High-Voltage Insulator Retainer for Self-Centering Flange Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-voltage engineering components, such as busbars and reactors, face issues with weak flange connections that are prone to errors due to environmental influences and require time-consuming on-site mounting, which can be misaligned.
Innovation Solution
A rotationally symmetrical fiberglass-reinforced epoxy resin insulator with a silicone shielding and a detachable retainer system, featuring a conical connection and safety bolts, allowing for a stable, form-fitting, and self-centering attachment of operating means like reactors or busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flange connections with screws and adhesive bonding are used to fasten mounting brackets to support insulators, then the connection can be made securely, but the mounting process becomes time-consuming and prone to misalignment errors
Solution Approach 1:
The mounting bracket is segmented into a first part (flange portion) and a second part (mounting portion), allowing the first part to be pre-assembled with the support insulator while the second part can be attached later to the operating means. This segmentation enables parallel preparation and reduces on-site assembly time and complexity.
Solution Approach 2:
The first part of the mounting bracket is pre-assembled with the support insulator during manufacturing or pre-installation, including pre-attaching the grounding means. This preliminary action eliminates the need for time-consuming on-site assembly of multiple components and ensures proper alignment before the actual installation at the high-voltage site.
2Strength
If flange connections are used to fasten mounting brackets to support insulators, then the connection can be made securely, but the connection becomes susceptible to environmental influences and forces
Solution Approach 1:
The grounding means is specifically designed with a grounding plate having a larger surface area than the flange portion, creating a local quality enhancement at the grounding interface. This larger surface area distributes mechanical forces and improves electrical contact, making the connection more resistant to environmental influences and mechanical stresses at the critical grounding point.
Solution Approach 2:
The mounting bracket is constructed as a composite structure with the first part (flange portion) and second part (mounting portion) that can be made from different materials optimized for their specific functions. The flange portion is designed for secure attachment to the insulator with grounding capabilities, while the mounting portion is optimized for attaching to the operating means, creating a composite solution that addresses multiple requirements simultaneously.
3Reliability
If mounting brackets are positioned and screwed tight with multiple screws on site, then the connection can be secured, but the process requires high manufacturing precision and angular alignment
Solution Approach 1:
The second part of the mounting bracket is designed to be nested within or attached to the first part, creating a hierarchical structure where the mounting portion fits into or onto the flange portion. This nesting arrangement provides built-in alignment features that guide the components into proper angular alignment during assembly, reducing the precision requirements for on-site installation.
Data Source
AI summary
An insulator for high-voltage applications has a rotationally symmetrical hollow tube made from fiberglass-reinforced epoxy resin; a silicone shielding attached to a periphery of the hollow tube; a base flange at a lower end of the hollow tube; a retainer, which is configured to retain an electrical operator, at an upper end of the hollow tube; and a plug, which is arranged inside the hollow tube and closes the front side of the upper end of the hollow tube and seals the hollow tube from the outside. The retainer has a rotationally symmetrical connection region. The insulator further has at the upper end of the hollow tube, a radially circumferential joining region which has no silicone shielding. The retainer is connectable to the insulator in such a way that the connection region of the retainer surrounds the joining region of the insulator in a form-fitting fashion.