Busbar Insulation Peeling Using Cryogenic Sandblasting
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Solution Overview
Problem
Current methods for removing insulation from conductor busbars in energy distribution systems are inefficient, damaging, costly, and not suitable for automation, particularly due to the flexibility of epoxy coatings and the inability to effectively peel off 0.5 mm thick insulation within desired cycle times, leading to material waste and increased labor costs.
Innovation Solution
The method involves immersing the insulation surface in nitrogen gas to lower the temperature between −50° C. and −70° C., making it brittle, followed by sandblasting with metal granules at high pressure to efficiently peel off the insulation without damaging the busbars, using a stainless-steel grid and compressed air to remove the epoxy coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sandblasting method is used to remove insulation, then insulation removal is attempted, but the flexible epoxy coating prevents effective peeling and requires excessive time
Solution Approach 1:
The patent applies parameter changes by immersing the epoxy-coated busbar in liquid nitrogen, reducing the temperature to between -50°C and -70°C. This temperature change transforms the flexible epoxy coating into a brittle state, enabling effective sandblasting removal within 10 seconds rather than the previously insufficient cycle time.
Solution Approach 2:
The patent employs preliminary action by pre-cooling the epoxy coating with liquid nitrogen before applying sandblasting. This preliminary treatment makes the coating brittle and susceptible to removal, so that when sandblasting is subsequently applied, the insulation is efficiently peeled off without damaging the underlying conductor.
2Ease of manufacture
If conventional insulation removal methods are used, then insulation is removed, but preliminary preparation and subsequent cleaning are required, increasing labor cost and process time
Solution Approach 1:
The patent enables continuity of useful action by creating a seamless process where liquid nitrogen immersion directly precedes sandblasting without intermediate preparation steps. The brittle epoxy coating is immediately removed by sandblasting, eliminating the need for separate preparation and cleaning operations that characterize conventional methods.
Solution Approach 2:
The patent extracts the problematic flexible epoxy coating from the busbar through the combined liquid nitrogen-sandblasting process. The brittle coating is selectively removed by sandblasting while leaving the metal conductor intact, achieving clean insulation removal without the extensive preparation and cleaning required by traditional mechanical scraping methods.
3Manufacturing precision
If sandblasting is applied to flexible epoxy coating, then insulation removal is attempted, but the coating flexibility prevents desired peeling and may damage the conductor
Solution Approach 1:
The patent changes the physical parameter of the epoxy coating by reducing its temperature to -50°C to -70°C using liquid nitrogen. This transformation from flexible to brittle state allows sandblasting to effectively peel the insulation without the coating's flexibility interfering with the removal process, achieving both high efficiency and conductor protection.
Solution Approach 2:
The patent applies preliminary cooling action with liquid nitrogen to transform the epoxy coating's mechanical properties before sandblasting. This preliminary treatment ensures the coating becomes brittle and can be cleanly removed by sandblasting within 10 seconds, preventing both ineffective peeling and potential conductor damage.
4Reliability
If thick epoxy coating (500 microns) is applied for insulation, then insulation effectiveness is improved, but sandblasting cannot remove it within desired cycle times
Solution Approach 1:
The patent applies parameter changes by reducing the temperature of the 500-micron epoxy coating to -50°C to -70°C through liquid nitrogen immersion. This temperature change makes the thick coating brittle, enabling complete removal by sandblasting within 10 seconds, thus maintaining insulation effectiveness while achieving rapid removal.
Solution Approach 2:
The patent employs preliminary liquid nitrogen treatment to prepare the thick epoxy coating for rapid removal. This preliminary action transforms the mechanical properties of the 500-micron coating, making it susceptible to sandblasting removal within the desired 10-second cycle time while preserving the insulation's protective function during the brief treatment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for rapid and efficient removal of 0.5 mm thick insulation within 10 seconds, preventing damage to the busbars and reducing environmental and labor costs, while enabling a more automated process.
Implementation Method 1
immersing it in nitrogen gas for approximately 5 seconds in order to bring the surface temperature to a value between -50° C. and -70° C.
Implementation Method 2
sandblasting by spraying metal granules on it
Data Source
AI summary
A method for forming contact surfaces by peeling the insulation on the insulated conductor busbars for energy distribution systems.