Methods and strategies for improving the performance of FPQ insulators

2025-10-19 15:22:47

1、 Fundamental innovation at the material level

The performance of materials is the cornerstone of insulator performance.

1. Optimize the formula of silicone rubber

Adopting high-performance silicone rubber: using high-purity and high molecular weight silicone rubber raw rubber as the substrate, fundamentally improving the mechanical strength and aging resistance of the material.

Nanofiller technology: Adding nano alumina (Al ? O ∝), nano silica (SiO ?) or nano clay to silicone rubber. These nanoparticles can greatly enhance the resistance of silicone rubber to electrical traces and corrosion, as well as improve its hydrophobicity and mechanical strength.

Optimize reinforcement and flame retardant system: Use gas-phase white carbon black as the main reinforcement filler, and add flame retardants such as aluminum hydroxide (ATH) to make the insulator have excellent self extinguishing properties and meet strict flame retardant requirements.

2. Improve the performance of the core rod and interface integration

Acid resistant core rod: using acid resistant core rod. The key is to apply a special coating at the interface between glass fiber and epoxy resin, effectively preventing acidic substances from invading and causing the core rod to "brittle fracture". This is a key technology for improving the long-term reliability of insulators.

Interface coupling agent: using high-performance silane coupling agent to form a strong chemical bond between the core rod and the silicone rubber umbrella skirt, rather than simple physical bonding. This can significantly improve the ability of the interface to resist water vapor penetration and electrochemical stress, preventing "cap shedding" or interface breakdown during operation.

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2、 Accurate optimization of structural design and electrical performance

Through refined design, the potential performance of materials can be maximized.

1. Optimize the umbrella skirt structure

Large diameter and fewer umbrella skirts design: while meeting the requirements of creepage distance, larger diameter and fewer umbrella skirts are used. This can reduce the area of accumulated dirt, enhance self-cleaning ability, and improve the effectiveness of wind and rain cleaning.

Aerodynamic appearance: Designed with a streamlined umbrella skirt to reduce wind resistance, suppress vibration and oscillation under strong winds, and enhance mechanical stability.

Differentiated creepage distance design: Accurately design the required creepage distance for different pollution levels in different regions. For heavily polluted areas (such as Class IV), a structure with alternating large and small umbrellas can be designed to prevent bridging while ensuring sufficient effective creepage distance.

2. Improve electric field distribution

Integrated voltage equalization ring/shielding ring: For FPQ insulators with higher voltage levels (such as 35kV and above) or critical positions, integrated voltage equalization devices can be designed. This can effectively homogenize the end electric field, suppress corona discharge, protect fittings and rubber materials, and extend their lifespan.

3. Strengthen end connections

Optimization of crimping process: crimping process is preferred for the connection between fittings and core rods. By precisely controlling the pressing force and mold, a stress free "plastic elastic" transition zone is formed to avoid the generation of microcracks and ensure that the connection strength is higher than that of the core rod body.

Innovative sealing structure: Multiple seals (such as silicone rubber sealing rings and high-performance sealant) are used to protect the end connection area, absolutely preventing moisture from entering the core rod.

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3、 Precision control of manufacturing processes

Excellent craftsmanship is the guarantee for achieving excellent design.

1. Mixing and vulcanization process

Vacuum kneading: Introducing a vacuum environment during the mixing process of silicone rubber to completely eliminate bubbles, ensure the compactness and uniformity of the rubber material, and eliminate internal defects.

Injection molding and pressure vulcanization: A computer-controlled injection molding machine is used to achieve precise injection molding. Apply constant pressure during the vulcanization process to ensure that the rubber material flows sufficiently, tightly adheres to the core rod, and suppresses the generation of bubbles.

2. Whole process quality inspection

Online inspection: During the production process, conduct a 100% steep wavefront impact test on the core rod to eliminate products with internal defects.

Sealing test: Conduct strict sealing tests on finished products (such as helium mass spectrometry leak detection) to ensure their long-term sealing reliability under extreme temperature differences.

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4、 Upgrading of Intelligence and Operations Strategy

Transforming insulators from passive components to intelligent nodes.

1. Condition monitoring and predictive maintenance

Integrated sensors: Wireless temperature, humidity, or leakage current sensors are integrated inside or at the ends of insulators.

Data driven decision-making: Real time or regular monitoring of data, analyzing its hydrophobicity degradation trend and pollution accumulation through cloud platforms, achieving "predictive maintenance" and actively intervening before faults occur.

2. New operation and maintenance technologies

Hydrophobic repair technology: When the hydrophobicity of the insulator decreases (HC level>5), a long-lasting hydrophobic repair coating can be sprayed on site to restore its anti fouling flashover ability and greatly extend its service life.

Live cleaning and coating: In heavily polluted areas where power cannot be cut off, specialized equipment and insulation cleaning solution are used for live cleaning, followed by the application of anti fouling flash coating (RTV).

Through the collaborative innovation of "materials design process operation and maintenance" mentioned above, the performance of FPQ insulators can be systematically improved to a new height, enabling them to play a more reliable and long-lasting role in future smart grids and harsh environments.