What is the manufacturing process for insulators?

1. Selection of insulator manufacturing materials

The manufacturing materials of insulators are generally divided into three categories: ceramics, composite materials and fiberglass. Among them, ceramic materials have high mechanical strength and puncture resistance, but are susceptible to contamination and require regular cleaning; composite materials are lightweight and wear-resistant, but have poor puncture resistance and relatively short service life; FRP insulators have many advantages such as lightweight, wear resistance, and penetration resistance, but the manufacturing cost is high.

In terms of material selection, manufacturers need to make comprehensive considerations based on the product's use environment and performance requirements to make the most appropriate choice.

2. Insulator mold design

The design of insulator molds has an important impact on product quality and cost. Commonly used mold materials include steel, plastic, ceramics, etc. Among them, the cost of ceramic molds is higher, but the accuracy and life are longer.

When designing the mold, factors such as the shape, size, and processing difficulty of the insulator need to be considered to minimize product defects and damage and improve molding efficiency.

3. Insulator molding process

Insulator molding is an important link in the entire manufacturing process, and its quality directly affects the service life and safety of the product. Common molding processes include extrusion, injection molding, molding, etc.

Among them, the extrusion process is suitable for the manufacture of long strips or perforated insulators; the injection molding process is suitable for smaller and more complex insulators, which can improve the consistency and sealing of the product; the molding process is suitable for large-volume, one-time molding of insulators.

4. Insulator sintering

Insulator sintering is a process in which the formed insulator is sintered at high temperatures. The rubber injection molding process makes it have good mechanical strength and insulation properties. Generally speaking, the higher the sintering temperature, the better the strength and voltage resistance of the insulator, but it will also increase the manufacturing cost.

During the sintering process, attention needs to be paid to controlling the sintering temperature and time to avoid problems such as uneven heating of the product and insufficient sintering.

5. Insulator packaging

Insulator packaging is the last link in product manufacturing, and its quality will affect the safe transportation and after-sales service of the product. Common packaging materials include plastic bags, foam boxes, wooden boxes, etc.

During the packaging process, manufacturers need to pay attention to avoid product damage or contamination and indicate necessary information such as product model and batch number to ensure product traceability and after-sales service.

6. Insulator faults and prevention methods

During use, insulators may be broken, damaged, dirty, etc., which will directly affect its insulation performance and safety. Common faults include breakdown, pollution flashover, insulator surface burst, etc.

Methods to prevent these failures include regular cleaning, inspection, and maintenance of insulators; selecting materials and manufacturing processes that meet product usage environment and performance requirements; monitoring operating status, and promptly discovering and handling problems.