Pagtambal sa Mekanikal nga mga Suliraning Analisis ug Teknikas sa Pagpuno sa Mataas nga Boltye nga Switches nga Disconnector

Bisag sa patuloy nga pag-usbong sa mekanisasyon sa modernong lipunan, ang pangangailangan sa elektrisidad sa pang-araw-araw nga kinabuhi nagsugyot pa. Aron masigurado nga ang abilidad sa kuryente makasunod sa kasagaran nga pangangailangan, ang sistema sa kuryente kinahanglan nga magoperasyon ngadto sa mas matibay, ligtas, ug real-time nga responsibo. Kini nagpakita sa kritikal nga importansya sa kalidad sa high-voltage disconnector switch sa panahon sa pagproseso.

Ang mga manUFACTURER kinahanglan pataasin ang ilang kamalayan sa responsibilidad aron masigurado ang handum nga operasyon sa high-voltage transmission lines ug bawasan ang frequency sa mga pagkamalas. Mahimo nga mahimong maipakita nga ang mga disconnector switch responsable sa pag-isolate sa electrical equipment bisan wala na sila nagloload sa panahon sa emergency. Dili pwede tangganan ang komprehensibong analisis sa umiiral nga mechanical faults, sumala sa tinuod nga solusyon para mapaliit ang mga risco.

1. Common Defects and Fault Analysis

Ang high-voltage transmission lines nanginahanglan og regular nga maintenance, na nagpasabot sa paborito nga pag-operate sa high-voltage disconnector switches aron ma-isolate ang power sources—masiguro ang seguridad sa mga tawo nga nag-maintenance. Apan, tungod sa inherent nga disenyo ug material flaws, ang mechanical faults gihapon ang pinaka-common nga klase sa failure. Ang imbestigasyon nagpakita nga ang dili maayo nga pag-install, insufficient commissioning, o corrosion sa metal mao ang nagresulta sa excess nga temperatura sa conductive circuit, insulation cracking, ug uban pa nga severe nga safety incidents.

Ang isang partikular nga dangerous nga mechanical fault mao ang fracture sa supporting porcelain insulators. Kini nga failure nagpakita sa pinaka-high nga risk ug mahimo molihok sa catastrophic consequences. Ang mga causa mahimo mopasabot gikan sa daghang aspeto:

• Material Quality Issues: Substandard nga kalidad sa insulator, tungod sa dili maayo nga pagkontrol sa pagproseso, nag-introduce og serious nga safety hazards. Ang pag-examine sa fractured insulators nagpakita og internal impurities, micro-cracks, poor bonding quality, ug sa pipila ka kaso, wala na nga asphalt bilang shock-absorbing layer.

• Design and Process Defects: Inherent nga design flaws, improper nga pagtrabaho, o insufficient firing processes sa panahon sa pagproseso mao ang nagresulta sa weak joints sa pagitan sa insulator ug flange, reducing service life ug reliability.

• Environmental Degradation: Long-term exposure sa harsh conditions—inclusive sa strong electromagnetic fields, chemical corrosion, ug weathering—accelerates aging.

• Seismic Impact: Sa panahon sa earthquake, intense nga vibrations mao ang nagresulta sa insulator fracture tungod sa structural resonance o mechanical stress.

Ang usa ka common nga fault mao ang operational failure sa disconnector switch, diin ang dili maayo nga pag-operate mao ang nagresulta sa incomplete opening o closing (misalignment), resulting sa poor contact, increased resistance, overheating, ug potential nga damage sa equipment. Ang mga contributing factors include:

• Design Flaws or Incorrect Material Selection: Inadequate nga structural design o unsuitable materials compromise performance.

• Severe Corrosion: Ang rotating components, typically made of metal, exposed sa outdoor environments. High humidity, lack of lubrication, ug prolonged exposure accelerate corrosion, reducing operational flexibility.

• Failure of Electric Control Systems: Defective nga electrical components sa motorized operating mechanisms mao ang nagresulta sa operational failure.

• Environmental Factors: Outdoor exposure subjects switches sa rain, snow, ug pollution. Sa recent years, severe smog ug increased atmospheric humidity exacerbated corrosion.

• Chemical Corrosion: Atmospheric dust ug moisture react to form corrosive electrolytes. When deposited on switch surfaces, these substances cause electrochemical corrosion.

• Internal Design Weaknesses: Poor sealing allows moisture ingress. Inappropriate material selection—such as metals with low corrosion resistance—or inadequate anti-corrosion coatings further degrade performance. Combined with insufficient maintenance and inspection, these factors lead to severe mechanical deterioration.

2. Improvement Measures for Mechanical Faults

2.1 Manufacturing and Quality Control

Ang mga manufacturer kinahanglan strict nga sundon ang design specifications sa panahon sa production, ensuring proper material selection ug overall quality control. To address porcelain insulator fractures:

• Ensure that switch design meets technical and operational requirements.

• Strengthen quality control in production by sourcing high-quality raw materials.

• Partner only with reputable, technically qualified suppliers.

• Establish quality assurance agreements with suppliers, including on-site inspections and product testing.

• Strictly follow operational procedures during production; address any technical errors or defects immediately—never force operation.

2.2 Overheating Prevention

Overheating in conductive circuits poses a serious safety hazard. Effective countermeasures include:

• Adjusting contact insertion depth to ensure optimal contact.

• Maintaining clean contact surfaces or adopting self-cleaning contact designs.

• Installing temperature sensors to monitor for abnormal heating and trigger early intervention.

• Implementing live-line cleaning to enhance maintenance efficiency.

2.3 Corrosion Protection

As corrosion is a major contributor to mechanical failure:

• Apply regular lubrication to moving parts.

• Use stainless steel or other corrosion-resistant materials.

• Improve sealing to enhance water resistance.

• Ensure high-quality anti-corrosion coatings are properly applied.

2.4 Maintenance and Inspection

Regular inspection and timely repair are essential. However, maintenance must be meaningful—not merely routine or perfunctory. Superficial repairs waste resources and fail to ensure safe operation. Only thorough, condition-based maintenance can prevent unexpected failures.

3. Diagnostic Methods for Mechanical Faults

Different diagnostic techniques offer distinct advantages and limitations. Personnel should select methods based on actual conditions, combining approaches to achieve accurate fault detection.

• Ultrasonic Testing: Before installation, use ultrasonic inspection to detect cracks in porcelain insulators and prevent latent defects.

• Stress Monitoring: After installation, monitor whether insulators are under abnormal mechanical stress.

• Infrared Thermography: Detect localized overheating in circuits. If hotspots are identified, take corrective actions promptly.

• Motor Current Monitoring: Measure motor current during operation to assess switch performance and identify anomalies.

• Strain Gauge Measurement: Use resistance strain gauges to detect abnormal stress on insulators.

• Signal Analysis: Analyze motor current signals to evaluate the health of the drive system.

4. Conclusion

Only after all diagnostic checks confirm normal operation and the absence of safety hazards should the disconnector switch be put into service.

This paper analyzes common mechanical faults in high-voltage disconnector switches, including porcelain insulator fracture, abnormal stress, circuit overheating, operational failure, and metal component corrosion. Based on current technical challenges, targeted improvement and preventive measures have been proposed. By implementing these recommendations, maintenance personnel can enhance the prevention of high-voltage insulation failures, improve system reliability, and ensure the safety of operating staff.