500kV Long Rod Composite Insulator for Transmission Lines

Product Overview

The 500kV long rod composite insulator is a critical insulation and mechanical support component used in extra-high-voltage overhead transmission systems. Wishpower designs 500kV composite insulators according to insulation coordination, mechanical loading, pollution severity, tower configuration and environmental conditions. Featuring a high-strength fiberglass core rod, silicone rubber housing, corrosion-resistant end fittings and an effective sealing system, the insulator provides reliable conductor suspension and electrical isolation. It is suitable for suspension towers, tension towers, long-span crossings and transmission projects operating in coastal, polluted, humid, windy or high-altitude environments.

Product Overview

The Wishpower 500kV long rod composite insulator is designed to support conductors, withstand tensile loads and maintain a safe electrical insulation distance between energized conductors and grounded tower structures.

Compared with conventional porcelain or glass insulator strings, it provides several practical advantages:

• Lightweight construction for easier transportation and installation

• High mechanical strength for EHV conductor suspension

• Excellent hydrophobicity and hydrophobicity transfer

• Reliable performance in polluted and humid environments

• Flexible creepage-distance and shed-profile design

• Reduced handling and tower-loading requirements

• Good resistance to ultraviolet radiation, ozone and weathering

• Customizable end fittings and grading-ring configurations

Wishpower can customize the insulator according to the required mechanical load, insulation level, creepage distance, section length, pollution class, altitude and connection arrangement.

 Core Features

1. Designed for 500kV EHV Systems
   The insulator is developed for 500kV AC overhead transmission lines and can be used for conductor suspension and tension applications.

2. High Mechanical Strength
   A fiberglass-reinforced resin core rod provides the tensile strength required for heavy conductors and long-term mechanical loading.

3. Excellent Pollution Performance
   The silicone rubber surface maintains hydrophobic properties that help reduce continuous conductive water films under wet and polluted conditions.

4. Lightweight Construction
   Composite construction significantly reduces product weight compared with conventional porcelain insulator strings, simplifying transportation and installation.

5. Optimized Electric-Field Distribution
   Grading rings can be installed at the energized end or at both ends to control electric-field concentration and reduce corona activity.

6. Weather and Ageing Resistance
   The housing is designed to withstand ultraviolet radiation, ozone, rain, snow, temperature variation and outdoor environmental exposure.

7. Reliable End Sealing
   The joint between the core rod, housing and end fittings is sealed to reduce the risk of moisture penetration.

8. Project-Specific Customization
   Mechanical rating, creepage distance, shed profile, section length, end fittings and grading rings can be adapted to project requirements.

Product Structure

1. Fiberglass Core Rod
   The core rod is the main mechanical load-bearing component. It is normally manufactured from high-strength fiberglass-reinforced resin with good tensile and corrosion-resistant properties.

2. Silicone Rubber Housing
   The housing protects the core rod and provides external insulation, weather resistance and resistance to tracking and erosion.

3. Silicone Rubber Sheds
   The sheds increase the creepage distance and improve insulation performance in rain, salt fog, industrial pollution and dusty environments.

4. End Fittings
   End fittings may be manufactured from hot-dip galvanized steel or other project-specified materials. Ball, socket, clevis, tongue, eye and customized connections are available.

5. Crimping and Sealing System
   Mechanical crimping connects the core rod to the end fittings, while the sealing structure protects the internal interface against moisture ingress.

6. Grading Rings
   Grading rings are normally selected according to electric-field calculations, corona requirements and the insulation design of the 500kV system.