CN111644596A - Casting method of integral water-cooled motor shell with prefabricated spiral water channel - Google Patents
Casting method of integral water-cooled motor shell with prefabricated spiral water channel Download PDFInfo
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- CN111644596A CN111644596A CN202010653709.7A CN202010653709A CN111644596A CN 111644596 A CN111644596 A CN 111644596A CN 202010653709 A CN202010653709 A CN 202010653709A CN 111644596 A CN111644596 A CN 111644596A
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- water channel
- motor shell
- casting method
- spiral water
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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- Manufacture Of Motors, Generators (AREA)
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Abstract
The invention discloses a casting method of an integral water-cooling motor shell with a prefabricated spiral water channel, which comprises the following steps: providing a prefabricated spiral water channel; fixing the prefabricated spiral water channel in a casting mold; introducing a cooling medium into the spiral water channel; the integral water-cooled motor shell with high quality can be obtained by low-pressure casting process forming. According to the invention, the cooling medium is introduced into the circulating water channel in the pouring process, so that the phenomenon that the prefabricated spiral water channel pipeline is softened, deformed and even melted by alloy liquid in the pouring process and the inner cavity of the pipeline is damaged can be prevented, and the reliability of the production process and the product is ensured. The spiral water channel can be prefabricated by adopting the material which is the same as or similar to the material of the motor shell body, so that the pollution of the water channel material to the base material of the motor shell in the process of recycling and melting the waste products of the motor shell can be avoided or reduced.
Description
Technical Field
The invention belongs to the technical field of new energy motor shell manufacturing, and particularly relates to a casting method of an integral water-cooling motor shell with a prefabricated spiral water channel.
Background
Referring to fig. 1, a motor housing 11 for cooling electric drive on a new energy automobile has built-in water channels 12 which do not allow leakage, cracks and the like, and is characterized in that two ends are thick, the middle of the motor housing has water channels, so that the motor housing is difficult to achieve feeding effect from top to bottom, and casting difficulty is high.
At present, the motor housings on the market are mainly of two types:
one type is a split type water-cooling circulation motor shell, an inner sleeve and an outer sleeve are mainly assembled by adopting the procedures of gravity casting, processing, sleeve heating, welding and the like, and the method has more production procedures, certain instability in the production process and large equipment investment, and the gravity casting hardly has good compactness; after the split water-cooling circulation motor casing is welded completely and is subjected to special operations such as vibration and extrusion, the split water-cooling circulation motor casing is easy to crack and the like, and the reliability of a product is seriously influenced.
The other type is formed by adopting a low-pressure casting process through integral casting, the water-cooling circulating water channel adopts a resin sand core, and the whole part blank is formed by one-step integral casting. Firstly, manufacturing a water channel sand core; placing the water channel sand core in a mould; low-pressure casting; taking out the cast motor shell from the cavity of the mold, cooling, and then burning sand, performing heat treatment, and shaking the sand to remove the water channel sand core; and obtaining a water-cooled motor shell blank. The water-cooled motor shell formed by the process has high safety and long service life. However, the process has the following problems: the sand core is made of resin sand, and irritant gases are emitted in the preparation process and the casting process, so that the working environment is deteriorated; in the sand shaking process, huge noise is generated and dust is released, so that the equipment investment is large; in addition, the waste sand is difficult to recycle, generates solid waste and needs special treatment.
In order to overcome the technical defects of sand cores, CN107498025A discloses a low-pressure casting method for an aluminum alloy motor casing with a built-in spiral coil water channel, wherein a stainless steel or copper spiral coil water channel is prefabricated, the prefabricated spiral coil water channel is fixed in a low-pressure casting die of the motor casing, no sand core is required to be cleaned in the motor casing after casting, the machining process is simpler and more reliable, the auxiliary time for manufacturing the sand core, vibrating sand filling, sand cleaning and the like is saved, the production takt is greatly shortened, and the production efficiency is effectively improved. In the method, the spiral coil water channel is a metal spiral coil water channel with a melting point higher than that of cast aluminum alloy, and the metal spiral coil water channel is preferably a stainless steel spiral coil water channel or a copper spiral coil water channel or a high-temperature-resistant aluminum alloy spiral coil water channel with a melting point higher than that of cast aluminum alloy; the melting point temperature difference of different metals is utilized to ensure that the spiral coil water channel does not melt and deform when the aluminum alloy is cast. The spiral coil water course material is different with the casing material, and the problem of existence includes at least:
(1) similar materials are similar in melting point, so that the spiral water channel is easy to deform or even melt in the alloy liquid filling process, and the practicability is poor;
(2) the prefabricated spiral water channel is made of a dissimilar material with a higher melting point, so that the problem of material pollution exists in remelting of a scrapped casting, or the spiral water tube material has to be taken out separately, so that the operation difficulty is increased. In addition, the prefabricated spiral water channel is different from the motor shell in material, so that the combination problem often exists, and if steel and iron materials are used, interface contact surface gaps and the like may exist.
Most of other water-cooling circulation integrated motor shells adopt a process method of machining and sealing a water channel surface through a sealing groove, the method is unsafety under complex working conditions, sealing parts are prone to aging and cracking, meanwhile, the production cost and the labor intensity are increased through machining, and the market requirements cannot be met.
How to provide a manufacturing method of a motor shell with strong universality, environmental protection and low cost is a problem which needs to be solved urgently.
Disclosure of Invention
An embodiment of the invention provides a casting process of an integral water-cooled motor shell with a prefabricated spiral water channel, which is used for solving the problem that the water channel and the shell of a spiral coil pipe in the prior art can only be made of different materials, and comprises the following steps:
in one embodiment, a casting method of an integral water-cooled motor shell with a prefabricated spiral water channel comprises the following steps:
providing a prefabricated spiral water channel;
fixing the prefabricated spiral water channel in a casting mold;
introducing a cooling medium into the spiral water channel;
and obtaining an integral water-cooled motor shell casting through casting.
Preferably, in the above method, the spiral water channel is made of the same or similar material as the base material of the motor casing. The term "close" as used herein means that the main elements are the same, such as aluminum and aluminum alloy, and include materials with similar melting points.
Preferably, in the above method, the material of the motor casing is selected from an aluminum alloy or a magnesium alloy. The materials conventionally used for manufacturing the motor casing in the prior art can also be adopted.
Preferably, in the above method, the material of the spiral water channel is selected from aluminum alloy or magnesium alloy. The materials conventionally used for manufacturing the motor casing in the prior art can also be adopted.
Preferably, in the above method, the cooling medium is water, gas or oil.
Preferably, in the above method, the spiral water channel is an integrally formed flat tube, and is made by extruding a metal bar through an extruder or rolling and deforming a tube.
Further, the inner hole section of the flat pipe is oval or rectangular.
Further, the spiral water channel needs to be heat treated to soften the spiral water channel before deformation.
Further, the metal bar or the metal round pipe adopts a standard specification sold in the market.
Compared with the prior art, the invention introduces the cooling medium into the prefabricated spiral circulating water channel in the casting process, and the technical effects of the method at least comprise the following steps:
(1) the prefabricated spiral circulating water channel is ensured not to deform or even melt during casting;
(2) the material selection requirement on the circulating water channel is low, and the universality is stronger;
(3) the spiral coil pipe water channel and the shell can be made of similar or even same materials, such as aluminum alloy, the combination problem of dissimilar materials does not exist in the casting and forming process, the aluminum alloy is not easy to rust and oxidize, the surface is easy to clean, and the aluminum alloy can be recycled for unlimited times with the materials or the similar materials, so that the problem of material pollution in the waste casting recycling and melting process can be avoided.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments described in the present application, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a cross-sectional view of a prior art motor housing;
FIG. 2 is a flow chart of a manufacturing process in one embodiment of the present application;
FIG. 3 is a schematic diagram of a prefabricated spiral raceway in accordance with an embodiment of the present application;
fig. 4 is a schematic structural diagram of a rolling device according to an embodiment of the present application.
Detailed Description
The present invention will be more fully understood from the following detailed description, which should be read in conjunction with the accompanying drawings. Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed embodiment.
Referring to fig. 2, in an embodiment of the present application, there is provided a casting process of an integrated water-cooled motor casing with a prefabricated spiral circulation water channel, including the following steps:
s1, providing a prefabricated spiral water channel.
Referring to fig. 3, the preformed spiral water channel is preferably a spiral coil made of metal, and is formed by deforming and winding a metal pipe.
The metal tube is selected to be as large as possible in the standard specification existing on the market, or can be customized by an aluminum profile supplier under the condition of large enough batch size.
The metal pipe preferably adopts the same or similar material with motor casing body material, for example aluminum alloy pipe, also can select other materials such as magnesium alloy for use.
The sectional area of the inner hole of the metal pipe is equal to the sectional area of the internal circulating water path of the water-cooled motor shell.
The wall thickness of the metal pipe is in accordance with the standard specification of the market, and the wall thickness of the pipe is as thin as possible. If the water circulation device is customized, the water circulation device can be used for ensuring that the spiral water channel pipelines do not interfere with each other and ensuring that the corresponding parts of the motor shell are cast and filled smoothly according to the size of the motor shell circulation water channel.
The chemical components of the metal pipe are selected to be as close to the main body components of the motor shell as possible, and the metal pipe does not contain or contains less impurity elements of the main body components, so that the change of material components caused by the waste products of the motor shell during recycling and smelting is minimized.
In one embodiment, the metal tubing needs to be heat treated to soften it prior to deformation, facilitating subsequent cross-sectional extrusion deformation and bending. The heat treatment process is an annealing heat treatment process, and the annealing temperature and the heat preservation time are slightly different according to the material and the size of the pipe. Annealing heat treatment may not be used if the metal tubing has sufficient plastic deformability.
Taking an aluminum alloy tube as an example, the annealing temperature is 280-300 ℃, the heat preservation is carried out for 2-4 hours, and then the aluminum alloy tube is cooled along with the furnace.
In one embodiment, the metal tubing is deformed by rolling, and referring to fig. 4, the rolling device comprises a pair of rollers 24, and the forming surface of the rollers 24 is customized according to the desired cross-section of the tubing. By the rotation of the roller 24, the metal pipe is rolled and deformed (the circular pipe 21 before deformation), and the cross section of the deformed metal pipe is changed into a flat pipe 23 or a square pipe with a required shape. The flat tube is then wound into a rigid spiral duct channel according to the motor casing product structure, as shown in fig. 3.
In other embodiments, the metal tube may be directly formed by extruding the alloy bar through a special die on an extruder, rather than by secondary rolling.
In the step, a standard aluminum alloy pipe existing in the market is adopted, and then the standard aluminum alloy pipe is softened through heat treatment and deformed to change the shape of the section. The spiral water channel has the advantages of wider material sources, lower cost and easier preparation.
And s2, placing the prefabricated spiral circulating water channel in a mold, closing the mold, connecting two ends of the circulating water channel with a cooling system and opening the cooling system, and performing low-pressure casting forming.
In one embodiment, the prefabricated spiral water channel is placed in a casting mold, the circulating water channel is fixed through the arranged compaction points, and then the mold is closed through the peripheral hydraulic stations; connecting two ends of the circulating water channel with a cooling system, and connecting for cooling; applying pressure to the casting liquid in the crucible by using an air pressure mold filling control system of a low-pressure casting machine; slowly lifting the height of the casting liquid through a liquid lifting pipe, and increasing air pressure when the casting liquid reaches a bottom die of the die so that the molten aluminum fills a complete cavity at the speed of 0.9-1.3 m/s; and continuously pressurizing after the mold cavity is filled, so that the motor shell is solidified under the solidification pressure of 0.02-0.05 MPa higher than the atmospheric pressure, and the motor shell is cast. And taking out the cast motor shell from the cavity of the mold, and completely cooling. And finally, removing a dead head and burrs to obtain a qualified water-cooling circulation integrated motor shell casting blank.
In the step, a cooling medium is introduced into the circulating water channel in the pouring process, so that the alloy pipeline is cooled, the solid state and certain strength are kept, and the phenomenon that the inner cavity of the pipeline is damaged by alloy liquid and even the prefabricated spiral pipeline is melted in the pouring process is prevented.
In addition, because the problem that the spiral circulating water channel deforms and even melts in the pouring process is solved, the material of the spiral circulating water channel is more widely selected, particularly, the circulating water channel and the motor shell body can be made of the same or similar materials, for example, aluminum alloy materials are adopted, so that the problem of combination of different materials cannot exist in the casting forming process (if steel and iron materials are used, a gap between cross-section contact surfaces and the like possibly exists), in addition, the aluminum alloy is not easy to rust and oxidize, and the surface is easy to clean. Moreover, the same material or similar material can be recycled for unlimited times without material pollution.
The cooling medium mainly aims at cooling the prefabricated spiral circulating water channel in the pouring process, and urban tap water is preferably used as the cooling medium in consideration of cost. In modern low-pressure casting machine equipment, a water cooling or air cooling system for cooling a mold is usually arranged, and a pipeline interface can be added to directly use a prefabricated spiral circulating water channel.
In other embodiments, other conventional media such as oil, cooled air, etc. may be used as the cooling medium.
The aspects, embodiments, features and examples of the present invention should be considered as illustrative in all respects and not intended to be limiting of the invention, the scope of which is defined only by the claims. Other embodiments, modifications, and uses will be apparent to those skilled in the art without departing from the spirit and scope of the claimed invention.
Unless specifically stated otherwise, use of the terms "comprising", "including", "having" or "having" is generally to be understood as open-ended and not limiting.
The use of the singular herein includes the plural (and vice versa) unless specifically stated otherwise. Furthermore, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise. In addition, where the term "about" is used before a quantity, the present teachings also include the particular quantity itself unless specifically stated otherwise.
It should be understood that the order of steps or the order in which particular actions are performed is not critical, so long as the teachings of the invention remain operable. Further, two or more steps or actions may be performed simultaneously.
Claims (9)
1. A casting method of an integral water-cooling motor shell with a prefabricated spiral water channel is characterized by comprising the following steps:
providing a prefabricated spiral water channel;
fixing the prefabricated spiral water channel in a casting mold;
introducing a cooling medium into the spiral water channel;
and obtaining an integral water-cooled motor shell casting through casting.
2. The casting method of the integral water-cooled motor shell with the prefabricated spiral water channel as claimed in claim 1, wherein the casting method comprises the following steps: the spiral water channel is made of a material which is the same as or similar to the base material of the motor shell.
3. The casting method of the integral water-cooled motor shell with the prefabricated spiral water channel as claimed in claim 1, wherein the casting method comprises the following steps: the motor casing is made of aluminum alloy or magnesium alloy.
4. The casting method of the integral water-cooled motor shell with the prefabricated spiral water channel as claimed in claim 1, wherein the spiral water channel is made of aluminum alloy or magnesium alloy.
5. The casting method of the integral water-cooled motor shell with the prefabricated spiral water channel as claimed in claim 1, wherein the casting method comprises the following steps: the cooling medium is water, gas or oil.
6. The casting method of the integral water-cooled motor shell with the prefabricated spiral water channel as claimed in claim 1, wherein the casting method comprises the following steps: the spiral water channel is an integrally formed flat pipe and is formed by extruding a metal bar through an extruder or rolling and deforming a pipe.
7. The casting method of the integral water-cooled motor shell with the prefabricated spiral water channel as claimed in claim 6, wherein the casting method comprises the following steps: the section of an inner hole of the flat pipe is oval or rectangular.
8. The casting method of the integral water-cooled motor shell with the prefabricated spiral water channel as claimed in claim 6, wherein the casting method comprises the following steps: the spiral water channel needs to be heat treated to soften the spiral water channel before deformation.
9. The casting method of the integral water-cooled motor shell with the prefabricated spiral water channel as claimed in claim 6, wherein the casting method comprises the following steps: the metal bar or the metal round tube adopts the standard specification sold in the market.
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| CN202010653709.7A CN111644596A (en) | 2020-07-08 | 2020-07-08 | Casting method of integral water-cooled motor shell with prefabricated spiral water channel |
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| CN202010653709.7A CN111644596A (en) | 2020-07-08 | 2020-07-08 | Casting method of integral water-cooled motor shell with prefabricated spiral water channel |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112247116A (en) * | 2020-10-23 | 2021-01-22 | 东风汽车有限公司 | Low-pressure casting process of motor casing with cooling water channel |
| CN112311173A (en) * | 2020-10-23 | 2021-02-02 | 东风汽车有限公司 | Aluminum alloy spiral water channel for motor shell and manufacturing method thereof |
| CN118341946A (en) * | 2024-06-18 | 2024-07-16 | 成都新航工业科技股份有限公司 | Casting device and casting method for special-shaped part |
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