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| Multi Scale Mechanical Simulation and Electromechanical Experimental Testing of GFRP Hollow Insulators Based on Different Process Parameters |
| Li Le1, Zhao Tianfang1, Liu Yunpeng1, Zhou Songsong2, Wu Wenhua2 |
1. Hebei Key Laboratory of Green and Efficient New Electrical Materials and Equipment North China Electric Power University Baoding 071003 China;
2. China Electric Power Research Institute Beijing 100192 China |
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Abstract Hollow post composite insulators are key components for supporting insulation in ultra-high voltage power equipment. Glass fiber reinforced polymer (GFRP) tubes serve as the inner insulation core, and their winding process has become a crucial factor affecting the mechanical and electrical performance of insulators. However, the existing GFRP pipe winding process parameters still rely on empirical exploration, and the layer design lacks effective basis, making it difficult to meet the high reliability requirements of hollow post composite insulators. Currently, there is still insufficient research on the bending failure of GFRP wrapped pipes under shear stress, and the equivalent modeling and damage analysis of composite materials at multiple scales need to be further studied. It is worth noting that the winding process conditions may affect the degree of bonding between the fiber/matrix resin interface, which in turn affects the internal insulation performance of hollow post composite insulators. Further exploration is needed on the interface and electrical performance of GFRP pipes under different winding processes. This article uses wet winding forming technology to prepare GFRP winding tube samples with different winding angles, layering methods, and fiber diameters. The microstructure, interface, mechanical and electrical properties of different winding process samples were compared and analyzed, and multi-scale mechanical simulation verification was carried out.
The results show, firstly, the winding angle significantly affects the bending resistance of the sample. As the winding angle increases, the bending modulus of the sample decreases, and the bending strength initially increases and then decreases. The bending strength of the sample is highest at a winding angle of ±40°, reaching 236.94 MPa. The breakdown strength is lowest at a winding angle of ±50°(46.23 kV/cm), with a relatively high leakage current of 152.58 μA. Conversely, the electrical performance of the sample is optimal at a winding angle of ±60°. Secondly, after introducing the intermediate winding layer, the bending and electrical properties of the sample decrease significantly. The bending strength is the lowest when the intermediate layer is ±80° (128.63 MPa), while the breakdown strength is the lowest when the intermediate layer is ±60°(34.15 kV/cm). This is due to the introduction of the intermediate winding layer, which increases the probability of air gaps between layers and the difficulty of defoaming, resulting in a varying degree of increase in the number of defects. In practical winding processes, it is advisable to avoid introducing intermediate winding layers. Thirdly, the fiber diameter has a limited impact on the bending modulus and bending strength of the sample, but using larger diameter fibers (2 400 g/km) increases the breakdown strength of the sample by 35.5% compared to conventional fibers (1 200 g/km), while the change in water diffusion leakage current is not significant. Therefore, increasing the fiber diameter is considered to be an effective method improving the breakdown strength of the sample. In addition, using a multi-scale modeling method combining micro/macro modeling with Hashin damage criteria could effectively analyze the bending failure process of GFRP wrapped tube samples and predict their bending strength. The simulation error is less than 25%, and the simulation accuracy meets the actual needs of engineering, which could reduce the time and cost associated with extensive testing.
In summary, considering the application requirements of GFRP winding tubes for hollow post composite insulators, it is advisable to appropriately reduce the winding angle, avoid introducing intermediate winding layers, and use larger fiber diameter yarns in the actual winding process, which could comprehensively improve the mechanical and electrical performance of hollow post composite insulators.
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Received: 08 November 2024
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2025, Vol. 40 
