Address
Nanzhai village, Liushi Town, yueqingCity, zhejiang Province, china
Tel
+86-13375775325
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Introduction:
This is a 115kV, 120kN Long Rod Composite Suspension Insulator, a high-performance component designed for electrical insulation and mechanical support in high-voltage transmission and distribution systems. It is engineered to provide reliable service in challenging environmental conditions. The insulator is characterized by its grey silicone rubber housing, which is molded into a profile of 24 sheds using an alternating large-small shed design. A key specification is its extensive creepage distance of 3150mm, which is critical for preventing flashovers in polluted atmospheres. The insulator is equipped with robust metal end fittings: a Y-type (clevis) on one end and a ball-head on the other, offering versatile and secure connection options.
Drawings:
Specifications:
Product Type | Dimensions | Mechanical | Electrical | ||||||||
Height | Mini Dry | Mini | Diameter | Number of | Diameter | Specified | Routine | Rated Voltage | Lightning | Power | |
FXBW-115-120 | 1240±15 | 1050 | 3150 | 18 | 24 | 142/112 | 120 | 60 | 115 | 650 | 275 |
Order Information: | |||||||||||
Key Features:
High Mechanical Strength (120kN): With a specified mechanical load (SML) of 120 kiloNewtons (approximately 12.2 metric tons), this silicone tension insulator can withstand significant mechanical stresses, including conductor weight, wind pressure, and ice loads.
Optimized Shed Design for Pollution Resistance: The 24-shed, large-small alternating profile is a critical design feature. This configuration prevents the bridging of the sheds by water during rain or by a continuous layer of pollution, thereby effectively increasing the leakage path and drastically reducing the risk of surface flashover.
Excellent Hydrophobicity: The housing is made from High-Temperature Vulcanized (HTV) Silicone Rubber. This material is inherently hydrophobic (water-repelling), causing water to bead up on the surface rather than forming a continuous conductive film. This property, which is maintained over time, significantly suppresses leakage currents.
Long Specific Creepage Distance (3150mm): The substantial creepage distance ensures a long and protected path for any leakage current, making the insulator exceptionally suitable for areas with high levels of contamination, such as coastal regions (salt fog) or industrial zones.
Lightweight and Vandal-Resistant: Compared to traditional porcelain or glass insulators, this polymer suspension insulator is significantly lighter, simplifying transportation and installation. The composite material is also highly impact-resistant, reducing the risk of damage from vandalism or flying debris.
Robust End Fittings (Y-type & Ball Head): The forged steel end fittings provide a secure and reliable connection to tower hardware and conductor assemblies. The Y-type and ball-head combination allows for flexible articulation, accommodating line movement.
Production Process and Workflow:
The manufacturing of this polymer tension insulator involves a precise, multi-stage process with strict quality control:
Core Rod Fabrication: The process begins with the production of the Fiberglass Reinforced Plastic (FRP) rod. This is created through a pultrusion process, where continuous glass fibers are saturated with epoxy resin and pulled through a heated die. This results in a rod with extremely high tensile strength and excellent dielectric properties.
Interface Treatment and Molding: The surface of the FRP rod is prepared to ensure a perfect, permanent bond with the silicone rubber. The rod is then placed in a mold that has the precise shape of the 24-shed profile.
Injection Molding and Vulcanization: This is the most critical step. HTV Silicone Rubber compound is injected into the closed mold under high temperature and pressure. This process simultaneously forms the sheds and vulcanizes (cures) the rubber, creating a permanent, waterproof, and inseparable bond with the FRP core rod.
End Fitting Assembly: The metal end fittings (Y-type and ball-head) are assembled onto the ends of the FRP rod. This is typically done using a high-pressure crimping or swaging process to ensure a strong mechanical grip. The interface is then sealed with a waterproof adhesive to prevent any moisture ingress into the core, which is crucial for long-term reliability.
Quality Control and Testing: Each insulator undergoes a series of rigorous tests, which typically include:
Visual and Dimensional Inspection: Checking for surface defects and verifying critical dimensions like creepage distance.
Mechanical Routine Test (MRT): Each unit is subjected to a proof load (e.g., 50% of SML) for a short duration to verify its mechanical integrity.
Electrical Tests: Including power frequency withstand voltage and lightning impulse withstand voltage tests to confirm the dielectric strength meets the 115kV system requirements.
Application Scenarios:
This type of high voltage insulator is specifically designed for demanding applications in high-voltage power systems:
115kV Overhead Transmission Lines: It is commonly used as a suspension or tension insulator to support conductors and maintain safe electrical clearance from the grounded transmission tower structure.
Substations (AIS): It serves as a post insulator for busbars, disconnect switches, circuit breakers, and other equipment in 115kV Air-Insulated Substations, providing both insulation and mechanical support.
Heavily Polluted Environments: Its long creepage distance and hydrophobic properties make it the ideal choice for areas with high contamination levels, such as:
Coastal Regions: Resistant to salt mist.
Industrial Areas: Resistant to chemical deposits, dust, and ash.
Areas Requiring High Reliability: Its robust construction makes it suitable for critical lines and infrastructure where minimal downtime is essential.
Two Ends Of Connecting Hardware List
| Attachedto the letter | WQ | WD | WU | CT | TT | UU | YQ | RR | |
| On behalfof fittings | Socket -Ball | Socket -Tongue | Socket- Clevis | Ball- Bal | Clevis-Tongue | Tongue-Tongue | Clevis- Clevis | Y-Ball | Ring-Ring |
| Connectionmark | 16-16 | 16-7 | 16-7 | 16-16 | 7-7 | 7-7 | 7-7 | 7-7 | 7-7 |
1. According to the requirements of hardware in models are indicated in the attached letter;
2. According to the requirements of users can formulate and match ends fitting;
3. Silicone rubber color gray as the default,can also choose the other colors.
4. Custom made according to customer's drawings
 |  |
 |  |
 |  |  |
Introduction:
This is a 115kV, 120kN Long Rod Composite Suspension Insulator, a high-performance component designed for electrical insulation and mechanical support in high-voltage transmission and distribution systems. It is engineered to provide reliable service in challenging environmental conditions. The insulator is characterized by its grey silicone rubber housing, which is molded into a profile of 24 sheds using an alternating large-small shed design. A key specification is its extensive creepage distance of 3150mm, which is critical for preventing flashovers in polluted atmospheres. The insulator is equipped with robust metal end fittings: a Y-type (clevis) on one end and a ball-head on the other, offering versatile and secure connection options.
Drawings:
Specifications:
Product Type | Dimensions | Mechanical | Electrical | ||||||||
Height | Mini Dry | Mini | Diameter | Number of | Diameter | Specified | Routine | Rated Voltage | Lightning | Power | |
FXBW-115-120 | 1240±15 | 1050 | 3150 | 18 | 24 | 142/112 | 120 | 60 | 115 | 650 | 275 |
Order Information: | |||||||||||
Key Features:
High Mechanical Strength (120kN): With a specified mechanical load (SML) of 120 kiloNewtons (approximately 12.2 metric tons), this silicone tension insulator can withstand significant mechanical stresses, including conductor weight, wind pressure, and ice loads.
Optimized Shed Design for Pollution Resistance: The 24-shed, large-small alternating profile is a critical design feature. This configuration prevents the bridging of the sheds by water during rain or by a continuous layer of pollution, thereby effectively increasing the leakage path and drastically reducing the risk of surface flashover.
Excellent Hydrophobicity: The housing is made from High-Temperature Vulcanized (HTV) Silicone Rubber. This material is inherently hydrophobic (water-repelling), causing water to bead up on the surface rather than forming a continuous conductive film. This property, which is maintained over time, significantly suppresses leakage currents.
Long Specific Creepage Distance (3150mm): The substantial creepage distance ensures a long and protected path for any leakage current, making the insulator exceptionally suitable for areas with high levels of contamination, such as coastal regions (salt fog) or industrial zones.
Lightweight and Vandal-Resistant: Compared to traditional porcelain or glass insulators, this polymer suspension insulator is significantly lighter, simplifying transportation and installation. The composite material is also highly impact-resistant, reducing the risk of damage from vandalism or flying debris.
Robust End Fittings (Y-type & Ball Head): The forged steel end fittings provide a secure and reliable connection to tower hardware and conductor assemblies. The Y-type and ball-head combination allows for flexible articulation, accommodating line movement.
Production Process and Workflow:
The manufacturing of this polymer tension insulator involves a precise, multi-stage process with strict quality control:
Core Rod Fabrication: The process begins with the production of the Fiberglass Reinforced Plastic (FRP) rod. This is created through a pultrusion process, where continuous glass fibers are saturated with epoxy resin and pulled through a heated die. This results in a rod with extremely high tensile strength and excellent dielectric properties.
Interface Treatment and Molding: The surface of the FRP rod is prepared to ensure a perfect, permanent bond with the silicone rubber. The rod is then placed in a mold that has the precise shape of the 24-shed profile.
Injection Molding and Vulcanization: This is the most critical step. HTV Silicone Rubber compound is injected into the closed mold under high temperature and pressure. This process simultaneously forms the sheds and vulcanizes (cures) the rubber, creating a permanent, waterproof, and inseparable bond with the FRP core rod.
End Fitting Assembly: The metal end fittings (Y-type and ball-head) are assembled onto the ends of the FRP rod. This is typically done using a high-pressure crimping or swaging process to ensure a strong mechanical grip. The interface is then sealed with a waterproof adhesive to prevent any moisture ingress into the core, which is crucial for long-term reliability.
Quality Control and Testing: Each insulator undergoes a series of rigorous tests, which typically include:
Visual and Dimensional Inspection: Checking for surface defects and verifying critical dimensions like creepage distance.
Mechanical Routine Test (MRT): Each unit is subjected to a proof load (e.g., 50% of SML) for a short duration to verify its mechanical integrity.
Electrical Tests: Including power frequency withstand voltage and lightning impulse withstand voltage tests to confirm the dielectric strength meets the 115kV system requirements.
Application Scenarios:
This type of high voltage insulator is specifically designed for demanding applications in high-voltage power systems:
115kV Overhead Transmission Lines: It is commonly used as a suspension or tension insulator to support conductors and maintain safe electrical clearance from the grounded transmission tower structure.
Substations (AIS): It serves as a post insulator for busbars, disconnect switches, circuit breakers, and other equipment in 115kV Air-Insulated Substations, providing both insulation and mechanical support.
Heavily Polluted Environments: Its long creepage distance and hydrophobic properties make it the ideal choice for areas with high contamination levels, such as:
Coastal Regions: Resistant to salt mist.
Industrial Areas: Resistant to chemical deposits, dust, and ash.
Areas Requiring High Reliability: Its robust construction makes it suitable for critical lines and infrastructure where minimal downtime is essential.
Two Ends Of Connecting Hardware List
| Attachedto the letter | WQ | WD | WU | CT | TT | UU | YQ | RR | |
| On behalfof fittings | Socket -Ball | Socket -Tongue | Socket- Clevis | Ball- Bal | Clevis-Tongue | Tongue-Tongue | Clevis- Clevis | Y-Ball | Ring-Ring |
| Connectionmark | 16-16 | 16-7 | 16-7 | 16-16 | 7-7 | 7-7 | 7-7 | 7-7 | 7-7 |
1. According to the requirements of hardware in models are indicated in the attached letter;
2. According to the requirements of users can formulate and match ends fitting;
3. Silicone rubber color gray as the default,can also choose the other colors.
4. Custom made according to customer's drawings
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