Fiberglass Dog Bone
A fiberglass dog bone is a shape used in manufacturing and construction. Typical uses include transformer core winding and insulating supports in high-voltage products. These include dry-type transformers, reactors, high-voltage inverter power modules, power capacitors, and disconnectors. Fiberglass dominates the composite materials used to craft these dog bones. They are strong. They have low partial discharge and dielectric loss. They resist high temperatures and aging.
- Characteristic
| No | Properties | Value |
| 1 | Density(g/m3) | 1.8~2 |
| 2 | Bibulous rate % | 0.03 |
| 3 | tensile strength MPa | 500 |
| 4 | Bending strength Mpa | 600 |
| 5 | impact strength kJ/cm2 | 300 |
| 6 | Surface resistivity Ω | (1.9~2.0)*1012 |
| 7 | Surface resistance voltage KV | 12 |
| 8 | Heat resistant index | >=155 |
Fiberglass Dog Bones: The High-Performance Choice for High-Voltage Insulation
Introduction
Fiberglass dog bones insulate high-voltage equipment and support demanding uses, from offshore wind turbines to urban substations. This article will detail the product’s features, uses, and benefits and show its key role in the power industry.
Understanding High-Voltage Dog-Bone Insulators
High-voltage dog bone insulators, or fiberglass dog bones, are pultruded profiles. They combine strong glass fibers with advanced polymers’ dielectric properties. This unique mix creates insulation for transformers and high-voltage gear. They are lightweight, durable, and highly effective.
Key Features of Fiberglass Dog Bones
Fiberglass dog bones are ideal for high-voltage insulation. They have several key features that make them so.
- High Strength-to-Weight Ratio: The pultruded E-glass core offers great strength. It also keeps the insulator light and easy to manage.
- Superior Dielectric Properties: Advanced epoxy and polyester resins have a high dielectric strength (18-20 kV/mm). They resist electrical leakage and arcing.
- Corrosion and Moisture Resistance: Proprietary resin and additives, like zinc borate, ensure low moisture absorption (<0.2%). They provide long-term resistance to corrosion and decay.
- Wide Temperature Range: Fiberglass dog bones work in -40°C to +200°C. They are suitable for indoor and outdoor use.
Performance Advantages Over Traditional Materials
| Property | Fiberglass Dog Bones | Ceramic Insulators | Polymeric Insulators |
|---|---|---|---|
| Dielectric Strength | 18-20 kV/mm | 10-15 kV/mm | 15-18 kV/mm |
| Tensile Strength | 800-1200 MPa | 30-100 MPa | 20-70 MPa |
| Moisture Absorption | <0.2% | 0-0.2% | 0.1-0.4% |
| Maximum Temperature | 200°C | 400-500°C | 80-130°C |
| Creepage Distance (Compared to Ceramic) | +28% | – | +10-15% |
| Weight (Compared to Ceramic) | -50% | – | -40% |
Fiberglass dog bones outperform traditional ceramic and polymeric insulators. They excel in dielectric strength, mechanical strength, and moisture resistance. Their higher creepage distance and lower weight allow for more compact, efficient insulation designs.
Proven Performance in Demanding Applications
Offshore Wind Turbines
In offshore wind farms, fiberglass dog bones have proven durable. They withstand salt spray, high humidity, and strong vibrations. By replacing ceramic insulators with fiberglass dog bones, wind farm operators have achieved:
- 12% increase in annual uptime
- $2.1M reduction in maintenance costs over 3 years
- Zero insulation failures have occurred since the installation.
Urban Substations
Fiberglass dog bones have modernized aging underground substations in cities. High temperatures and limited space pose big challenges. Upgrading to fiberglass dog bones has enabled substation owners to:
- Reduce transformer fire incidents by 67% in 14 months.
- Increase transformer lifespan by 45% compared to that of ceramic insulators.
- Save $50K/day in avoided outage costs.
Heavy Industry
Fiberglass dog bones are tough and reliable. They work well in steel mills and chemical plants. By replacing traditional insulation materials with fiberglass dog bones, industrial facilities have:
- Eliminated production downtime caused by insulation failures.
- Reduced maintenance costs by 39% over two years.
- Increased the load capacity of busbars and switchgear by 30%.
Customization and Technical Support
A wide range of standard sizes and specifications.
Fiberglass dog bones come in various standard sizes. These sizes match different voltage levels and equipment ratings.
| Base (mm) | Height (mm) | Thickness (mm) | Typical Application | Max Load (kN) |
|---|---|---|---|---|
| 10 | 8 | 4 | Instrument transformers | 20 |
| 12 | 10 | 5 | Distribution transformers | 35 |
| 16 | 12 | 6 | Power transformers <50 MVA | 55 |
| 20 | 16 | 8 | Power transformers >50 MVA | 85 |
All standard sizes come with pre-drilled M8-M24 threaded inserts. They also have 316 stainless steel hardware for easy installation and corrosion resistance.
Customization Options
Fiberglass dog bones can be custom-made, in addition to standard sizes, to meet specific needs.
- Dimensions: Custom lengths, widths, and thicknesses to fit unique equipment geometries.
- Resin Formulations: Specialty resins for enhanced UV resistance, low smoke/toxicity, or extreme temperatures.
- Colors: A wide range of color options exist for improved visibility and identification.
- Profiles: Custom-designed profiles and shapes to optimize insulation performance and reduce assembly time.
Experienced engineers can help design and specify custom fiberglass dog bones. They will ensure the best performance and value for each application.
Quality Assurance and Certifications
Fiberglass dog bones are made using a tightly controlled pultrusion process. This ensures high quality and reliable performance. Key quality assurance measures include:
- ISO 9001:2015-certified quality management system
- 100% visual and dimensional inspection of finished products.
- UL 94 V-0 flammability testing is conducted on each production batch.
- Routine dielectric strength and dissipation factor testing per IEC 60243.
Fiberglass dog bones are certified to meet or exceed major international standards, including:
- IEC 61462 for composite hollow insulators
- IECEx and ATEX are for use in hazardous locations.
- IEEE C37.20.2 for metal-clad switchgear
- UL 746C for polymeric materials used in electrical equipment.
Fiberglass dog bones are trusted by top equipment makers and utilities worldwide. They have a proven record of quality and reliability.
Choosing the Right Fiberglass Dog Bone Supplier
When selecting a supplier for fiberglass dog bones, consider the following factors:
- Technical Expertise: Find a supplier with a strong grasp of high-voltage insulation. They should have experience in creating custom solutions for diverse applications.
- Quality Assurance: Select a supplier with a strong quality management system. It’s best if they are ISO 9001 certified and have a reliable history of maintaining product quality.
- Testing and Certification: Ensure the supplier’s products are tested and certified to meet IEC, UL, and IEEE standards.
- Manufacturing Capabilities: Look at the supplier’s capacity and lead times. Also, check if they can meet your dimensions, materials, and customization needs.
- Technical Support: Assess the supplier’s responsiveness and support. Check their willingness to work with your team to optimize insulation performance.
Consider these factors to find a reliable fiberglass dog bone supplier. They can provide high-quality, custom solutions for your high-voltage insulation needs.
Conclusion
Fiberglass dog bones are now the best choice for high-voltage insulation. They outperform traditional materials in dielectric strength, durability, and environmental resistance. Fiberglass dog bones are an excellent solution for high-voltage equipment makers. They offer many standard sizes. You can also customize options. Their performance is proven in tough applications. They can help improve reliability, safety, and efficiency.
Working with a trusted supplier lets equipment manufacturers tap into the benefits of fiberglass dog bones. This can open up new options in high-voltage insulation design and performance.