Universal porcelain cross arm replacement type composite insulator

Abstract

The utility model relates to an electric power equipment fitting, in particular to a universal porcelain cross arm replacement type composite insulator, which comprises a rod body, a fixing fitting and a wire hanging fitting, and the rod body comprises a circular glass fiber core rod and a silicon rubber jacket. The fixing fitting is made of a honeycomb structure high-strength cast steel material, the advantages of high strength, light weight, fatigue resistance, efficient space utilization, high flexibility and adaptability, cost saving, environmental protection, sustainability and the like are integrated, a labyrinth structure is designed, and the sealing performance, strength and stability of the connecting position are enhanced. The cable has the advantages of excellent mechanical property, enhanced insulating property, innovative connection design, convenient wire hanging fitting design, longer service life and wider application range, the reliability and safety of an electric power system can be remarkably improved, the maintenance cost is reduced, the environmental friendliness is improved, and the cable is suitable for popularization and application. And the width of the corridor is compressed through reasonable design, the house demolition amount is reduced, and remarkable social and economic benefits are brought.

Description

Technical Field

[0001] The utility model relates to an electric power equipment accessory, in particular to a universal porcelain cross-arm replacement type composite insulator. Background Art

[0002] As a traditional power line support device, porcelain crossarms have significant limitations. First, due to their fragile material, porcelain crossarms are prone to breakage during installation, transportation, and use, posing significant risks to the stable operation of power systems. Second, their relatively low mechanical strength makes them unable to withstand the challenges of inclement weather or long-term loads, leading to their proneness to breakage and impacting power safety. Furthermore, their heavy weight complicates installation and transportation, potentially placing additional stress on power poles. Furthermore, porcelain crossarms have poor weather resistance and are difficult to adapt to extreme climates, prone to performance degradation or even failure. Furthermore, traditional porcelain crossarms are often designed and manufactured for specific applications and pole shapes, lacking versatility. This limits their applicability across different transmission lines and poles, reducing their flexibility. In summary, porcelain crossarms have numerous limitations in terms of material strength, weight, weather resistance, and versatility. These limitations not only increase the cost and difficulty of power system maintenance but also pose a potential threat to the stability and security of power supply. Utility Model Content

[0003] To address the issues raised in the aforementioned background technology, this utility model provides a universal composite insulator that can replace porcelain crossarms. Compared to traditional porcelain crossarm insulators, this composite insulator exhibits significant advantages in terms of UV aging resistance and ability to meet the requirements of various transmission line scenarios, helping to improve the reliability and safety of power systems.

[0004] In order to achieve the above purpose, the technical solution adopted by the utility model is:

[0005] This universal porcelain crossarm replacement composite insulator primarily consists of a rod, fixing hardware, and a wire hanging hardware. The rod has a fixing hardware at one end and a wire hanging hardware at the other. The rod structure includes a core rod and an insulating sheath, which is placed over the outer surface of the core rod.

[0006] The rod body is composed of an insulating core rod and a silicone rubber insulating jacket. The insulating core rod is a round fiberglass rod. This material not only has excellent mechanical properties and can withstand bending loads from any direction on the horizontal plane, but also has stable insulation performance, thus meeting the insulation requirements. The silicone rubber insulating jacket serves as the outer insulation part of the crossarm and has excellent UV resistance and aging resistance, as well as good water-repellent and anti-fouling properties. This jacket provides effective protection for the internal structure. In addition, its outer wall is designed in an umbrella skirt shape. Such a structure can provide sufficient creepage distance to ensure that the crossarm can maintain sufficient insulation capacity under various weather conditions.

[0007] Among them, the fixing hardware is fastened to the rod body by crimping. The honeycomb structure combined with high-strength cast steel material makes the fixing hardware have an extremely high load-bearing capacity. This material has the characteristics of high strength and high hardness, can withstand large external forces and pressures, and ensure the stability and safety of the power lines. And the design of the honeycomb structure can effectively reduce the amount of material without sacrificing strength, thereby achieving lightweight hardware. This is not only convenient for installation and maintenance, but also reduces the load on the supporting structure. In particular, the end of the fixing hardware connected to the core rod is designed with a first maze structure. This design not only ensures the sealing performance of the fixing hardware connection, but also improves the strength and stability of the connection, reduces the direct impact and friction of the medium on the connection, and further extends the service life of the fixing hardware.

[0008] The wire hanging fitting utilizes a novel structure, specifically a wedge-shaped pressure block. The tail end of the fitting body is also crimped to the rod, supporting and suspending the wire. A traction hole is designed at the front end of the fitting body to facilitate installation. The pressure block utilizes a beveled contact surface with the wire, working in conjunction with the fastener to grip and secure the wire, maintaining a firm grip for various wire diameters within a certain range.

[0009] Compared with the prior art, the beneficial effects of the present invention are:

[0010] 1. Superior Mechanical Performance: The insulating core rod used in this utility model is a round fiberglass rod, which has excellent mechanical properties and can withstand bending loads from all directions. In comparison, traditional porcelain crossarms may not be able to match its mechanical strength, especially when subjected to complex external forces.

[0011] 2. Enhanced insulation performance: The insulating core rod not only has strong mechanical properties but also provides stable insulation performance. Combined with the silicone rubber insulation jacket as the outer insulation part, its UV resistance, anti-aging capabilities, and excellent water repellency and anti-fouling properties make this utility model superior to traditional porcelain crossarms in terms of insulation performance, especially in adverse weather conditions.

[0012] 3. Innovative connection and fixing design: The fixings are made of high-strength cast steel with a honeycomb structure, combining high strength with lightweight, excellent fatigue resistance, and flexible adaptation to various environments. They are also cost-effective and environmentally sustainable, making them a preferred solution for power systems. A labyrinthine structure enhances the sealing, strength, and stability of the connection. This design is more stable and durable than traditional porcelain crossarm connections.

[0013] 4. Convenient wire hanging hardware design: The new wedge-shaped pressure block wire hanging hardware greatly simplifies the construction and installation process, eliminating the wire binding installation step. This design can also flexibly adapt to wires of different diameters and adds auxiliary lifting holes, providing greater safety and convenience during the installation process.

[0014] 5. Longer service life: Due to the use of high-strength materials and weather-resistant outer shells, coupled with a stable connection design, this utility model has a longer service life than traditional porcelain crossarms, reducing the frequency of maintenance and replacement.

[0015] 6. Wider scope of application: The design of the utility model enables it to meet the needs of different application scenarios such as straight poles and corner poles, effectively reducing the inventory pressure of insulator products.

[0016] 7. Environmentally friendly: Composite materials are easy to process and have adjustable colors, which can better coordinate with the environment and enhance the environmental friendliness of the circuit.

[0017] 8. Compress corridor width: By utilizing the insulating properties of composite cross-arm insulators and reasonable design, the corridor width can be compressed, thereby reducing the amount of house demolition. This advantage can bring significant social and economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation to the present invention.

[0019] In the attached figure:

[0020] Figure 1 This is a schematic diagram of the structure of the utility model;

[0021] Figure 2 It is a cross-sectional view taken along the AA line of the structure of the present invention;

[0022] Figure 3 for Figure 1 Schematic diagram of the structure of the general-purpose porcelain cross-arm replacement composite insulator fixing hardware;

[0023] Figure 4 for Figure 1Schematic diagram of the structure of the terminal fittings of the general-purpose porcelain cross-arm replacement composite insulator;

[0024] Figure 5 This is a three-dimensional model of the structural parts of the utility model (excluding the silicone rubber insulating jacket).

[0025] In the figure: 1. Fixing hardware; 2. Silicone rubber insulating jacket; 3. Mandrel; 4. Wire hanging hardware; 5. First maze structure; 6. Sleeve; 7. Connecting seat; 8. Through hole; 9. Second maze structure; 10. Wire trough; 11. Lifting auxiliary hole; 12. Sleeve; 13. Strip hole; 14. Wedge-shaped pressure block; 15. Threaded through hole; 16. Spring washer; 17. Fastener. DETAILED DESCRIPTION

[0026] The following examples further illustrate the content of the present invention, but should not be construed as limiting the present invention. Without departing from the spirit and essence of the present invention, modifications or substitutions made to the methods, steps or conditions of the present invention are within the scope of the present invention.

[0027] The following is a detailed description of the implementation of the present invention in conjunction with the accompanying drawings and examples. Figure 1-Figure 5 As shown in the figure, the universal porcelain cross-arm replacement composite insulator provided by the present invention is mainly composed of three parts: a rod body, 1 fixing hardware and 4 hanging wire hardware. Among them, the rod body is the core structure, which is composed of 3 core rods and 2 silicone rubber insulating jackets tightly combined. The fixing hardware 1 is a honeycomb structure cast steel part, including 5 first labyrinth structures, 6 sleeves, 7 connecting seats, and 8 through holes are provided on the connecting seats; the hanging wire hardware 4 is made of aluminum alloy material, including 9 second labyrinth structures, 10 wire grooves, 11 lifting auxiliary holes, 12 sleeves, 13 bar holes, 14 wedge-shaped pressure blocks, 15 threaded holes, 16 spring washers, and 17 fasteners.

[0028] The following are the detailed manufacturing and installation steps of the insulator:

[0029] The core rods are made of round fiberglass, a material with excellent mechanical properties that can withstand bending loads from all directions. The surface of the three core rods is treated to increase their surface roughness and improve adhesion to the two silicone rubber insulation jackets. After roughening, the three core rods are thoroughly cleaned to ensure that the surface is free of oil, dirt, and impurities, preparing for subsequent gluing and vulcanization.

[0030] Connect the fitting to the finished mandrel. After cleaning the mandrel, insert one end of the mandrel into the sleeve of the fixing fitting and the other end into the sleeve of the hanging fitting. This crimping method ensures a secure connection between the fitting and the mandrel while maintaining good electrical performance.

[0031] After the core rods are connected to the fittings, a special glue is evenly applied to the surfaces of the three core rods. Then, four silicone rubber insulating jackets are placed over the three coated core rods. A high-temperature vulcanization process secures the four silicone jackets to the three core rods, forming a single, integrated unit. Thanks to the ingenious design of the five first labyrinth structures of the fixing fittings and the nine second labyrinth structures of the hanging fittings, after the four insulator jackets are vulcanized, the entire composite crossarm exhibits a labyrinthine structure. This effectively reduces current leakage or flashover that can occur in humid or polluted environments, significantly improving the insulator's resistance to pollution and moisture.

[0032] Designed specifically for crossarm installation based on real-world scenarios, this universal composite insulator is suitable for various single-cement pole applications in 10kV distribution lines, including three basic types: tension poles, corner poles, and straight poles. Tension poles utilize clamps, universal composite insulators, connection plates, and tension clamps to tension the conductors. Straight poles utilize clamps and universal composite insulators to suspend and support the conductors. Corner poles are used for both small and large angles. For small angles, clamps and universal composite insulators are used to transition the conductors. For large angles and terminal poles, tension poles are used.

[0033] Use lifting equipment to lift the crossarm steadily and slowly to the predetermined installation height through the 11 auxiliary lifting holes preset on the crossarm, ensuring that the crossarm remains stable during the entire process and does not collide with any obstacles.

[0034] Connecting the crossarm to the pole: Use fasteners to connect the fixing hardware in step 1 to the appropriate clamp, then securely connect the clamp to the pole. Ensure a tight fit between the clamp and the pole, and between the clamp and the crossarm, with no looseness, to ensure a secure and safe installation.

[0035] Select a clamp that matches the pole diameter and ensure it is of qualified quality. Use high-quality fasteners to securely connect the fixture to the clamp. Then, use the fasteners to securely install the clamp on the pole, ensuring a tight fit with no gaps. Check the connections between the crossarm, fixture, and clamp to ensure there is no looseness or movement, ensuring the overall structural stability and safety.

[0036] Cable Installation and Securement: Place the cable in the 10th cable trough of the 4th cable hanging fixture, ensuring it is centered and free of skew. Next, place the 14th wedge-shaped clamp over the cable, ensuring close contact and stable support. Finally, secure the 14th clamp to the 10th cable trough using the 16th spring washer and 17th fastener. During the tightening process, ensure moderate force to ensure a secure connection while avoiding damage to the cable. After completing these steps, perform a final inspection of the cable to ensure it will not move or become dislodged due to external factors (such as wind or vibration), thereby ensuring the stability and safety of the entire system.

[0037] The above steps complete the manufacture and installation of the utility model's universal porcelain crossarm replacement composite insulator. This insulator not only offers excellent mechanical strength and electrical performance, but also is easy to install and has low maintenance costs. It effectively replaces traditional porcelain crossarms, improving the safety and reliability of transmission lines. Furthermore, its unique structural design makes cable installation and fixing more convenient and efficient, significantly improving work efficiency.

[0038] Finally, it should be noted that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will be able to modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein with equivalents. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A universal porcelain cross-arm replacement composite insulator, characterized in that: include: The rod body is provided with a fixing hardware (1) at one end and a wire hanging hardware (4) at the other end. The rod body is composed of an insulating core rod (3) and a silicone rubber insulating jacket (2). The insulating core rod (3) is a round glass fiber rod. The silicone rubber insulating jacket (2) is sleeved on the outer surface of the core rod and serves as the outer insulating part of the cross arm.

2. The universal porcelain cross-arm replacement composite insulator according to claim 1, characterized in that The fixing hardware is a honeycomb structure cast steel part, comprising a first labyrinth structure (5), a sleeve (6), and a connecting seat (7), wherein a through hole (8) is provided on the connecting seat.

3. The universal porcelain cross-arm replacement composite insulator according to claim 1, characterized in that The wire hanging hardware is made of aluminum alloy and comprises a second labyrinth structure (9), a wire trough (10), a lifting auxiliary hole (11), a sleeve (12), a strip hole (13), a wedge-shaped pressure block (14), a threaded hole (15), a spring washer (16), and a fastener (17).

4. The universal porcelain cross-arm replacement composite insulator according to claim 1, characterized in that The two ends of the roughened and cleaned core rod (3) are respectively fastened to the fixing hardware (1) and the hanging hardware (4) by octagonal crimping, and the surface of the core rod (3) is then coated with glue, and the silicone rubber insulating jacket (2) is bonded to the core rod (3) by hot vulcanization. The composite cross arm composed of the first labyrinth structure of the fixing hardware, the second labyrinth structure of the hanging hardware and the silicone rubber insulating jacket presents a labyrinth structure as a whole, so as to improve the sealing performance of the hardware connection.

5. The universal porcelain cross-arm replacement composite insulator according to claim 3, characterized in that A lifting auxiliary hole is designed at the end of the hanging wire fitting.

6. The universal porcelain cross-arm replacement composite insulator according to claim 3, characterized in that The cable is fixed on the cross arm by the combined action of the wire trough and the wedge-shaped pressing block; during installation, the cable is placed centrally in the wire trough (10), and the wedge-shaped pressing block (14) is placed above the cable. The contact surface between the pressing block and the conductor adopts an inclined surface design, and the pressing block (14) is fastened to the wire trough (10) by a spring washer (16) and a fastener (17).

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