Single-Part Shield Forming for Reliable High-Voltage Insulators
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Solution Overview
Problem
Conventional shieldings for insulators in high-voltage technology require multiple parts that need to be interconnected through hard soldering or welding, which is labor-intensive and prone to connection failures.
Innovation Solution
A single-part shielding is produced by tensile compressive forming, eliminating the need for hard soldering or welding by integrating a conical and tubular portion with a circumferential slot, allowing seamless integration with insulators and metallic parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple parts are interconnected through hard soldering or welding to form a shielding, then the shielding can be assembled from separate components, but the production effort increases and connection failures may occur
Solution Approach 1:
The patent merges multiple separate shielding parts into a single integrated shielding component. The shielding is formed as one continuous piece that encompasses both insulators, eliminating the need for separate parts to be connected through hard soldering or welding. This integration directly reduces production effort and eliminates connection failure risks.
Solution Approach 2:
The shielding is designed with functional segmentation through the circumferential slot that separates the two insulators while maintaining structural integrity as a single piece. The slot allows the shielding to adapt to the insulator arrangement without requiring separate components, thus avoiding connection processes while maintaining functional separation.
2Adaptability or versatility
If multiple parts are interconnected through hard soldering or welding, then the shielding can be constructed from modular components, but the risk of connection failure increases
Solution Approach 1:
The shielding is formed as one continuous piece that encompasses both insulators, eliminating the need for separate parts to be connected through hard soldering or welding. This integration directly reduces production effort and eliminates connection failure risks.
3Ease of manufacture
If a single-part shielding is produced by tensile compressive forming, then production effort is reduced and connection failures are eliminated, but the shielding must accommodate complex geometries
Solution Approach 1:
The patent employs tensile compressive forming to transform a flat or simple starting material into a complex three-dimensional shielding geometry. By changing the physical parameters (tension and compression) during forming, the process creates the necessary complex shape including the circumferential slot and insulator accommodation regions without requiring multiple assembly steps.
Solution Approach 2:
The shielding incorporates curved surfaces and rounded transitions, particularly in the regions accommodating the insulators and forming the circumferential slot. These curved geometries are naturally achieved through tensile compressive forming, which excels at creating complex curved shapes from flat materials, thereby managing geometric complexity through the forming process itself.
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
Reduces production effort and eliminates connection failures, ensuring a robust and efficient shielding solution.
Implementation Method 1
The single-part shielding according to the invention is produced from a flat sheet (not shown) by tensile compressive forming
Data Source
AI summary
A single-part shield is produced by tensile compressive forming for tubular insulators in high-voltage technology. The single-part shield does not require the production process needed to connect, by hard soldering or welding, the parts in a conventional multi-part shield. This eliminates a connection point which also eliminates the risk that the closure soldering will not succeed.