To improve the quality of UHV disc-shaped suspension porcelain insulators for ±800 kV lines and address the issue of excessive zero values

we systematically researched how to improve the quality from various aspects

including the porcelain components

cementitious materials

overall performance

and testing methods

as well as automated intelligent manufacturing. This research focuses on optimizing the control indicators of key raw materials for porcelain components

such as high-temperature alumina

quartz powder

and low-sodium feldspar

and on enhancing the impulse puncture test performance of products through the optimization of product head parameters. Moerover

the cementitious material formula is improved by incorporating efficient water-reducing agents

artificial porcelain sand

and defoaming agents. The cement curing process is also optimized to enhance the performance of the cementitious material. In terms of automatically intelligent manufacturing

we developed equipment for automatically molding

sanding and glazing

cementing

and measuring

and established an intelligent and precise production process. Testing methods are strengthened

the water pressure test pressure for porcelain components increases to 36 MPa

and a more rigorous thermal mechanical test is proposed to evaluate the long-term performance of the insulator products. The results show that the porcelain insulator products

manufactured by high-temperature alumina raw materials

a cylindrical head structure

and high-alumina cement assembly

are able to pass 100% of the enhanced thermal machine tests

reaching international advanced levels. This resolves the difficulty in measuring zero values

theoretically achieving fewer or even no zero measurements.