CN112589077A - Cooling system and method for integrated forming die of complex motor end cover with junction box - Google Patents
Cooling system and method for integrated forming die of complex motor end cover with junction box Download PDFInfo
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- CN112589077A CN112589077A CN202011587134.XA CN202011587134A CN112589077A CN 112589077 A CN112589077 A CN 112589077A CN 202011587134 A CN202011587134 A CN 202011587134A CN 112589077 A CN112589077 A CN 112589077A
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- cooling
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- junction box
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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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
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Abstract
The invention relates to a cooling system of an integrated forming die for a complex motor end cover of a new energy automobile, which comprises an upper die and a lower die, wherein a cavity which is beneficial to end cover casting is formed between the upper die and the lower die, the cavity comprises a first part cavity for casting a main body part of the end cover and a second part cavity for casting a junction box part, the upper die is provided with a first air cooling unit and a second air cooling unit which are used for cooling the corresponding positions of the first part cavity, and second air cooling branch pipes of the second air cooling unit are arranged in one-to-one correspondence with gates on the lower die; and a water cooling device is arranged on the mould corresponding to the second part cavity. The invention also relates to a cooling method using the cooling system, and the cooling method can realize rapid sequential solidification of the integrated casting molding of the complex end cover with the junction box, obviously improve the molding quality of the casting and improve the mechanical property of the casting.
Description
Technical Field
The invention relates to the field of new energy automobile casting, in particular to a cooling system and method of a motor end cover integrated forming die with a complex structure of a junction box.
Background
The motor end cover is a cover at two ends of a motor shell and generally comprises a front end cover and a rear end cover, and the end covers are fixed on the base in a screw or riveting mode and play a role in supporting and protecting a motor rotor. The motor end cover has a complex appearance structure, and a plurality of concave-convex structures are designed on the end face to enhance heat dissipation and improve mechanical strength. The motor end cover is mostly made of cast iron in the past, and along with the requirement of light weight of an automobile, the cast iron part is gradually replaced by aluminum alloy. At present, most of aluminum alloy motor end covers are produced by adopting a mode of casting molding and machining.
Along with the complication of the end cover structure, the requirement on the end cover junction box is improved, and in order to reduce the further machining of the end cover with the junction box complex structure and improve the production efficiency, the complex motor end cover with the junction box needs to be integrally cast and formed. However, the manufacturing of the general structure end cover casting can be realized by adopting the traditional end cover mold and cooling system such as the mold shown in the Chinese utility model patent "a high-precision new energy automobile motor end cover mold", the publication number of which is CN209565478U, but the rapid sequential solidification integral molding of the motor end cover with the junction box and the complex structure is difficult to realize, so that the casting quality of the product is poor, and the mechanical property is low.
Disclosure of Invention
The invention aims to solve the technical problem of providing a cooling system and a cooling method of a motor end cover mould with a junction box, which can realize the rapid sequential solidification of the casting process of the end cover with the complex structure of the junction box and can obviously improve the casting quality.
The technical scheme adopted by the invention for solving the technical problems is as follows: a cooling system of a new energy automobile motor end cover mold comprises an upper mold and a lower mold, wherein a cavity for casting an end cover is formed between the upper mold and the lower mold, the cavity comprises a first part cavity for casting a main body part of the end cover and a second part cavity for casting a junction box part, the upper mold is provided with a first air cooling unit and a second air cooling unit for cooling the corresponding positions of the first part cavity, and second air cooling branch pipes of the second air cooling unit are arranged in one-to-one correspondence with gates on the lower mold; and a water cooling device is arranged on the mould corresponding to the second part cavity.
In order to better cool the end cover main body in the shape of a large circular disc, the first air cooling unit comprises a first air cooling main pipe and a plurality of first air cooling branch pipes extending from the first air cooling main pipe, and the first air cooling branch pipes are arranged on the upper die at intervals along the circumferential direction of the end cover main body;
the second air cooling unit comprises a second air cooling main pipe and a plurality of second air cooling branch pipes extending from the second air cooling main pipe, and the second air cooling branch pipes are arranged on the upper die at intervals along the circumferential direction of the end cover main body.
In order to have a better cooling effect, the diameters of the first air-cooling main pipe and the second air-cooling main pipe are D, the diameters of the first air-cooling branch pipe and the second air-cooling branch pipe are D, the number of the corresponding air-cooling branch pipes on each air-cooling main pipe is n, and then
In order to have better cooling effect, the first air-cooled branch pipes and the second air-cooled branch pipes are arranged in a staggered mode along the circumferential direction.
For more reasonable arrangement, the corresponding central angle α between the adjacent first and second air-cooling branch pipes is 0 ° less than α ≦ 90 °, and more preferably 45 ° less than α ≦ 60 °.
In order to have better cooling effect, the water cooling device comprises a first water cooling unit positioned on the upper die and a second water cooling unit positioned on the lower die. The first water-cooling unit and the second water-cooling unit comprise water-cooling integrated blocks and water inlet/outlet pipes arranged on the water-cooling integrated blocks, and water-cooling cavities used for installing the water-cooling integrated blocks are correspondingly arranged on the upper die and the lower die.
The cooling method of the cooling system using the new energy automobile motor end cover die comprises the following steps:
(a) after the mold filling is finished, immediately starting the water cooling device;
(b) then starting the first air cooling unit;
(c) and then the second air cooling unit is started.
Preferably, the water cooling duration of the step (a) is 25-35 s, and the water cooling flow rate is 8-12L/min.
Preferably, after the mold filling is finished for 0s to 5s, the air cooling duration time of the step (b) is 200s to 260s, and the flow rate of the first air cooling main pipe is 45 Nm to 55Nm3/h。
Preferably, after the mold filling is finished for 120-160 s, the air cooling duration time of the step (c) is 260-300 s, and the flow rate of the second air cooling main pipe is 60-80 Nm3/h。
Compared with the prior art, the invention has the advantages that: the mold comprises a first air cooling unit, a second air cooling unit and a water cooling device, and the mold can realize good sequential solidification by utilizing the cooling devices, particularly sequential solidification of thick and large positions, so that the casting quality is improved, and the specific process is as follows:
after the molten metal is filled, firstly, a water cooling device is started to forcibly cool a thick and large part (a junction box part) at the far end of the casting to balance the whole temperature field, thereby creating a condition beneficial to sequential solidification of the casting; then, a first air cooling unit is started, the first air cooling unit can cool the hot spot part of the outer ring of the end cover main body, and a condition beneficial to sequential solidification is created in order to balance the integral temperature field of the casting, and the air cooling starting time is longer because the air cooling efficiency is lower than that of water cooling; the second air cooling unit is started in the middle and later stages of casting solidification, and is used for cooling a pouring gate part of the casting, so that the casting beat can be shortened, and the production efficiency is improved; in order to avoid blocking of a feeding channel of the sprue and influence on the internal quality of the casting, the second air cooling unit is started at the latest;
in addition, the water cooling device can also cool the core pulling device positioned at the position, protect the core pulling device and prolong the service life of the core pulling device.
Drawings
FIG. 1 is a schematic structural view of an end cap casting according to an embodiment of the present invention;
FIG. 2 is a schematic view of the overall structure of a mold according to an embodiment of the present invention;
FIG. 3 is a schematic view of another angle configuration of a mold according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of a first air-cooling unit and a second air-cooling unit of the mold according to the embodiment of the invention;
FIG. 5 is a schematic cross-sectional view of a mold according to an embodiment of the invention;
fig. 6 is a schematic view of the overall structure of the cooling system according to the embodiment of the present invention.
Detailed Description
The following detailed description of embodiments of the present invention is provided in connection with the accompanying drawings and examples.
As shown in fig. 1, the end cover 1 includes an end cover main body 11 portion and a terminal box 12 portion for the cast product structure of the motor end cover with the terminal box 12 prepared in the present embodiment.
As shown in fig. 2 to 6, the cooling system of the motor end cover mold with the terminal box 12 of the embodiment includes an upper mold 2 and a lower mold 3, a cavity for casting an end cover is formed between the upper mold 2 and the lower mold 3, the cavity includes a first partial cavity for casting a part of the end cover main body 11 and a second partial cavity for casting a part of the terminal box 12, the upper mold 2 is provided with a first air cooling unit 4 and a second air cooling unit 5 for cooling corresponding positions of the first partial cavity, and second air cooling branch pipes 52 of the second air cooling unit 5 are arranged in one-to-one correspondence with gates 31 on the lower mold 3; and a water cooling device 6 is arranged on the mould at a position corresponding to the second part cavity.
In order to better cool the end cover main body 11 in the shape of a large circular disc, the first air-cooling unit 4 of the present embodiment includes an annular first air-cooling main pipe 41 and a plurality of first air-cooling branch pipes 42 extending from the first air-cooling main pipe 41, and the first air-cooling branch pipes 42 are arranged on the upper die 2 at intervals in the circumferential direction of the end cover main body 11; the second air-cooling unit 5 includes an annular second air-cooling main pipe 51 and a plurality of second air-cooling branch pipes 52 extending from the second air-cooling main pipe 51, and the second air-cooling branch pipes 52 are arranged on the upper die 2 at intervals in the circumferential direction of the end cover main body 11.
In order to have a good cooling effect, the diameters of the first main air-cooling pipe 41 and the second main air-cooling pipe 51 are D, the diameters of the first branch air-cooling pipe 42 and the second branch air-cooling pipe 52 are D, and the number of the corresponding branch air-cooling pipes on each main air-cooling pipe is n, so that the following formula is satisfied:
the diameter of the first air-cooled main pipe 41 of the embodiment is 12-16mm, and the number of the first air-cooled branch pipes 42 is two; the diameter of the second main air-cooled pipe 51 is 20-26mm, and the number of the second branch air-cooled pipes 52 is three.
For better cooling effect, the first air-cooled branch pipes 42 and the second air-cooled branch pipes 52 are arranged in a staggered mode along the circumferential direction. The first air-cooled branch pipe 42 and the second air-cooled branch pipe 52 of the present embodiment are located on a circle, and the first air-cooled branch pipe 42 may also be disposed outside the second air-cooled branch pipe 52. Preferably, the central angle α between the adjacent first and second air- cooling branch pipes 42 and 52 is 0 ° less than α ≦ 90 °, and more preferably 45 ° less than α ≦ 60 °. The central angle α between first air-cooling branch pipes 42 and second air-cooling branch pipes 52 of the present embodiment is 60 °.
In order to enable a better cooling effect, the water cooling device 6 includes a first water cooling unit 61 on the upper die 2 and a second water cooling unit 62 on the lower die 3. The first water cooling unit 61 and the second water cooling unit 62 comprise a water cooling manifold block 63, and a water inlet pipe 631 and a water outlet pipe 632 which are mounted on the water cooling manifold block 63, wherein water cooling cavities 64 for mounting the water cooling manifold block 63 are correspondingly arranged on the upper die 2 and the lower die 3, and the water cooling cavities 64 of the embodiment are arranged on the insert. The water cooling manifold block 63 of this embodiment is made of H13 steel, the water inlet/outlet pipe is made of stainless steel, and the inner diameter of the water inlet/outlet pipe is 10mm to 12 mm.
The die is used for casting a certain motor end cover, the material is A356 alloy, and the composition range is shown in Table 1. When the motor end cover is cast, defects are often generated on the outer edge of the end cover main body 11 and the thick part of the junction box 12, and the mechanical property and the air tightness of a product are seriously influenced.
Table 1: main chemical composition wt.% of motor end cap
| Si | Mg | Fe | Cu | Ti | Zn | Mn |
| 6.5～7.5 | 0.25～0.45 | ≤0.2 | ≤0.1 | ≤0.2 | ≤0.1 | ≤0.1 |
The motor end cover is produced according to the method of the invention, and the specific process is as follows:
and when the aluminum liquid is filled, immediately starting the first and second water cooling units 62, wherein the water cooling duration is 25s, the cooling water flow is adjusted to 8L/min, and the junction box 12 of the end cover is rapidly cooled.
After the mold filling is finished for 5s, the first air cooling unit 4 is started, the air cooling duration is 250s, and the flow of the first air cooling main pipe is adjusted to 55Nm3And h, cooling the outer edge of the end cover main body 11.
After the mold filling is finished for 150s, the second air cooling unit 5 is started, the air cooling duration is 280s, and the flow of the second air cooling main pipe is adjusted to 80Nm3And h, cooling the three gates 31 of the casting, shortening the casting takt and improving the production efficiency.
And demolding to obtain the casting product.
The outer edge position of the end cover main body 11 of the casting product is sampled by a method in GB/T228.1-2010, the mechanical property of the sample is detected after the sample is subjected to T6 heat treatment, and the detection result is shown in Table 2. It can be seen that the mechanical property of the motor end cover cast by the method is obviously improved. The position of the junction box 12 of the casting of the embodiment also has a similar effect, and the mechanical property is obviously improved.
Table 2: mechanical results for castings prepared in this example
The embodiment uses the mold for aluminum alloy casting, and can be applied to other alloy casting such as copper alloy, cast steel, cast iron and the like in addition to the aluminum alloy casting, and has similar effects.
The technical means disclosed in the invention scheme are not limited to the technical means disclosed in the above embodiments, but also include the technical scheme formed by any combination of the above technical features. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and such improvements and modifications are also considered to be within the scope of the present invention.
Claims (10)
1. The cooling system of the integrated forming die for the motor end cover with the junction box complex structure comprises an upper die (2) and a lower die (3), wherein a cavity for casting the end cover is formed between the upper die (2) and the lower die (3), the cavity comprises a first part cavity for casting a part of an end cover main body (11) and a second part cavity for casting a part of the junction box (12),
the method is characterized in that: the upper die (2) is provided with a first air cooling unit (4) and a second air cooling unit (5) which are used for cooling the corresponding positions of the first part of the cavity, and second air cooling branch pipes (52) of the second air cooling unit (5) are arranged in one-to-one correspondence with the gates (31) on the lower die (3); and a water cooling device (6) is arranged on the mould at a position corresponding to the second part cavity.
2. The cooling system of the integrated forming die for the motor end cover with the junction box and the complex structure as claimed in claim 1, wherein: the first air cooling unit (4) comprises a first air cooling main pipe (41) and a plurality of first air cooling branch pipes (42) extending from the first air cooling main pipe (41), and the first air cooling branch pipes (42) are arranged on the upper die (2) at intervals along the circumferential direction of the end cover main body (11);
the second air cooling unit (5) comprises a second air cooling main pipe (51) and a plurality of second air cooling branch pipes (52) extending from the second air cooling main pipe (51), and the second air cooling branch pipes (52) are arranged on the upper die (2) at intervals along the circumferential direction of the end cover main body (11).
3. The cooling system of the integrated forming die for the motor end cover with the junction box and the complex structure as claimed in claim 2, wherein: the diameters of the first air-cooling main pipe (41) and the second air-cooling main pipe (51) are D, the diameters of the first air-cooling branch pipe (42) and the second air-cooling branch pipe (52) are D, the number of the corresponding air-cooling branch pipes (42, 52) on each air-cooling main pipe (41, 51) is n, and then
4. The cooling system of the integrated forming die for the motor end cover with the junction box and the complex structure as claimed in claim 2, wherein: the first air-cooled branch pipes (42) and the second air-cooled branch pipes (52) are arranged in a staggered mode along the circumferential direction.
5. The cooling system of the integrated forming die for the motor end cover with the junction box and the complex structure as claimed in claim 4, wherein: the central angle alpha between the adjacent first air-cooling branch pipes (42) and second air-cooling branch pipes (52) is 0 degrees < alpha < 90 degrees.
6. The cooling system of the integrated forming die for the motor end cover with the junction box and the complex structure as claimed in claim 1, wherein: the water cooling device (6) comprises a first water cooling unit (61) located on the upper die (2) and a second water cooling unit (62) located on the lower die (3).
7. A cooling method using a cooling system of the integrated molding die for the complex motor end cover with junction box according to any one of claims 1 to 6, characterized by comprising the steps of:
(a) after the mold filling is finished, the water cooling device (6) is immediately started;
(b) then the first air cooling unit (4) is started;
(c) and subsequently the second air-cooling unit (5) is started.
8. The cooling method of a motor end cover mold with junction box according to claim 7, characterized in that: the water cooling duration time of the step (a) is 25-35 s, and the water cooling flow rate is 8-12L/min.
9. The cooling method of a motor end cover mold with junction box according to claim 7, characterized in that: after the mold filling is finished for 0-5 s, the air cooling duration time of the step (b) is 200-260 s, and the flow rate of the first air cooling main pipe is 45-55 Nm3/h。
10. The cooling method of a motor end cover mold with junction box according to claim 7, characterized in that: after the mold filling is finished for 120-160 s, the air cooling duration time of the step (c) is260-300 s, and the flow rate of the second air cooling main pipe is 60-80 Nm3/h。
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011587134.XA CN112589077A (en) | 2020-12-29 | 2020-12-29 | Cooling system and method for integrated forming die of complex motor end cover with junction box |
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| CN202011587134.XA CN112589077A (en) | 2020-12-29 | 2020-12-29 | Cooling system and method for integrated forming die of complex motor end cover with junction box |
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| CN112589077A true CN112589077A (en) | 2021-04-02 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113976857A (en) * | 2021-11-08 | 2022-01-28 | 浙江保康轮毂制造有限公司 | Novel fast-assembling type aluminum alloy kappa wheel hub mould |
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2020
- 2020-12-29 CN CN202011587134.XA patent/CN112589077A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113976857A (en) * | 2021-11-08 | 2022-01-28 | 浙江保康轮毂制造有限公司 | Novel fast-assembling type aluminum alloy kappa wheel hub mould |
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