Railway Insulator

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Railway Insulator

Railway Insulator

Insulators for railway traction applications are a different category from conventional insulators because they require extremely stringent performance and safety requirements. Modern insulators set the standard for the design, manufacture, testing and supply of insulators for railway traction applications. We manufacture various types of 25kV railway insulators to meet the various needs of electrification of railway lines.

The insulators are manufactured to not only meet but exceed the requirements set by the RDSO (Regulatory Body for Electric Traction Insulator Applications). Manufactured insulators undergo routine and acceptance testing in accordance with RDSO standards. The sample size is greatly increased to demonstrate the consistency of product performance.
These insulators are subject to the following tests in addition to the routine tests

 flexural strength of the specimen.
 X-ray Diffraction (XRD) Analysis
 Scanning Electron Microscope (SEM) Investigation
 Energy Dispersive X-ray (EDX) Analysis
 Check elastic modulus
 Power arc test
These tests, along with strict control of the manufacturing process and strict adherence to quality control, set modern railway insulators apart from the competition. Hyundai continues to maintain its reputation as the largest supplier of insulators for railway applications in India.

What is a railway insulator?

A railway insulator is a device that is used to electrically isolate the tracks in a railway system from the ground. This is important because the tracks are typically electrified with a high-voltage current, and the insulator helps to prevent that current from flowing into the ground and potentially causing an electrical hazard.

Railway insulators are typically made of a non-conductive material, such as porcelain, glass, or composite materials, and are attached to the supporting structure of the railway tracks. They may be in the form of discs, cylinders, or other shapes, and are typically mounted on posts or brackets to hold them in place.

Railway insulators are used in both overhead and ground-level systems, and play a critical role in ensuring the safe and reliable operation of railway systems. They help to prevent electrical accidents, such as electric shocks or fires, and also help to protect the infrastructure and equipment of the railway system.

It can effectively prevent pollution flashover accidents and reduce the workload of cleaning and maintenance. Due to its small size, especially when the tunnel clearance is small, it is irreplaceable for ceramic insulator and glass insulators.

Why insulated?

Rails are main parts of the rail tracks. They lead the train and transfer the pressure of the wheels to the sleepers. It must have a continuous smooth surface with minimum resistance. Currently in the electrified railways or automatic block zone the two rails double as signal lines of track circuits and loop line for locomotive traction. So rails must be insulated in case of stray current interference. Usually insulators and insulated rail joints are used in rail tracks.

What are the types of railway insulators?

The following is the classification method of railway insulators:

1. Classification by structure

Insulators are divided into: column (post) insulators, suspension insulators, pin insulators, butterfly insulators, tension insulators, anti-fouling insulators and bushing insulators. In addition, the cross arm can be regarded as a generalized insulator.

2. According to different functions

It is divided into ordinary insulators and anti-fouling insulators.

With years of experience designing and manufacturing railway insulators, SAA GRID has developed a new concept to improve safety and performance while optimizing cost considerations for our customers. SAA GRID is willing to cooperate with colleagues from all over the world and customers in the wider power field.

Application of railway insulator

Railway insulators are used in a variety of applications within a railway system to help electrically isolate different components and prevent the flow of electrical current into the ground. Some of the main applications of railway insulators include:

  1. Overhead contact systems: In an overhead contact system, the electrical power for the trains is supplied through an overhead wire, which is supported by insulators mounted on poles along the tracks. The insulators help to prevent the electrical current from flowing into the ground or other conductive surfaces, and also help to support the weight of the overhead wire.

  2. Ground-level systems: In a ground-level system, the tracks are electrified and the trains pick up their power through a pantograph, which is a device mounted on the roof of the train that makes contact with an overhead wire. In this case, the insulators are used to electrically isolate the tracks from the ground and prevent the flow of electrical current into the earth.

  3. Switching systems: Railway insulators are also used in switching systems, which allow trains to be directed onto different tracks. The insulators help to isolate the various tracks from one another and prevent the electrical current from flowing between them.

  4. Signal systems: Railway insulators are also used in signal systems to help isolate the electrical components and prevent electrical accidents.

Overall, railway insulators play a critical role in ensuring the safe and reliable operation of railway systems, and are an essential component of the infrastructure and equipment used in these systems.

Feature:

Railway insulators are designed to meet specific requirements in order to effectively isolate electrical current and ensure the safe and reliable operation of railway systems. Some of the key features of railway insulators include:

  1. Non-conductive material: Railway insulators are typically made of a non-conductive material, such as porcelain, glass, or composite materials, in order to prevent the flow of electrical current through them.

  2. High strength and durability: Railway insulators must be able to withstand the weight of the overhead wire in an overhead contact system, as well as the mechanical and thermal stresses that they may be subjected to. They must also be able to withstand the harsh environmental conditions in which they are used, such as extreme temperatures, wind, rain, and snow.

  3. Good electrical insulation properties: Railway insulators must have good electrical insulation properties in order to effectively isolate the electrical current and prevent electrical accidents.

  4. High mechanical strength: Railway insulators must have high mechanical strength in order to support the weight of the overhead wire and withstand the mechanical stresses that they may be subjected to.

  5. High resistance to weathering: Railway insulators must have a high resistance to weathering in order to withstand the harsh environmental conditions in which they are used.

  6. Easy maintenance: Railway insulators should be easy to maintain in order to ensure that they remain in good working condition and can be easily replaced if necessary.

Overall, railway insulators must be able to meet these and other requirements in order to effectively isolate electrical current and ensure the safe and reliable operation of railway systems.

Structure:

Made of silicone housing, mandrel and end fittings.

Manufacturing process:

Complete injection molding technology Advantages: The mandrel and the silicone shell glue have no openings, and the internal insulation performance is good, which can avoid the breakdown of the interface.

Note: Product size, characteristics, connection method, shed color, etc. can be designed and manufactured according to customer requirements.

Overhead line catenary

One-piece core insulators are designed for horizontal or angled mounting on cross arms, providing maximum safety for wire connections to locomotives and trains.

pantograph post

We supply different types of insulators for locomotive and railway builders. Our design department can help you customize your solution.

Rods and Posts for Air Disconnect Switches

Considering each site installation, PPC insulators can work upright, horizontally, or pendant.

Rail and Light Rail Insulators

Reliable rail networks require reliable insulators, and while many new designs have been added to our existing product range since the last few years, our formula hasn't changed even once, and our history of trusted service has always been our greatest asset.

Molded on high-strength GPR rods, our wide range of insulators use a unique cladding. From the different types of desert conditions in Africa to the icy expanses of Canada, this extremely successful material has been well proven around the world and they have also been used by many power companies over the years.

Innovative self-cleaning design

In order to overcome different types of problems related to the environment, replacement, cleaning and addition of pieces are required with the help of traditional ceramic technology, while the use of polymer technology, open design, and self-cleaning properties of insulators help to ensure highly improved system performance .

The design of our insulators is deliberately low profile. This is an important feature that ensures that the railway signal is always free from any obstructions. Additionally, the product's light weight, vandal resistance and self-cleaning properties provide further benefits for initial maintenance and construction, reducing line shutdowns due to vandalism or damage.

Railway Insulator

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