Integrated Insulator Seal and Shield Assembly
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Solution Overview
Problem
Conventional corona protection devices for electrical insulators require numerous parts for assembly, leading to high manufacturing costs and inefficient installation, with poor seals and connections resulting in ineffective protection against corona discharge.
Innovation Solution
An insulator shielding assembly featuring a rubber housing with radial weathersheds and a tapered end connected to a metal fitting via a collar assembly with multiple sealing surfaces and apertures for sealant receipt, creating a secure and effective compression seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional corona protection devices use multiple separate parts for assembly, then the device can be designed with functional specialization, but the manufacturing cost increases and installation efficiency decreases
Solution Approach 1:
The patent combines multiple separate components (collar, seal elements, shielding elements, and connection parts) into a single integrated collar assembly. This merging eliminates the need for multiple separate parts, reducing manufacturing costs and simplifying installation while maintaining all necessary functions including sealing, corona protection, and mechanical connection to the insulator.
2Productivity
If conventional corona protection devices use multiple separate parts, then each part can be optimized for its specific function, but the installation speed and efficiency decrease
Solution Approach 1:
The integrated collar assembly combines sealing elements, shielding elements, and connection structures into a single pre-assembled unit that can be installed in one operation. This eliminates the need for multiple installation steps and reduces the time required to complete the corona protection device installation, directly improving installation productivity.
3Reliability
If conventional corona protection devices use simple connection methods, then the assembly process is simplified, but the seal quality and connection reliability deteriorate
Solution Approach 1:
The collar assembly incorporates multiple sealing surfaces at specific locations where contact with the insulator occurs. These localized sealing features include protrusions and recesses that create compression seals, ensuring high seal quality and connection reliability at critical interfaces without requiring complex assembly procedures throughout the entire structure.
4Reliability
If conventional corona protection devices lack proper sealing structures, then the device design is simpler, but the corona protection effectiveness decreases
Solution Approach 1:
The collar assembly includes specifically designed sealing surfaces and compression seal structures positioned at the interface with the insulator. These localized sealing features ensure effective corona protection by preventing electrical discharge paths, while the overall device design remains relatively simple and easy to manufacture.
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 reduces manufacturing costs, simplifies installation, and ensures a reliable seal and connection, enhancing the effectiveness of corona protection by forming a secure bond between the rubber housing and metal fitting.
Implementation Method 1
there are preferably multiple sealing surfaces disposed between the collar assembly and a bottom end of the rubber housing for securing the connection therebetween
Implementation Method 2
A metal fitting is disposed adjacent to the endmost radial weathershed and receives the tapered end of the rubber housing
Data Source
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AI summary
An integrated insulator sealing and shielding assembly includes a rubber housing having a plurality of radial weathersheds and a tapered end adjacent an endmost radial weathershed. A metal fitting is disposed adjacent to the endmost radial weathershed and receives the tapered end. A collar assembly is disposed at an upper end of the metal fitting and includes two apertures between an outer surface thereof and the rubber housing for receiving a sealant. At least one sealing surface, preferably four, is disposed between the collar assembly and a bottom end of the rubber housing for securing the connection therebetween.