Insulator Housing Flange Strengthening Element
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Solution Overview
Problem
Insulator housing flanges often weaken due to mechanical overloading or cracking, leading to a reduced ability to withstand initial mechanical loads, necessitating costly and time-consuming replacement.
Innovation Solution
A strengthening element, such as clamps or a ring with split sections, is attached to the flange of an insulator housing, distributing stress from the original fixing points to a second end, using flexible components like tube sleeves or springs to enhance mechanical strength and facilitate on-site repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flange is attached to the external device with bolts at the original fixing points, then the insulator housing can be securely mounted, but the flange becomes weakened due to mechanical overloading or cracks over time
Solution Approach 1:
The strengthening element is divided into at least two sections that can be attached separately to the flange. This segmentation allows the strengthening function to be distributed across multiple attachment points, reducing stress concentration at any single location while maintaining overall flange strength
Solution Approach 2:
The invention introduces a new spatial dimension by adding a strengthening element that extends along the flange in a direction perpendicular to the original bolt alignment. This distributes the mechanical load across a larger area and multiple dimensions, preventing the stress concentration that causes flange weakening
2Strength
If the insulator housing with a damaged flange is replaced with a new one, then the mechanical strength is restored, but the process becomes complicated, expensive and time consuming
Solution Approach 1:
The strengthening element is designed to be attached to the existing flange before the flange completely fails. This preliminary reinforcement prevents the need for complete replacement by addressing the weakening issue while the insulator housing is still in service, allowing for simpler on-site repairs
Solution Approach 2:
The strengthening element acts as an intermediary component between the damaged flange and the external device. It transfers and distributes the mechanical loads away from the weakened flange areas, allowing the existing insulator housing to continue functioning without complete replacement
3Force
If bolts are used to attach the flange to the external device, then secure mounting is achieved, but stress concentration at the fixing points weakens the flange over time
Solution Approach 1:
The strengthening element is divided into sections with attachment surfaces that distribute the bolt forces across multiple locations on the flange. This segmentation prevents stress concentration at single fixing points by spreading the mechanical loads across a broader area of the flange structure
Solution Approach 2:
The flexible component in series with the bolts introduces dynamic compliance to the mounting system. This allows the strengthening element to adapt to slight movements and stress variations, distributing loads more evenly across the flange and preventing the rigid stress concentration that leads to flange weakening
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
The solution effectively increases the mechanical strength of insulator housings, allowing for easy and cost-effective repairs without disassembly, while maintaining or exceeding the declared mechanical data without redesigning the flanges.
Implementation Method 1
the bolts are tightened with a flexible component in series with the bolts. The flexible component comprises tube sleeves or springs
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
According to a first aspect there is provided an insulator housing suitable for electrical products for high voltage, for example, surge arresters, breakers or bushings. The insulator housing comprises a first cylindrical end and a second cylindrical end having a hollow insulator body. The first end and/or second end is provided with a cylindrical flange for attaching the insulator housing to an external device at a first end of the flange. At least one strengthening element is arranged at a second end of the flange.