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Iron caps for custom-shaped insulators
Application areas: insulator accessories for circuit transmission, surge arresters, substations, and more.
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Iron caps for custom-shaped insulators
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Description
1. Materials and Implementation Standards
- Main material: Ductile iron.
- Grade: Commonly used QT450-10 or QT400-15 (compliant with GB/T 1348 or the equivalent ISO 1083 / EN 1563).
- Implementation Standard:
* Dimensional standard: IEC 60120 (ball-and-socket connection dimensions).
2. Core Mechanical Properties
- Tensile strength: ≥450 MPa.
- Elongation: ≥10%–15% (to ensure sufficient toughness under stress and prevent brittle fracture).
- Breakage Load: Customized according to insulator class; common specifications are:
- Hardness: 130–180 HB.
3. Surface Treatment and Corrosion Protection
- Corrosion protection method: Hot-dip galvanizing.
- Galvanizing standard: ISO 1461 / GB/T 13912.
- Zinc coating quality:
4. Geometric Features and Special Design
- Socket size: Strictly conforms to IEC 60120 standard; common ratings include 16, 20, and 24.
- Internal Cavity Structure: The inner cavity surface is typically equipped with anti-slip serrations or a roughened design to enhance grip with the cementitious adhesive.
- HL Design (High Leakage): For 120 kN/160 kN pollution-resistant insulator caps used in coastal or highly polluted areas, the skirt design must meet enhanced creepage distance requirements and ensure perfect matching with glass or porcelain insulators.
- Locking position: Precisely machined mounting holes for W pins or R pins are provided to ensure that the ball joint does not come loose after locking.
5. Quality Control
- Nondestructive Testing: Critical components shall undergo 100% magnetic particle testing (MT) to ensure that the casting is free of internal cracks, shrinkage porosity, and gas porosity.
- Heat Treatment: Annealing is mandatory to relieve casting stresses and prevent cracking under severe cold or high mechanical stress.
- Dimensional Tolerances: Tolerances for critical features are typically controlled within ±0.5 mm to ±1.0 mm.
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Iron caps for custom-shaped insulators
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