the manufacturing process of suspension disc-type glass insulators involves several key stages to ensure quality and reliability. here is an overview of the typical manufacturing process:
manufacturing process of suspension disc-type glass insulators
1.preparation of raw materials:
raw materials such as quartz, sand, soda ash, calcite, feldspar, and dolomite are stored in computer-controlled silos.
these materials undergo chemical analysis and screening to ensure consistent chemical composition.
2.batch mixture preparation:
the raw materials are combined using a computer-controlled batching system to achieve precise composition.
3.glass melting:
the batch mixture is melted in a glass furnace to form molten glass.
4.glass shell production:
high-speed molding machines shape the molten glass into glass shells with accurate geometry.
air and water cooling conveyors are used to cool and solidify the glass shells.
5.insulators’ assembling:
glass shells are assembled with metallic caps and pins to form complete insulator units.
hardware components are treated with pitch (bitumen) for corrosion protection before assembly.
6.testing:
insulators undergo rigorous testing to ensure quality and performance.
mechanical strength tests are conducted on production samples to verify compliance with standards.
tensile mechanical strength tests are performed on every unit after curing.
7.packaging:
insulators that pass quality control tests are packaged in crates for storage and transportation.
8.quality control:
quality control measures, such as monitoring acceptance rates and analyzing production data, are implemented to maintain consistent quality.
manufacturers may use counters on production lines to track process parameters and ensure product reliability.
9.curing process:
after assembly, insulators undergo curing in a hot water bath at specific temperatures based on the mechanical rating of the insulator.
10.final inspection:
final inspection is conducted to verify the integrity and performance of the manufactured suspension disc-type glass insulators before distribution.
this manufacturing process ensures that suspension disc-type glass insulators meet stringent quality standards and perform effectively in power distribution systems. this detailed manufacturing process outlines the key steps involved in producing suspension disc-type glass insulators, emphasizing quality control measures and precision in manufacturing for optimal performance in power distribution systems.