Prestressed Ceramic Suspension Insulator Assembly for High-Tonnage Strength
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Solution Overview
Problem
Low-tonnage disc-shaped suspension ceramic insulators face issues with insufficient strength, loosening of metal fittings, and assembly deviations, leading to instability and potential accidents in harsh environments, especially in ultra-high-voltage power systems.
Innovation Solution
A large-tonnage disc-shaped suspension ceramic insulator assembly using an adhesive material with an expansion agent and toughening agent, coated with a primer, and a prestressing assembling device for precise alignment and cementing, ensuring even compressive prestress distribution and improved coaxiality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tonnage and weight of the ceramic body are increased to improve strength, then the strength is improved, but the cementing strength of the integrated structure becomes insufficient
Solution Approach 1:
The patent changes the physical and chemical parameters of the adhesive material by adding an expansion agent that generates expansion force during curing. This expansion force creates compressive prestress on the ceramic body and metal fittings, transforming the adhesive material from a passive binder to an active prestressing element that enhances cementing strength without increasing ceramic body weight
Solution Approach 2:
The expansion agent performs preliminary action by generating expansion force during the curing process to create compressive prestress before the insulator is subjected to operational loads. This preliminary prestressing prevents loosening and falling off of metal fittings during service
2Ease of manufacture
If the adhesive material is used to fix and cure the ceramic body and metal fittings, then the assembly is achieved, but concentricity deviation occurs
Solution Approach 1:
The patent introduces a primer as an intermediary substance between the adhesive material and the assembly interfaces. The primer improves adhesion and reduces shrinkage of the adhesive material, thereby minimizing concentricity deviation during curing while maintaining ease of assembly
Solution Approach 2:
The primer modifies the physical and chemical parameters of the assembly interface by improving wetting and adhesion properties. This reduces the shrinkage stress of the adhesive material during curing, thereby maintaining concentricity while enabling easy assembly
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
Enhances assembly strength and stability, improving tensile strength and interface shear strength by 78%, ensuring reliable operation under extreme conditions, and reducing assembly deviations.
Implementation Method 1
the expansion agent is configured to make the adhesive material expand after hardened so as to create a prestress between the ceramic insulator body and the metal pin as well as the metal cap
Implementation Method 2
the toughening agent comprises: 72-82 wt % of alpha-alumina (α-Al2O3), 15-22 wt % of yttrium-stabilized zirconia with yttrium oxide in a mole fraction of 8%, and 3-7 wt % of a flux
Data Source
AI summary
A large-tonnage disc-shaped suspension ceramic insulator includes a ceramic insulator body, and a metal pin and a metal cap coaxially assembled with the ceramic insulator body through adhesive material, assembly interfaces of the ceramic insulator body, the metal cap, and the metal pin are coated with a primer; the adhesive material includes an expansion agent; and the expansion agent is configured to make the adhesive material expand after hardening so as to create a prestress between the ceramic insulator body and the metal pin as well as the metal cap. The present disclosure achieves overall compressive prestress distribution of the ceramic insulator product, mitigating thermal stress caused by temperature changes and improving the tensile strength of the large-tonnage disc-shaped suspension ceramic insulator assembly. By treating the assembly interfaces with the primer, the present disclosure significantly improves the assembly strength of the ceramic insulator/metal assembly.