Description:AUTOMATED INSULATOR COATING APPARATUS AND METHOD THEREOF
FIELD OF THE INVENTION
[001] The present invention belongs to the field of machine system design and process engineering, and more particularly relates to an automated apparatus and method for factory-based room temperature vulcanized (RTV) silicone coating of electrical insulators. The invention is specifically directed towards coating of insulator of different dimensions and varieties addressing both equipment design and process improvements suitable for industrial-scale application.
BACKGROUND OF THE INVENTION
[002] In industrial practice, a wide variety of methods are employed for coating articles to improve surface properties, enhance durability, and impart specialized characteristics. In the field of the electrical power sector, particularly in the context of outdoor insulators, the coating process assumes critical importance. Outdoor insulators in transmission networks perform a dual function: providing mechanical support to conductors and ensuring adequate electrical clearance between energized and grounded elements. Although insulators represent only a small fraction of overall line capital cost, their failures account for a disproportionately high percentage of line outages and maintenance costs.
[003] A principal source of insulator failure is contaminant accumulation on the insulator surface. On hydrophilic surfaces, the presence of atmospheric moisture enables leakage current flow, leading to dry band formation, scintillation, and pollution flashover events that compromise grid reliability. To mitigate these risks, silicone-based hydrophobic coatings are applied to insulators, with room temperature vulcanized silicone coatings being widely recognized as an effective solution.
[004] RTV coatings may be applied either under field conditions or within factory environments. Factory-based coating offers significant advantages over field application, including controlled environment, greater uniformity in coating thickness, improved curing, and reduced wastage. However, despite these advantages, there is currently no automated apparatus specifically designed for factory-based RTV coating of insulators. Existing practices rely heavily on manual intervention, limiting consistency, throughput, and scalability.
[005] The present invention addresses this need by providing a specialized automated insulator coating apparatus adapted for applying RTV silicone coatings in a factory environment. The invention integrates mechanical design, process control, and automation to enable synchronized rotation of the insulator and traversal of a spray applicator, thereby ensuring uniform deposition. By reducing human involvement and introducing process repeatability, the invention provides a reliable and scalable solution for coating long rod, post, hollow, railway porcelain and composite insulators.
OBJECT OF THE INVENTION
[006] An object of the present invention is to provide an automated apparatus for coating insulators and a coating method thereof.
[007] Another object of the invention is to reduce human involvement in the coating process, thereby enhancing consistency, repeatability, and productivity.
[008] Yet another object of the invention is to provide an automated apparatus and process for applying RTV coatings to long rod, post, hollow, railway porcelain, and composite insulators in a factory setting.
[009] Further object of the invention is to achieve uniform circumferential coating deposition by synchronizing insulator rotation with controlled movement of the spray applicator assembly.
[0010] Still another object of the invention is to incorporate process improvements and equipment design enabling reliable operation under industrial conditions, including dust protection, uninterrupted power supply, and dual-mode motor drive power.
[0011] Yet another object of the invention is to provide coatings applied by the apparatus with superior adhesion and durability, resistance to high-pressure water blasting, and long-term reliability in field conditions.
[0012] Further object of the invention is to offer an ergonomic and user-friendly structure, including features like handles for easy transport, wheels for mobility, and a stable support frame for safe operation in varied field conditions.
[0013] Still another object of the invention is to introduce a dual-bed configuration comprising a fixed bed for conventional curing and a portable bed for scalable, continuous operation.
SUMMARY OF THE INVENTION
[0014] The present invention provides an automated apparatus and method for coating insulators, offering significant improvements over manual and semi-automatic processes. The apparatus integrates a coordinated spray applicator assembly, traveller mechanism, and motor-driven insulator support to enable precise synchronization of spray traversal with insulator rotation. This results in a uniform circumferential coating layer, minimizing operator dependence while enhancing consistency and productivity.
[0015] The invention introduces a dual-bed configuration, which includes a fixed bed for conventional in-situ curing and a portable bed that enables immediate replacement of coated insulators. This arrangement allows continuous operation in industrial settings, making the system adaptable for both batch and high-volume production requirements. The apparatus accommodates long rod, post, hollow, railway porcelain and composite insulators, ensuring broad applicability within the electrical transmission, distribution, and transportation sector.
[0016] Another notable aspect of the invention is its ability to produce coatings that meet or exceed international standards of adhesion and durability. Coated insulators exhibit superior performance in adhesion, water immersion, and high-pressure blasting tests, confirming their long-term reliability in field conditions. The process consistently achieves statistically uniform coating thickness, with over 95% of measurements falling within controlled limits, thereby demonstrating high repeatability and robustness.
[0017] The invention also incorporates robust design features such as dust-protected slide mechanisms, uninterrupted power supply integration, and dual-mode motor drive operation. These features provide stable, reliable operation under diverse environmental and industrial conditions while minimizing maintenance demands. Furthermore, the apparatus is designed to be ergonomic and user-friendly, incorporating handles, wheels, and a rigid support frame for mobility and safe deployment.
[0018] Finally, the invention is scalable and material-flexible, enabling adaptation for coating materials beyond RTV silicone with minor system adjustments. By combining indigenous development with industrial scalability and global standard compliance, the invention significantly reduces dependence on imported technologies while ensuring durable, uniform, and cost-effective insulator coatings.

BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Having thus described the subject matter of the present invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein
FIG. 1 illustrates a schematic representation of an automated insulator coating apparatus in a general configuration, showing the principal components including the spray pump unit, spray applicator assembly, traveller unit, slide mechanism, insulator support assembly, and support structure;
FIG. 2 illustrates an embodiment of the apparatus in which the insulator support assembly is configured as a fixed bed type, showing the components such as headstock, three-jaw chuck, tailstock with wheel-type handle, and motor drive assembly mounted on rigid structural supports;
FIG. 3 illustrates an embodiment of the apparatus in which the insulator support assembly is configured as a portable bed type, showing the components such as headstock, adaptor, tailstock with L-type handle, power driven motor drive assembly mounted on a mobile wheelbase assembly, and the wheelbase engaged with a track section of the support structure;
FIG. 4 illustrates an embodiment of the apparatus, showing the components such as traveller unit, encoder, various motors, and slide mechanism among others; and
FIG. 5 illustrates a method or steps of coating insulator using apparatus according to an embodiment of the invention.
Skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. Further, the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
DESCRIPTION OF THE INVENTION
[0020] The subject matter of the present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of subject matter of the present invention are shown. The subject matter of the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the subject matter of the present invention set forth herein will come to mind to one skilled in the art to which the subject matter of the present invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention. Therefore, it is to be understood that the subject matter of the present invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.
[0021] As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure.
[0022] Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one”, but does not exclude a plurality unless the contextual use dictates otherwise. When used herein to join a list of items, “or” denotes “at least one of the items”, but does not exclude a plurality of items of the list. Finally, when used herein to join a list of items, “and” denotes “all of the items of the list”.
[0023] For the better understanding of the objects, technology and advantages of the present invention, the instant invention will be further explained in detail with respect to embodiments and accompanying figures as given above. It should be understood that the specific embodiments described herein are only to be used for explaining the present invention but not used to limit the present invention.
[0024] The present invention relates to an automated insulator coating apparatus for consistent deposition of coating like room temperature vulcanized (RTV) silicone material on insulator surfaces, improving insulator’s life and performance.
[0025] An aspect of the invention relates to an automated insulator coating apparatus comprising a spray delivery unit, a traveller unit, a spray applicator assembly, a slide mechanism unit, an insulator support assembly, and a support structure.
[0026] In certain embodiments, spray delivery unit configured to deliver a coating material, the spray delivery unit comprising at least one of a spray pump unit, a pressurized feed unit, a fluid dispensing unit, or an equivalent thereof.
[0027] In an embodiment, the spray delivery unit is fluidly connected to the spray applicator assembly via a hose or pipe. The delivery unit is adapted to deliver coating material such as RTV silicone in liquid form under controlled pressure. The liquid is supplied from the pump to the spray gun within the spray applicator assembly.
[0028] In an embodiment, the traveller unit is a movable carriage configured to support and transport the spray applicator assembly along the length of the insulator.
[0029] The traveller unit comprises three stepper motors. One of the stepper motors is adapted to provide linear displacement of the spray applicator assembly in forward and backward directions towards the insulator. A second stepper motor is configured to actuate a spray gun unit of the spray applicator assembly, controlling opening and closing of the spray output, and a third stepper motor adapted for fine positional adjustment of a nozzle head of the spray applicator assembly, for accurate targeting during coating.
[0030] The traveller unit also is mounted with a servo motor and an encoder is mounted on the servo motor. The traveller unit traverses bidirectionally along the slide mechanism by means of a servo motor operating at a controlled velocity in the range of 5-50 mm/s. The encoder provides closed-loop feedback, continuously monitoring traveller position and ensuring precise motion control and repeatability.
[0031] In an embodiment, the spray applicator assembly comprises a spray gun unit and a nozzle. The spray gun is adapted to atomize RTV liquid into a fine mist which is emitted through the nozzle. The nozzle functions as the outlet and defines the spray pattern and distribution. The applicator is mounted on the traveller unit, allowing its motion along the insulator.
[0032] Controlled integration of servo and stepper motors ensures repeatable coating thickness and pattern quality.
[0033] In an embodiment, the slide mechanism unit supports and guides the traveller unit along a linear path. The slide mechanism is enclosed in a bellow cover, which prevents ingress of dust, contaminants, or coating overspray, thereby extending the operational life of the mechanism. The slide mechanism is elevated and supported by a plurality of support elements mounted on the support structure.
[0034] In an embodiment, the insulator support assembly is configured to support the insulator during coating. It includes a drive mechanism, such as a stepper or servo motor, to rotate the insulator about its longitudinal axis. The controlled rotation enables uniform circumferential coating.
[0035] In certain embodiments, the insulator support assembly may be embodied or configured as bed configuration like a fixed bed type/configuration or a portable bed type/configuration. In some configurations, the insulator support assembly comprises a headstock and a tailstock, or equivalents thereof.
[0036] The insulator support assembly is configured to support the insulator to be coated. The insulator support assembly includes opposing support fixtures adapted to hold the insulator along its longitudinal axis, and a motor drive mechanism configured to impart controlled rotational motion to the insulator during the coating process.
[0037] In certain embodiments, the support structure (or support platform) is configured to carry the slide mechanism unit and the insulator support assembly, and may include a track section or equivalent guiding arrangement for enabling linear displacement of a portable wheelbase assembly. The support structure forms a rigid foundation that supports the slide mechanism unit and the insulator support assembly. It ensures alignment, stability, and vibration-free operation of the apparatus during coating.
[0038] The apparatus is further connected to a single-phase uninterruptible power supply (UPS). The UPS ensures continuity of coating operation in the event of a primary power supply failure, thereby preventing incomplete or inconsistent coatings.
[0039] In one embodiment, the insulator support assembly is embodied as (or configured as) a fixed bed type/configuration. In the fixed bed configuration, the fixed bed assembly is the insulator support system and includes a motor drive assembly, both rigidly mounted to a support structure.
[0040] The fixed bed/insulator support system includes a headstock, configured as a rigid fixture located at one end of the bed assembly, a tailstock, positioned opposite to the headstock, configured to provide axial support and maintain longitudinal alignment of the insulator, and plurality of three-jaw chucks with appropriate adaptors are connected to the headstock and tailstock, adapted to grip and rotate the insulator during coating. The insulator to be coated is mounted between the headstock and the tailstock, thereby maintaining stable alignment during the coating process.
[0041] As used herein or later on, the term “appropriate adaptor” refers to an adaptor selected or configured in accordance with the dimensions, profile, or geometry of the insulator to be coated, so as to ensure secure engagement with the three-jaw chucks while maintaining axial alignment.
[0042] The motor drive assembly comprises a servo motor and a drive panel box. The servo motor is mechanically coupled to the headstock, thereby imparting controlled rotational motion to the insulator.
[0043] In certain embodiments, the insulator is rotated at 5-50 revolutions per minute in a clockwise or anticlockwise direction, although other rotational speeds and directions may be programmed.
[0044] The drive panel box is electronically interfaced with the centralized control panel, enabling programmable speed control, directional control, and synchronization with the spray applicator assembly. This integration ensures uniform circumferential coating deposition.
[0045] In certain embodiments, the tailstock is further provided with a wheel-type handle adapted for manual locking and adjustment. The handle allows secure engagement of the insulator’s end portion, thereby maintaining axial stability during rotation.
[0046] In an embodiment, the headstock, servo motor, and drive panel box are mounted on a support stand which is fixed to the support structure assembly. Similarly, the tailstock is mounted on a corresponding support stand. Both stands are in turn rigidly fixed to the support structure assembly using structural channel members (for example ISMC structural channels or any other equivalent load-bearing channel) ensuring permanent and stable alignment.
[0047] In an embodiment, the coated insulator is retained within the fixed bed assembly during the curing period of the RTV silicone material. The insulator remains mounted between the opposing support fixtures (headstock and tailstock) until curing is complete, after which it is removed from the bed assembly. This configuration ensures stable alignment during curing and prevents surface defects that may arise from premature handling or removal.
[0048] In another embodiment, the insulator support assembly is embodied as (or configured as) a portable bed assembly/type/configuration. In the portable bed type/configuration, the portable bed assembly is designed to allow mobility, rapid positioning, and ease of deployment, while still ensuring that the insulator is rotated securely between a headstock and a tailstock during the coating operation.
[0049] In an embodiment, the portable bed assembly is the insulator support system and includes a motor drive assembly, both of which are mounted on a mobile wheelbase assembly that is guided along a track section provided on the support structure.
[0050] The insulator support system includes a headstock, disposed at one end of the bed assembly and configured as a rigid fixture for supporting and rotating the insulator, a tailstock, disposed opposite to the headstock for supporting the other end of the insulator and maintaining its longitudinal alignment, and plurality of adaptors, coupled to the headstock and tailstock, adapted to engage the end fitting of the insulator and transmit torque from the drive motor. Further includes an L-type handle, integrated with the tailstock, enabling manual locking and secure positioning of the insulator during coating.
[0051] In certain embodiment the adaptors are selected or configured in accordance with the dimensions, profile, or geometry of the insulator to be coated.
[0052] The insulator to be coated is mounted between the headstock and the tailstock, ensuring axial stability and uniform rotation throughout the coating process.
[0053] In an embodiment, the motor drive assembly comprises a servo motor and a drive panel box. The servo motor is operatively coupled to the headstock and adaptor to impart controlled rotational motion to the insulator. In one embodiment, the rotation is programmable at a controlled speed, for example 5-50 revolutions per minute in either clockwise or anticlockwise direction. The drive panel box is electronically interfaced with the centralized control panel, enabling programmable speed control, directional control, and synchronization with the spray applicator assembly. This integration ensures uniform circumferential coating deposition.
[0054] In certain embodiments, the motor drive assembly is further powered by a dual-mode supply system. To facilitate rotation of the insulator during post-coating deposition or curing, the motor drive assembly operates from a battery-based supply when detached from the mains-connected apparatus. Upon reconnection to a single-phase AC power source, the system automatically bypasses the battery and switches to mains power, ensuring uninterrupted operation and energy efficiency. This configuration significantly enhances the operational flexibility and reliability of the insulator rotation mechanism, maintaining continuous functionality during precoating, coating and post-deposition curing processes.
[0055] The insulator support system and motor drive assembly are collectively mounted on a mobile wheelbase assembly. The wheelbase engages with a track section provided on the support structure with a slope, enabling linear displacement of the entire bed unit along the predefined track. This arrangement facilitates convenient insertion of the insulator into the coating zone and easy removal upon completion of the process.
[0056] In certain embodiments. the wheelbase assembly may further include a locking mechanism such as mechanical clamps, stoppers, or detents to immobilize the bed unit during coating operations, thereby ensuring positional stability.
[0057] In certain embodiments, the tailstock is mounted on a carriage that is slidably/ directly supported by a linear bearing arrangement, the linear bearing being slidably engaged with a guideway extending along the longitudinal axis of the insulator. The carriage is operatively coupled to a displacement mechanism comprising a lead screw and a lead nut engaging the lead screw, and a linear bearing arrangement, such that rotation of the lead screw results in controlled forward or backward movement of the carriage and tailstock relative to the headstock. This arrangement enables precise adjustment of the tailstock position to accommodate insulators of different lengths, while an L-type handle may be provided to allow manual locking or fine adjustment.
[0058] In some embodiments, a bellow cover is disposed over the guideway to protect the linear bearing and lead screw assembly from dust, debris, or coating material, thereby enhancing durability and operational reliability.
[0059] The combination of the mobile wheelbase assembly and track section provides a portable and modular bed structure/assembly (i.e. insulator support assembly) that enables field operability, compact storage, and rapid reconfiguration while maintaining reliable coating performance comparable to the fixed bed type/assembly/configuration.
[0060] In an embodiment, following completion of the coating operation, the insulator support system and motor drive assembly together with the wheelbase assembly are disengaged from the track section and relocated to a curing area, allowing the coated insulator to cure without occupying the coating station. A new insulator support system and motor drive assembly are immediately positioned on the track section to commence coating of the next insulator. This arrangement enables continuous operation without interruption and provides a scalable configuration for high-throughput coating processes.
[0061] In another embodiment, to facilitate rotation of the insulator during post-coating deposition or curing, the motor drive assembly is powered by a dual-mode supply system. The stepper motor is driven by a battery-based supply when detached from the mains-connected apparatus, thereby maintaining insulator rotation during curing. Upon reconnection to a single-phase AC power source, the system automatically bypasses the battery and transitions to mains supply, ensuring uninterrupted operation and enhanced energy efficiency. This dual-mode configuration provides operational flexibility and reliability, ensuring continuous rotation of the insulator irrespective of external power availability.
[0062] The operations of the automated insulator coating apparatus are now described in the following paragraphs. The description illustrates, by way of example, how the individual units and sub-assemblies’ function, both independently and in coordination, to facilitate coating of insulators. It will be understood that the operational sequence may vary depending on the particular embodiment or configuration of the apparatus.
[0063] In an embodiment, during operation, the automated insulator coating apparatus functions through the coordinated interaction of the spray delivery unit, the spray applicator assembly, the traveller unit, the slide mechanism, and the insulator support assembly.
[0064] Initially, the insulator to be coated is mounted between the opposing support fixtures adapted to hold the insulator along its longitudinal axis of the insulator support assembly (i.e. fixed bed or portable bed assembly). In the fixed bed type, the headstock and tailstock are rigidly mounted on structural supports, whereas in the portable bed type, they are mounted on a mobile wheelbase assembly positioned along a track section of the base assembly. In both configurations, the insulator is secured axially and is rotated during coating by means of the motor drive assembly operatively coupled to the headstock.
[0065] Upon activation, the spray delivery unit delivers coating material like RTV silicone liquid under controlled pressure through a hose or pipe to the spray gun of the spray applicator assembly. The spray gun atomizes the liquid and expels it through a nozzle as a fine mist. The nozzle defines the spray pattern and distribution, ensuring uniform material deposition.
[0066] The spray applicator assembly is supported on the traveller unit, which traverses along the slide mechanism positioned parallel to the insulator. The traveller unit is actuated by a servo motor and guided by an encoder-based closed-loop feedback system to ensure precise linear displacement along the insulator’s length. In other words, the encoder continuously monitors the traveller unit position and provide real-time feedback for accurate motion control.
[0067] The stepper motors integrated in the traveller unit perform additional operations: a first motor displaces the spray applicator forward and backward relative to the insulator to adjust spray distance, a second motor actuates the spray gun for controlled opening and closing, and a third motor adjusts the nozzle orientation for fine-tuned targeting.
[0068] During coating, the traveller unit moves bidirectionally along the slide mechanism at a controlled velocity (for example, in the range of 5-50 mm/s), while the insulator simultaneously rotates at a controlled speed (for example, in the range of 5-50 revolutions per minute in the clockwise or anticlockwise direction). The coordinated motion results in a helical spray path that covers the entire outer surface of the insulator.
[0069] The motor drive assembly, interfaced with the centralized control panel, enables programmable speed and directional control of the insulator rotation in synchronization with the spray applicator motion, thereby ensuring uniform circumferential coating deposition.
[0070] To maintain smooth traveller motion, the slide mechanism is enclosed within a bellow cover that prevents ingress of dust or overspray, thereby extending service life.
[0071] The entire coating process is governed by the control panel, which enables centralized operation of the pump unit, traveller motion, nozzle actuation, spray pressure, and bed rotation. Predefined coating parameters may be programmed into the control system, allowing for repeatable and consistent coating application.
[0072] In the event of a primary power failure, the apparatus is supported by a single-phase uninterruptible power supply (UPS), ensuring uninterrupted continuation of the coating process and preventing incomplete coating deposition.
[0073] In certain embodiments, after completion of spray deposition, the apparatus is configured to support a curing phase of the coating. In the fixed bed configuration, the insulator is retained within the bed assembly until curing is complete. In the portable bed configuration, the insulator support system and motor drive assembly may be detached along with the coated insulator and relocated to a curing zone, while a new assembly is introduced onto the track section to continue coating operations without delay. During curing, insulator rotation is maintained by means of a battery-powered drive system that automatically switches to mains supply when available, thereby ensuring continuous rotation, consistent curing quality, and uninterrupted scalability of the coating process.
[0074] In one embodiment, an automated insulator coating apparatus (100) is provided, as illustrated in FIG. 1. The apparatus comprises a spray delivery unit (110), a spray applicator assembly (120), a traveller unit (130), a slide mechanism unit (140), an insulator support assembly (150), and a support structure (160).
[0075] Referring to FIG. 1, the spray delivery unit (110) fluidly connected via a supply hose (112) to a spray applicator assembly (120), enabling the delivery of coating material, such as room temperature vulcanizing (RTV) silicone, under controlled pressure. The spray applicator assembly (120), which includes a spray gun (122) and a nozzle (124), is mounted on a traveller unit (130). The traveller unit (130) is movably supported on a slide mechanism (140), which in turn is secured on a support structure (160). The nozzle (124) determining the atomization pattern and spray distribution on the insulator surface.
[0076] Referring to FIGS. 1 and 4, the traveller unit (130) includes a plurality of motors, such as stepper or servo motors, for enabling forward/backward displacement of the spray applicator assembly, actuation of the spray gun, and fine orientation of the nozzle. Specifically, the traveller unit (130) comprises a first motor (132) for linear displacement of the spray gun, a second motor (134) for actuation of the spray trigger, and a third motor (136) for fine positional adjustment of the nozzle head (124). In the present embodiment, these motors are stepper motors.
[0077] Referring again to FIGS. 1 and 4, the traveller unit (130) is further provided with a servo motor (138), which is configured for bidirectional traversal of the traveller unit along the slide mechanism. The servo motor (138) is operatively coupled with an encoder (139), which continuously monitors the position of the traveller unit and provides real-time feedback for accurate motion control, thereby ensuring precise operation and repeatability.
[0078] Again, referring to FIG. 1 and 4, the traveller unit (130) is movably supported on a slide mechanism (140). In other words, the traveller unit (130) is supported and guided by the slide mechanism (140), which is enclosed within a bellow cover (142) to prevent ingress of contaminants i.e. to protect against dust and contaminants. The slide mechanism (140) is supported on the support structure assembly (150) using support elements (144a and 144b).
[0079] Referring to FIG 1, the insulator support assembly (150) functions as the support system for the insulator (10) and includes a motor drive assembly (170) for controlled rotation of the insulator during coating. In other words, the insulator support assembly (150) configured to support an insulator (10) during coating. The insulator support assembly (150) includes opposing support fixtures (152, 154) for holding the insulator along its longitudinal axis and motor drive assembly (170) for imparting controlled rotational motion to the insulator.
[0080] The entire apparatus is operatively controlled by a centralized control panel (180). The apparatus may further include a UPS unit to ensure uninterrupted operation in the event of power failure.
[0081] Referring now to FIG. 2, an embodiment of the apparatus (200) is illustrated in which the insulator support assembly is configured as a fixed bed type/assembly/configuration. The fixed bed assembly (250) includes a headstock (252), a tailstock (256) disposed opposite to the headstock for axial alignment and plurality of three-jaw chucks (254a, 254b) with plurality of appropriate adaptors (254c, 254d) operatively connected to the headstock and tailstock for engaging the insulator.
[0082] A motor drive assembly (270), including a servo motor (272) and a drive panel box (274), is coupled to the headstock (252) to impart controlled rotational motion to the insulator. The drive panel box (274) is electronically interfaced with the centralized control panel, enabling programmable speed control, directional control, and synchronization with the spray applicator assembly.
[0083] The headstock (252), servo motor (272), and drive panel box (274) are mounted on a first mounting platform (262), while the tailstock (256) is mounted on a second mounting platform (264). Both mounting platforms are rigidly affixed to the support structure (260) using ISMC structural channels (268), ensuring permanent and stable alignment. In this embodiment, the insulator is retained within the bed assembly during the curing period, and is removed only after the curing process is complete.
[0084] In an embodiment, a wheel-type handle (258) is provided on the tailstock for manual locking and stabilization of the insulator during rotation.
[0085] Referring now to FIG. 3, an embodiment of the apparatus (300) is illustrated in which the insulator support assembly is configured as a portable bed assembly/type/configuration. The portable bed assembly (350) includes a headstock (352), a tailstock (356) aligned opposite the headstock, and plurality of adaptors (354a and 354b) connected to the headstock and tailstock for engaging the insulator.
[0086] The tailstock (356) is mounted on a carriage (356a) slidably/ directly supported by a linear bearing arrangement (356b), the linear bearing being slidably engaged with a guideway (358) extending along the longitudinal axis of the insulator and thereby permitting smooth guided movement relative to the headstock (352). A lead screw (357) extends along the displacement axis of the tailstock, with a lead screw nut (357a) coupled to the carriage (356a) to engage with the lead screw (357). Rotation of the lead screw (357) enables precise forward or backward displacement of the carriage and tailstock (356) along the guideway (358), allowing accurate accommodation of insulators of different lengths.
[0087] An L-type handle (359a) is integrated into the tailstock (356) for manual locking and secure positioning of the insulator after adjustment.
[0088] In an embodiment, a bellow cover (359b) is provided over the guideway (358) to prevent ingress of dust, debris, or coating material, thereby improving operational reliability. In some configurations, the bellow cover (359b) may further extend to shield the linear bearing arrangement.
[0089] The motor drive assembly (370) comprises a stepper motor (372) and a drive panel box (374), both mounted together with the portable bed assembly (350) on a mobile wheelbase assembly (362). The wheelbase assembly (362) is engaged with a track section (364a) formed on the support assembly (360), enabling linear displacement of the entire bed unit along the track. The support assembly is further provided with a slope surface (364b) for easy sliding of wheelbase assembly (362) over the track section(364a).
[0090] In certain embodiments, the wheel assembly (362) includes plurality of support frames (362a, 362b).
[0091] In other words, a track section (364a) is provided on the support assembly (360) for guiding the linear displacement of the wheelbase assembly (362). This arrangement enables the entire bed assembly to be detached after coating and relocated to a curing area, while a fresh assembly is slid into place for uninterrupted coating operations.
[0092] The drive panel box (374) is interfaced with the centralized control panel, thereby enabling programmable control and synchronization with the spray applicator assembly.
[0093] In an embodiment, the motor drive assembly (370) is further powered by a dual-mode supply system, operating from a battery-based source (378) during post-coating curing, and automatically switching to mains supply upon connection to a single-phase AC power source. In other words, during coating, the stepper motor (372) is powered by the main AC source and for post-coating curing, the motor is powered by a battery backup system, ensuring uninterrupted rotation.
[0094] The portable configuration enables scalability: after completion of coating, the wheelbase assembly (362) with the insulator is detached from the track section (364a) and relocated to a curing area, while a fresh wheelbase assembly with a new insulator is slid into position for immediate continuation of the coating process.
[0095] An aspect of the invention relates to a method of coating an insulator using apparatus of the present invention, the method comprising following steps.
a) placing the insulator onto an insulator support assembly having opposing support fixtures;
b) securing the insulator in position along its longitudinal axis;
c) supplying a coating material from a spray delivery unit to a spray applicator assembly;
d) rotating the insulator by means of a motor drive assembly;
e) traversing a traveller unit supporting the spray applicator assembly, along a slide mechanism parallel to the insulator while atomizing and spraying the coating material onto the insulator surface using a spray gun and a nozzle of the spray applicator assembly; and
f) controlling, via a centralized control panel, the rotational motion of the insulator and the traversal of the spray applicator assembly in synchronization to achieve uniform deposition of the coating material.
[0096] In an embodiment, the method further comprising cleaning the insulator surface with a cleaning agent such as isopropyl alcohol or acetone or any with any other suitable or appropriate cleaning agent, prior to coating.
[0097] In an embodiment, traversing the spray applicator assembly comprises a forward traverse applying a coating layer and a reverse traverse applying a coating layer, each followed by a partial curing interval. This traversing is continued until the insulator is completely coated with coating material according the preset or predetermined thickness.
[0098] In an embodiment, the insulator is rotated continuously during both coating and curing to ensure uniform deposition.
[0099] In an embodiment, in a fixed bed configuration, the insulator is retained in the bed assembly until curing is completed and in a portable bed configuration, the insulator together with the bed assembly is detached post-coating and relocated to a curing zone, while a fresh bed assembly is introduced to continue coating without interruption.
[00100] Referring now to FIG. 5, an embodiment of a method (500) for coating an insulator is illustrated. The method (500) comprises a sequence of steps performed using the automated coating apparatus described with reference to FIGS. 1–4.
[00101] In step 510, an inspected and cleaned insulator is positioned on the insulator support assembly, either fixed bed assembly or portable bed assembly, using a sling and hoist arrangement.
[00102] In step 520, the insulator is secured in position by engaging the tailstock of the bed assembly, thereby aligning the insulator along its longitudinal axis and ensuring axial stability.
[00103] In step 530, surface contaminants are removed by wiping/treating the insulator with a cleaning agent such as isopropyl alcohol (IPA) or acetone or with any other suitable or appropriate cleaning agent. Within a few minutes thereafter (for example, about 10 minutes in an embodiment), the coating process is initiated to minimize recontamination.
[00104] In step 540, the coating process is performed in two stages. In stage one (541), the traveller unit traverses in a forward direction along the length of the insulator while spraying atomized RTV silicone through the spray applicator assembly. The applied layer is allowed to undergo a partial curing phase, typically about 3–5 minutes in summer or 5–10 minutes in winter. In stage two (542), the traveller unit traverses in the reverse direction (backward), depositing an additional layer of RTV coating. The applied layer undergoes further curing for about 10–15 minutes in summer or 15–20 minutes in winter. During both curing intervals, the insulator is maintained in continuous rotation by the motor drive assembly, preventing sagging and ensuring uniform surface deposition.
[00105] In step 550, curing is completed according to the type of bed assembly employed. In the fixed bed type, the insulator is allowed to remain within the bed assembly until curing is completed, after which it is removed. In the portable bed type, the insulator support system and motor drive assembly together with the wheelbase assembly are detached from the track section and relocated to a curing area, while a fresh insulator support system and motor drive assembly are introduced onto the track section, enabling uninterrupted continuation of the coating process.
[00106] In step 560, the fully cured insulator is removed from the bed assembly and made ready for deployment.
[00107] The method (500) enables high-quality, uniform RTV silicone deposition with controlled curing cycles and continuous scalability. The distinction between fixed and portable bed configurations provides operational flexibility for both workshop and field applications.
[00108] Yet another aspect of the invention relates to a system for automated coating of an insulator, comprising: an apparatus according to the present invention and a control scheme configured to perform the method of coating according to the present invention.
[00109] The control scheme is implemented through the centralized control panel and is operative to coordinate the delivery of coating material from the spray delivery unit, the traversal of the traveller unit, and the rotation of the insulator by the motor drive assembly, thereby ensuring synchronized and uniform circumferential deposition of the coating material on the insulator surface.
[00110] In the fixed bed configuration, the insulator being secured between a headstock and a tailstock, and wherein the insulator is retained in the bed assembly until curing of the coating is complete.
[00111] In the fixed bed configuration, the insulator support system and motor drive assembly being mounted on a mobile wheelbase assembly engaged with a track section of the base assembly, such that the bed assembly is detachable post-coating and relocatable to a curing zone and upon detachment of the coated insulator and wheelbase assembly, a replacement insulator support system and motor drive assembly are slid into the track section to enable uninterrupted continuation of the coating process.
[00112] In an embodiment, the motor drive assembly is powered by a dual-mode supply system operable in a battery-powered mode during pre-coating, coating, post-coating curing and in a mains-powered mode during active coating, the supply system being automatically switchable between the two modes.
[00113] The control scheme comprises programmable speed control, directional control, and synchronization functions between the motor drive assembly and the spray applicator assembly and the traveller unit components such as encoder, thereby enabling precise circumferential coating deposition.
[00114] In certain embodiments, the apparatus includes a spillage collection unit configured to receive excess coating material that drips or falls from the surface of the insulator during the coating operation.
[00115] The spillage collection unit may comprise an acrylic surface/reservoir or tray positioned beneath the insulator so as to intercept surplus coating composition. The spillage collection unit may be removably secured above either (i) a fixed bed assembly or (ii) a portable bed assembly, enabling use of the same spillage unit with different support configurations.
[00116] Optionally, the spillage unit may include guides, brackets, or quick-release fasteners to facilitate mounting and removal, permitting easy cleaning or replacement without disturbing the alignment of the bed assembly. The shape and dimensions of the unit may be adapted to correspond to the geometry of the insulator being coated and apparatus dimension, thereby minimizing waste and keeping the surrounding work area free of coating material.
[00117] In certain embodiment, the various structural components of the apparatus, including the base assembly, structural supports, and wheelbase assembly are fabricated from mild steel channels or equivalent structural steel members to ensure rigidity and load-bearing strength. The slide mechanism may include hardened steel guide rails in combination with linear bearings for smooth and wear-resistant motion. The bellow cover may be formed of elastomeric or polymeric materials such as neoprene or polyurethane to provide flexibility and protection against dust ingress.
[00118] The spray applicator assembly including the spray gun and nozzle may be constructed from stainless steel or other corrosion-resistant alloys suitable for handling RTV silicone and cleaning solvents. The chuck and tailstock may be fabricated from hardened steel to provide secure gripping of the insulator body.
[00119] In another embodiment, the dimensions of the apparatus may be adapted according to the type and size of the insulator to be coated. The length of the slide mechanism and corresponding travel of the traveller unit may vary between 0.5 meters to 5.0 meters to accommodate long-rod, post, hollow, railway-porcelain, or composite insulators. The three-jaw chuck may be adapted to grip insulators of varying shank diameters, ranging from 40 mm to 500 mm. The base frame may be dimensioned to support loads in the range of 50 kg to 500 kg, depending on insulator length and weight.
[00120] It will be appreciated that these material selections and dimensional ranges are exemplary and not limiting. Alternative materials and dimensions may be employed without departing from the scope of the invention, provided that the components retain sufficient structural strength, durability, and compatibility with RTV silicone coating processes.
[00121] The apparatus, method and system can also accommodate other coating materials with only minor adjustments to the settings.
[00122] In another embodiment, the apparatus is configured with a modular design, wherein the bed assembly, motor drive assembly, and spray applicator assembly are designed as interchangeable modules. The bed assembly may be selectively configured as a fixed bed type or a portable bed type without altering the fundamental spray applicator assembly, traveller unit, or slide mechanism. This modular arrangement allows the apparatus to be adapted for different factory layouts, insulator sizes, and production scales with minimal reconfiguration.
[00123] In certain embodiment, the motor drive assembly comprising the servo or stepper motor and drive panel box may be detached from one bed assembly and mounted on another, ensuring cost-effective scalability. Similarly, the spray applicator assembly may be interchanged with nozzles of varying spray cone angles and flow rates to suit specific insulator geometries. Such modularity reduces downtime, facilitates maintenance, and allows rapid transition between coating setups for long rod, post, hollow, railway porcelain and composite insulators.
[00124] The inventors of the present invention have undertaken extensive research and development to arrive at the current configuration and design features of the apparatus. These design choices have been deliberately made to overcome the limitations associated with conventional methods and to provide several operational advantages.
[00125] Non-limiting advantages of the present invention include the following:
[00126] An advantage of the present invention is that it provides, for the first time, an indigenous in-house automated RTV coating system developed and tested successfully at both national and global levels, thereby reducing dependence on imported solutions.
[00127] Another advantage of the invention is that the apparatus is capable of coating diverse insulator types, including long rod, post, hollow, railway porcelain and composite insulators, making it universally adaptable within the electrical transmission, distribution and transportation sector.
[00128] Further advantage of the invention is that it incorporates a state-of-the-art dual bed configuration comprising a fixed bed and a portable bed, wherein the fixed bed enables in-situ curing with consistent rotation and the portable bed enables immediate replacement of coated insulators, thereby enhancing productivity and scalability.
[00129] Yet another advantage of the invention is that automation of the spraying, traversal, and rotation operations reduces human intervention, improves process repeatability, and minimizes material wastage, thereby saving time and resources.
[00130] Still another advantage of the invention is that insulators coated using the apparatus successfully pass all performance and adhesion tests prescribed by IEEE and CIGRE, thereby ensuring compliance with international standards for RTV silicone coatings.
[00131] An additional advantage of the invention is that the coating process achieves a statistically uniform RTV thickness distribution, with more than 95% of thickness measurements falling within two standard deviations of the target value, thereby demonstrating consistency, robustness, and repeatability superior to manual coating methods.
[00132] Further advantage of the invention is that coatings applied by the apparatus exhibit superior adhesion and durability, as validated through boiling water immersion, high-pressure water blasting, square comb adhesion tests and pollution severity withstand test, thereby confirming repeatability, reproducibility, and long-term reliability in field conditions.
[00133] Another advantage of the present invention is that it overcomes the limitations of prior art methods by providing an advanced coating machine design, methodology and application process that results in significantly improved surface hydrophobicity. Insulators coated in accordance with the present invention exhibit a higher contact angle, a smaller droplet size, and achieve a hydrophobicity class 1 rating. These superior properties lead to enhanced performance, increased reliability, and a longer service life for the coated insulators in diverse environmental conditions.
[00134] Additionally, prior art methods, especially manually applied RTV coatings, have been shown to produce sub-optimal results. These coatings often exhibit a poor contact angle and significantly larger droplet sizes, indicating a lack of uniform surface hydrophobicity and compromised performance.
[00135] Yet another advantage of the invention is that the system is designed for industrial scalability, providing reliable operation across diverse seasonal and environmental conditions and enabling uninterrupted high-volume factory-based production.
[00136] An additional advantage of the invention is that the system architecture is material-flexible, such that coating materials other than RTV silicone can be applied with only minor adjustments in system settings, thereby extending the applicability of the apparatus.
[00137] Still another advantage of the invention is that operational reliability is enhanced by features such as dust protection, uninterrupted power supply integration, and dual-mode motor drive, thereby reducing maintenance requirements and ensuring stable factory operation.
[00138] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
[00139] Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open-ended as opposed to limiting. As examples of the fore going: the term “including” should be read as mean “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive limiting list thereof; and adjectives such as “conventional,” “traditional,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. Furthermore, although item, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.
[00140] All publications, patent applications, patents, and other references mentioned in the specification, if any, are indicative of the level of those skilled in the art to which the presently disclosed subject matter pertains. All publications, patent applications, patents, and other references are herein incorporated by reference to the same extent as if each individual publication, patent application, patent, and other reference was specifically and individually indicated to be incorporated by reference. It will be understood that, although a number of patent applications, patents, and other references are referred to herein, such reference does not constitute an admission that any of these documents forms part of the common general knowledge in the art. Although the foregoing subject matter has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be understood by those skilled in the art that certain changes and modifications can be practiced within the scope of the appended claims.
[00141] The above description of the invention, together with the accompanying examples below, should not be construed as limiting the invention because those skilled in the art to which this invention pertains will be able to devise other forms thereof within the ambit of the appended claims.

EXAMPLES
[00142] Example 1 – Water Boiling Test: An RTV-coated insulator prepared using the apparatus and method of the present invention was immersed in boiling water for a continuous period of 100 hours to assess coating adhesion under combined heat and moisture stress. After completion of the test, the coating surface exhibited no bubbles, blisters, lumps, or disintegration, thereby confirming strong adhesion and thermal stability.
[00143] Example 2 – High-Pressure Water Test: Coated insulator samples were subjected to a high-pressure water wash test in accordance with IEEE 957. The insulators were exposed to a water blast at 3800 kPa from a distance of 3 meters for a duration of 2 minutes. No coating peel-off, abrasion, or scratches were observed on the sheds or shank, confirming robust adhesion even under high-impact hydrodynamic forces.
[00144] Example 3 – Square Comb Adhesion Test: A square comb adhesion test was performed on coated insulators following the guidelines of EN-ISO 2409. Parallel traces were made along both longitudinal and orthogonal axes of the coated surface. After removal of silicone residue using a soft brush, the RTV coating remained firmly adhered to the insulator without exposing the dielectric surface, confirming reliable adhesion performance.
[00145] Example 4 – Thickness Measurement: To validate coating uniformity, 5000 surface thickness readings were recorded from coated insulators. The coating system was set to apply a 500-micron RTV layer. Statistical analysis revealed a normal distribution of thickness data, with 95% of readings falling within the first and second standard deviation. This confirms the process capability, precision, and repeatability of the automated coating apparatus and method.
[00146] Example 5 – Pollution severity withstand test: Insulators coated in accordance with the present invention have been subjected to pollution severity tests and have demonstrated superior performance, successfully withstanding the highest severity levels recommended by IEC 60507. Furthermore, in testing where the voltage across the insulator was raised while maintaining the highest possible pollution severity, the insulator coated with the present invention was able to comfortably withstand voltages up to 2 times higher than its rated system voltage. This exceptional performance ensures enhanced reliability and a greater safety margin in highly polluted and high-stress environments.
[00147] Comparative Example 1: Manual Spray Coating-Thickness Variation: Insulators coated using conventional manual spray techniques were evaluated for coating thickness uniformity. Surface measurements from extensive readings showed wide variation, with more than 60% of samples not meeting the targeted coating thickness. This indicates high operator dependency, poor process repeatability, and increased material wastage compared to the automated coating process of the present invention.
[00148] Comparative Example 2: RTV-coated insulators produced by manual spraying were subjected to a 100-hour water boiling test under identical conditions as Example 1. Several samples exhibited localized blistering and partial detachment of the coating from the insulator surface, confirming lower adhesion strength when compared to insulators coated using the automated apparatus of the present invention.
[00149] The foregoing examples and comparative evaluations indicate that the apparatus and method of the present invention may provide improvements in coating uniformity, adhesion strength, curing control, and process scalability when compared to conventional manual coating techniques. The automated configuration is capable of reducing operator dependency, supporting repeatable performance, and achieving consistent RTV coating deposition across long rod, post, hollow, railway porcelain and composite insulators.

, Claims:We claim:
1. An automated insulator coating apparatus, comprising:
a spray delivery unit configured to deliver a coating material;
a spray applicator assembly fluidly connected to the spray delivery unit, the spray applicator assembly includes a spray gun and a nozzle;
a traveller unit supporting the spray applicator assembly and configured for controlled movement along a longitudinal axis parallel to an insulator;
a slide mechanism unit supporting the traveller unit and permitting its linear displacement;
an insulator support assembly configured to support the insulator and including a motor drive assembly for imparting controlled rotational motion to the insulator;
and a support structure supporting the slide mechanism and the insulator support assembly.
2. The apparatus as claimed in claim 1, wherein the coating material is room temperature vulcanized (RTV) silicone material.
3. The apparatus as claimed in claim 1, wherein the apparatus comprises a control panel operatively connected to the traveller unit, and the motor drive assembly, the control panel being configured to synchronize rotational motion of the insulator with traversal of the traveller unit to achieve uniform coating deposition.
4. The apparatus as claimed in claim 1, wherein the motor drive assembly comprises a servo motor or a stepper motor operatively coupled to the insulator support assembly and a drive panel box electronically interfaced with the control panel.
5. The apparatus as claimed in claim 1, wherein the traveller unit includes a plurality of motors, comprising: a first motor configured to displace the spray applicator assembly toward or away from the insulator; a second motor configured to actuate the spray gun; a third motor configured to adjust nozzle orientation; and a servo motor for traversing the traveller unit bidirectionally along the slide mechanism and the servo motor is mounted with a encoder for continuously monitoring the traveller unit position and provide real-time feedback for accurate motion control.
6. The apparatus as claimed in claim 1, wherein the slide mechanism is enclosed within a bellow cover to prevent ingress of dust and contaminants.
7. The apparatus as claimed in claim 1, wherein the apparatus comprises an uninterruptible power supply (UPS) to maintain continuity of operation during mains power failure.
8. The apparatus as claimed in claim 1, wherein the insulator support assembly is a fixed bed assembly comprising a headstock, plurality of three-jaw chuck, plurality of adaptors and a tailstock with a wheel-type handle, the headstock and motor drive assembly are mounted on first mounting platform and the tailstock is mounted on second mounting platform and both the platforms are rigidly affixed to the support structure.
9. The apparatus as claimed in claim 1, wherein the insulator support assembly is a portable bed assembly comprising a headstock, plurality of adaptors, and a tailstock, the motor drive assembly along with portable bed assembly are mounted on a wheelbase assembly, the wheelbase assembly being engaged with a track section formed on the support structure with a slope to enable linear displacement of the bed assembly.
10. The apparatus as claimed in claim 1, wherein the motor drive assembly is powered by a dual-mode supply system, the system being operable in a battery mode during pre-coating, coating and post-coating curing and in a mains power mode during active coating upon connection to an external AC supply.
11. The apparatus as claimed in claim 8, wherein tailstock is mounted on a carriage supported by a linear bearing arrangement, the linear bearing being slidably engaged with a guideway extending along the longitudinal axis of the insulator and thereby permitting smooth guided movement relative to the headstock, a lead screw extends along the displacement axis of the tailstock, with a lead screw nut coupled to the carriage to engage with the lead screw, and the rotation of the lead screw enables precise forward or backward displacement of the carriage and tailstock along the guideway for accommodating insulator of different lengths.
12. A method of coating an insulator, comprising steps of:
a. placing the insulator onto an insulator support assembly having opposing support fixtures;
b. securing the insulator in position along its longitudinal axis;
c. supplying a coating material from a spray delivery unit to a spray applicator assembly;
d. rotating the insulator by means of a motor drive assembly;
e. traversing a traveller unit supporting the spray applicator assembly, along a slide mechanism parallel to the insulator while atomizing and spraying the coating material onto the insulator surface using a spray gun and a nozzle of the spray applicator assembly; and
f. controlling, via a centralized control panel, the rotational motion of the insulator and the traversal of the spray applicator assembly in synchronization to achieve uniform deposition of the coating material.
13. The method as claimed in claim 12, the method comprises a step of cleaning the insulator surface with a cleaning agent comprising isopropyl alcohol or acetone, prior to coating and the coating material is RTV silicone.
14. The method as claimed in claim 12, wherein the traversing the spray applicator assembly comprises a forward and a reverse or backward traverse applying coating layers continuously, each followed by a partial curing interval.
15. The method as claimed in claim 12, wherein in a fixed bed configuration, the insulator is retained in the insulator support assembly until curing is complete.
16. The method as claimed in claim 12, wherein in a portable bed configuration, the insulator together with the bed assembly is detached post-coating and relocated to a curing zone, while a fresh bed assembly is introduced to continue coating without interruption.