How To Design Aluminum Grading Rings For High Voltage Insulators

Aluminum grading rings are similar to corona rings, but they encircle high voltage insulators rather than HV conductors. The aluminum grading rings surround the end of the high voltage insulators next to the high voltage conductor.

It reduces the gradient at the end, resulting in a more even voltage gradient along the high voltage insulator.

Although they may also serve to suppress corona, their main function is to reduce the potential gradient along the high voltage insulator, preventing premature electrical breakdown.

When design aluminum grading rings with Chinese manufacturers, if you are worried about the results of products design. If yes, here is the right place you come to visit.

Without further ado, let’s jump straight into the topic to find the right solutions on aluminum grading ring design.


If client’s inquiry grading ring has same bending pipe diameter and size, then the ring will be produced as bend tubing process. If the grading ring outer diameter is customized or it has no same die casting mould in stock. Then the new mould of aluminum grading rings will be designed and developed.

If the mould is our stock standard, the mould is free of charge. If it is customized one, the extra design drawing and fee will be needed.

The mould of aluminum grading ring refers to the tooling used to produce ring in molding. Traditionally moulds have been expensive to manufacture and were only used in high-volume production applications where thousands of aluminum parts were produced.

Aluminum moulds cost substantially less than steel ones.

Usually production the die casting or pressure die casting aluminum grading ring needs the special moulds.

Choosing The Right Raw Materials For Aluminum Grading Ring Design

Aluminum alloy, it is a popular raw material to use for aluminum grading rings production.

There are main two kinds aluminum materials used in grading rings production.

It depends on aluminum grading rings design and manufacturing process.

Pressure die casting rings materials are usually aluminum alloy A380 and ZL101.

ZL101 die casting aluminum alloy and A380 type die casting aluminum alloy can be used for die casting aluminum rings.

The customized outer diameter aluminum grading rings are usually made from 6061 thin wall tubing or pipe that is formed and welded; with appropriate supporting brackets and other bush standards.

Aluminum Grading Ring Wall Thickness Design


Aluminum pressure die casting grading ring wall thickness is standard as mould shape in our Highv factory.

Here we should discuss the pipe bending and welding type aluminum grading ring wall thickness.

Wall thickness of bending and welding pipe will be from 2.0mm to 10mm.

Usually the 3mm wall thickness is for 1000mm outer diameter ring.
The larger tube wall thickness rings strength is high.

In a word, the wall thickness of tube will be designed and discussed with customers together.

Aluminum Grading Ring Outer Diameter Design


Outer diameter of aluminum grading ring depends on high voltage grade on insulators.

As the high voltage level of insulators becomes higher, the diameter of the corresponding aluminum ring must be enlarged.

Here we should introduce our design and processing capabilities of the large outer diameter of these rings.

The biggest diameter dimension of one ring is 16000mm. And pipe inner diameter of ring is 3000mm.

During the aluminum ring production process, our team will check the sizes frequently and input our Just-in-Time record.

This could ensure all grading rings are within the good tolerances.

Installation Distance And Dimensions Design

Installation distance and dimensions are the important factors which should be considered by us.

You need to think of the detailed installation size when designing the high voltage insulator’s use aluminum grading rings.

The installation distance from insulator head to its bottom. The installation dimensions of grading rings, such as brackets, clamps and bush holes should be designed.

Likewise, the structural analysis of the load needs to be analyzed for the integrity of the structural design.

Such as gantry crane size configuration, lift platform stability, lift wire safety confirmation, measuring device and equipment function, etc.

Brackets And Clamps Design


Aluminum grading ring is also known as phase to earth ring ring set, which is used for high voltage insulators and surge arresters application.

So we should design brackets and clamps on aluminum grading ring set. One piece bracket is welded on the ring body for connection.

And one piece bush clamp is connected with two pieces stainless steel standard fasteners.

Usually the bush hole are designed as insulators diameter.

Choosing The Right Aluminum Grading Ring Design Expert

If designing the aluminum grading rings for high voltage insulators still seems overly complex, the best thing to do is consult an design and manufacturing expert of grading rings.

HIGHV is one such specialist, with years of experience design, manufacturing, developing and creating aluminum grading rings for a range of customers.

Our professional engineers team are skilled at AUTO CAD, PROE, SOLID WORKS and UG softwares. We are able to design, develop, produce and deliver grading rings according to customer detailed drawings, samples or just an idea.

We offer a reasonably priced fabrication service, with corona shielding components available in a range of aluminum alloy, copper and stainless steel.

Contact HIGHV team members today to get a quote or learn more about what we do.