Insulators play a crucial role in overhead transmission lines by supporting conductors and preventing current from flowing back to the ground. To ensure reliable operation, they must withstand various electromechanical stresses caused by environmental conditions and electrical loads. Any failure in these aspects can compromise the integrity and lifespan of the entire transmission line.
The introduction of composite insulators has significantly enhanced the pollution flashover resistance of transmission and distribution lines while reducing maintenance efforts, making them a preferred choice for power utilities.
Composite insulator material components
Composite insulators are made up mainly of high-temperature vulcanized silicone rubber and fiberglass resin core rods. The insulator's housing and sheds are made of silicone rubber, which provides the necessary creepage distance while also keeping the core rod secure. On the other hand, the fiberglass resin core rod bears the mechanical load of cables and other equipment.
The silicone rubber housing shaped by whole injection has good hydrophobicity, hydrophobicity migration and soil resistance, as well as excellent electrical insulation properties and aging resistance,which could prevent effectively those accidents of pollution flashovers so as to ensure the safe running of high voltage transmission lines.
The modified ECR fiberglass reinforced epoxy resin rod is used as it has good resistance to high temperature, stress corrosion & acid attack, as well as fine damping action, high tensile strength (> 1200Mpa) and resistance to creep and fatigue failure, which effectively ensure the internal insulation quality and mechanical strength of insulators.
The end fittings are crimped onto the fiberglass rods with voice-operated displacement crimpers. The insulators with this crimping technique have high mechanical strength and small dispersion.
The connection location between end fittings & rods is fused with sheds housing by the overall high temperature vulcanized silicone rubber injection molding as it could minimize the interface. The internal radia multi-seal structure effectively guarantees a long-term reliability of seal around the connection between end fittings & rods.
The company holds the most advanced Automatic Silicone Injection Molding Machines and Voice-operated Displacement Crimping Machines,which means the world's most advanced process technology level.
The company is equipped with 1000kV Power Frequency Testing Transformer, 1800kV Impulse Voltage Generator set and 2000kN Automatic Tensile Test Machine, as well as well-equipped Physical Laboratory and Electrical Laboratory
Wuhan Line Power’s composite insulators' quality and reliability are proven through internationally recognized certifications.
At Wuhan Line Power, we make sure the quality and reliability of our composite insulators through internationally recognized certifications and strict compliance with industry standards:
ISO 9001 Certification-Our manufacturing follows the ISO 9001 quality management system, making sure regular product firstrate and nonstop improvement.
SGS Certification – Verified by using SGS, a globally recognized leader in trying out and certification, confirming our insulators meet global security and fine standards.
CNAS Accreditation-Our laboratory is accepted by using CNAS, demonstrating our capability in conducting correct and dependable testing.
CE Marking-Compliant with European protection and environmental standards, allowing clean get right of entry to to international markets.
Type Test Reports – Our insulators bear rigorous kind trying out in authorized labs to meet or exceed IEC, IEEE, and different enterprise standards.
National Grid Approval– Certified by using the State Grid Corporation of China (SGCC) and China Southern Power Grid (CSG), proving their reliability for key electricity transmission projects.
These certifications reflect our commitment to delivering highquality, durable, and reliable composite insulators to the international market.
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Insulators play two vital roles:
Electrical isolation - Preventing current leakage between conductors and towers
Mechanical support - Bearing the weight of overhead lines
Glass Insulators
Key Benefits:
Considerations:
Moisture condensation may increase leakage current
Limited design flexibility affects stress distribution
High-performance glass insulators for harsh environments
Applications: High-voltage transmission lines in polluted areas where insulation integrity is critical.
Porcelain Insulators
Key Benefits:
Considerations:
Heavier weight increases installation difficulty
Brittle nature makes them prone to cracking
Traditional porcelain insulators for reliable performance
Applications: Overhead transmission and distribution lines, especially in low-pollution zones.
Composite Polymer Insulators
Key Benefits:
Modern composite insulators for demanding applications
Applications: HV/EHV transmission lines in harsh environments (coastal regions, heavy pollution).
Here is our manufacturing process. The function of the crimping machine is to tightly combine the core rod and the end metal accessories into an integrated component with a certain mechanical strength.
The crimping machine has several grades according to the pressure size: 300 tons, 600 tons, and 800 tons.
Wuhan Line Power Transmission Equipment Co., Ltd., specializes in manufacturing composite insulator ,located in Miaoshan Development Zone - Wuhan City. Since 2008, Wuhan Line focused on the development and production of various types of insulators.With the continuous development of the enterprise, when we focus on the design and production of composite insulators, we do not forget to better meet the individual needs of customers. At present, we can meet the needs of customers for complete sets of solutions, and can provide products including composite insulators, hollow composite insulators Insulators, tempered glass insulators, porcelain insulators, power fittings, etc.
The company products are covering composite station post insulators with electricity voltage from 72.5kV to 252kV, strength grade from 10kN to 20kN; the overhead line composite insulators with AC electricity class from 10kV to 1000kV and DC from 400kV to 1100 kV which strength grade from 70kN to 1000kN; and electrified railway composite insulators which includes long rod suspension 100 (120)kN and 160kN in ordinary type, reinforced type, highland type and double insulation type, and long rod post 8kN,12kN,16kN in ordinary type, reinforced type, highland type and double insulation type. All specifications and models have past the domestic or international test, whose comprehensive technical performance is in the leading place of the world.
Find professional composite insulator manufacturers and suppliers in China here. With more than 10 years' experience, we warmly welcome you to wholesale high quality composite insulator for sale here from our factory. Good service and competitive price are available.
