Extra-high voltage line large tonnage insulator fixture with force measuring system

Abstract

The application discloses a large-tonnage insulator clamp with a force measuring system for an extra-high voltage line, comprising a first clamp seat and a second clamp seat. The first clamp seat is connected with a first tensioning device and a second tensioning device at two ends respectively, and the two tensioning devices are connected with the two ends of the second clamp seat through a first sensing unit and a second sensing unit. The tensioning devices apply tension to the two clamp seats, so that the to-be-replaced insulator is not subjected to force for replacement. The first sensing unit and the second sensing unit detect the tension of the corresponding tensioning device respectively. The clamp seat is composed of a hinge clamp body and an upper cover, and is internally provided with a detachable clamp. The tensioning device is driven by a straight gear and a screw rod, and a hand group assembly is arranged. The hand group assembly comprises a double-end pawl and a light shaft gear, and is provided with a force amplification transmission gear set. The sensing unit comprises a bearing body and a deformation sensor. The application has the advantages of compact structure, labor saving, real-time tension monitoring, and safety and reliability of the replacement operation of the extra-high voltage line insulator.

Description

Technical Field

[0001] This invention relates to the field of power transmission technology, and in particular to large-tonnage insulator clamps for ultra-high voltage lines with force measurement systems. Background Technology

[0002] With the continuous improvement of my country's power grid construction level, ultra-high voltage direct current (UHVDC) transmission lines have become the core backbone of the national power grid. During the long-term operation of UHV lines, insulators are susceptible to degradation due to factors such as lightning strikes, flashover, and material aging, leading to spontaneous explosions, zero values, and low values. Timely replacement is crucial; otherwise, it will pose a serious threat to the safe and stable operation of the power grid. In transmission line maintenance, closed clamps combined with tensioning devices are typically used for insulator replacement. The basic principle is to clamp and fix the steel caps of the two insulators to be replaced using clamps, and then use a tensioning device to tighten or loosen the insulator string, thereby transferring the load on the insulator to be replaced and completing the removal and installation of the insulator. However, with the continuous advancement of UHVDC projects and the expanding scale of line construction, the labor-saving performance and load-bearing capacity of tensioning devices have reached a bottleneck, making it difficult to meet the demands of large-tonnage UHV operations. This has exposed several prominent problems in the practical application of existing insulator replacement devices.

[0003] For example, the industry currently widely uses hydraulic screws or traditional single-axis screws as tensioning devices for insulator replacement. However, hydraulic screws suffer from problems such as hydraulic oil leakage, poor stability in strong electric fields, and poor clamping force retention. Traditional single-axis screws are far from meeting the tonnage requirements in scenarios involving large spans and heavy load transfers. Although improved solutions such as worm gear drives are being gradually promoted, they still have shortcomings such as large operating torque and low efficiency. Replacing heavy-tonnage insulators is laborious and difficult for operators. Furthermore, in the replacement of single-piece insulators on the side of 550kN and above tension conductors, due to the extremely large load, there is a risk of the insulator cap bursting due to uneven stress during operation, placing higher demands on the tensioning adjustment accuracy and stress balance of the clamps.

[0004] Existing clamps and lead screw devices generally lack effective secondary protection measures, posing significant safety risks. During insulator replacement operations, the insulator strings bear extremely heavy loads. When the insulators loosen, the lead screw and the clamps before and after it must bear the entire load of the insulator to be replaced. If the lead screw breaks unexpectedly or trips due to improper operation, it could lead to serious accidents such as insulator string breakage and conductor collapse, causing significant personal injury and damage to power grid equipment. Although some centrifugal clamps have begun to incorporate protective components, the reliability and safety of the secondary protection structure still need further improvement.

[0005] Furthermore, most currently used closed-type insulator clamps can only be used for replacing insulators of the same model from the same manufacturer; that is, the clamp and insulator must be used in a one-to-one matching manner. This is because the steel cap clamps of insulators from different manufacturers and models differ, and insulators produced by a particular manufacturer can usually only be installed and removed using the clamps provided by that manufacturer. A transmission line often has multiple suppliers and various insulators of different tonnages, models, and manufacturers due to repeated technical upgrades and overhauls. Maintenance work requires carrying multiple types of clamps, resulting in a large number of spare parts, consuming significant funds and warehouse space, and directly reducing maintenance efficiency. Related literature also points out that existing insulator clamps typically only correspond to one size of insulator, requiring different sized clamps for different sizes of insulators, which is extremely inconvenient. Although the industry has proposed several universal clamp solutions, such as using replaceable bushings to adapt to different models of insulators or using telescopic claws for self-adaptive clamping, the compatibility with different tonnages and manufacturers of insulators in practical applications remains limited, and the versatility needs further improvement.

[0006] The connection structure of tension tower insulators is relatively complex. Both the crossarm end and the conductor end are connected to the insulator string via triangular connecting plates. Different models and structural variations of triangular connecting plates have significant differences in thickness and style. Traditional clamps cannot simultaneously ensure a reliable connection with the triangular connecting plates and precise clamping of the insulator caps. On some lines, when replacing the first and last insulator pieces of a tension string, manual tightening using tools such as chain hoists is still used, which is labor-intensive, inefficient, and poses safety hazards. For complex tension string structures such as six-connection, three-point suspension points in UHVDC transmission lines, it is necessary to design specialized clamps with triangular connecting plates and insulator caps as anchor points. Only by organically combining end clamps, insulator live clamps, and screw adjustment components can the removal and replacement of the first and last insulator pieces at both ends be effectively completed.

[0007] For example, the patent application number "CN 201911287087.4" discloses a "clamp for replacing insulators". As mentioned above, it does not have a force measuring device, which poses a risk that the steel cap of the insulator may crack due to uneven force. At the same time, the inner wall of its clamp does not have a replaceable sub-clamp for contacting the insulator, making it unable to adapt to insulators of different manufacturers and different models and specifications. In addition, it requires adjusting the distance between the two clamps through a hydraulic screw, and also requires an auxiliary device that works with the hydraulic system, making it inconvenient to use. Summary of the Invention

[0008] The purpose of this invention is to provide a clamp for large-tonnage insulators on ultra-high voltage lines with a force measurement system, which can detect the clamping force on the insulator in real time to ensure operational safety; at the same time, it can replace the inner clamp with one that is compatible with different insulators to improve the adaptability of the equipment; and the tensioning of the insulator is achieved through a manual tensioning device, which is simple in structure and easy to operate.

[0009] To achieve the above objectives, the present invention adopts the following technical solution: A large-tonnage insulator clamp for ultra-high voltage lines with a force measuring system includes a first clamp seat for clamping a first insulator and a second clamp seat for clamping a second insulator. The first clamp seat is connected to a first tensioning device and a second tensioning device at its two ends respectively. The first tensioning device is connected to one end of the second clamp seat through a first sensing unit, and the second tensioning device is connected to the other end of the second clamp seat through a second sensing unit. The first tensioning device and the second tensioning device tension the first clamp seat and the second clamp seat. The first sensing unit is used to detect the tension of the first tensioning device, and the second sensing unit is used to detect the tension of the second tensioning device. At this time, the insulator to be replaced between the first insulator and the second insulator is not under force, so that it can be replaced.

[0010] Preferably, the first clamp holder and the second clamp holder have the same structure. The first clamp holder includes a clamp body and a clamp cover. One end of the clamp body and the clamp cover are hinged, and the other end of the clamp body and the clamp cover are detachably connected. Both ends of the clamp body have connection holes for connecting the first tensioning device / the second tensioning device. The inner walls of both the clamp body and the clamp cover are provided with sub-clamps for clamping the first insulator. The sub-clamps are detachably connected to the clamp body and the clamp cover.

[0011] Preferably, the clamp body is hinged with a quick-release screw, which has a fastening screw; the clamp cover includes a cover body, one end of which is provided with a cover boss, and a through groove is provided on the cover boss for the fastening screw to extend into.

[0012] Preferably, the first tensioning device and the second tensioning device have the same structure. The first tensioning device includes a spur gear screw, and the two ends of the spur gear screw are respectively connected to two identical screw spools. The two screw spools are respectively connected to a first clamp seat and a first sensing unit. The spur gear screw is connected to a hand assembly that drives its rotation. The manual assembly drives the spur gear screw to rotate, causing both ends of the spur gear screw to enter or exit the screw drum.

[0013] Preferably, the hand assembly includes a pressure cylinder, a handle head is provided at the end of the pressure cylinder, the handle head has a hole for accommodating an optical shaft gear, a double-headed pawl is also hinged on the handle head, and a ball head pin and an elastic element are installed inside the pressure cylinder; The elastic element causes the ball head pin to abut against the double-headed pawl, and one head of the double-headed pawl to mesh with the optical shaft gear. When the pressure handle is turned, the double-headed pawl drives the optical shaft gear to rotate.

[0014] Preferably, the first tensioning device further includes a force-amplifying transmission gear set, which includes a transmission shaft. A first transmission gear and a second transmission gear are coaxially arranged on the transmission shaft. The diameter of the first transmission gear is larger than the diameter of the second transmission gear. The first transmission gear meshes with an optical shaft gear, and the second transmission gear meshes with a spur gear screw.

[0015] Preferably, the optical axis gear is rotatably mounted on the optical axis body, and the end of the optical axis body is provided with a quick-acting and limiting part.

[0016] Preferably, the spur gear screw includes a screw body, a screw gear is provided in the middle of the screw body, the two ends of the screw body have threads with opposite directions of rotation, and both screw drums have screw holes that are adapted to the threads of the aforementioned screw body.

[0017] Preferably, the first tensioning device further includes a shaft support, which has a first support hole for the optical shaft body to pass through and a second support hole for the wire spool to pass through; The first tensioning device further includes a shaft tooth support, which has a third support hole for the optical shaft body to pass through, a fourth support hole for the lead screw body to pass through, and a fifth support hole for the transmission shaft to pass through.

[0018] Preferably, the first sensing unit and the second sensing unit have the same structure. The first sensing unit includes a support body, and the two ends of the support body are respectively connected to a first tensioning device and a second clamp seat. The support body is provided with a sensor that detects its deformation and converts its deformation signal into a force signal.

[0019] The beneficial effects of this invention are as follows: The sensing unit is integrated into the load-bearing path and can display information such as tension force, battery level, and channel address in real time. It also features zeroing, unit switching, and parameter setting functions. Furthermore, it supports wireless data transmission, facilitating ground monitoring and data recording, and providing quantitative data for maintenance quality assessment.

[0020] The clamp base and its internal sub-clamps are detachably connected. When the model and specifications of the insulator change, the appropriate sub-clamp can be replaced, which greatly expands the application range of the clamp and reduces the unnecessary labor of workers passing tools.

[0021] The tensioning device features a hand assembly and a force-amplifying gear set. By operating the hand assembly, the connected pawl and gear transmission are driven, which in turn rotates the spur gear screw. The rotation of the spur gear screw causes the drum to move laterally, completing the tensioning or loosening action required for insulator replacement. A large-diameter first transmission gear drives a small-diameter second transmission gear, amplifying the torque. The long handle increases the operating torque, and the small-step transmission of the optical shaft gear makes transferring heavy loads easy and controllable, reducing work intensity. Spring preload ensures reliable pawl engagement at any working angle, preventing disengagement due to vibration or load changes. The drum and spur gear screw use a self-locking thread, preventing reverse rotation due to gravity or load, providing secondary protection. A ball-head pin reduces friction with the pawl, allowing for more flexible swing. The set screw adjusts the spring preload to adapt to different load conditions. A quick-acting and limiting structure prevents excessive drum movement that could cause the shaft support to disengage, ensuring safe travel. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the device; Figure 2 This is a schematic diagram of the overall structure of the clamp holder; Figure 3 This is the front view of the fixture cover; Figure 4 This is a top view of the clamp's top cover; Figure 5 This is a top view of the sub-card; Figure 6 This is the front view of the quick-release screw; Figure 7 This is a top view of the clamp body; Figure 8 This is the front view of the fixture body; Figure 9 This is a schematic diagram of the overall structure of the tensioning device; Figure 10 This is a sectional view of the hand assembly; Figure 11 This is a schematic diagram of the handle head structure; Figure 12 This is a cross-sectional view of the handle head; Figure 13 This is a schematic diagram of the force-increasing transmission gear set; Figure 14 This is a schematic diagram of the lead screw optical axis; Figure 15 This is a schematic diagram of the quick-acting and limiting parts; Figure 16 This is a schematic diagram of the wire spool structure; Figure 17 This is a schematic diagram of a shaft-supported structure. Figure 18 This is a sectional view of a spur gear lead screw; Figure 19 This is a schematic diagram of the limit card structure; Figure 20 This is the front view of the shaft gear support; Figure 21 This is the left view of the hand assembly (showing the assembly relationship between the limit clip and the shaft tooth support). Figure 22 This is a partial top view of the tensioning device; Figure 23 This is a partial sectional view of the tensioning device; Figure 24 This is the front view of the sensing unit.

[0023] The accompanying drawings are for illustrative purposes only and should not be construed as limiting the scope of this patent. To better illustrate this embodiment, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings. Detailed Implementation

[0024] The invention will now be further described with reference to the accompanying drawings.

[0025] Example like Figure 1 As shown, the UHV line large-tonnage insulator clamp with force measurement system in this embodiment includes a first clamp seat 1 for clamping a first insulator (not shown in the figure) and a second clamp seat 4 for clamping a second insulator (not shown in the figure). The two ends of the first clamp seat 1 are respectively connected to a first tensioning device 2 and a second tensioning device 5. The first tensioning device 2 is connected to one end of the second clamp seat 4 through a first sensing unit 3, and the second tensioning device 5 is connected to the other end of the second clamp seat 4 through a second sensing unit 6.

[0026] Ultra-high voltage AC / DC transmission lines require insulator string structures that possess both electrical insulation and mechanical connection properties to connect the tower body to the live conductor. Common insulator string types include tension insulator strings arranged horizontally to bear the tension of the conductor along the line direction, and suspension (or V-shaped) insulator strings arranged perpendicular or inclined to the ground to bear the weight of the conductor. Both types mainly consist of connecting hardware and disc suspension insulators (available in glass and ceramic materials) connected in series. This clamp can be used to replace any disc suspension insulator in either of these two types of insulator strings. This embodiment mainly describes the process of replacing a single disc suspension insulator in a tension insulator string. ① Stress Analysis Before Operation: Transmission line conductors are catenary conductors. Their tension is mainly affected by parameters such as the weight per unit length of the conductor (including attachments), span, line length (affected by thermal expansion and contraction), height difference between the two hanging points, and wind load. During replacement operations, weather conditions are restricted, such as ensuring the conductor is not covered with ice and the wind force is no greater than level 5, thereby controlling the conductor tension at a low safety level. The stress on a single insulator string connected to the conductor via a complex hardware structure is generally 100-120kN. ② Operation Process Description: When using this clamp to replace a single insulator, the general method is to use a four-for-two or five-for-three clamp method. The four-for-two clamp method is used as an example. The replacement process involves grouping four adjacent insulators in the insulator string together. Two clamp seats clamp the two outer insulators respectively, and then two tensioning devices tighten them, so that the two inner insulators are no longer under tension. The two inner insulators can then be removed and replaced with new insulators. The five-for-three clamp method is similar, that is, grouping five adjacent insulators together and replacing the three inner insulators. ③ Stress Analysis During Replacement: During the aforementioned replacement process, when tensioning with the tensioning device, the two clamps lock the two insulators at both ends, pulling them inward. This reduces the total length of the insulator string, which is equivalent to increasing the span while keeping the conductor length constant. The conductor tension will increase rapidly and non-linearly. If the tension is too high, the tension on the insulator string (already transferred to the tensioning device) will exceed the design working load of the clamp, thereby reducing the safety factor and causing safety risks, potentially leading to serious accidents.

[0027] Therefore, in this embodiment, during the tensioning process of the first tensioning device 2 and the second tensioning device 5 on the first clamp seat 1 and the second clamp seat 4, the first sensing unit 3 can detect the tension of the first tensioning device 2, and the second sensing unit 6 can detect the tension of the second tensioning device 5. When the tension exceeds the dangerous set value, an alarm signal is issued in a timely manner. When the tension is within the allowable range, the insulator to be replaced between the first insulator and the second insulator is not under stress, and it can be replaced at this time.

[0028] like Figure 2 , Figure 7 and Figure 8As shown, the first clamp holder 1 and the second clamp holder 4 have the same structure. The first clamp holder 1 includes a clamp body 1-7 and a clamp cover 1-2. The clamp body 1-7 is provided with four body protrusions 1-7-1, which are symmetrically arranged in pairs at both ends of the clamp body 1-7. The two body protrusions 1-7-1 in each pair are symmetrically arranged in the width direction of the clamp body 1-7. The lower end of the clamp cover 1-2 is located between two body protrusions 1-7-1. Two main body bosses 1-7-1 are machined with two main body pin holes 1-7-2, and a first pin 1-1 and a second pin 1-6 are fixedly installed inside them respectively. The inner wall of the clamp body 1-7 is machined with a first sub-clamp mounting groove 1-7-3. The two ends of the clamp body 7 are machined with connecting holes 1-7-4. The two connecting holes 1-7-4 are used to connect the first tensioning device 2 and the second tensioning device 5 respectively (the second clamp seat 4 is slightly different from it. The difference is that the two connecting holes of the second clamp seat 4 are connected to the first sensing unit 3 and the second sensing unit 6 respectively).

[0029] like Figure 3 and Figure 4 As shown, the upper cover 1-2 of the clamp is made of titanium alloy and includes an upper cover body 1-2-2. The inner wall of the upper cover body 1-2-2 is machined with a second sub-clamp mounting groove. One end of the upper cover body 1-2-2 is machined with an upper cover pin hole 1-2-1 for mounting the first pin shaft 1-1. The other end of the upper cover body 1-2-2 is provided with an upper cover boss 1-2-4. A through groove 1-2-7 is opened in the middle of the upper cover boss 1-2-4. Two sets of upper cover plates 1-2-5 are provided at the lower edge of the upper cover boss 1-2-4 near the through groove 1-2-7. The two sets of upper cover plates 1-2-5 are symmetrically arranged on both sides of the through groove 1-2-7. A semi-circular second pin groove 1-2-6 is provided at the lower edge of the upper cover plate 1-2-5. When the clamp seat is locked, the second pin shaft 1-6 is located in the second pin groove 1-2-6.

[0030] like Figure 2 and Figure 5As shown, there are two symmetrically arranged sub-clamps 1-3, made of 40Cr alloy steel. When the clamp base is locked, the two sub-clamps 1-3 cooperate to clamp the insulator steel cap. Sub-clamp 1-3 includes an integrally formed sub-clamp body 1-3-2. One end of the sub-clamp body 1-3-2 has a sub-clamp boss 1-3-1 protruding outward from its outer wall. The first sub-clamp mounting groove 1-7-3 and the second sub-clamp mounting groove are provided with stepped grooves that are adapted to the sub-clamp boss 1-3-1. The sub-clamp body 1-3-2 has a groove 1-3-3 that is adapted to the insulator steel cap. The groove 1-3-3 is adapted to different manufacturers and specifications of insulators. During on-site construction, workers can replace the sub-clamp 1-3 with the corresponding groove 1-3-3 according to different insulators, so that the same clamp base can be adapted to different insulators, forming a universal clamp structure with one clamp for multiple uses. The side wall of the sub-card body 1-3-2 is radially machined with sub-card mounting holes 1-3-4. The first sub-card connection hole 1-7-5 is provided in the card body 1-7. The second sub-card connection hole 1-2-3 is provided in the upper cover body 1-2-2. The number of sub-card mounting holes 1-3-4, the first sub-card connection holes 1-7-5, and the second sub-card connection holes 1-2-3 are matched. The sub-card and the card holder can be detachably connected by the first screw 1-8.

[0031] like Figure 2 and Figure 6 As shown, the first clamping seat 1 also includes a quick-clamping screw 1-4, which comprises an integrally formed fastening screw 1-4-1 and a collar 1-4-2. The collar 1-4-2 has a second pin hole 1-4-3, which is fitted onto the outside of the second pin 1-6, allowing the collar 1-4-2 to rotate relative to the second pin 1-6. When the clamping seat is locked, the operator rotates the fastening screw 1-4-1 to enter the through groove 1-2-7, then installs the nut 1-5 onto the fastening screw 1-4-1 and tightens it, thus clamping the insulator. At this time, the second pin 1-6 is located within the second pin groove 1-2-6. When the clamping seat is opened, the operator loosens the nut 1-5, rotates the fastening screw 1-4-1 to disengage from the through groove 1-2-7, and then lifts the clamping cover 1-2.

[0032] like Figure 1 and Figure 9 As shown, the first tensioning device 2 and the second tensioning device 5 have the same structure. The first tensioning device 2 includes a spur gear screw 2-7. The two ends of the spur gear screw 2-7 are respectively connected to two identical screw drums 2-5. The two screw drums 2-5 are respectively connected to the first clamp seat 1 and the first sensing unit 3. The spur gear screw 2-7 is connected to a hand assembly 2-1 that drives its rotation. After both clamps lock the two insulators, the manual assembly 2-1 of the two tensioning devices drives the spur gear screw 2-7 to rotate, causing both ends of the spur gear screw 2-7 to simultaneously enter or exit the screw drum 2-5. During the entry into the screw drum 2-5, the two locking insulators are tensioned, so that the insulator to be replaced in the middle is no longer under stress, making replacement easier. After replacement, the insulator is removed from the screw drum 2-5. During this process, the two locking insulators are loosened, allowing the replaced insulator in the middle to gradually bear normal stress. Then, the clamps are opened to release the locking of the insulator, and the next operation can begin.

[0033] like Figure 9 — Figure 12 As shown, the hand assembly 2-1 includes a pressure cylinder 2-1-8, a handle head 2-1-1 is provided at the end of the pressure cylinder 2-1-8, a double-headed pawl 2-1-2 is also hinged on the handle head 2-1-1, and a ball head pin 2-1-3 and an elastic element 2-1-4 are installed inside the pressure cylinder 2-1-8. The handle head 2-1-1 is integrally machined from the handle head body 2-1-1-1 and the handle head connecting rod 2-1-1-2. The handle head body 2-1-1-1 has a positive ball table structure. The bottom surface of the ball table structure is machined with a stepped mounting hole 2-1-1-5. The large diameter part of the stepped mounting hole 2-1-1-5 is fitted onto the optical shaft gear 2-3-2 of the lead screw optical shaft 2-3, and the small diameter part serves as a limiting plate to restrict the lateral displacement of the optical shaft gear 2-3-2. The handlebar connecting rod 2-1-1-2 is a stepped cylinder. The large-diameter end of the cylinder is integrally formed with the handlebar body 2-1-1-1, and the small-diameter end is fixed to the inner end of the pressure handle cylinder 2-1-8. A pawl hole 2-1-1-3 is machined inside the handlebar connecting rod 2-1-1-2. A third pin hole 2-1-1-4, which communicates with the pawl hole 2-1-1-3, is machined on the side wall of the handlebar connecting rod 2-1-1-2. A pawl pin 2-1-7 is fixedly installed in the third pin hole 2-1-1-4. The pawl pin 2-1-7 has an anti-disengagement structure (such as a cotter pin or interference fit). The pawl 2-1-2 is installed in the pawl hole 2-1-1-3 through the pawl pin 2-1-7, and the pawl 2-1-2 can rotate around the pawl pin 2-1-7. The center of the right end of the head connecting rod 2-1-1-2 is axially machined with a top pin movable hole 2-1-1-6 that communicates with the pawl hole 2-1-1-3. The top pin movable hole 2-1-1-6 is machined with an internal thread, which is used to install a second screw 2-1-5. The right end of the elastic element 2-1-4 is installed on the second screw 2-1-5, and the left end of the elastic element 2-1-4 is connected to the upper end face of the ball head top pin 2-1-3. Under the elastic force of the elastic element 2-1-4, the top of the ball head pin 2-1-3 is tightly attached to the end face of the pawl 2-1-2, causing one head of the double-headed pawl 2-1-2 to mesh with the optical shaft gear 2-3-2. When the pressure handle 2-1-8 is turned, the optical shaft gear 2-3-2 can be rotated in one direction through the double-headed pawl 2-1-2. The double-headed pawl 2-1-2 can be turned so that its other head meshes with the optical shaft gear 2-3-2. At this time, turning the pressure handle 2-1-8 can drive the optical shaft gear 2-3-2 to rotate in the opposite direction.

[0034] like Figure 10 As shown, to make operating the lever cylinder 2-1-8 easier and more convenient, a handle 2-1-6 is also provided inside the lever cylinder 2-1-8. The handle 2-1-6 is connected to the handle rosette 2-1-10 via a third screw 2-1-9. The surface of the handle rosette 2-1-10 is machined with an anti-slip pattern to increase the friction between the operator's hand and the handle head, preventing slippage when hands are wet or when applying force, thus improving operating comfort and safety.

[0035] In this embodiment, the elastic element 2-1-4 is a spring, and the second screw 2-1-5 presses the right end of the elastic element 2-1-4 onto the end face of the top pin movable hole 2-1-1-6. By adjusting the screwing depth of the second screw 2-1-5, the pre-compression of the spring can be changed, thereby adjusting the meshing pressure between the double-headed pawl 2-1-2 and the gear to adapt to different load requirements. The lower end of the ball-headed top pin 2-1-3 is a ball head, which can reduce the friction between it and the double-headed pawl 2-1-2, making the swing of the double-headed pawl 2-1-2 more flexible; at the same time, it concentrates the elastic force of the elastic element 2-1-4 onto the double-headed pawl 2-1-2, ensuring that the double-headed pawl 2-1-2 always presses against the gear.

[0036] like Figure 13 As shown, the first tensioning device 2 also includes a force-amplifying transmission gear set 2-2. The force-amplifying transmission gear set 2-2 includes a transmission shaft 2-2-3. A first transmission gear 2-2-1 and a second transmission gear 2-2-2 are coaxially mounted on the transmission shaft 2-2-3. The diameter of the first transmission gear 2-2-1 is larger than the diameter of the second transmission gear 2-2-2. The first transmission gear 2-2-1 meshes with the optical shaft gear 2-3-2, and the second transmission gear 2-2-2 meshes with the spur gear screw 2-7. The force-amplifying transmission gear set 2-2 amplifies the driving force transmitted from the optical shaft gear 2-3-2, and then transmits this amplified torque to the spur gear screw 2-7 to drive its rotation, making it easier for the operator.

[0037] like Figure 14 As shown, the optical shaft gear 2-3-2 is rotatably mounted on the optical shaft body 2-3-1, and the end of the optical shaft body 2-3-1 is provided with a quick-release and limiting part 2-4 to prevent the shaft support 2-6 from disengaging from the optical shaft body 2-3-1.

[0038] It should be noted that the thickness of the optical shaft gear 2-3-2 is relatively large (approximately equal to the sum of the thicknesses of the stepped mounting hole 2-1-1-5 and the first transmission gear 2-2-1). This design allows a portion of the optical shaft gear 2-3-2 to extend into the stepped mounting hole 2-1-1-5 and rotate under the drive of the double-headed pawl 2-1-2, while the other portion meshes with the first transmission gear 2-2-1, driving the first transmission gear 2-2-1 to rotate. For example... Figure 22 As shown, an adjusting shim 2-12 is also provided between the hand assembly 2-1 and the shaft gear support 2-9. This adjusting shim is a common plastic flat shim, which is used to clamp the hand assembly 2-1 so that the small diameter part of the stepped mounting hole 2-1-1-5 is in close contact with the end of the optical shaft gear 2-3-2, thereby limiting the lateral displacement of the hand assembly 2-1 on the optical shaft gear 2-3-2.

[0039] like Figure 15As shown, one end of the quick-action and limiting part 2-4 is provided with a central hole 2-4-2 for the optical axis body 2-3-1 to be inserted. The side wall of the quick-action and limiting part 2-4 is provided with a first limiting hole 2-4-1, which is a threaded hole. After the fourth screw is inserted, the quick-action and limiting part 2-4 can be fixed on the optical axis body 2-3-1.

[0040] like Figure 23 As shown, after the optical axis body 2-3-1 is inserted into the center hole 2-4-2, it is radially tightened with the fourth screw. The diameter of the quick-acting and limiting part 2-4 is larger than the upper diameter of the shaft support 2-6 to prevent the shaft support 2-6 from detaching from the optical axis body 2-3-1 when it slides with the wire drum 2-5.

[0041] like Figure 16 As shown, the wire drum 2-5 includes a wire drum body 2-5-1, a connecting plate 2-5-2, and a mounting platform 2-5-3. The wire drum body 2-5-1 is a hollow cylindrical rod. The connecting plate 2-5-2 is integrally machined at one end of the wire drum body 2-5-1. The connecting plate 2-5-2 is connected to the first clamping seat 1 or the first sensing unit 3 by a fifth screw (the left wire drum 2-5 is connected to the connecting hole 1-7-4, and the right wire drum 2-5 is connected to the first sensing unit 3). The other end of the wire drum body 2-5-1 is machined with a mounting platform 2-5-3. The inner wall of the mounting platform 2-5-3 is machined with a threaded screw hole 2-5-4. A spur gear screw 2-7 is fitted into the screw hole 2-5-4.

[0042] like Figure 9 and Figure 17 As shown, the first tensioning device 2 also includes a shaft support 2-6, which has a first support hole 2-6-1 through which the optical axis body 2-3-1 passes and a second support hole 2-6-2 through which the wire spool 2-5 (i.e., the mounting platform 2-5-3) passes; a copper sleeve 2-10 can also be installed on the inner wall of the first support hole 2-6-1 to reduce the friction between it and the optical axis body 2-3-1.

[0043] like Figure 18 As shown, the spur gear screw 2-7 includes a screw body 2-7-1, with a screw gear 2-7-2 located in the middle of the screw body 2-7-1. The screw gear 2-7-2 meshes with the second transmission gear 2-2-2. The two ends of the screw body 2-7-1 have threads with opposite directions of rotation, and the threads at both ends are respectively screwed into two screw holes 2-5-4. When the screw gear 2-7-2 rotates, the screw body 2-7-1 rotates within the screw holes 2-5-4, which will drive the two screw drums 2-5 to move towards each other (at which time the tensioning device shortens) or away from each other (at which time the tensioning device extends).

[0044] like Figure 20As shown, the first tensioning device 2 also includes a gear support 2-9, with two gear supports 2-9 symmetrically arranged. The gear supports 2-9 have a third support hole 2-9-2 for the optical shaft body 2-3-1 to pass through, a fourth support hole 2-9-1 for the lead screw body 2-7-1 to pass through, and a fifth support hole 2-9-3 for the transmission shaft 2-2-3 to pass through. The hand assembly 2-1, the optical shaft gear 2-3-2, and the lead screw gear 2-7-2 are all located between the two gear supports 2-9, connecting the force-increasing transmission gear set 2-2, the lead screw optical shaft 2-3, and the spur gear lead screw 2-7 together via the gear supports 2-9.

[0045] like Figure 19 and Figure 21 As shown, the first tensioning device 2 also includes two limit clips 2-8, which are symmetrically arranged and located on the outer sides of the two shaft tooth supports 2-9 respectively. The limit clip 2-8 includes a limit clip body 2-8-1, on which are provided a first limit groove 2-8-2 (for radial limiting of the force-increasing transmission gear set 2-2), a second limit groove 2-8-3 (for radial limiting of the lead screw shaft 2-3), and a third limit groove 2-8-4 (for radial limiting of the spur gear lead screw 2-7).

[0046] Two limit cards 2-8 and two shaft tooth supports 2-9 are provided and correspond one to one. The corresponding limit cards 2-8 and shaft tooth supports 2-9 are connected through the threaded hole 2-9-4 of the shaft tooth support 2-9 and the light hole of the limit card 2-8.

[0047] During use, this clamp first uses two clamp holders to secure the two insulators at both ends. Then, the two tensioning devices are operated to tension the two insulators, eliminating the tension between them and facilitating the replacement of the insulator in the middle. The specific operating procedure is as follows: During forward swing (tensioning stroke): The operator presses the handle rose 2-1-10 backward → the handle rod 2-1-6 drives the handle head 2-1-1 to swing backward together → at this time, one side of the double-headed pawl 2-1-2 is tightly attached to the gear drive surface under the action of the elastic element 2-1-4 → one side of the double-headed pawl 2-1-2 firmly locks the optical shaft gear 2-3-2 → the thrust is transmitted to the optical shaft gear 2-3-2 through the double-headed pawl 2-1-2 → driving the optical shaft gear 2-3-2 to rotate one tooth → the optical shaft gear 2-3-2 drives the first transmission gear 2-2-1 and the second transmission gear 2-2-2 to rotate → driving the lead screw gear 2-7-2 to rotate → the lead drum 2-5 advances a certain distance.

[0048] During reverse swing (scaling stroke): The operator pushes the handle 2-1-10 forward → the handle 2-1-6 swings in the reverse direction → the double-headed pawl 2-1-2 rotates around the pawl pin 2-1-7 so that the other head of the pawl contacts and presses against the other side of the ratchet's inclined surface → at this time, the double-headed pawl 2-1-2 is tightly attached to the drive surface of the optical shaft gear 2-3-2 under the action of the elastic element 2-1-4 → the other head of the pawl 2-1-2 firmly locks the optical shaft gear 2-3-2 → the thrust is transmitted to the optical shaft gear 2-3-2 through the pawl 2-1-2 → driving the optical shaft gear 2-3-2 to rotate one tooth in the opposite direction → the optical shaft gear 2-3-2 drives the first transmission gear 2-2-1 and the second transmission gear 2-2-2 to rotate → driving the lead screw gear 2-7-2 to rotate → the lead screw 2-5 retracts a certain distance.

[0049] The double-headed ratchet 2-1-2 drives the spur gear screw 2-7 to move. Through continuous unidirectional movement, the tensioning or loosening actions required for replacing large-tonnage insulators are gradually completed. The screw's self-locking function (the spur gear screw 2-7 and the screw drum 2-5 have a self-locking function due to their threaded connection) prevents reverse rotation due to gravity or load, providing secondary protection for the tensioning device. The long handle amplifies the operating torque, and combined with the ratchet's small stepping, makes the transfer of large-tonnage loads easy and controllable. The second screw 2-1-5 adjusts the preload of the adjustable elastic element 2-1-4, ensuring reliable engagement while allowing slippage protection in case of overload. The double-headed ratchet 2-1-2, elastic element 2-1-4, ball-head pin 2-1-3, etc., are all integrated inside the handle, resulting in a compact structure suitable for high-altitude live-line working environments.

[0050] like Figure 24 As shown, the first sensing unit 3 and the second sensing unit 6 have the same structure. The first sensing unit 3 includes a support body 3-1. The two ends of the support body 3-1 are respectively connected to the first tensioning device 2 and the second clamp seat 4. The support body 3-1 is provided with a sensor that detects its deformation and converts its deformation signal into a force signal.

[0051] The first tensioning device 2 and the second clamp seat 4 are connected to both ends of the support body 3-1 via connecting bolts 3-5. The sensors and their connected data acquisition and display circuits are all housed inside the support body 3-1. When the tensioning device is tightened, the support body 3-1 will undergo strain deformation. At this time, the sensors transmit the monitored signals to the data acquisition and display circuit, which, after calibration and calculation, displays and alarms, and can also perform wireless data transmission. Data transmission uses 2.4G wireless transmission. The sensor communication address is settable, and the communication distance in open areas is greater than 100 meters. Measurement data or alarm status of the sensors is received and displayed via a dedicated receiver display or an Android mobile APP or WeChat mini-program. A single receiver can simultaneously receive measurement data from 10 sensors. Each sensor has a modifiable communication address. The data receiver reads the measurement data of each sensor using a patrol inspection method, with a patrol inspection cycle of 0.5 seconds for the 10 sensors. This is existing conventional technology and will not be described in detail in this embodiment.

[0052] The sensor is also connected to an alarm module with a configurable alarm value. When an alarm is triggered, a buzzer sounds and an alarm message is displayed on the screen. As mentioned earlier, in this implementation case, assuming the insulator string bears a tension of 120 kN under normal conditions, and after reserving a certain safety margin, the tension on the conductor is set to exceed the rated working load of the clamp when it reaches 145 kN. By setting the alarm threshold to 145 kN, during normal insulator replacement, under normal operating conditions, after the worker tightens the tensioning device to approximately 120 kN, it can be visually observed that the insulator to be replaced is no longer under tension (i.e., not under stress), and replacement can proceed. However, if the worker lacks experience, or if multiple workers coordinate improperly, and the tensioning device is over-tightened, the conductor tension may become too high. This could result in the sensor displaying a tension value exceeding the alarm threshold, but the insulator to be replaced still being under stress, or the adjacent insulator location being inconvenient for disassembly, making replacement impossible. Continuing to tighten in this situation could damage the clamp and potentially lead to a safety accident. Therefore, the alarm module should issue a signal at this time to remind that it is not advisable to work at this time, or to pay special attention to this section of insulator, improve the work method, and ensure safety.

[0053] The side wall of the carrier body 3-1 can also be provided with a charging port, which is electrically connected to the lithium battery located inside the carrier body 3-1 for charging the lithium battery. The lithium battery powers the data acquisition and display circuit and the sensor.

[0054] A protective panel 3-2 is detachably installed on the support body 3-1, which facilitates the maintenance and replacement of components installed in the support body 3-1, and also provides a certain degree of protection.

[0055] A display screen 3-3 is provided on the protection panel 3-2, which is electrically connected to the data acquisition and display circuit and is used to display information such as measurement values, battery level, and channel address.

[0056] A button 3-4 is also provided on the protection panel 3-2, which is electrically connected to the data acquisition and display circuit. In this embodiment, a total of four buttons are provided, which can be used to turn the power on and off, zero the measurement value, switch units, and set parameters.

[0057] When in use, this device can be customized with different inner edge dimensions for various insulators (because under normal circumstances, a transmission line often has insulators of different tonnages, models, and manufacturers due to multiple suppliers and various technical upgrades and overhauls). Each sub-clip 1-3 has the same outer edge dimension, fitting the inner edge of the clamp base. When replacing insulators of different models, simply install the corresponding sub-clip 1-3 into the clamp base, forming a universal clamp with multiple uses.

[0058] Meanwhile, the tensioning device combines the efficient force amplification of gear transmission with the precise self-locking of screw transmission. The mechanical gear set speed-changing screw makes the tool more labor-saving. At the same time, the tensioning device has a built-in secondary protection (i.e., screw self-locking), which can prevent the potential hazards caused by screw disengagement and ensure the safety of operators.

[0059] The above embodiments are not intended to limit the shape, material, structure, etc. of the present invention in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

[0060] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to facilitate the description of this invention and to simplify the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of this invention.

[0061] If the terms "first" or "second" are used in this document to define components, those skilled in the art should know that the use of "first" or "second" is merely for the convenience of describing the invention and simplifying the description, and unless otherwise stated, the above terms have no special meaning.

[0062] 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. However, 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.

Claims

1. A clamp for large-tonnage insulators on ultra-high voltage lines with a force measuring system, comprising a first clamping seat (1) for clamping a first insulator and a second clamping seat (4) for clamping a second insulator, characterized in that: The first clamp seat (1) is connected to a first tensioning device (2) and a second tensioning device (5) at both ends. The first tensioning device (2) is connected to one end of the second clamp seat (4) through a first sensing unit (3), and the second tensioning device (5) is connected to the other end of the second clamp seat (4) through a second sensing unit (6). The first tensioning device (2) and the second tensioning device (5) tension the first clamp seat (1) and the second clamp seat (4). The first sensing unit (3) is used to detect the tension of the first tensioning device (2), and the second sensing unit (6) is used to detect the tension of the second tensioning device (5). At this time, the insulator to be replaced between the first insulator and the second insulator is not under force, so that it can be replaced.

2. The UHV line large-tonnage insulator clamp with a force measuring system according to claim 1, characterized in that, The first clamp holder (1) and the second clamp holder (4) have the same structure. The first clamp holder (1) includes a clamp body (1-7) and a clamp cover (1-2). One end of the clamp body (1-7) and the clamp cover (1-2) are hinged together, and the other end of the clamp body (1-7) and the clamp cover (1-2) are detachably connected. Both ends of the clamp body (1-7) have connection holes (1-7-4) for connecting the first tensioning device (2) / the second tensioning device (5). The inner walls of both the clamp body (1-7) and the clamp cover (1-2) are provided with a sub-clamp (1-3) for clamping the first insulator. The sub-clamp (1-3) is detachably connected to both the clamp body (1-7) and the clamp cover (1-2).

3. The UHV line large-tonnage insulator clamp with a force measuring system according to claim 2, characterized in that, The clamp body (1-7) is hinged with a quick-release screw (1-4), and the quick-release screw (1-4) has a fastening screw (1-4-1); the clamp cover (1-2) includes a cover body (1-2-2), one end of the cover body (1-2-2) is provided with a cover boss (1-2-4), and the cover boss (1-2-4) is provided with a through groove (1-2-7) for the fastening screw (1-4-1) to extend into.

4. The UHV line large-tonnage insulator clamp with a force measuring system according to claim 1, characterized in that, The first tensioning device (2) and the second tensioning device (5) have the same structure. The first tensioning device (2) includes a spur gear screw (2-7). The two ends of the spur gear screw (2-7) are respectively connected to two identical screw spools (2-5). The two screw spools (2-5) are respectively connected to the first clamp seat (1) and the first sensing unit (3). The spur gear screw (2-7) is connected to a hand assembly (2-1) that drives its rotation. The hand assembly (2-1) drives the spur gear screw (2-7) to rotate, so that both ends of the spur gear screw (2-7) enter the screw drum (2-5) or move out of the screw drum (2-5).

5. The UHV line large-tonnage insulator clamp with a force measuring system according to claim 4, characterized in that, The hand assembly (2-1) includes a pressure handle cylinder (2-1-8), and a handle head (2-1-1) is provided at the end of the pressure handle cylinder (2-1-8). The handle head (2-1-1) has a hole for accommodating an optical shaft gear (2-3-2). A double-headed pawl (2-1-2) is also hinged on the handle head (2-1-1). A ball head pin (2-1-3) and an elastic element (2-1-4) are installed inside the pressure handle cylinder (2-1-8). The elastic element (2-1-4) causes the ball head pin (2-1-3) to abut against the double-headed pawl (2-1-2), and engages one head of the double-headed pawl (2-1-2) with the optical shaft gear (2-3-2). When the pressure handle cylinder (2-1-8) is turned, the optical shaft gear (2-3-2) is driven to rotate through the double-headed pawl (2-1-2).

6. The UHV line large-tonnage insulator clamp with a force measuring system according to claim 5, characterized in that, The first tensioning device (2) further includes a force-increasing transmission gear set (2-2), which includes a transmission shaft (2-2-3). The transmission shaft (2-2-3) is coaxially provided with a first transmission gear (2-2-1) and a second transmission gear (2-2-2). The diameter of the first transmission gear (2-2-1) is larger than the diameter of the second transmission gear (2-2-2). The first transmission gear (2-2-1) meshes with the optical shaft gear (2-3-2), and the second transmission gear (2-2-2) meshes with the spur gear screw (2-7).

7. The UHV line large-tonnage insulator clamp with a force measuring system according to claim 6, characterized in that, The optical shaft gear (2-3-2) is rotatably mounted on the optical shaft body (2-3-1), and the end of the optical shaft body (2-3-1) is provided with a quick-acting and limiting part (2-4).

8. The UHV line large-tonnage insulator clamp with a force measuring system according to claim 7, characterized in that, The spur gear screw (2-7) includes a screw body (2-7-1), a screw gear (2-7-2) is provided in the middle of the screw body (2-7-1), the two ends of the screw body (2-7-1) have threads with opposite directions of rotation, and the two screw drums (2-5) each have screw holes (2-5-4) that are adapted to the threads of the aforementioned screw body (2-7-1).

9. The UHV line large-tonnage insulator clamp with a force measuring system according to claim 8, characterized in that, The first tensioning device (2) further includes a shaft support (2-6), on which a first support hole (2-6-1) for the optical shaft body (2-3-1) to pass through and a second support hole (2-6-2) for the wire spool (2-5) to pass through are provided. The first tensioning device (2) further includes a shaft tooth support (2-9), which has a third support hole (2-9-2) for the optical shaft body (2-3-1) to pass through, a fourth support hole (2-9-1) for the lead screw body (2-7-1) to pass through, and a fifth support hole (2-9-3) for the transmission shaft (2-2-3) to pass through.

10. The large-tonnage insulator clamp for ultra-high voltage lines with a force measuring system according to claim 1, characterized in that, The first sensing unit (3) and the second sensing unit (6) have the same structure. The first sensing unit (3) includes a bearing body (3-1). The two ends of the bearing body (3-1) are respectively connected to the first tensioning device (2) and the second clamp seat (4). The bearing body (3-1) is provided with a sensor that detects its deformation and converts its deformation signal into a force signal.

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