A motor casing structure and a production process thereof

Abstract

The present application relates to a novel motor casing structure and its production process, the motor casing structure comprises an integrally formed outer shell, cooling fins, inner shell, the cooling fins have multiple and are arranged around the outer shell peripheral side, the outer shell outer side is provided with a water inlet channel and a water outlet channel, the inner shell is arranged in the outer shell, the water inlet arc-shaped cooling water channel, the intermediate arc-shaped cooling water channel and the water outlet arc-shaped cooling water channel are formed between the outer wall of the outer shell and the inner wall of the inner shell, the outer shell, the cooling fins and the inner shell of the motor casing are integrally formed, which is fast and simple to process, reduces the manufacturing process, when in use, the wind flow of high-speed driving of the automobile flows to the cooling fins to take away the heat of the motor casing, at the same time, the cooling water flows into the water inlet channel, then sequentially passes through the water inlet arc-shaped cooling water channel, the intermediate arc-shaped cooling water channel and the water outlet arc-shaped cooling water channel, and finally flows out from the water outlet channel to take away the heat, the water and air cooling simultaneously quickly take away the heat, realizing efficient and rapid cooling.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle motors, specifically to a motor housing structure and its manufacturing process. Background Technology

[0002] New energy vehicles refer to automobiles that use unconventional vehicle fuels as their power source and integrate advanced technologies in vehicle power control and drive, resulting in vehicles with advanced technical principles and new technologies and structures. Currently, new energy vehicles on the market all use electric motors as their power drive device. Because electric motors rotate at high speeds and generate a lot of heat, water-cooling structures are generally used on the motor housing for cooling. Existing motor housings have spiral water channels formed inside the housing, through which cooling water is continuously circulated to remove heat from the housing. The drawback of this spiral water channel cooling method is that the limited area of ​​the spiral water channels prevents the cooling water from fully contacting the housing, and the complex structure makes the water channels prone to clogging, resulting in a very slow cooling rate.

[0003] The main manufacturing processes for the aforementioned spiral water channel motor housings are the sand core mold method and the split mold method. The sand core mold method involves placing a sand core mold into the housing mold, then pouring molten aluminum into the housing mold to cover the sand core mold. After demolding, the motor housing is removed, and the sand core mold is broken by striking the housing, thus forming the sand core water channel. The drawbacks of the sand core mold method are that it requires an additional sand core mold, involves multiple processes, is prone to clogging, has high processing costs, requires sand cleaning which generates solid waste pollution, and the subsequent drilling may cause shrinkage cavities or cracking in the housing, affecting product quality. The split mold method involves using two sets of molds to create two halves of the motor housing, then assembling the two parts into a single housing. The drawbacks of the split mold method are that it requires two sets of molds for casting, involves more processing steps and assembly, has lower efficiency, and increases production costs. Summary of the Invention

[0004] To address the aforementioned shortcomings of existing technologies, this invention provides a novel motor housing structure and its manufacturing process. The novel motor housing offers advantages such as a rational structural design, rapid and efficient cooling, and ease of use. The novel motor housing manufacturing process boasts advantages such as a rational process design and rapid one-step molding of the motor housing. The specific technical solution is as follows:

[0005] A novel motor housing structure includes an integrally formed outer shell, cooling fins, and an inner shell. Multiple cooling fins are arranged around the outer periphery of the outer shell, with adjacent fins spaced apart. An inlet channel and an outlet channel are provided on the outer side of the outer shell. The inner shell is located inside the outer shell. An inlet arc-shaped cooling water channel, a middle arc-shaped cooling water channel, and an outlet arc-shaped cooling water channel are formed between the inner wall of the outer shell and the outer wall of the inner shell. The inlet channel communicates with the inlet arc-shaped cooling water channel. One end of the inlet arc-shaped cooling water channel is connected to the middle arc-shaped cooling water channel, and the other end of the middle arc-shaped cooling water channel is connected to the outlet arc-shaped cooling water channel. The outlet arc-shaped cooling water channel is connected to the outlet channel. The inlet arc-shaped cooling water channel and the outlet arc-shaped cooling water channel are separated and not connected by ribs.

[0006] As a preferred embodiment of the structure of the present invention, the inlet arc-shaped cooling water channel, the middle arc-shaped cooling water channel, and the outlet arc-shaped cooling water channel are arranged in a circle.

[0007] As a preferred embodiment of the structure of the present invention, the intermediate arc-shaped cooling water channel includes a first arc-shaped cooling water channel, a second arc-shaped cooling water channel, a third arc-shaped cooling water channel, and a fourth arc-shaped cooling water channel. The inlet arc-shaped cooling water channel, the first arc-shaped cooling water channel, and the second arc-shaped cooling water channel are mirror images of the outlet arc-shaped cooling water channel, the third arc-shaped cooling water channel, and the fourth arc-shaped cooling water channel, respectively. The inlet arc-shaped cooling water channel is connected to the first arc-shaped cooling water channel, the first arc-shaped cooling water channel is connected to the second arc-shaped cooling water channel, the second arc-shaped cooling water channel is connected to the third arc-shaped cooling water channel, the third arc-shaped cooling water channel is connected to the fourth arc-shaped cooling water channel, and the fourth arc-shaped cooling water channel is connected to the outlet arc-shaped cooling water channel.

[0008] As a preferred embodiment of the structure of the present invention, the outer shell includes an upper circular plate and a lower circular plate, and cooling gratings are disposed between the upper circular plate and the lower circular plate, with adjacent cooling gratings spaced apart.

[0009] A novel manufacturing process for motor housings includes the following steps:

[0010] ① Assemble the mold. First, assemble the first side template, the second side template, the third side template, and the fourth side template above the lower template. The inner sides of the first side template, the second side template, the third side template, and the fourth side template form a cavity for forming the motor housing. Then, install the cooling water channel insert and the inner shell insert at the bottom of the upper template. The inner shell insert is located in the center, while the cooling water channel insert is located on the outside of the inner shell insert. The cooling water channel insert is used to form the cooling water channel of the motor housing, and the inner shell insert is used to form the inner shell of the motor housing. The cooling water channel insert and the inner shell insert extend into the cavity. The initial assembly of the motor housing mold is completed.

[0011] ②Heating the mold: Place the entire motor housing mold into the baking oven for heating until the mold reaches a temperature of 400°C or higher;

[0012] ③ Casting the motor housing: The preheated mold is loaded into the casting machine, and the casting machine works to cast the raw material into the cavity to form the motor housing.

[0013] As a preferred embodiment of the production process of this invention, the cooling water channel insert undergoes the following processing steps before being installed onto the upper template: a. sandblasting to remove dirt, b. heating and spraying with casting coating.

[0014] As a preferred embodiment of the production process of this invention, the cooling water channel insert is heated and sprayed with casting coating in three stages. The first stage is heated to 178-182°C and the first layer of casting coating is sprayed. The second stage is heated to 243-247°C and the second layer of casting coating is sprayed. The third stage is heated to 348-352°C and the third layer of casting coating is sprayed.

[0015] As a preferred embodiment of the manufacturing process of the present invention, the cooling water channel insert includes a first arc-shaped insert, a second arc-shaped insert, a third arc-shaped insert, a fourth arc-shaped insert, a fifth arc-shaped insert, and a sixth arc-shaped insert. The first arc-shaped insert, the second arc-shaped insert, the third arc-shaped insert, the fourth arc-shaped insert, the fifth arc-shaped insert, and the sixth arc-shaped insert are circular around the inner shell insert. The first arc-shaped insert, the second arc-shaped insert, and the third arc-shaped insert are mirror images of the fourth arc-shaped insert, the fifth arc-shaped insert, and the sixth arc-shaped insert, respectively.

[0016] As a preferred embodiment of the production process of the present invention, the inner sides of the first side template, the third side template, and the fourth side template are provided with a plurality of spaced grid plate protrusions, and the inner side of the second side template is equipped with ejector pins for forming water inlet channels and water outlet channels.

[0017] As a preferred embodiment of the manufacturing process of this invention, the cooling water channel insert is made of high-temperature resistant H13 steel that has been heat-treated to 55 degrees Celsius.

[0018] Beneficial effects: The novel motor housing structure and its manufacturing process of this invention are reasonably designed. The outer shell, cooling fins, and inner shell of the motor housing are integrally formed, which makes processing quick and simple, reduces manufacturing steps, and helps to reduce costs. Moreover, when the car is in use, the airflow at high speed carries away the heat of the motor housing from the cooling fins. At the same time, cooling water flows in from the water inlet channel, and then passes through the inlet arc-shaped cooling water channel, the middle arc-shaped cooling water channel, and the outlet arc-shaped cooling water channel in sequence, and finally flows out from the outlet channel to carry away the heat. The water and air cooling work together to quickly remove heat, achieving efficient and rapid cooling. Attached Figure Description

[0019] Figure 1 This is a perspective view of the motor housing of the present invention;

[0020] Figure 2 This is a cross-sectional view of the motor housing of the present invention;

[0021] Figure 3 This is a front view of the motor housing of the present invention;

[0022] Figure 4 yes Figure 3 A cross-sectional view along the AA direction;

[0023] Figure 5 This is a perspective view of the mold of the present invention;

[0024] Figure 6 This is an exploded view of the mold of the present invention;

[0025] Figure 7 This is an exploded view of the first side template, second side template, third side template, and fourth side template of the mold of the present invention during assembly;

[0026] Figure 8 This is a perspective view of the cooling water channel insert and inner shell insert of the mold of the present invention installed on the upper template. Detailed Implementation

[0027] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings:

[0028] In the description of this invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the position or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0029] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0030] like Figures 1-4As shown, a novel motor housing structure includes an integrally formed outer shell 1, cooling fins 2, and inner shell 3. Multiple cooling fins 2 are arranged around the outer periphery of the outer shell 1, with adjacent cooling fins 2 spaced apart. An inlet channel 4 and an outlet channel 5 are provided on the outer side of the outer shell 1. The inner shell 3 is located inside the outer shell 1. An inlet arc-shaped cooling water channel 6, a middle arc-shaped cooling water channel, and an outlet arc-shaped cooling water channel 7 are formed between the inner wall of the outer shell and the outer wall of the inner shell. The inlet channel 4 communicates with the inlet arc-shaped cooling water channel 6. The inlet arc-shaped cooling water channel 6 is connected to one end of the middle arc-shaped cooling water channel, and the other end of the middle arc-shaped cooling water channel is connected to the outlet arc-shaped cooling water channel 7. The outlet arc-shaped cooling water channel 7 is connected to the outlet channel 5. The inlet arc-shaped cooling water channel 6 and the outlet arc-shaped cooling water channel 7 are separated and not connected by ribs 8.

[0031] Specifically, the outer casing 1 includes an upper circular plate 1a and a lower circular plate 1b. The cooling grating 2 is arranged between the upper circular plate 1a and the lower circular plate 1b to help strengthen the structure. The inlet arc-shaped cooling water channel 6, the middle arc-shaped cooling water channel, and the outlet arc-shaped cooling water channel 7 form a circle to ensure that the maximum area of ​​cooling water contacts the motor wall for rapid heat dissipation.

[0032] Specifically, the intermediate arc-shaped cooling water channel includes a first arc-shaped cooling water channel 11, a second arc-shaped cooling water channel 12, a third arc-shaped cooling water channel 13, and a fourth arc-shaped cooling water channel 14. The inlet arc-shaped cooling water channel 6, the first arc-shaped cooling water channel 11, and the second arc-shaped cooling water channel 12 are mirror images of the outlet arc-shaped cooling water channel 7, the third arc-shaped cooling water channel 13, and the fourth arc-shaped cooling water channel 14, respectively. The inlet arc-shaped cooling water channel 7 is connected to the first arc-shaped cooling water channel 11, the first arc-shaped cooling water channel 11 is connected to the second arc-shaped cooling water channel 12, the second arc-shaped cooling water channel 12 is connected to the third arc-shaped cooling water channel 13, the third arc-shaped cooling water channel 13 is connected to the fourth arc-shaped cooling water channel 14, and the fourth arc-shaped cooling water channel 14 is connected to the outlet arc-shaped cooling water channel 8. Adjacent arc-shaped cooling water channels are separated by a partition 9, and water will only flow to the adjacent cooling water channel when it is full.

[0033] When the car is traveling at high speed, the airflow reaches the cooling fins 2. Since there are multiple cooling fins 2 arranged around the outer periphery of the outer casing 1, they can quickly dissipate heat from the motor housing. Simultaneously, coolant enters the bottom of the arc-shaped cooling water channel 6 from the inlet channel 4. Once the arc-shaped cooling water channel 6 is full, the coolant flows from the top into the first arc-shaped cooling water channel 11. After the first arc-shaped cooling water channel 11 is full, the coolant flows from the top into the second arc-shaped cooling water channel 12. After the first arc-shaped cooling channel 12 is filled with cooling water, the cooling water will flow from the top into the third arc-shaped cooling channel 13. After the third arc-shaped cooling channel 13 is filled with cooling water, the cooling water will flow from the top into the fourth arc-shaped cooling channel 14. After the fourth arc-shaped cooling channel 14 is filled with cooling water, the cooling water will flow from the top into the outlet arc-shaped cooling channel 7 and then be discharged from the outlet channel 5. The continuous inflow and outflow of water fully removes heat to achieve water cooling. Water and air cooling simultaneously remove heat quickly, achieving efficient and rapid cooling.

[0034] A novel manufacturing process for motor housings includes the following steps:

[0035] ①Assembling molds, such as Figures 5-7 As shown, the first side template 15, the second side template 16, the third side template 17, and the fourth side template 18 are first assembled on top of the lower template 19. The inner sides of the first side template 15, the second side template 16, the third side template 17, and the fourth side template 18 form a cavity 20 for forming the motor housing. Then, the cooling water channel insert 21 and the inner shell insert 22 are installed at the bottom of the upper template 23. The inner shell insert 22 is located at the center, while the cooling water channel insert 21 is located on the outside of the inner shell insert 22. The cooling water channel insert 21 is used to form the cooling water channel of the motor housing. Here, the cooling water channel refers to the inlet arc-shaped cooling water channel 6, the middle arc-shaped cooling water channel, and the outlet arc-shaped cooling water channel 7. The inner shell insert 22 is used to form the inner shell 3 of the motor housing. The cooling water channel insert 21 and the inner shell insert 22 extend into the cavity 20. The initial assembly of the motor housing mold is completed.

[0036] ②Heating the mold: Place the entire motor housing mold into the baking oven for heating until the mold reaches a temperature of 400°C or higher;

[0037] ③ Casting the motor housing: The heated mold is loaded into the casting machine. The casting machine works and the casting raw material enters the cavity to form the motor housing. The motor housing here is the new type of motor housing structure mentioned above. After one production cycle, the product can be demolded. Check the housing for defects, check the inserts, and check the mold cavity for aluminum adhesion. If there are defects or aluminum adhesion, they should be dealt with in time. If not, the casting raw material continues to enter the cavity to produce the next product.

[0038] Specifically, before the cooling channel insert 21 is installed onto the upper template, it undergoes the following processing steps: a. Sandblasting removes dirt and effectively removes surface oil, dust, etc.; b. Heating and spraying with casting coating: The cooling channel insert is heated and sprayed with casting coating in three stages. The first stage involves heating to 178-182℃ and then spraying the first layer of casting coating; the second stage involves heating to 243-247℃ and then spraying the second layer of casting coating; and the third stage involves heating to 348-352℃ and then spraying the third layer of casting coating. The coating is casting coating 395. The three-stage heating and spraying process ensures that the coating has a stronger viscosity, is less likely to fall off, and has a longer service life.

[0039] Specifically, such as Figure 8 As shown, the cooling water channel insert 21 includes a first arc-shaped insert 211, a second arc-shaped insert 212, a third arc-shaped insert 213, a fourth arc-shaped insert 214, a fifth arc-shaped insert 215, and a sixth arc-shaped insert 216. The first arc-shaped insert 211, the second arc-shaped insert 212, the third arc-shaped insert 213, the fourth arc-shaped insert 214, the fifth arc-shaped insert 215, and the sixth arc-shaped insert 216 form a circle around the inner shell insert. The first arc-shaped insert 211, the second arc-shaped insert 212, and the third arc-shaped insert 216... 3 corresponds to the fourth arc-shaped insert 214, the fifth arc-shaped insert 215, and the sixth arc-shaped insert 216 respectively. The first arc-shaped insert 211, the second arc-shaped insert 212, the third arc-shaped insert 213, the fourth arc-shaped insert 214, the fifth arc-shaped insert 215, and the sixth arc-shaped insert 216 are applied to form the inlet arc-shaped cooling water channel 6, the first arc-shaped cooling water channel 11, the second arc-shaped cooling water channel 12, the third arc-shaped cooling water channel 13, the fourth arc-shaped cooling water channel 14, and the outlet arc-shaped cooling water channel 7.

[0040] Specifically, the inner sides of the first side template 15, the third side template 17, and the fourth side template 18 are provided with multiple spaced grid plate protrusions 24. The heat dissipation grid plate 1 of the motor housing is formed between the grid plate protrusions 24. The inner side of the second side template 16 is equipped with ejector pins 25 for forming the water inlet channel 4 and the water outlet channel 5. There are two ejector pins 25, one corresponding to the water inlet channel and the other corresponding to the water outlet channel. The outer sides of the first side template 15, the second side template 16, the third side template 17, and the fourth side template 18 are connected to the moving plates through connecting rods. The four moving plates drive the first side template 15, the second side template 16, the third side template 17, and the fourth side template 18 to move outwards respectively to facilitate the demolding of the motor housing after molding. In addition, the cooling water channel insert 21 is made of high temperature resistant H13 steel and heat-treated to 55 degrees.

[0041] The above description is a further detailed explanation of the present invention in conjunction with specific preferred embodiments. It should not be considered that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, several simple deductions or substitutions can be made without departing from the concept of the present invention, and all such deductions or substitutions should be considered to fall within the protection scope of the present invention.

Claims

1. A process for producing an electrical machine housing, characterized in that: Comprising the following steps, ① Assemble the mold, first assemble the first side mold plate, the second side mold plate, the third side mold plate and the fourth side mold plate above the lower mold plate, the inner side of the first side mold plate, the second side mold plate, the third side mold plate and the fourth side mold plate form a cavity for forming a motor shell, then install the cooling water channel insert and the inner shell insert at the bottom of the upper mold plate, the inner shell insert is located at the center and the cooling water channel insert is located outside the inner shell insert, the cooling water channel insert is used for forming the cooling water channel of the motor shell, and the inner shell insert is used for forming the inner shell of the motor shell, the cooling water channel insert and the inner shell insert extend into the cavity, and the motor shell mold is preliminarily assembled; ②Heat the mold, put the whole motor shell mold into the mold heating box for heating, heat the mold to above 400℃; ③Casting motor shell, put the heated mold into the casting machine, the casting machine works to cast the raw materials into the cavity to form the motor shell, the motor shell structure includes an integrally formed outer shell, cooling fins and an inner shell, the cooling fins are arranged around the outer periphery of the outer shell, and the adjacent two cooling fins are separated, the outer shell includes an upper circular plate and a lower circular plate, the cooling fins are arranged between the upper circular plate and the lower circular plate, and the adjacent two cooling fins are separated, the outer shell is provided with a water inlet channel and a water outlet channel outside, the inner shell is arranged inside the outer shell, and the inner wall of the outer shell and the outer wall of the inner shell form a water inlet arc-shaped cooling water channel, a middle arc-shaped cooling water channel and a water outlet arc-shaped cooling water channel, the water inlet arc-shaped cooling water channel, the middle arc-shaped cooling water channel and the water outlet arc-shaped cooling water channel are arranged in a circular shape, the water inlet channel is communicated with the water inlet arc-shaped cooling water channel, one end of the water inlet arc-shaped cooling water channel is communicated with the middle arc-shaped cooling water channel, the other end of the middle arc-shaped cooling water channel is communicated with the water outlet arc-shaped cooling water channel, the water outlet arc-shaped cooling water channel is communicated with the water outlet channel, and the water inlet arc-shaped cooling water channel and the water outlet arc-shaped cooling water channel are separated by a rib plate and are not connected.

2. The process for producing a motor housing according to claim 1, wherein: The cooling water channel insert is treated by the following processes before being installed on the upper mold plate, a. sand blasting treatment to remove stains, b. heating and spraying casting paint.

3. The process for producing a motor housing according to claim 1, wherein: The cooling water channel insert is heated and sprayed with casting paint three times, the first section is heated to 178-182℃, then the first layer of casting paint is sprayed, the second section is heated to 243-247℃, then the second layer of casting paint is sprayed, and the third section is heated to 348-352℃, then the third layer of casting paint is sprayed.

4. The process for producing a motor casing according to any one of claims 1 to 3, characterized in that: The cooling water channel insert piece includes a first arc-shaped insert piece, a second arc-shaped insert piece, a third arc-shaped insert piece, a fourth arc-shaped insert piece, a fifth arc-shaped insert piece, and a sixth arc-shaped insert piece, the first arc-shaped insert piece, the second arc-shaped insert piece, the third arc-shaped insert piece, the fourth arc-shaped insert piece, the fifth arc-shaped insert piece, and the sixth arc-shaped insert piece are circular around the inner shell insert piece, the first arc-shaped insert piece, the second arc-shaped insert piece, and the third arc-shaped insert piece are mirror-symmetrically corresponding to the fourth arc-shaped insert piece, the fifth arc-shaped insert piece, and the sixth arc-shaped insert piece, respectively, the intermediate arc-shaped cooling water channel includes a first arc-shaped cooling water channel, a second arc-shaped cooling water channel, a third arc-shaped cooling water channel, and a fourth arc-shaped cooling water channel, the inlet arc-shaped cooling water channel, the first arc-shaped cooling water channel, and the second arc-shaped cooling water channel are mirror-symmetrically corresponding to the outlet arc-shaped cooling water channel, the third arc-shaped cooling water channel, and the fourth arc-shaped cooling water channel, respectively, the inlet arc-shaped cooling water channel is connected to the first arc-shaped cooling water channel, the first arc-shaped cooling water channel is connected to the second arc-shaped cooling water channel, the second arc-shaped cooling water channel is connected to the third arc-shaped cooling water channel, the third arc-shaped cooling water channel is connected to the fourth arc-shaped cooling water channel, and the fourth arc-shaped cooling water channel is connected to the outlet arc-shaped cooling water channel, the first arc-shaped insert piece, the second arc-shaped insert piece, the third arc-shaped insert piece, the fourth arc-shaped insert piece, the fifth arc-shaped insert piece, and the sixth arc-shaped insert piece are used for forming the inlet arc-shaped cooling water channel, the first arc-shaped cooling water channel, the second arc-shaped cooling water channel, the third arc-shaped cooling water channel, the fourth arc-shaped cooling water channel, and the outlet arc-shaped cooling water channel.

5. The process for producing an electric machine housing according to claim 1, characterized in that: The first side mold plate, the third side mold plate, and the fourth side mold plate are internally provided with a plurality of spaced-apart grid plate protrusions, and the second side mold plate is internally provided with a plurality of top pins for forming the water inlet channel and the water outlet channel.

6. The process for producing an electric machine housing according to claim 1, characterized in that: The cooling water channel insert piece is made of high-temperature-resistant H13 steel and is heat-treated to 55 degrees.

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