High-Voltage Electrical Vacuum Casting Solution
2025-12-03 15:23:14High-Voltage Electrical Vacuum Casting Solution
—— A Precision Process System Born for Reliable Insulation and Long-Term Operation
In power transmission and distribution systems, the long-term reliability of high-voltage electrical apparatus (such as instrument transformers, transformers, reactors, and insulators) is directly critical to grid stability and safety. Traditional potting processes struggle to eliminate microscopic air bubbles and voids within the insulation material. Under long-term electrical stress, thermal cycling, and environmental humidity, these defects can initiate partial discharge (PD), ultimately leading to insulation degradation or even failure.
GOOGIO Machinery's High-Voltage Electrical Vacuum Casting Solutionis a complete system integrating precision equipment, process technology, and professional services. It is designed to eradicate insulation defects at their root, providing customers with the manufacturing capability to produce high-quality, maintenance-free products for life.
Core Challenges & Our Solutions
| Industry Core Challenge | GOOGIO Vacuum Casting Solution |
|---|---|
| Bubbles & Voids: Lower partial discharge inception voltage, shortening insulation life. | Full-Process Deep Deaeration: Material degassing, mixing, and casting are completed in a high vacuum environment ≤50Pa, ensuring zero-porosity insulation. |
| Insufficient Impregnation: Dry spots inside complex winding structures create local weak points. | Low-Pressure Slow Penetration Technology: Utilizes vacuum and precise injection control to allow low-viscosity resin to automatically, slowly, and completely penetrate every fiber gap. |
| Stress Cracking: Resin curing shrinkage creates internal stress, leading to cracks during thermal cycling. | Gradient Temperature Management & Stress-Optimized Formulations: Multi-stage programmed curing and dedicated modified materials significantly reduce internal stress and improve mechanical toughness. |
| Consistency Issues: High manual intervention leads to significant batch-to-bquality variation. | Full Automation & Data Traceability: PLC fully automates process parameters. Each product has a complete process data record, ensuring absolute repeatability. |
Three Pillars of the Solution
1. Precision & Reliable Hardware Platform
Vacuum System: Integrates rotary vane and Roots pumps to rapidly achieve and maintain the process vacuum ≤50Pa.
Metering & Mixing System: Uses servo-driven gear/plunger pumps for precise resin-hardener ratio control (±0.5%), with high-efficiency static mixers for homogenization.
Temperature Control System: Independent high-precision control (±1.5°C) for material tanks, delivery lines, mixing head, and vacuum casting chamber ensures stable material viscosity.
Automated Dispensing: Integrated 3-axis servo robot for precise, complex path dispensing within the vacuum chamber.
2. Validated Process Database
We provide not only equipment but also process parameter packagesvalidated by numerous successful cases. These cover various material systems (epoxy, polyurethane, silicone) and are tailored to the curing profiles and pressure curves for products of different voltage ratings and structures.
3. Full-Cycle Professional Service
Pre-sale Process Support: Assists with material selection and mold runner design.
Installation, Commissioning & Training: Ensures optimal equipment performance and certifies the operation and maintenance team.
Continuous Process Optimization: Provides long-term optimization advice based on production data to help customers maintain technological leadership.
Application Scenarios & Value Delivered
Dry-Type Transformers/Reactors: Achieves bubble-free, full-impregnation encapsulation of large coils, significantly improving lightning impulse withstand and long-term overload reliability.
10-35kV Indoor/Outdoor Instrument Transformers: Meets stringent partial discharge requirements (<2pC), especially for harsh environments like high humidity and salt fog.
High-Voltage Insulating Bushings & Busbar Supports: Achieves极高的 mechanical and electrical strength, ensuring long-term safe operation of switchgear.
New Energy Sector: Used for manufacturing high-voltage insulation components in PV inverters and Battery Energy Storage Systems (BESS).
Core Value for Customers:
Quality Leap: Reduces product insulation failure rate by an order of magnitude, building a premium brand reputation.
Efficiency Gain: Stable automated production cycle, predictable output, and over 60% reduction in labor demand.
Cost Optimization: Drastically reduces scrap, rework, and field maintenance costs caused by insulation defects.
Market Access: Helps products easily pass the most stringent type tests and certifications (e.g., IEC, GB, UL standards).
Towards the Future: Intelligence & Sustainability
Our next-generation solutions will deeply integrate IoTand AItechnologies to enable:
Predictive Maintenance: Forecasts critical component lifespan based on data models for proactive alerts.
Adaptive Process Optimization: Automatically fine-tunes parameters for optimal performance based on environmental and material batch variations.
Carbon Footprint Tracking: Supports customers in achieving green manufacturing and sustainability goals.
GOOGIO Machineryis committed to being the most trustworthy process equipment partner for high-voltage electrical manufacturers. We provide not just a set of machines, but a long-term commitment to "Insulation Reliability."