Transformation – from Porcelain to Polymer
Transformation – von Porzellan zu Polymer
Industrial change in the energy sector and the use of new methods is to a certain extent causing cut-throat competition between technologies. Added to this is a globally networked world, which acts as a catalyst in some sectors and can, for example, quickly bring traditional manufacturing of porcelain insulators in Europe into economically unviable situations. Disadvantages of the production of porcelain insulators such as long lead times or lower flexibility meet with disadvantages in functionality such as high weight, low hydrophobicity in long-term use, or increased risk due to the fragility of the insulators.
New Principle Thinking
This leads to the fact that almost every year porcelain plants are closed and the know-how behind them is lost. This progressive development is irreversible and prompts far-sighted companies like our customer GEVEA to make their products fit for the future at an early stage. The change to alternative technologies requires pioneering spirit and trust, which was shown to us on a large scale for the pilot project of a guy insulator. First, the requirements of the so-called stay insulator were analyzed. This porcelain insulator was to be replaced by a suitable composite product.
Our engineering department developed an insulator based on given technical specifications and requirements. After presentation of the concept, the tooling was ordered and test samples were manufactured. On the initial samples, the mechanics in particular were put through their paces in use with original guy ropes in order to simulate the application in the best possible way. The requirements were met or exceeded at the first attempt and it was possible to ramp up series production within a very short time. The polymer material also has other advantages, such as lower brittleness, which helps to prevent damage during assembly.