Traditional glass insulators production relies on manual batching and manual control of kiln temperature, which not only leads to large errors in raw material proportioning (easily causing unstable insulation performance of products) but also makes temperature fluctuations during the melting and forming process prone to defects such as glass bubbles and cracks, with the product qualification rate only maintained at around 85%. Today, the popularization of intelligent production equipment has completely changed this situation.​

In the raw material proportioning link, the intelligent batching system automatically and accurately weighs raw materials such as quartz sand, soda ash, and feldspar through computer preset formulas, with the proportioning error controlled within ±0.1%, ensuring uniform composition of raw materials in each batch and guaranteeing stable insulation performance of products from the source. In the melting link, the new electric melting kiln replaces the traditional coal-fired kiln, and the temperature inside the kiln is monitored in real-time through the PLC control system (accurately controlled at 1550-1600℃). The power is automatically adjusted according to the glass melting state to avoid problems such as bubbles and stones caused by temperature fluctuations. In the forming link, the automatic forming machine accurately controls the pouring amount of glass liquid and mold positioning through a robotic arm, with production efficiency 3 times higher than that of manual work. The product size error is reduced to ±0.5mm, far exceeding the ±2mm standard of traditional manual production.​

The annealing and cooling link is the key to ensuring the mechanical strength of glass insulators. The intelligent annealing furnace effectively eliminates internal stress of glass through segmented temperature control (gradually cooling from 500℃ to room temperature, with the cooling rate accurately controlled at 5℃/h), avoiding cracking caused by excessive cooling speed. At the same time, the digital detection system runs through the entire process — high-definition cameras automatically identify surface defects of products, ultrasonic waves detect internal structures, and unqualified products are rejected in real-time, increasing the product qualification rate to over 99%.​

Intelligent production not only improves the quality stability of glass insulators but also reduces energy consumption and labor costs. Data shows that after adopting the intelligent production line, the energy consumption per unit product is reduced by 25%, the labor demand is reduced by 60%, and the production cycle is shortened from the traditional 72 hours to 24 hours, providing strong support for meeting the large-scale demand for glass insulators in the power industry.