Intelligent Device para sa Restoration sa Insulation sa Low-Voltage Overhead Cables: Automated, Efficient, ug Precise nga Solutions

1. Kasinungan sa Karon ug mga Problema

Ang mga low-voltage overhead cables kasagaran magdula og pinsala sa insulation. Ang urbanization ug pagtukod sa infrastructure nagpakita kanila sa komplikado nga environment (construction, severe weather sama sa matangis na hangin/ulan nga nagpadala og scratches o impacts, pinsala gikan sa mga hayop), madaling maputli ang layers sa insulation. Ang long-term operation usab mograbi sa insulation tungod sa aging, corrosion, ug prolonged sunlight—e.g., ang mga cables sa lumad nga mga komunidad mograbi ug moputli, nagdaghan sa panganak sa failure.

Ang eksisting nga mga paraan sa restoration (heat-shrinkable tubes: measure, select, cut, heat; insulating tapes: tilt-wrap yellow wax tape then overlap black tape) adunay daghang oras, labor-intensive, ug dili handa. Aron mubuntog niining mga problema, gi-develop kini nga paper og intelligent device. Kini makapugos sa uban nga specifications sa cable, mas rapido nga mahimong lokalisar ug precise nga irepair ang damage, wala nanginahanglan og komplikado nga equipment/specialists, ug molihok sa maintenance time.

2. Komprehensibong Disenyo

Ang intelligent device alang sa insulation restoration sa low-voltage overhead cables nagintegre sa mga function sa automatic detection, precise positioning, ug efficient restoration. Kini gisulbaran sa automatic detection module, hot-melt module, injection molding module, plastic particle feeding mechanism, pre-clamping/clamping mechanisms, cooling module, multi-specification cable molds, restoration control module, wireless remote control, ug insulating materials.

Technical Approaches

• Image Acquisition and Processing: Gamiton ang high-resolution technology aron automatic nga makuha ang surface insulation damage sa overhead cables, accurately capture minor damages, ug ipasabot ang data support alang sa repairs.

• Hot-Melt Injection Molding and Curing: Imbestigar ang hot-melt injection molding ug rapid cooling curing technologies aron sigurado nga ang insulating materials makapugos ug uniform nga fill ang molds ug quick nga solidify, forming a robust insulation layer.

• Intelligent Control System: Develop a system to automatically control the restoration process, precisely operate the pre-clamping/clamping mechanisms, and stably supply insulating materials, ensuring the continuity and efficiency of repairs.

• High-Performance Insulating Materials: Develop insulating materials with high strength, strong adhesion, high elongation at break, and flame retardancy. These materials can adapt to extreme environments such as high temperatures, low temperatures, and humidity, ensuring the device’s applicability and stability.

3. Electronic Design

Ang intelligent device alang sa insulation restoration sa low-voltage overhead cables nagintegre sa lifting, heating, mold clamping, injection molding, cooling, ug mold opening modules aron maabot ang efficient restoration sa overhead cables. Ang electronic scheme sa intelligent device nakita sa Figure 1

Pindoton ang remote key 1 aron iactivate ang lifting motor, raising the device to the damaged cable. During ascent, press key 3 to preheat restoration material. Upon arrival, press key 5 to clamp the mold around the cable (indicator lights preheating completion).

Pindoton ang key 7 aron iminject ang preheated material sa damage, ensuring full filling. After injection, press key 3 to stop heating (saving energy for cooling). Press key 4 to cool and solidify the material; once done, press key 4 again to turn off cooling. Then press key 6 to open the mold, resetting it. Finally, press key 2 to lower the device back. The process is monitored via mobile app for stability and safety.

2. 433 Remote Control Module

Ang device gamiton ang 433 module aron remote control sa lifting, heating, clamping, injection, cooling, ug mold opening. Ang users mogamit sa keys wala na langgamin sa restoration area, boosting safety ug simplicity.

Composed of a transmitter and receiver, it sends commands as radio waves (via modulation-demodulation). The receiver decodes and triggers actions. With strong anti-interference, stable signals, and long transmission, it suits outdoor/high-altitude/complex scenarios.

3. Mechanical Design

Ang housing gamiton ang high-quality SUS304 stainless steel (oxidation/corrosion/high-temp resistance, high strength) aron long-term stability. Advanced mold technology ensures precision; a refined surface adds fingerprint resistance and easy cleaning. Ergonomic and aesthetic, it’s easy to operate/maintain (physical product in Figure 2).

4 Experiments and Tests
4.1 10 - Square Copper Cable Insulation Restoration Test

Para sa 10 - square copper cable insulation restoration test, gamiton ang Mold #1: The fluidity and adhesiveness of the insulation restoration material meet the requirements. After compression molding, cool for 3 minutes, then demold. At this point, the material is semi-fully solidified. Continue cooling for 10 minutes: the restored insulation layer is smooth overall, has sufficient hardness, and the insulation restoration effect is quite satisfactory. The 10 - square insulation restoration test is shown in Figure 3a.

4.2 95 - Square Copper Cable Insulation Restoration Test

Para sa 95 - square copper cable insulation restoration test, gamiton ang Mold #2: The fluidity and adhesiveness of the insulation restoration material meet the requirements. After compression molding, cool for 5 minutes, then demold (the material is semi-fully solidified at this time). Continue cooling for 12 minutes: the restored insulation layer is smooth overall, has acceptable hardness, and the insulation restoration effect is quite satisfactory. The 95 - square insulation restoration test is shown in Figure 3b.

5 Conclusion

Ang intelligent device alang sa insulation restoration sa low-voltage overhead cables adopts a modular design approach. It highly integrates multiple functional modules to form a complete and efficient automated restoration device. It not only achieves precise positioning of cable insulation damage and automatic lifting processing but also ensures accurate operations during the restoration process through advanced motor control technology.

The intelligent device has developed a software, enabling real-time monitoring of the entire process from lifting, material preheating, injection molding restoration to cooling via a mobile APP. This greatly improves restoration efficiency and precision. The intelligent device enhances safety, guarantees insulation restoration quality, and has an extremely broad application prospect.