550kV Aluminum free ring basin insulator

The 550kV aluminum free ring pot insulator is a key insulation component in high-voltage GIS equipment, and its design achieves miniaturization and environmental protection through structural optimization and material innovation. The following is a comprehensive technical analysis:
Core design features
Geometry optimization
Adopting a contour design of "thick on both sides and thin in the middle", the maximum electric field strength along the concave surface is reduced by 25.4%, and the deformation is reduced by 29.9%
Optimize thickness variables (H ₁, H ₂, etc.) and contour variables (C ₁ ₂, C ₁ ∝, etc.) through genetic algorithm to balance electrical and mechanical performance
Advantages of aluminum free ring structure
Cancel traditional metal shielding rings to avoid local electric field distortion and simplify manufacturing processes
Reduce SF6 gas usage by 15% and epoxy composite material usage by 6.1%
2、 Application of dielectric gradient materials
3D printing+casting process
Using aluminum oxide/photosensitive resin 3D printing low dielectric constant body (ε=3.98-4.20), titanium dioxide/epoxy resin casting high dielectric constant region (ε=11.32-14.58)
The electric field distortion near the grounding flange has been significantly improved, and the flashover voltage has increased by 13.8%
Electric field regulation effect
After optimization, a high dielectric constant region is formed on one side of the convex surface near the outer flange of the insulator, greatly alleviating the phenomenon of electric field concentration
3、 Performance parameters and validation
Electrical performance
Power frequency withstand voltage 230kV, lightning impulse withstand voltage 550kV, local discharge capacity ≤ 5pC
When metal foreign objects are present, the flashover voltage can still be increased by 6.7%
Mechanical strength
The maximum deformation is reduced to 0.45mm, and the interface stress is below 70MPa
Verify reliability through hydraulic failure test (1.5 times rated pressure)
4、 Application and Environmental Benefits
Typical scenario
Suitable for 550kV GIS equipment, such as ultra-high voltage transmission projects or high-altitude environments
Can replace the traditional "R-arc" metal shielding structure and simplify the miniaturization transformation of GIS
Environmental Contribution
Reduce SF6 gas usage by 15%, in line with environmental trends
5、 Patent and tooling technology
Pressure resistant tooling design: adopting a transition tank body and conductive spring structure, supporting synchronous detection of multiple bowl insulators
Embedded optimization: The cylindrical conductive electrode is designed with arc-shaped protrusions to improve sealing and electric field uniformity