Design and Construction of an Advanced Tracking Wheel for Insulator Materials Testing

This account details the design and construction of a sophisticated tracking wheel for the accelerated aging of polymer insulators by subjecting them to surface contamination and high voltage. Automated control of wet-dry cycles is achieved by means of a computer-controlled lift mechanism that operates in tandem with the rotation. The applied voltage is continuously variable and can accommodate insulators of mixed lengths. The design incorporates a fail-safe control system that automates the selected test cycle, provides an intuitive user interface, and integrates multiple safety measures. This is achieved by implementing a programmable logic controller with digital and analog inputs and outputs. An associated ladder logic program automates the actuation of electromechanical hardware while also processing the inputs provided from control hardware, such as limit switches, optical encoders, variable frequency drives, and sensors. A touch-screen human interface module provides feedback and allows the user a means of input. Programmed fault detection, flood sensors, and a trapped key system increase the level of user safety and provide environmental and infrastructure protection.