An integrated sand core casting disc motor housing and casting process

Abstract

The disk motor housing provided by this solution, which adopts an integral sand core casting, forms a motor end cover with an integral casting structure by means of a casting process. An internal water channel is provided on the inner cavity wall, and a sand discharge groove communicating the outside with the internal water channel of the motor end cover is arranged on the end face of the motor end cover. The area of the sand discharge groove is relatively large, so that sand can be cleared more quickly. After the sand discharge cleaning is completed, a water channel sealing plate with the same shape is embedded into the sand discharge groove and welded for sealing. This solution also provides a casting process for applying the above disk motor housing. The prefabricated water channel sand core and sand discharge groove sand core are placed in the casting mold of the motor housing, and the motor housing intermediate body with sand cores can be processed only by one-time forming. After removing the sand discharge groove sand core and the water channel sand core, the motor end cover with an internal water channel can be obtained. The casting process is simple. The design of reserving the sand discharge position makes the mold easy to clean sand, easy to seal, and does not increase the welding cost.

Description

Technical Field

[0001] The present invention belongs to the technical field of motor casings, and particularly relates to a disc-type motor casing cast by an integral sand core and a casting process. Background Art

[0002] In the prior art, the structure of an axial-flux disc-type motor is generally a flat disc-shaped structure. Structurally, it is generally that the front end cover and the rear end cover are directly butted without an intermediate casing. The wire stator assembly is arranged on the front and rear end covers on both sides, and cooling water channels are arranged inside the end covers to meet the heat dissipation requirements of the wire stator assembly. There are many sealing methods for the cooling water channels arranged on the end covers, such as O-ring sealing, sealant sealing, integral sand core casting and welding sealing method, etc.

[0003] For the integral sand core casting and welding sealing method, the current design of the reserved sand discharge position is unreasonable. If the reserved position is too small, it is not easy to discharge sand, and if it is too large, the welding cost will increase. Therefore, the position of the reserved sand discharge is very crucial. Summary of the Invention

[0004] The purpose of the present invention is to provide a disc-type motor casing cast by an integral sand core and a casting process, in which the design of the reserved sand discharge position is reasonable, it is easy to discharge sand and the welding cost is not increased.

[0005] To solve the above technical problems, the present invention provides a disc-type motor casing cast by an integral sand core, including a motor end cover, an internal water channel and a water channel sealing plate;

[0006] Wherein, the internal water channel for the circulation of cooling water is arranged on the inner cavity wall of the motor end cover, and the motor end cover and the internal water channel are an integral casting;

[0007] A sand discharge groove is formed on the end face of the motor end cover, and the sand discharge groove is at least used for discharging the molding sand of the water channel sand core of the internal water channel;

[0008] The water channel sealing plate is matched with the sand discharge groove, and the water channel sealing plate is placed in the sand discharge groove of the motor end cover and is sealed and connected by welding.

[0009] Preferably, in the above disc-type motor casing, the shape of the water channel sealing plate is a closed ring, a non-closed ring, a non-ring special shape, a multi-ring or a segmented arc.

[0010] Preferably, in the above disc-type motor casing, the motor end cover and the water channel sealing plate are welded by friction stir welding.

[0011] Preferably, in the above disc-type motor casing, after assembly, the gap between the sand discharge groove and the welding surface of the water channel sealing plate is 0.05 mm - 0.2 mm.

[0012] Preferably, in the above-mentioned disc motor housing, the built-in water channel includes a cooling channel and a water channel inlet and outlet, and the water channel inlet and outlet are exposed on the upper part of the outer wall of the motor end cover.

[0013] Preferably, in the above-mentioned disc motor housing, the built-in water channel is arranged in a circuitous manner to form a hollow ring and is attached to the end face of the motor end cover on the side close to the sand discharge groove.

[0014] This solution also provides a casting process for a disc motor housing, which is used to cast the disc motor housing cast by the integral sand core as described above. The casting process includes the following steps:

[0015] a. Process and manufacture a water channel sand core and a sand discharge groove sand core;

[0016] b. Place the water channel sand core and the sand discharge groove sand core in a casting motor housing mold to form the built-in water channel of the disc motor housing to be cast. One end face of the sand discharge groove sand core is attached to the inner wall of the casting motor housing mold and the other end face is attached to the water channel sand core to form a sand discharge groove communicating the outside of the motor end cover and the built-in water channel;

[0017] c. Fill with molten metal, and wait for the molten metal to cool and solidify to form an intermediate motor housing;

[0018] d. Remove the sand discharge groove sand core and the water channel sand core to obtain a motor end cover with the built-in water channel.

[0019] Preferably, in the above-mentioned casting process, step d is specifically: the water channel sand core is arranged in the center of the casting motor housing mold, the sand discharge groove sand core is removed from the end face of the intermediate motor housing to form the sand discharge groove, and the water channel sand core is removed through the sand discharge groove to obtain a motor end cover with the built-in water channel.

[0020] Preferably, in the above-mentioned casting process, in step a, the sand discharge groove sand core and the water channel sand core are made of fine sand, or a mixture of fine sand and resin.

[0021] Preferably, in the above-mentioned casting process, in step d, the sand discharge groove sand core and the water channel sand core are removed from the intermediate motor housing by means of heating, vibration and / or high-pressure flushing.

[0022] The disc motor housing provided by this solution, which adopts an integrated sand core casting, forms a motor end cover with an integrated casting structure by casting process. An internal water channel is arranged on the inner cavity wall, and a sand discharge groove communicating the outside with the internal water channel of the motor end cover is arranged on the end face of the motor end cover. The sand discharge groove has a large area, and the sand can be cleared more quickly. After the sand discharge cleaning is completed, a water channel sealing plate with the same shape is embedded into the sand discharge groove and welded for sealing. The integrated casting design of the motor end cover has a high integration degree and improves the housing strength. At the same time, the internal water channel is arranged on the inner cavity wall of the motor end cover and is not completely closed before assembly, and the sand discharge groove is arranged on the end face of the motor end cover to form a sand discharge channel. The design of reserving a sand discharge position makes it easy to clean the sand in the mold and does not increase the welding cost. This solution also provides a casting process for applying the above disc motor housing. The prefabricated water channel sand core and sand discharge groove sand core are placed in the mold for casting the motor housing, and the motor housing intermediate body with sand cores can be processed only by one molding. After removing the sand discharge groove sand core and the water channel sand core, the motor end cover with an internal water channel can be obtained. The casting process is simple. The design of reserving a sand discharge position in the above structure makes it easy to clean the sand in the mold, easy to seal, and does not increase the welding cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only the embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained according to the provided drawings without creative efforts.

[0024] Figure 1 It is the front view of the disc motor housing provided by this solution;

[0025] Figure 2 It is Figure 1 the sectional view of the disc motor housing in the A-A direction;

[0026] Figure 3 It is the rear view of the disc motor housing provided by this solution;

[0027] Figure 4 It is the structural schematic diagram of the internal water channel provided by this solution;

[0028] Figure 5 It is the structural schematic diagram of the disc motor housing provided by this solution;

[0029] Figure 6 It is the structural schematic diagram of the water channel sealing plate with a non-closed circular ring shape in this solution;

[0030] Figure 7 It is the structural schematic diagram of the water channel sealing plate with a non-circular ring special shape in this solution;

[0031] Figure 8 Schematic structural diagram of the shape of the water channel sealing plate in this solution being a multi-circular ring shape;

[0032] Figure 9 Schematic structural diagram of the shape of the water channel sealing plate in this solution being a segmented arc shape;

[0033] Figure 10 Schematic structural diagram of the built-in water channel and the water channel sealing plate provided on the inner end surface of the motor end cover in this solution.

[0034] In the above figure:

[0035] 1 - Motor end cover, 101 - Sand discharge groove, 2 - Built-in water channel, 3 - Water channel sealing plate, 4 - Sealed welding position, 5 - Water channel inlet and outlet. Specific implementation manners

[0036] The core of the present invention is to provide a disk-type motor housing and a casting process by integral sand core casting, with a reasonable design for reserving sand discharge positions, easy sand discharge and no increase in welding cost.

[0037] In order to enable those skilled in the art to better understand the technical solutions provided by the present invention, the present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0038] Please refer to Figures 1-10 , Figure 1 Front view of the disk-type motor housing provided in this solution; Figure 2 For Figure 1 Cross-sectional view of the disk-type motor housing in the A - A direction in Figure 3 Rear view of the disk-type motor housing provided in this solution; Figure 4 Schematic structural diagram of the built-in water channel provided in this solution; Figure 5 Schematic structural diagram of the disk-type motor housing provided in this solution; Figures 6-10 Schematic structural diagram of different forms of water channel sealing plates in the disk-type motor housing provided in this solution. Among them, Figure 6 Schematic structural diagram of the shape of the water channel sealing plate being a non-closed circular ring shape; Figure 7 Schematic structural diagram of the shape of the water channel sealing plate being a non-circular ring special shape; Figure 8 Schematic structural diagram of the shape of the water channel sealing plate being a multi-circular ring shape; Figure 9 Schematic structural diagram of the shape of the water channel sealing plate being a segmented arc shape; Figure 10 Schematic structural diagram of the built-in water channel and the water channel sealing plate provided on the inner side motor end cover (the sand discharge groove and the sealed welding position are not marked on the inner end surface).

[0039] The present invention provides a disk-type motor housing by integral sand core casting, including a motor end cover 1, a built-in water channel 2, and a water channel sealing plate 3;

[0040] Among them, the motor end cover 1 and the built-in water channel 2 are integrally castings. The built-in water channel 2 for the circulation of cooling water is arranged on the inner cavity wall of the motor end cover 1. A sand discharge groove 101 is formed on the end face of the motor end cover 1, and the sand discharge groove 101 is at least used to discharge the molding sand of the water channel core of the built-in water channel 2. In this solution, the function of the sand discharge groove 101 is to discharge the molding sand of the water channel core of the built-in water channel 2, but it is not limited to this function. When other structures are also arranged in the motor end cover 1, it may still be necessary to discharge similar molding sand through the sand discharge groove 101.

[0041] The water channel sealing plate 3 matches the sand discharge groove 101. The water channel sealing plate 3 is placed in the sand discharge groove 101 of the motor end cover 1 and is connected by welding for sealing. At the same time, the inner end face of the motor end cover 1 has an installation position for motor components, and an installation position for passing through the rotating shaft is arranged at the central part.

[0042] It should be noted that the sand discharge groove 101 is usually formed on one end face of the motor end cover 1. The two ends of the motor end cover 1 close to the motor are the inner end faces, and the ends far from the motor are the outer end faces. Preferably, the sand discharge groove 101 is arranged on the outer end face of the motor end cover 1, and the built-in water channel 2 is arranged on the inner cavity wall of the motor end cover close to the outer end face, so that slight leakage will not cause the motor to fail. Of course, the sand discharge groove 101 can also be formed on the inner end face of the motor end cover 1, and the built-in water channel 2 is arranged on the inner cavity wall of the motor end cover close to the inner end face.

[0043] The disk-type motor housing provided by this solution is integrally sand-cast. The motor end cover 1 with an integrally cast structure is formed by a casting process. The built-in water channel 2 is arranged on the inner cavity wall of the motor end cover 1. A sand discharge groove 101 communicating the outside with the built-in water channel 2 of the motor end cover 1 is arranged on the end face of the motor end cover 1. The area of the sand discharge groove 101 is relatively large, and the sand can be cleared more quickly. After the sand discharge and cleaning are completed, the water channel sealing plate 3 with the same shape is embedded into the sand discharge groove 101 and welded to complete the sealing. The integrated design of the motor end cover 1 and the built-in water channel 2 has a high integration degree and improves the strength of the housing. At the same time, the built-in water channel is arranged on the inner cavity wall of the motor end cover and is not completely closed before assembly. The sand discharge groove 101 is arranged on the end face of the motor end cover to form a sand discharge channel. The design of reserving a sand discharge position in the above structure makes it easy to clean the sand in the mold, easy to seal, with low labor and production costs and no increase in welding costs.

[0044] In a preferred embodiment, as Figures 6-9 shown, the shape of the water channel sealing plate 3 can be derived into a closed ring, a non-closed ring, a non-ring special shape, a multi-ring or a segmented arc, etc. according to actual needs. Of course, other annular structures or corresponding deformed structures of the water channel sealing plate 3 can also be used. The deformed structures and sand discharge grooves adapted to actual applications are all within the protection scope of this case.

[0045] Preferably, the sand discharge groove 101 of the motor end cover 1 and the water channel sealing plate 3 are welded by friction stir welding. Friction stir welding has low welding cost and high reliability for welding of such regular routes. Thus, the built-in water channel can be sealed.

[0046] Specifically, the sand discharge groove 101 of the end cover and the water channel sealing plate 3 need to be processed to form certain matching dimensions. The unilateral welding gap between the groove wall of the sand discharge groove 101 and the water channel sealing plate 3 is set to 0.05 mm - 0.2 mm, which is beneficial to the welding of the two.

[0047] In a specific embodiment, as Figure 2 、 4 and shown in Figure 5, the built-in water channel 2 includes a cooling channel and a water channel inlet and outlet 5. The water channel inlet and outlet 5 is exposed on the upper part of the outer wall of the motor end cover 1. The motor end cover 1 is a hollow cylinder. A cooling channel is provided on the end face side of the motor end cover 1, and a water channel inlet and outlet 5 communicating with the cooling channel is provided on the cylindrical surface. Water continuously flows into the cooling channel from the inlet and then discharges from the outlet, quickly cooling and dissipating heat from the motor end cover, and increasing the service life of the motor.

[0048] As Figure 4 shown, the built-in water channel 2 is arranged in a circuitous manner to form a hollow ring. The built-in water channel 2 is similar to a serpentine tube structure and fits the end face of the motor end cover 1 close to the sand discharge groove 101. Of course, the built-in water channel 2 can also be arranged in a cylindrical shape and circumferentially arranged along the motor end cover. Since the wire stator assembly is arranged on the front and rear end covers on both sides, arranging the above cooling water channels inside the end cover can effectively meet the heat dissipation requirements of the wire stator assembly. When both the sand discharge groove 101 and the built-in water channel 2 are symmetric structures, their symmetric centerlines are collinear, that is, the sand discharge groove and the built-in water channel 2 are coaxially arranged.

[0049] The present invention also provides a casting process for a disc motor housing, which is used for casting the disc motor housing cast by the integral sand core casting described above. The casting process includes the following steps:

[0050] a. Process and manufacture a water channel sand core and a sand discharge groove sand core;

[0051] b. Place the water channel sand core and the sand discharge groove sand core in a casting mold for the motor housing to form the built-in water channel 2 of the to-be-cast disc motor housing. One end face of the sand discharge groove sand core fits the inner wall of the casting mold for the motor housing and the other end face fits the water channel sand core to form a sand discharge groove 101 communicating the outside of the motor end cover and the built-in water channel 2;

[0052] c. Fill with molten metal and wait for the molten metal to cool and solidify to form an intermediate motor housing;

[0053] d. Remove the sand discharge groove sand core and the water channel sand core to obtain a motor end cover 1 with a built-in water channel 2.

[0054] Using the above casting process, placing the prefabricated water channel sand core and the sand discharge groove sand core in the casting motor housing mold, the motor housing intermediate body can be machined with just one molding. At the same time, removing the sand discharge groove sand core and the water channel sand core, a motor end cover 1 with an internal water channel 2 is obtained. The casting process is simple. The design of reserving the sand discharge position in the above structure makes it easy to clean the sand from the mold, easy to seal, and does not increase the welding cost.

[0055] It should be noted that the molten metal in step c above can specifically be aluminum liquid, obtained by melting aluminum ingots. Of course, one metal or multiple metals, such as aluminum alloy, etc., can also be selected as the processing material, and the mass percentage of each element component can be configured according to actual applications, all within the protection scope of this solution.

[0056] Preferably, the water channel sand core is arranged at the center of the casting motor housing mold. The water channel sand core can be designed as a centrally symmetric structure and placed at the center position of the mold, which is convenient for casting and can effectively improve the cooling and heat dissipation effect. Of course, according to actual needs, the water channel sand core can also be designed as an asymmetric structure.

[0057] Further, step d is specifically: removing the sand discharge groove sand core from the end face of the motor housing intermediate body to form a sand discharge groove 101, and removing the water channel sand core through the sand discharge groove 101 to obtain a motor end cover 1 with an internal water channel 2.

[0058] Specifically, in step a, the sand discharge groove sand core and the water channel sand core are made of fine sand, or a mixture of fine sand and resin. Adding a small amount of resin and curing agent to the fine sand and stirring and mixing it is beneficial to improving the quality of the casting and reducing defects such as vein marks and mechanical sand sticking.

[0059] Specifically, in step d, the sand discharge groove sand core and the water channel sand core are cleaned out of the motor housing intermediate body by means of heating, vibration, and / or high-pressure flushing. After cleaning, the motor end cover with an integrated internal casting water channel is formed.

[0060] In this article, specific examples are used to elaborate on the principle and implementation mode of the present invention. The description of the above embodiments is only used to help understand the method and its core idea of the present invention. It should be pointed out that for those of ordinary skill in the art in this technical field, without departing from the principle of the present invention, several improvements and modifications can still be made to the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A disc-type motor housing cast with an integral sand core, characterized in that, It includes a motor end cover (1), an internal water channel (2), and a water channel sealing plate (3); Among them, the internal water channel (2) for the circulation of cooling water is arranged on the inner cavity wall of the motor end cover (1), and the motor end cover (1) and the internal water channel (2) are integrally castings; A sand discharge groove (101) is formed on the end face of the motor end cover (1), and the sand discharge groove (101) is at least used to discharge the molding sand of the water channel core of the internal water channel (2); The water channel sealing plate (3) matches the sand discharge groove (101), and the water channel sealing plate (3) is placed in the sand discharge groove (101) of the motor end cover (1) and is connected by welding and sealing.

2. The disc motor housing according to claim 1, characterized in that, The shape of the water channel sealing plate (3) is a closed ring, a non-closed ring, a non-ring special shape, a multi-ring or a segmented arc.

3. The disc motor housing according to claim 1, characterized in that, The motor end cover (1) and the water channel sealing plate (3) are welded by friction stir welding.

4. The disc-type motor housing according to claim 1, characterized in that, After assembly, the gap between the welding surface of the sand discharge groove (101) and the water channel sealing plate (3) is 0.05 mm - 0.2 mm.

5. The disc motor housing according to claim 1, wherein, The internal water channel (2) includes a cooling channel and a water channel inlet and outlet (5), and the water channel inlet and outlet (5) is exposed on the upper part of the outer wall of the motor end cover (1).

6. The disc motor housing according to any one of claims 1-5, characterized in that, The internal water channel (2) is arranged in a circuitous manner in a hollow ring shape and is attached to the end face of the motor end cover (1) close to the sand discharge groove (101).

7. A casting process for a disc motor housing, characterized in that, For casting a disc motor housing with an integral sand core casting as described in any one of claims 1 - 6, the casting process includes the following steps: a. Processing and manufacturing a water channel core and a sand discharge groove core; b. Placing the water channel core and the sand discharge groove core in a casting motor housing mold to form the internal water channel (2) of the to-be-cast disc motor housing. One end face of the sand discharge groove core is attached to the inner wall of the casting motor housing mold and the other end face is attached to the water channel core to form a sand discharge groove (101) communicating the outside of the motor end cover and the internal water channel (2); c. Filling molten metal, and waiting for the molten metal to cool and solidify to form a motor housing intermediate; d. Removing the sand discharge groove core and the water channel core to obtain a motor end cover (1) with the internal water channel (2).

8. The casting process according to claim 7, characterized in that, The specific step d is: The water channel core is arranged at the center of the casting motor housing mold. The sand discharge groove core is removed from the end face of the motor housing intermediate to form the sand discharge groove (101), and the water channel core is removed through the sand discharge groove (101) to obtain a motor end cover (1) with the internal water channel (2).

9. The casting process according to claim 7, wherein In the step a, the sand discharge groove core and the water channel core are made of fine sand, or a mixture of fine sand and resin.

10. The casting process according to claim 7, characterized in that, In the step d, the sand discharge groove core and the water channel core are cleaned out of the motor housing intermediate by means of heating, vibration or high-pressure flushing.

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