Insulator Crimping Machine CTCPM-140AS for Silicone Rubber Insulator Production

Crimping machine CTCPM-140AS at a glance

• Purpose: crimps the metallic end fittings onto the fibreglass rod of a composite (silicone rubber) insulator, on the production line.
• Voltage class covered: insulators from 11 kV to 33 kV — pin, post, suspension and tension polymeric insulators.
• Pressing force: 3200 kN, crimping range 8 to 200 mm, 1000 crimps per hour.
• Integrated acoustic emission system: since 2024 the AES is built into the machine, so micro-cracks in the fibreglass core are detected during crimping — previously an option that cost about USD 22,000 on the larger machines.
• Control: single cylinder control mode with 8 dies distributed equally, for high synchrony precision.
• Supply: 380 V / 50 Hz, 5.6 kW, noise level 69 dB.

1. What this machine is used for

The crimping machine presses the metal end fittings of a high voltage composite insulator onto its fibre glass rod. The hydraulic system presses the fitting from all directions at once, so the fitting ends up firmly attached to the rod and can carry the mechanical load of the insulator.

The CTCPM-140AS is the compact machine of the range. It is built for the distribution and sub-transmission classes — insulators from 11 kV to 33 kV of every polymeric type — and since 2024 it carries the acoustic emission system as standard equipment instead of as a paid option.

The machine is made up of three parts: the host, the hydraulic system and the electronic control system. Its control is a single cylinder mode with eight dies distributed equally, which gives a high synchrony precision with a simpler structure and less to go wrong.

2. What the crimped joint has to meet

• IEC 61109 – Composite suspension and tension insulators for overhead lines with a nominal voltage greater than 1000 V – Definitions, test methods and acceptance criteria, including the mechanical verification of the end fitting attachment.
• GB/T 19519-2004 – the Chinese national standard corresponding to IEC 61109:1992, MOD, with the same requirements.
• In-process verification – the crimping quantity and the crimping force are controlled on every crimp, and the integrated acoustic emission system watches the rod while the crimp is being made.

3. Technical parameters

The acoustic emission system (AES) is integrated as standard. It is a micro-crack detection system: a highly sensitive sensor shows the acoustic waveform of the crimping process, so a minute fracture in the fibreglass core that the eye cannot see is detected while the unit is still on the machine.

4. Key functions

• Integrated acoustic emission system – detects minute fractures in the fibreglass core during crimping, which raises the yield of the line. On the larger machines this was an option at about USD 22,000; on the CTCPM-140AS it is included.
• Back stopper – the insulator is pushed into the machine until it touches the back stopper switch, and the crimping starts automatically, so the operator does not need the foot switch.
• Automatic lubricating system – grease is pumped to the points that need it, which saves the time and the trouble of manual lubrication and keeps the machine running.
• Upgraded control panel – a new floating touch screen replaces the old embedded screen, at a more convenient position and more sensitive in a working environment.
• Upgraded software interface – clearer logic and easier use, laid out the way the worker works.
• Soft crimping and double control – slow crimping with pressure holding and pressure set by sections, and both the crimping quantity and the crimping force used to control the quality, which gives the maximum tensile load with the minimum discreteness.
• Single cylinder with 8 dies – high synchrony precision, a simpler structure, fewer faults and lower maintenance cost for the oil pump and the tubes.

5. Typical applications

• Distribution class production – polymeric insulators from 11 kV to 33 kV: pin type, post type, suspension type and tension type.
• Composite insulator factories – the crimping station of a line that is dedicated to the distribution classes.
• Quality-critical production – where every crimp has to be verified for core damage, the integrated AES makes the check automatic.
• Second or satellite lines – the compact machine is used next to a larger model for the higher voltage classes.

6. Frequently asked questions

1. What is the acoustic emission system and why is it built in?

The AES is a micro-crack detection system. A highly sensitive sensor listens to the crimping process and displays the acoustic waveform, so a minute fracture in the fibreglass core – invisible to the eye – is detected while the insulator is still on the machine. It was previously an option at about USD 22,000 on the larger crimping machines; on the CTCPM-140AS it is integrated, so the manufacturer gets the capability within the standard machine price.

2. Which insulators can be crimped on this machine?

All polymeric insulators from 11 kV to 33 kV, including pin type, post type, suspension type and tension type, with a crimping range of 8 to 200 mm.

3. What is the difference from the CTCPM-165?

The 165 is the larger machine: 6000 kN against 3200 kN, an opening up to 250 mm, and it is built for insulators up to 800 kV with a large core diameter and a large flange base. The 140AS is the compact machine for the 11 kV to 33 kV classes, with the acoustic emission system integrated as standard.

4. How fast is the machine?

The crimp frequency is 1000 crimps per hour. The single cylinder control with eight dies distributed equally keeps the synchrony precise at that rate.

5. Does the operator have to hold a foot switch?

No. The machine has a back stopper: the insulator is pushed in until it touches the back stopper switch, and the crimping starts automatically, the same as with the foot switch.

6. What maintenance does the machine need?

Very little. The automatic lubricating system pumps grease to the points that need it, so manual lubrication is not needed. The single cylinder control has fewer parts than a multi-cylinder design, so there is less chance of a fault and a lower maintenance cost for the oil pump and the tubes.

Related composite insulator production machines

For higher voltage classes up to 800 kV the crimping machine CTCPM-165 for up to 800 kV is used. The micro-crack detection used on this machine is also available as the acoustic emission system for crimping, and the marking is done on the laser marking machine. The complete line is listed under insulator production machines.