production process
The production process of glass insulators is as follows:
Batching Process
Batching refers to the uniform mixing of different raw materials according to a specific ratio. Currently, forced vertical-axis mixers are commonly used for this process. The key requirement is achieving homogeneous blending of all components.
▲ Glass insulator automatic batching mixer
Melting & Fining Process
Melting and clarification: Melting refers to the formation of a uniform glass liquid by heating the ingredients at high temperatures, while clarification refers to the exhaust treatment of the liquid formed by melting the raw materials.
Press forming
Pressing: After melting and clarification, the glass liquid enters the pressing process through the feeding system, that is, the glass is hydraulically made into glass insulation parts, usually achieved through a fully automatic hydraulic forming machine. The pressing shape is controlled by the glass mold, and the amount of glass liquid used to press one insulator is also controlled to ensure the consistency of the insulator product.
▲ Hydraulic Forming
Tempering
The glass component subsequently undergoes tempering treatment, which involves controlled cooling to induce permanent compressive stress on the surface. Key equipment used in this stage includes homogenization furnaces and tempering machines.
▲ Tempered area
Thermal Shock Testing
The tempered glass component is subjected to thermal shock testing using specialized nickel sulfide treatment furnaces and elimination processes. The homogenization treatment and effectiveness of nickel sulfide removal directly impact a critical operational metric of glass insulators—the spontaneous breakage rate.
▲ Thermal Shock Test Line
Cementing Assembly
A cementing assembly machine equipped with steel pin positioning assistance is used to assemble the insulator's dielectric component, steel pin, and cap. This step requires strict attention to maintaining coaxial alignment among the steel pin, dielectric component, and cap, as poor coaxiality can also lead to elevated spontaneous breakage rates.
▲ Cemented Assembly
Inspection
Conduct a 50% tensile load test on the glass insulators that have been glued together, check the height of the insulator structure, etc., to ensure that the insulators meet the standard requirements.
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