A new type of anti-corrosion DC suspension porcelain insulator

Abstract

The utility model discloses a novel anticorrosive direct current suspension type porcelain insulator belongs to involve power transmission and distribution equipment technical field, include: porcelain piece, the iron cap is fixedly installed on the porcelain piece, steel foot is fixedly installed between the porcelain piece and the iron cap, and the steel foot is installed in the inside of porcelain piece and iron cap, the partial area of porcelain piece surface is coated with semiconductor glaze, and the rest area of porcelain piece surface is coated with electric porcelain glaze, the hat mouth edge of iron cap is fixedly installed with the protection iron ring, the middle part fixed mounting of the pole body of steel foot has annular convex. The utility model porcelain piece surface is equipped with the iron titanium semiconductor glaze in specific area, and the surface resistance of this glaze layer is between electric porcelain glaze and metal, forms the transition zone between porcelain piece and iron cap, effectively adjusts the electric field distribution of both, makes it more uniform, avoids local electric field concentration to reduce the corrosion risk.

Description

Technical Field

[0001] This utility model relates to the field of power transmission and distribution equipment technology, and in particular to a novel corrosion-resistant DC suspension porcelain insulator. Background Technology

[0002] DC suspension porcelain insulators play a crucial role in ensuring the stable operation of transmission lines. However, due to their long-term exposure to complex natural environments and continuous exposure to strong DC electric fields, the metal fittings (iron caps and steel feet) of DC suspension porcelain insulators are prone to corrosion. This not only significantly shortens the service life of the insulators but also reduces their mechanical strength and gradually deteriorates their insulation performance, posing a serious threat to the safe operation of the power grid.

[0003] The existing anti-corrosion method uses sacrificial anode protection, which involves adding zinc rings and zinc sleeves to the iron cap and steel foot where corrosion is likely to occur. However, this technology has the following drawbacks: (1) Zinc has low hardness, and the zinc rings on the iron cap are prone to plastic deformation when the clamps are installed, which weakens or even fails the anti-corrosion effect; (2) The zinc sleeve is fused to the steel foot, and the thermal expansion coefficients of the two are very different. Under alternating temperature conditions, the interface is prone to peeling, resulting in loss of anti-corrosion effect; (3) Zinc is more expensive than steel and cast iron; (4) The electric field distribution between the porcelain part and the iron cap is uneven, which makes it easy to corrode. Conventional electric porcelain glaze is difficult to achieve electric field control. Therefore, there is an urgent need for an innovative solution to enhance the anti-corrosion performance of DC suspension porcelain insulators. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing a novel corrosion-resistant DC suspension porcelain insulator.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A novel corrosion-resistant DC suspension porcelain insulator includes:

[0007] A ceramic piece, on which an iron cap is fixedly installed, and a steel foot is fixedly installed between the ceramic piece and the iron cap, with the steel foot installed inside the ceramic piece and the iron cap;

[0008] A portion of the surface of the ceramic component is coated with semiconductor glaze, while the remaining portion of the surface is coated with electric porcelain glaze. A protective iron ring is fixedly installed on the edge of the cap of the iron cap, and an annular protrusion is fixedly installed in the middle of the rod of the steel foot.

[0009] Preferably, the semiconductor glaze is an iron-titanium composite glaze, applied to the surface of the ceramic part starting 10-15 mm from the bottom edge of the iron cap, extending no more than 44 mm, with a glaze thickness of 0.2-0.5 mm and a surface resistivity controlled at 10 Ω·cm. 5~10 8 Ω.

[0010] Preferably, the iron ring is integrally cast onto the iron cap using a mold and a sand core through molten iron casting.

[0011] Preferably, the mass of the iron ring and the annular protrusion can be calculated using Faraday's law, as shown in the following formula:

[0012] W = T × I T ×Z

[0013] In the formula:

[0014] W: Mass of corrosion material on the iron ring or annular protrusion (g);

[0015] T: Expected service life (a);

[0016] I T : The amount of electricity passed per year (C / a) observed when DC is applied;

[0017] Z: Electrochemical constant (g / C);

[0018] Among them, I T It can be observed by applying a direct current to the insulator string, where Z is a constant and T is the expected service life of the insulator.

[0019] Compared with the prior art, the beneficial effects of this utility model are:

[0020] 1. A specific area on the surface of the ceramic part is provided with an iron-titanium semiconductor glaze. The surface resistance of this glaze layer is between that of electric porcelain glaze and metal, forming a transition zone between the ceramic part and the iron cap. This effectively adjusts the electric field distribution of both, making it more uniform and avoiding local electric field concentration, thereby reducing the risk of corrosion.

[0021] 2. The thickened iron ring at the cap simplifies the production process and reduces production costs. Without affecting the installation of the clamps, it effectively avoids material deformation defects. This integrated structure meets the requirements for corrosion resistance while achieving better mechanical stability.

[0022] 3. The steel foot pole has a ring-shaped protrusion in the middle, which simplifies the previous production process, reduces costs, and solves the problem of insufficient bonding strength between zinc and steel dissimilar materials. The protrusion design forms a deep mechanical interlock with the cement adhesive, preventing the steel foot from loosening due to vibration or temperature difference changes, and simultaneously achieving the dual technical effects of corrosion prevention and loosening prevention.

[0023] In summary, the design features and advantages of this utility model work together to significantly improve the corrosion resistance, mechanical stability and service life of the DC suspension porcelain insulator, making it particularly suitable for DC transmission lines in highly corrosive environments. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of a novel corrosion-resistant DC suspension porcelain insulator proposed in this utility model;

[0025] Figure 2 This is a schematic diagram of the ceramic component structure of a novel corrosion-resistant DC suspension porcelain insulator proposed in this utility model;

[0026] Figure 3 This is a schematic diagram of the iron cap structure of a novel corrosion-resistant DC suspension porcelain insulator proposed in this utility model;

[0027] Figure 4 This is a schematic diagram of the steel foot structure of a novel corrosion-resistant DC suspension porcelain insulator proposed in this utility model.

[0028] In the picture: 1 ceramic piece, 2 iron cap, 3 steel foot, 4 cement adhesive, 11 semiconductor glaze, 12 electric porcelain glaze, 21 iron ring, 31 annular protrusion. Detailed Implementation

[0029] Reference Figures 1-4 A novel corrosion-resistant DC suspension porcelain insulator includes:

[0030] A ceramic component 1 is fixedly mounted with an iron cap 2. A steel foot 3 is fixedly mounted between the ceramic component 1 and the iron cap 2. The steel foot 3 is installed inside the ceramic component 1 and the iron cap 2. The ceramic component 1, the iron cap 2 and the steel foot 3 are glued together by cement adhesive 4, so that the ceramic component 1, the iron cap 2 and the steel foot 3 are connected into a whole.

[0031] The surface of the ceramic part 1 is coated with semiconductor glaze 11, and the remaining area of ​​the surface of the ceramic part 1 is coated with electric porcelain glaze 12. A protective iron ring 21 is fixedly installed on the edge of the cap of the iron cap 2, and an annular protrusion 31 is fixedly installed in the middle of the rod of the steel foot 3.

[0032] Semiconductor glaze 11 uses an iron-titanium composite glaze. The iron-titanium composite glaze has good electrical conductivity and is simple to prepare. It is applied to the surface of ceramic part 1 starting 10-15 mm below the iron cap 2, extending no more than 44 mm. The glaze layer thickness is 0.2-0.5 mm, and the surface resistance is controlled at 10 ohms. 5 ~10 8 Ω;

[0033] The resistance of the semiconductor glaze layer 11 is between that of the electric porcelain glaze 12 on the ceramic part 1 and the metal body of the iron cap 2, which is 4 to 7 orders of magnitude lower than that of ordinary electric porcelain glaze 12. This transition design can significantly reduce the conductivity gradient between the ceramic part 1 and the iron cap 2, so as to make the electric field distribution uniform, suppress corona discharge and local electric field concentration, and reduce the risk of surface corrosion. In addition, the semiconductor glaze 11 is only coated in the area where the electric field is concentrated, which not only improves the electric field distribution, but also maintains the overall insulation performance of the insulator.

[0034] The iron ring 21 is integrally cast onto the iron cap 2 using a mold and sand core through molten iron casting. The position of the iron ring 21 does not affect the installation of the clamps for replacing insulators. Compared with the zinc ring on the iron cap of the traditional DC suspension porcelain insulator, the iron cap 2 body is thickened to form a seamless protective iron ring 21. The ductile iron material is used instead of zinc material, which significantly reduces the manufacturing cost while ensuring corrosion resistance. The shape design of the cap opening of the iron cap 2 enhances the edge structure strength without affecting the installation of the clamps, avoiding the defect of deformation during the installation of the clamps due to the softness of the traditional zinc ring.

[0035] The annular protrusion 31 is integrally formed with the steel foot 3 through hot forging. In the easily corroded area in the middle of the steel foot 3, the annular protrusion 31 is integrally formed through hot forging, replacing the expensive zinc sleeve in the previous design. There are no gaps between the annular protrusion 31 and the steel foot 3, which fundamentally solves the problem of insufficient bonding force between the zinc sleeve and the steel foot 3, avoiding the risk of loosening or falling off. At the same time, the annular protrusion 31 can also fix the steel foot 3 and prevent the steel foot 3 from falling off due to vibration or temperature difference, achieving the dual technical effect of corrosion prevention and loosening prevention.

[0036] The masses of iron ring 21 and annular protrusion 31 can be calculated using Faraday's law, as shown in the following formula:

[0037] W = T × I T ×Z

[0038] In the formula:

[0039] W: Mass of corrosion material on the iron ring or annular protrusion (g);

[0040] T: Expected service life (a);

[0041] I T : The amount of electricity passed per year (C / a) observed when DC is applied;

[0042] Z: Electrochemical constant (g / C);

[0043] Among them, I TThe insulator string can be observed when a direct current is applied. Z is a constant and T is the expected service life of the insulator. This formula can be used to scientifically design the mass of the iron ring 21 and the annular protrusion 31, ensuring that the iron cap 2 and the steel foot 3 can resist corrosion during their service life, thereby achieving a synergistic improvement in structural strength, corrosion resistance and economy.

[0044] In this invention, during use, the resistance of the semiconductor glaze layer 11 on the surface of the ceramic component 1 is between that of the electric porcelain glaze 12 on the ceramic component 1 and the metal body of the iron cap 2, which is 4 to 7 orders of magnitude lower than that of ordinary electric porcelain glaze 12. This transition design can significantly reduce the conductivity gradient between the ceramic component 1 and the iron cap 2, making the electric field distribution more uniform, suppressing corona discharge and local electric field concentration, and reducing the risk of surface corrosion. In addition, the semiconductor glaze 11 is only coated in the area where the electric field is concentrated, which improves the electric field distribution and maintains the overall insulation performance of the insulator. The iron cap 2 body is thickened to form a seamless protective iron ring 21, and ductile iron material is used instead of zinc material, which significantly reduces the risk of corrosion while ensuring corrosion resistance. To reduce manufacturing costs, the design of the cap 2's opening enhances the edge structure strength without affecting the clamp installation, avoiding the defect of traditional zinc rings deforming during clamp installation due to their softer material. In the easily corroded area in the middle of the steel foot 3's rod, an annular protrusion 31 is integrally formed through hot forging, replacing the expensive zinc sleeve in previous designs. There are no gaps between the annular protrusion 31 and the steel foot 3, fundamentally solving the problem of insufficient bonding force between the zinc sleeve and the steel foot 3, avoiding the risk of loosening or falling off. At the same time, the annular protrusion 31 can also fix the steel foot 3, preventing it from falling off due to vibration or temperature changes, achieving a dual technical effect of corrosion prevention and loosening prevention.

Claims

1. A novel corrosion-resistant DC suspension porcelain insulator, characterized in that, include: A ceramic piece (1) is fixedly installed with an iron cap (2), and a steel foot (3) is fixedly installed between the ceramic piece (1) and the iron cap (2). The steel foot (3) is installed inside the ceramic piece (1) and the iron cap (2). The ceramic piece (1), the iron cap (2) and the steel foot (3) are glued together as one piece by cement adhesive (4). A portion of the surface of the ceramic part (1) is coated with semiconductor glaze (11), and the remaining portion of the surface of the ceramic part (1) is coated with electric porcelain glaze (12). A protective iron ring (21) is fixedly installed on the edge of the cap of the iron cap (2), and an annular protrusion (31) is fixedly installed in the middle of the rod of the steel foot (3).

2. The novel corrosion-resistant DC suspension porcelain insulator according to claim 1, characterized in that, The semiconductor glaze (11) is made of iron-titanium composite glaze. It is applied to the surface of the ceramic part (1) starting from a 10-15mm area below the iron cap (2), with an extension distance not exceeding 44mm. The glaze layer thickness is 0.2-0.5mm, and the surface resistance is controlled at 10 ohms. 5 ~10 8 Ω.

3. The novel corrosion-resistant DC suspension porcelain insulator according to claim 1, characterized in that, The iron ring (21) is cast onto the iron cap (2) in one piece using a mold and sand core by pouring molten iron. The annular protrusion (31) is integrally formed with the steel foot (3) by hot forging process.

4. A novel corrosion-resistant DC suspension porcelain insulator according to claim 3, characterized in that, The mass of the iron ring (21) and the annular protrusion (31) can be calculated using Faraday's law, as shown in the following formula: W=T×I T ×Z In the formula: W: Mass of corrosion material on the iron ring or annular protrusion (g); T: Expected service life (a); I T : The amount of electricity passed per year (C / a) observed when DC is applied; Z: Electrochemical constant (g / C); Among them, I T It can be observed by applying a direct current to the insulator string, where Z is a constant and T is the expected service life of the insulator.

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