedly connected to both the left and right ends of the core tube (301). A friction wheel (304) is fixedly connected to one of the fittings (303). The surface of the friction wheel (304) is provided with friction patterns. A drive wheel (204) is rotatably connected to the molding table (101). The drive wheel (204) contacts the friction wheel (304).

5. The insulator manufacturing process according to claim 4, characterized in that: Two rotating rods (205) are rotatably connected to the forming table (101), and positioning rollers (207) are rotatably connected to both rotating rods (205). Torsion springs (206) are fixedly connected between the two rotating rods (205) and the forming table (101).

6. The insulator manufacturing process according to claim 4, characterized in that: The forming table (101) is fixedly connected to guard plates (202) at both ends.

7. An insulator manufacturing process according to claim 4, characterized in that: Two cutting rollers (203) are rotatably connected to the forming table (101).

8. An insulator manufacturing process according to claim 7, characterized in that: A collection box (101) is fixedly connected to the lower end of the forming table (101). A screw (102) is rotatably connected inside the collection box (101). A discharge port (103) is opened inside the collection box (101). Pulleys (105) are fixedly connected to both the screw (102) and the drive wheel (204). The two pulleys (105) are connected by a synchronous belt. A drive motor (104) is fixedly connected to the collection box (101). The screw (102) is fixedly connected to the output shaft of the drive motor (104).

9. An insulator manufacturing process according to claim 8, characterized in that: Two hydraulic cylinders (401) are fixedly connected to the collection box (101). A lifting plate (402) is fixedly connected to the moving end of the two hydraulic cylinders (401). Two limiting rods (404) are slidably connected to the lifting plate (402). A snap-fit ​​mold (405) is fixedly connected to the lower end of the two limiting rods (404). A spring (403) is sleeved on each of the two limiting rods (404). The spring (403) is located between the lifting plate (402) and the snap-fit ​​mold (405). Two racks (406) are fixedly connected to the lower end of the snap-fit ​​mold (405). Gears (407) are fixedly connected to each of the two cutting rollers (203). The racks (406) are located inside the gears (407).

10. An insulator produced using the insulator manufacturing process according to claim 9, characterized in that: The insulator consists of a core tube, silicone material, fittings, and a friction wheel.

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