Hybrid insulator preparation method

Abstract

A hybrid insulator preparation method, belonging to the technical field of insulators. During a hybrid insulator preparation process, firstly, green bodies that meet production standards are screened out by means of green body inspection; and secondly, on the basis of the requirements of a hybrid insulator coating mold, produced porcelain insulators are classified by means of shed inspection plates including marking apparatuses, and a marked region is repaired when the marked area on a surface of a shed structure of each porcelain insulator is ≤ 10%, so as to meet the requirements of the coating mold. While ensuring the yield rate of hybrid insulators, the hybrid insulator preparation method improves the production efficiency of hybrid insulators and reduces the loss during a production process of the hybrid insulators.

Description

A method for preparing a hybrid insulator Technical Field

[0001] This disclosure relates to the field of insulator technology, and specifically to a method for preparing a hybrid insulator. Background Technology

[0002] The new hybrid insulator for transmission lines is a novel insulator that uses a high-temperature injection molding process to coat a traditional porcelain or glass insulator with a layer of high-temperature vulcanized silicone rubber (HTV). It combines the advantages of long service life and high mechanical strength of traditional porcelain or glass insulators with the pollution resistance and flashover resistance of HTV composite insulators, and has broad application prospects in heavily polluted areas of my country.

[0003] The coating of the new hybrid insulator is modeled and molded using a three-dimensional measurement method based on structured light scanning and precise registration. Since the porcelain or glass insulator in the core has a complete shed structure and the thickness of the HTV coating is about 3mm, the process has high requirements for the structural accuracy of the mold, porcelain insulator and glass insulator.

[0004] To improve the consistency of the structure of mass-produced porcelain or glass insulators, patent CN113921208B proposed a fully automated production line for ceramic suspension insulators. This line incorporates both rough and fine finishing mechanisms in the porcelain insulator production process, enhancing product consistency. While existing insulator production technologies utilize automated molding, achieving near-mechanization, standardization, and automation of the entire production process from clay preparation, molding, glazing and sanding, drying and firing, to gluing, thus improving product quality stability and consistency, current production technologies still cannot fully meet the precision requirements of surface HTV coating for hybrid insulators. For example, under tight production conditions, some produced porcelain insulator structures do not meet the precision requirements of the coating mold (e.g., the skirt diameter exceeds the mold's requirement by 2mm), necessitating the re-production of porcelain insulators, causing delays and significant economic losses. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and to provide a method for preparing hybrid insulators, which can improve the yield and production efficiency of hybrid insulators and reduce losses during the production process.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a method for preparing a hybrid insulator, comprising the following steps: blank inspection and structural inspection;

[0007] The steps for testing the clay blanks are as follows: place the clay blanks on a weight measuring device for weighing, obtain the weight measurement results of the clay blanks to be tested, compare the weight measurement results, and qualified products proceed to the next step.

[0008] The structural inspection steps are as follows: The fired porcelain insulator is inspected using an umbrella skirt structure inspection device. This device includes an umbrella skirt inspection plate with a detection surface matching the porcelain insulator's umbrella skirt structure. The detection surface is equipped with a marking device to obtain the marking results on the surface of the porcelain insulator. Taking the surface area of ​​the porcelain insulator's umbrella skirt structure as 100%, if the marked area on the surface of the porcelain insulator's umbrella skirt structure is 0, proceed to the next step. If the marked area on the surface of the porcelain insulator's umbrella skirt structure is ≤10%, the marked area of ​​the porcelain insulator is repaired until the marked area on the surface of the porcelain insulator's umbrella skirt structure is 0. If the marked area on the surface of the porcelain insulator's umbrella skirt structure is >10%, it is marked as unqualified.

[0009] In some embodiments, a gap is provided between the detection surface and the skirt structure of the porcelain insulator.

[0010] In some embodiments, the umbrella skirt detection plate includes a first detection plate, a second detection plate, and a third detection plate, wherein the third detection plate is connected to the first detection plate and the second detection plate, respectively.

[0011] In some embodiments, the umbrella skirt detection plate further includes a driving device connected to the first detection plate.

[0012] In some embodiments, the umbrella skirt structure detection device further includes a base for fixing the porcelain insulator.

[0013] In some embodiments, the marking device is a color marking device.

[0014] In some implementations, the weight measurement results are compared in one of the following ways: weight comparison or weight percentage deviation comparison.

[0015] In some implementations, the comparison of weight measurement results is performed in measurement software.

[0016] In some embodiments, the method for preparing the hybrid insulator further includes the following steps: kneading clay, shaping, trimming, drying, glazing, firing, and vulcanization coating.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: The present disclosure adds a clay blank inspection step and a structural inspection step to the existing technology for preparing hybrid insulators. First, the clay blanks that meet the production standards are screened out through clay blank inspection. Second, the porcelain insulators produced are classified according to the requirements of the hybrid insulator covering mold by using a skirt inspection plate containing a marking device. The marked area on the surface of the porcelain insulator skirt structure is ≤10% and repaired to meet the requirements of the covering mold. While ensuring the yield of hybrid insulators, the production efficiency of hybrid insulators is improved and the losses in the production process of hybrid insulators are reduced. Attached Figure Description

[0018] Figure 1 is a process flow diagram for preparing hybrid insulators according to this disclosure;

[0019] Figure 2 is a flowchart of the porcelain insulator structure inspection process of this disclosure; wherein, 3-1, porcelain insulator head; 3-2, upper umbrella shape; 3-3, lower umbrella shape; 5, base; 6-1, upper plate; 6-2, lower plate; 6-3, middle plate; 7, drive shaft;

[0020] Figure 3 is a classification diagram of the results of the structural testing of the porcelain insulators disclosed in this invention.

[0021] Figure 4 is a schematic diagram of the structure of a double-umbrella porcelain insulator; where 1 is the steel cap; 2-1 and 2-2 are the adhesives; 3-1 is the porcelain insulator head; 3-2 is the upper umbrella shape; 3-3 is the lower umbrella shape; and 4 is the steel foot. Detailed Implementation

[0022] To better illustrate the purpose, technical solution, and advantages of this invention, the invention will be further described below with reference to specific embodiments and comparative examples. The purpose of this description is to provide a detailed understanding of the invention, not to limit its scope. All other embodiments obtained by those skilled in the art without inventive effort are within the protection scope of this invention. Unless otherwise specified, the experimental reagents and instruments involved in the implementation of this invention are commonly used reagents and instruments.

[0023] In the description of this disclosure, it should be understood that the terms “center,” “upper,” “lower,” “front,” “back,” “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, and are only for the convenience of describing this disclosure and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this disclosure.

[0024] In the description of this disclosure, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure based on the specific circumstances.

[0025] To address the issues of low yield and low production efficiency of hybrid insulators in the existing manufacturing process.

[0026] Based on existing technologies for preparing hybrid insulators, this disclosure adds steps for blank inspection and structural inspection, as shown in Figure 1. This disclosure provides a method for preparing hybrid insulators, including the following steps:

[0027] S1: Material preparation: Weigh the required raw materials according to the requirements of porcelain insulators;

[0028] S2: Vacuum plucking: The raw materials are plucking into mud segments using a vacuum plucking machine and then output.

[0029] The purpose of vacuum kneading is to remove the minimum gas content in the clay, eliminate air, and knead and compress the clay to improve its plasticity, density, and uniformity, thereby improving the plasticity and strength of the clay blank. In addition, it can also disrupt the directional arrangement of the clay, improve the qualification rate of the clay blank, and thus improve the yield of porcelain insulators.

[0030] Specifically, prior to the vacuum pumice step, those skilled in the art may perform at least one of the following steps as needed: mixing, screening, iron removal, pressing, and aging.

[0031] Screening the mixed slurry can control the fineness of the raw material and maintain the uniformity of the slurry, as well as remove harmful impurities, further purify the slurry, and remove residues such as coarse particles, hard mud lumps, sawdust, cotton scraps, and oil residue; this is beneficial for molding and firing, and improves the strength of porcelain insulators.

[0032] Iron removal is used to eliminate iron spots on products and improve their purity and electromechanical properties. Iron removal and screening are complementary processes and are one of the methods for purifying mud.

[0033] The purpose of pressing mud is to remove water from the mud slurry. Only after the mud slurry has been dehydrated can it be used for plastic molding.

[0034] Aging involves storing the pressed and dehydrated clay cake in a properly sized sealed chamber (i.e., a clay storage room) for one to two weeks to improve the plasticity and formability of the clay, make the moisture in the clay cake more uniform, and improve the electromechanical properties of the clay body.

[0035] S3: Shaping, air-drying, and trimming: The clay material after vacuum pugging is shaped according to the requirements of the product size to obtain the initial embryo of the porcelain insulator; the initial embryo of the porcelain insulator is air-dried naturally until the surface of the porcelain body appears white visually, and then it is trimmed to meet the accuracy requirements of the product.

[0036] S4: Inspection of clay blank: Place the clay blank on a weight measuring device to weigh it, obtain the weight measurement result of the clay blank to be measured, and compare the weight measurement results. Qualified products enter the next step;

[0037] Specifically, the present disclosure can measure the weight of the clay blank through a weight measuring device, screen out the clay blanks with unqualified weights through an identification device. The unqualified clay blanks can be used as raw materials for other standard parts, or can be conveyed to the batching step through a cleaning device for reuse, so as to improve the yield rate of porcelain insulators and reduce the production cost of porcelain insulators.

[0038] The weight of the clay blank can be evaluated whether it meets the standard by the weight value or the weight percentage change rate. The weight standards of porcelain insulators with different standards are different. Those skilled in the art can, according to the actual situation, design different weight values or weight percentage change rates that meet the standards to evaluate the qualification rate of porcelain insulators.

[0039] Taking the standard weight of the clay blank as 10 kg, according to the calculation, when the weight deviation of the clay blank is within the range of ±0.5 kg or the weight percentage change rate is within the range of ±5%, the clay blank meets the requirements. Therefore, a weight sensing device can be installed on the robotic arm for transferring the clay blank, and the weight values are designed as 10 kg and 10.5 kg. When the weight m ≤ 10.0 kg, the robotic arm transfers the clay blank to the A-class partition, denoted as excellent products. When the weight 10.0 kg < m ≤ 10.5 kg, the robotic arm transfers the clay blank to the B-class partition, denoted as qualified products. When the weight m > 10.5 kg, the robotic arm transfers the clay blank to the C-class partition. Assuming that the clay blanks in the C-class partition meet the requirements of porcelain insulators with other standards, they can be used as raw materials for porcelain insulators with other standards and enter the next process of preparing porcelain insulators with other standards; assuming that the clay blanks in the C-class partition do not meet the requirements of porcelain insulators with other standards, or there is no production demand for porcelain insulators with other standards, the clay blanks in the C-class partition return to the batching step and are used as raw materials to produce porcelain insulators again; the clay blanks in the A-class partition and the B-class partition directly proceed to the next step.

[0040] S5: Drying, glazing, and firing: Dry the qualified clay blank measured by the weight measuring device. The drying method is not particularly limited, as long as the blank can be dried to a moisture content of less than 0.05%. The drying method can be baking or microwave drying;

[0041] There are no specific limitations on the glazing method. Those skilled in the art can choose an appropriate method to glaze according to actual needs, such as dip coating or spray coating.

[0042] After glazing and before firing, there is also a sanding step. The purpose of this is to lay the foundation for perfect binding and increase the stability and firmness of the binding accessories. The sand can be obtained by drying, crushing and screening the scraps from the blank making process, and its composition is the same as that of the blank.

[0043] There are no specific limitations on the firing temperature, time, and number of firings. Those skilled in the art can choose the appropriate firing temperature, firing time, and number of firings according to actual needs.

[0044] For example, the firing process is a staged firing process, including: preheating period, oxidation period, reduction period, holding period and cooling period.

[0045] The preheating period is characterized by a temperature of 250-400℃ and a duration of 10-15 hours. The preheating period primarily involves preheating the insulator blanks to remove residual moisture and a small amount of crystal water.

[0046] The oxidation period is carried out at a temperature of 700-900℃ for 25-30 hours. During the oxidation period, most of the water of crystallization is discharged, and organic matter, carbonates and some sulfates are decomposed.

[0047] The reduction period is characterized by a temperature of 1000-1250℃ and a duration of 25-30 hours. During the reduction period, most oxides are reduced, sulfates are decomposed, and carbon and carbonaceous materials are oxidized, thereby forming ceramic materials.

[0048] The heat preservation period involves slowly reducing the temperature from 1000-1250℃ during the reduction period to 600℃, with a cooling rate of 50-80℃ / h. During the heat preservation period, the green blank is completely calcined into ceramic to prevent the insulator quality from being reduced due to incomplete calcination.

[0049] The cooling period is 4-6 hours; the kiln is cooled to room temperature to prevent the ceramics from cracking due to rapid cooling and damaging the insulator structure.

[0050] S6: Structural Inspection: The fired porcelain insulator is inspected using an umbrella skirt structure inspection device. The umbrella skirt inspection device includes an umbrella skirt inspection plate, which includes an inspection surface that matches the umbrella skirt structure of the porcelain insulator. The inspection surface is equipped with a marking device to obtain the marking results on the surface of the porcelain insulator to be tested. Taking the surface area of ​​the porcelain insulator umbrella skirt structure as 100%, if the marked area on the surface of the porcelain insulator umbrella skirt structure is 0%, proceed to the next step. If the marked area on the surface of the porcelain insulator umbrella skirt structure is ≤10%, the marked area of ​​the porcelain insulator is repaired until it passes the structural inspection. If the marked area on the surface of the porcelain insulator umbrella skirt structure is >10%, it is marked as unqualified.

[0051] This disclosure uses a specific structured umbrella skirt test plate to perform structural testing on fired porcelain insulators. When the outline of the porcelain insulator specimen is smaller than the dimensional deviation, the marking device cannot mark the surface of the porcelain insulator. When the outline of the porcelain insulator specimen is larger than the dimensional deviation, the marking device marks the unqualified area. For porcelain insulators whose dimensional deviation is within the standard range, a grinding machine can be used to grind the marked positions of the porcelain insulator until the surface of the porcelain insulator is unmarked after testing, and then proceed to the next step.

[0052] The umbrella skirt structure testing device disclosed herein can determine whether the umbrella skirt structure of porcelain insulators meets the standards by observing the markings on the porcelain insulators. The testing is convenient and the results are intuitive. It can also mark porcelain insulators that do not meet the standards, providing accurate marking areas for the grinding and repair steps. In the production process of porcelain insulators, it can not only ensure the yield rate of porcelain insulators, but also improve the production efficiency and reduce losses in the production process.

[0053] In some embodiments, a gap is provided between the detection surface and the umbrella skirt structure of the porcelain insulator. The gap is designed according to the requirements of the covering accuracy. For example, assuming that the diameter of the umbrella skirt is required to be no more than 2mm of the covering mold, the width of the gap is 1-2mm.

[0054] As shown in Figure 2, based on the data obtained from the measurement of the standard porcelain insulator using three-dimensional laser scanning, a skirt inspection plate is fabricated using 3D printing. The structure of the skirt inspection plate is completely consistent with the structure of the injection vulcanization mold for the hybrid insulator, and the skirt inspection plate has an inspection surface that matches the structure of the porcelain insulator skirt. Then, the skirt inspection plate is processed into a multi-piece assembly. The skirt inspection plate disclosed in this invention consists of three pieces, namely a lower plate 6-1, an upper plate 6-2, and a middle plate 6-3. Then, according to the requirements of the covering accuracy, a marking device is installed on the inspection surface. The marking device can be a color marking device, but this invention is not limited to this.

[0055] If the umbrella skirt detection plate is a single piece, and the umbrella skirt structure is more complex, such as a three-umbrella structure and the height difference of the outer edge of the umbrella skirt is much greater than the height difference of the middle part, the insulator will be difficult to install into the umbrella skirt detection plate.

[0056] The specific methods for structural inspection are as follows:

[0057] S61: As shown in Figure 2a, the lower plate 6-1 of the umbrella skirt detection plate is installed on the horizontal part of the base 5.

[0058] S62: As shown in Figure 2b, the interior of the porcelain insulator head 3-1 is installed on the vertical part of the base 5, and the lower umbrella shape 3-3 of the porcelain insulator umbrella structure is placed on the lower plate 6-1 of the umbrella detection plate.

[0059] S63: As shown in Figure 2c, the upper plate 6-2 of the umbrella skirt detection plate connected to the drive shaft 7 is fixed to the head of the porcelain insulator.

[0060] S64: As shown in Figure 2d, fix the middle plate 6-3 of the umbrella skirt test plate between the upper plate 6-1 and the upper plate 6-2 of the umbrella skirt test plate. If the installation of the umbrella skirt test plate fails, the porcelain insulator under test does not meet the requirements of the porcelain insulator standard parts and is marked as unqualified.

[0061] S65: As shown in Figure 2e, fix the porcelain insulator, start the motor to drive the drive shaft 7 to rotate the shed detection plate 6 at a constant speed for one revolution, and obtain the marking results on the surface of the porcelain insulator to be tested; taking the surface area of ​​the shed structure of the porcelain insulator as 100%, if the marking area on the surface of the shed structure of the porcelain insulator is 0 (as shown in Figure 3a), proceed to the next step; if the marking area on the surface of the shed structure of the porcelain insulator is ≤10% (as shown in Figure 3b), then the marking area of ​​the porcelain insulator is repaired until it passes the structural test; if the marking area on the surface of the shed structure of the porcelain insulator is >10% (as shown in Figure 3c), it is marked as unqualified.

[0062] For porcelain insulators that need to be repaired, the porcelain insulators need to be fixed on the grinding base, and the marked area is ground with a grinding machine. The appropriate grinding force and number of times are selected according to the depth of the color of the marked area until the umbrella-shaped test result of the ground porcelain insulator is as shown in Figure 3a. Then, the vulcanization coating step is carried out.

[0063] The structure of the umbrella skirt testing plate used in this disclosure is completely consistent with the structure of the injection vulcanization mold for hybrid insulators, which improves the accuracy of the porcelain insulator testing results. In addition, the umbrella skirt testing plate of this disclosure is a self-rotating structure, which eliminates the need to install porcelain insulators into the testing structure. The porcelain insulators are simply placed on the base, and the testing results are obtained by relying on the motor to drive the umbrella skirt testing plate to rotate at a uniform speed for one revolution. The testing results are intuitive, and the testing process is simple, convenient, time-saving, and energy-efficient.

[0064] S7: Surface treatment, vulcanization coating:

[0065] Qualified products that pass structural testing will undergo surface treatment, including but not limited to surface cleaning, degreasing, and using silane coupling agents to change the hydrophilicity of the glaze layer of porcelain insulators to hydrophobicity.

[0066] The surface-treated porcelain insulator is placed into a covering mold and covered with a high-temperature silicon sulfide umbrella sleeve under set temperature, pressure and time parameters.

[0067] Remove the vulcanized and coated hybrid insulators, trim the coating, install the iron cap and steel feet, and after passing routine mechanical and electrical inspections, package and store them in the warehouse.

[0068] Example 1

[0069] As shown in Figure 1, this embodiment provides a method for preparing a hybrid insulator, including the following steps:

[0070] Taking the production of the double-umbrella hybrid insulator shown in Figure 4 as an example, the double-umbrella hybrid insulator mainly consists of a steel cap 1, adhesive 2, porcelain insulator, and steel foot 4. The porcelain insulator includes a porcelain insulator head 3-1, an upper umbrella 3-2, and a lower umbrella 3-3. The top of the porcelain insulator is connected to the steel cap 1 through adhesive 2-1, and the inside of the top of the porcelain insulator is connected to the steel foot 4 through adhesive 2-2. The standard weight of the clay blank used to prepare the porcelain insulator is 10 kg. According to calculations, when the weight deviation of the clay blank is within ±0.5 kg or the weight percentage change rate is within ±5%, the clay blank meets the requirements.

[0071] S1: Material preparation: Weigh the required raw materials according to the requirements of porcelain insulators;

[0072] S2: Vacuum plucking: The raw materials are plucking into mud segments using a vacuum plucking machine and then output.

[0073] S3: Spin forming, air drying, and trimming: The clay material after vacuum kneading is shaped according to the product size requirements to obtain the initial porcelain insulator blank; the initial porcelain insulator blank is air dried naturally until the porcelain surface appears white, and then trimmed to meet the product's precision requirements.

[0074] S4: Mud blank detection: Install a weight sensing device on the robotic arm for transferring mud blanks. Set the designed weight values as 10 kg and 10.5 kg. When the weight m ≤ 10.0 kg, the robotic arm transfers the mud blank to Area A, which is marked as high-quality products. When the weight 10.0 kg < m ≤ 10.5 kg, the robotic arm transfers the mud blank to Area B, which is marked as good-quality products. When the weight m > 10.5 kg, the robotic arm transfers the mud blank to Area C. Assume that the mud blanks in Area C meet the requirements of other standard porcelain insulators and can be used as raw materials for other standard porcelain insulators to enter the next process of preparing other standard porcelain insulators. Assume that the mud blanks in Area C do not meet the requirements of other standard porcelain insulators or there is no production demand for other standard porcelain insulators. The mud blanks in Area C return to the stock preparation step and are used as raw materials to produce porcelain insulators again. The mud blanks in Area A and Area B directly proceed to the next step.

[0075] S5: Drying, glazing, and firing: Dry the qualified mud blanks measured by the weight measuring device. The drying method is not particularly limited as long as the blank can be dried to a moisture content of less than 0.05%. The drying method can be baking or microwave drying.

[0076] The glazing method is not specifically limited, and those skilled in the art can choose a suitable glazing method according to actual needs. For example, it can be dip coating or spraying.

[0077] Before firing after glazing, there is also a sanding step. The above purpose is to lay a foundation for cementing to increase the stability and firmness of the cementing accessories. The sand can be obtained by air-drying, crushing, and screening the waste materials from blank making, and its components are the same as those of the blank material.

[0078] The firing temperature, time, and number of firing times are not specifically limited, and those skilled in the art can choose suitable firing temperature, firing time, and number of firing times according to actual needs.

[0079] For example, the firing is carried out in stages, including: preheating period, oxidation period, reduction period, heat preservation period, and cooling period.

[0080] Among them, the temperature of the preheating period is 250 - 400 °C, and the time is 10 - 15 h. The preheating period is mainly to preheat the green body of the insulator, remove residual moisture and a small amount of crystal water.

[0081] Among them, the temperature of the oxidation period is 700 - 900 °C, and the time is 25 - 30 h. During the oxidation period, most of the crystal water is discharged, and the organic matter, carbonate, and part of the sulfate are decomposed.

[0082] Among them, the temperature of the reduction period is 1000 - 1250 °C, and the time is 25 - 30 h. During the reduction period, most of the oxides are reduced, the sulfate is decomposed, and carbon and carbonaceous substances are oxidized, thus forming ceramic materials.

[0083] The heat preservation period involves slowly reducing the temperature from 1000-1250℃ during the reduction period to 600℃, with a cooling rate of 50-80℃ / h. During the heat preservation period, the green blank is completely calcined into ceramic to prevent the insulator quality from being reduced due to incomplete calcination.

[0084] The cooling period is 4-6 hours; the kiln is cooled to room temperature to prevent the ceramics from cracking due to rapid cooling and damaging the insulator structure.

[0085] S6: Structural Inspection: As shown in Figure 2, based on the data obtained from the measurement of the standard porcelain insulator using three-dimensional laser scanning, a skirt inspection plate is fabricated using 3D printing. The structure of the skirt inspection plate is completely consistent with the structure of the injection vulcanization mold for the hybrid insulator, and the skirt inspection plate has an inspection surface that matches the structure of the porcelain insulator's skirt. Then, the skirt inspection plate is processed into a multi-piece assembly. The skirt inspection plate disclosed in this invention consists of 3 pieces, namely the lower plate 6-1, the upper plate 6-2, and the middle plate 6-3. According to the requirements of the covering accuracy, the gap width between the inspection surface and the skirt structure of the porcelain insulator is 1mm, and a color marking device is installed on the inspection surface.

[0086] The specific methods for structural inspection are as follows:

[0087] S61: As shown in Figure 2a, the lower plate 6-1 of the umbrella skirt detection plate is installed on the horizontal part of the base 5.

[0088] S62: As shown in Figure 2b, the interior of the porcelain insulator head 3-1 is installed on the vertical part of the base 5, and the lower umbrella shape 3-3 of the porcelain insulator umbrella structure is placed on the lower plate 6-1 of the umbrella detection plate.

[0089] S63: As shown in Figure 2c, the upper plate 6-2 of the umbrella skirt detection plate connected to the drive shaft 7 is fixed to the head of the porcelain insulator.

[0090] S64: As shown in Figure 2d, fix the middle plate 6-3 of the umbrella skirt test plate between the upper plate 6-1 and the upper plate 6-2 of the umbrella skirt test plate. If the installation of the umbrella skirt test plate fails, the porcelain insulator under test does not meet the requirements of the porcelain insulator standard parts and is marked as unqualified.

[0091] S65: As shown in Figure 2e, fix the porcelain insulator, start the motor to drive the drive shaft 7 to rotate the shed detection plate 6 at a constant speed for one revolution, and obtain the marking results on the surface of the porcelain insulator to be tested; taking the surface area of ​​the shed structure of the porcelain insulator as 100%, if the marking area on the surface of the shed structure of the porcelain insulator is 0 (as shown in Figure 3a), proceed to the next step; if the marking area on the surface of the shed structure of the porcelain insulator is ≤10% (as shown in Figure 3b), then the marking area of ​​the porcelain insulator is repaired until it passes the structural test; if the marking area on the surface of the shed structure of the porcelain insulator is >10% (as shown in Figure 3c), it is marked as unqualified.

[0092] For porcelain insulators that need to be repaired, the porcelain insulators need to be fixed on the grinding base, and the marked area is ground with a grinding machine. The appropriate grinding force and number of times are selected according to the depth of the color of the marked area until the umbrella-shaped test result of the ground porcelain insulator is as shown in Figure 3a. Then, the vulcanization coating step is carried out.

[0093] The structure of the umbrella skirt testing plate used in this disclosure is completely consistent with the structure of the injection vulcanization mold for hybrid insulators, which improves the accuracy of the porcelain insulator testing results. In addition, the umbrella skirt testing plate of this disclosure is a self-rotating structure, which eliminates the need to install porcelain insulators into the testing structure. The porcelain insulators are simply placed on the base, and the testing results are obtained by relying on the motor to drive the umbrella skirt testing plate to rotate at a uniform speed for one revolution. The testing results are intuitive, and the testing process is simple, convenient, time-saving, and energy-efficient.

[0094] S7: Surface treatment, vulcanization coating:

[0095] The qualified products that pass the structural test are then cleaned and degreased, and then a silane coupling agent is used to change the hydrophilicity of the glaze layer of the porcelain insulator to hydrophobicity.

[0096] The surface-treated porcelain insulator is placed into a covering mold and covered with a high-temperature silicon sulfide umbrella sleeve under set temperature, pressure and time parameters.

[0097] Remove the vulcanized and coated hybrid insulators, trim the coating, install the iron cap and steel feet, and after passing routine mechanical and electrical inspections, package and store them in the warehouse.

[0098] Finally, it should be noted that the above embodiments are used to illustrate the technical solutions of the present invention and not to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A method for preparing a hybrid insulator, characterized in that, Includes the following steps: Clay blank inspection and structural inspection; The steps for testing the clay blanks are as follows: place the clay blanks on a weight measuring device for weighing, obtain the weight measurement results of the clay blanks to be tested, compare the weight measurement results, and qualified products proceed to the next step. The structural inspection steps are as follows: The fired porcelain insulator is inspected using an umbrella skirt structure inspection device. This device includes an umbrella skirt inspection plate, which has an inspection surface matching the porcelain insulator's umbrella skirt structure. The inspection surface is equipped with a marking device to obtain the marking results on the surface of the porcelain insulator to be tested. Taking the surface area of ​​the porcelain insulator's umbrella skirt structure as 100%, if the marked area on the surface of the porcelain insulator's umbrella skirt structure is 0%, proceed to the next step. If the marked area on the surface of the porcelain insulator's umbrella skirt structure is ≤10%, the marked area of ​​the porcelain insulator is repaired until it passes the structural inspection. If the marked area on the surface of the porcelain insulator's umbrella skirt structure is >10%, it is marked as unqualified.

2. The preparation method according to claim 1, characterized in that, A gap is provided between the detection surface and the umbrella skirt structure of the porcelain insulator.

3. The preparation method according to claim 1, characterized in that, The umbrella skirt detection plate includes a first detection plate, a second detection plate, and a third detection plate, wherein the third detection plate is connected to the first detection plate and the second detection plate respectively.

4. The preparation method according to claim 3, characterized in that, The umbrella skirt detection plate also includes a driving device, which is connected to the first detection plate.

5. The preparation method according to claim 1, characterized in that, The umbrella skirt structure detection device also includes a base, which is used to fix the porcelain insulator.

6. The preparation method according to claim 1, characterized in that, The marking device is a color marking device.

7. The preparation method according to claim 1, characterized in that, The weight measurement results are compared in one of the following ways: weight comparison or weight percentage deviation comparison.

8. The preparation method according to claim 1, characterized in that, The comparison of the weight measurement results was completed in the measurement software.

9. The preparation method according to claim 1, characterized in that, It also includes the following steps: The process involves kneading clay, shaping, trimming, drying, glazing, firing, and sulfur coating.

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