Revealing the Process Flow of Busbar Insulation Dip Coating Line to Enhance Electrical Safety
In the electrical industry, busbars, as key components for power transmission, their insulation performance is of utmost importance. The emergence of the busbar insulation dip coating line provides an efficient solution for improving the insulation quality of busbars and ensuring the stable operation of power systems. Recently, the reporter delved into relevant enterprises to explore the process flow of the busbar insulation dip coating line.
Pretreatment Process: Laying a Solid Foundation
Before the dip coating insulation treatment, busbars need to go through a series of pretreatment processes. First is the degreasing step. The busbars are either immersed in a tank filled with degreaser or sprayed to remove oil stains, grease, and other organic pollutants on the surface of the busbars. This step is crucial. If oil stains remain, it will seriously affect the adhesion of the subsequent insulation coating. The busbar dip molding line of Suzhou Hengjiu Jinyi is equipped with a special degreasing tank to ensure the degreasing effect.
After degreasing, the busbars enter the water washing tank and go through multiple water washing processes to thoroughly remove the residual degreaser on the surface. 紧接着 comes the pickling step. Acid solution is used to remove the oxide layer and rust and other impurities on the surface of the busbars, further improving the surface cleanliness and activity, and creating conditions for the better adhesion of the insulation coating. After pickling, the busbars enter the neutralization tank, and a weak alkaline solution is used to neutralize the residual acid solution to prevent its adverse effects on subsequent processes. After that, through hot water washing, not only the residual neutralization solution can be removed, but also the busbars can be preheated, which helps to improve the dip coating quality. Finally, through a hot air drying oven or a hot air circulation drying system, the moisture on the surface of the busbars is quickly dried, making the busbars reach a dry state and preparing for the dip coating process.
Dip Coating Process: Endowing Busbars with Insulation Performance
Dip coating is the core link of the entire process flow. Depending on the dip coating process, the dip molding tank contains thermoplastic powder (such as polyethylene, polyvinyl chloride, etc.) in a molten state or liquid dip molding material. Taking the epoxy powder fluidized coating process as an example, the busbars need to be heated to a temperature above the melting point of the powder coating and below the decomposition temperature, and then immersed in the fluidized bed coating tank filled with epoxy powder. On the surface of the busbars, the hot - melted powder coating will form an insulating film.
The dip molding tank is equipped with an accurate temperature control system, which can strictly control the temperature in the tank to ensure that the plastic powder or dip molding liquid is always in the best working condition. At the same time, the suspension conveying system will evenly suspend and convey the busbars through the dip molding tank to ensure that the plastic powder or dip molding liquid adheres evenly to the surface of the busbars. The conveying speed can be flexibly adjusted according to the requirements of the dip coating process to meet the dip coating needs of different busbars. After dip coating, the busbars are lifted out of the dip molding tank and enter the dripping area. The excess plastic powder or dip molding liquid will drip back into the dip molding tank, which not only reduces material waste but also ensures the uniform thickness of the dip coating layer.
Curing Process: Strengthening the Performance of the Insulation Coating
After dip coating, the busbars need to enter the curing furnace for curing treatment. The curing furnace usually adopts methods such as electric heating, gas heating, or fuel oil heating. Under the set temperature and time conditions, the dip molding layer undergoes physical and chemical changes and cures rapidly, thus forming a hard, smooth plastic coating with good insulation performance.
The temperature distribution inside the curing furnace is uniform, and the temperature and curing time can be accurately adjusted according to the characteristics of the dip molding material. For example, in some application scenarios with extremely high requirements for insulation performance, a specific heating curve and a longer curing time will be adopted to ensure that the coating is fully cross - linked and cured and has excellent mechanical and electrical properties.
Cooling and Testing Process: Ensuring Product Quality
After curing, the busbars need to be cooled and shaped. Generally, an air - cooling device is first used. A fan blows air towards the busbars to quickly reduce their surface temperature. For some dip molding processes with higher requirements for cooling speed, a water - cooling device will also be used, but the water - cooling temperature and time need to be strictly controlled to prevent defects such as cracks in the dip molding layer due to excessive cooling speed.
After cooling, the busbars enter the testing stage. Through appearance inspection equipment such as visual inspection stations and optical detectors, it is checked whether the surface of the dip molding layer is flat and smooth, and whether there are defects such as bubbles, cracks, and plastic leakage. Thickness testing equipment such as coating thickness gauges is used to measure whether the thickness of the dip molding layer meets the specified requirements. Insulation performance testing equipment is used to detect the electrical performance indicators such as the insulation resistance of the dip - molded busbars. Only busbars that meet all the indicators will enter the next stage for packaging or be put into use.
Each link in the process flow of the busbar insulation dip coating line is closely connected and interlocked, jointly ensuring that the busbars have excellent insulation performance. With the continuous progress of technology, the busbar insulation dip coating line is also continuously optimized and upgraded, injecting new vitality into the development of the electrical industry and providing a solid guarantee for the safe and stable operation of power system
