Aluminum casting shell with water cooling structure and manufacturing method thereof

Abstract

The application discloses a cast aluminum shell with a water cooling structure and a manufacturing method thereof. The cast aluminum shell comprises a shell body and a cooling water pipe. The shell body is provided with a water channel bump matching the shape and size of the cooling water pipe. The cooling water pipe is located in the water channel bump. The water channel bump is provided with a water inlet joint and a water outlet joint at two ends respectively. The water inlet joint and the water outlet joint are connected with the water inlet and the water outlet of the cooling water pipe respectively. The manufacturing method comprises the following steps: S100, placing the cooling water pipe in a casting mold and fixing it firmly; S200, closing the mold and pouring to obtain a shell assembly containing the cooling water pipe; S300, opening the mold and taking out the shell assembly. The cast aluminum shell with the water cooling structure is directly cast into shape by pre-embedding the cooling water pipe in the casting mold, and the design and manufacturing process are relatively simple. The cooling water pipe can be made of a seamless steel pipe and a stainless steel pipe, and has the advantages of high structural strength and smooth water channel surface.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of new energy vehicle motors, in particular to a cast aluminum shell with a water cooling structure and a manufacturing method thereof. BACKGROUND

[0002] The arrangement structure of existing hybrid or pure electric vehicles is more compact, and a large amount of heat is generated during operation of an electric drive assembly or a motor, which needs to be balanced in time to prevent damage to rotor, bearing and other components and affect the normal operation of the vehicle. At present, domestic new energy electric drive or motor often adopts water-cooled electric drive or motor, which mainly relies on the cooling liquid water channel of the electric drive or motor shell to take away the heat generated by the transmission components inside.

[0003] The existing utility model patent with application number CN201920419993.4 proposes a motor shell water cooling structure, which includes a motor shell and an inner water jacket arranged in the motor shell. The outer circumference of the inner water jacket is provided with a water passing groove in the form of a spiral around the circumference. The end wall of one end of the inner water jacket is provided with a boss, and the center of the boss is provided with an assembly hole. The end wall of the inner water jacket is fixed with the front bearing seat of the motor through interference fit through the assembly hole, and the joint gap at this position is sealed by welding. The other end of the inner water jacket is fixed with the motor shell through interference fit, and the joint gap at this position is sealed by welding. The front end side wall of the motor shell is provided with a water inlet, and the rear end side wall is provided with a water outlet. The water inlet, water outlet and water passing groove of the inner water jacket are in communication to form a closed cooling water channel.

[0004] The shell with this structure in the prior art usually adopts sand casting to form the water channel or water cavity. The water channel is directly used for passing cooling liquid or is used for passing cooling liquid after adding a water jacket. The structure is complex, the structural strength of the water channel is difficult to guarantee, the manufacturing mold is complex, the casting difficulty is large, welding sealing is required, the waste rate is high, and the surface of the water channel is rough, resulting in large flow resistance. SUMMARY

[0005] The present application aims to provide a cast aluminum shell with a water cooling structure and a manufacturing method thereof, which aims to improve the problems of the existing water cooling structure of the motor shell, such as complex structure, difficult to guarantee the structural strength of the water channel, high waste rate, and rough surface of the water channel resulting in large flow resistance.

[0006] In order to achieve the above object, according to one aspect of the present application, a cast aluminum shell with water cooling structure is provided, comprising a shell body, further comprising a cooling water pipe made of metal material with a melting point higher than that of aluminum; the shell body has a water channel bump matching the shape and size of the cooling water pipe, the cooling water pipe is located in the water channel bump, and the water channel bump has a water inlet joint and a water outlet joint at its two ends respectively, which are connected with the water inlet and water outlet of the cooling water pipe respectively.

[0007] Further, the cooling water pipe has a multiple U-shaped arc-shaped tubular structure, the water inlet of the cooling water pipe has a water inlet pipe part with a common central axis with the water inlet joint, and the water outlet of the cooling water pipe has a water outlet pipe part with a common central axis with the water outlet joint.

[0008] Further, the cooling water pipe has a multiple U-shaped arc-shaped tubular structure, the water inlet of the cooling water pipe has a water inlet pipe part with a common central axis with the water inlet joint, and the water outlet of the cooling water pipe has a water outlet pipe part with a common central axis with the water outlet joint.

[0009] Further, the length of the water inlet pipe part is between 1mm and 3mm, and the length of the water outlet pipe part is also between 1mm and 3mm.

[0010] Further, the cooling water pipe is made of seamless steel pipe or stainless steel pipe, and the wall thickness of the cooling water pipe is between 1mm and 2mm.

[0011] According to a second aspect of the present application, a manufacturing method of a cast aluminum shell with water cooling structure is provided, characterized by comprising the following steps:

[0012] S100, placing the cooling water pipe in the casting mold and fixing it firmly;

[0013] S200, closing the mold and pouring to obtain a shell assembly containing the cooling water pipe;

[0014] S300, opening the mold and taking out the shell assembly.

[0015] Further, the manufacturing method further comprises the following steps:

[0016] S400, machining the water inlet joint and the water outlet joint to obtain a joint structure with a required structure; the joint structure comprises one or more of internal thread structure, external thread structure, and sealing ring installation groove structure;

[0017] S500, polishing the shell body to remove burrs.

[0018] Further, the casting mold comprises two sealing members, the sealing member comprises a sealing plate, the sealing plate is provided with a limiting tube and a limiting cylinder, the limiting cylinder is located inside the limiting tube, and the limiting tube and the limiting cylinder have a common central axis, the inner diameter of the limiting tube is same as the outer diameter of the water inlet joint and the water outlet joint, and the diameter of the limiting cylinder is same as the inner diameter of the water inlet joint and the water outlet joint and same as the inner diameter of the water inlet and the water outlet of the cooling water pipe.

[0019] Further, the casting mold comprises two sealing members, the sealing member comprises a sealing plate, the sealing plate is provided with a limiting tube and a limiting cylinder, the limiting cylinder is located inside the limiting tube, and the limiting tube and the limiting cylinder have a common central axis, the inner diameter of the limiting tube is same as the outer diameter of the water inlet joint and the water outlet joint, and the diameter of the limiting cylinder is same as the inner diameter of the water inlet joint and the water outlet joint and same as the inner diameter of the water inlet and the water outlet of the cooling water pipe.

[0020] Further, the outer cylindrical wall of the limiting tube is provided with a rounded structure at the end away from the sealing plate, and the limiting cylinder is also provided with a rounded structure at the end away from the sealing plate.

[0021] Compared with the prior art, the present application has the following advantages:

[0022] 1. The cast aluminum shell with a water cooling structure is directly cast into shape by pre-buried cooling water pipes in the casting mold, and the design and manufacturing process are relatively simple.

[0023] 2. The water channel body is a cooling water pipe, which can be made of seamless steel pipe and stainless steel pipe, and has the advantages of high structural strength and smooth water channel surface, and can ensure small flow resistance.

[0024] 3. The cast aluminum shell with a water cooling structure does not need to be welded and sealed, and is not prone to scrap problems due to poor sealing of the water channel.

[0025] 4. The casting mold used in the present application has two sealing members, the sealing member comprises a sealing plate, the sealing plate is provided with a limiting tube and a limiting cylinder, the sealing member can realize the casting of the water inlet joint and the water outlet joint, and the limiting cylinder can effectively block the water inlet and the water outlet of the cooling water pipe, preventing the aluminum liquid from entering the cooling water pipe during casting and causing the cooling water pipe to be blocked, thereby effectively reducing the product scrap problem caused by the blocking of the cooling water pipe. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 is a schematic view of the shell assembly of the present application;

[0027] Figure 2is an exploded structural schematic view of the shell assembly of the present application;

[0028] Figure 3 is a sectional view of the cooling water pipe and the shell body at the joint of the present application;

[0029] Figure 4 is a second structural schematic view of the cooling water pipe of the present application;

[0030] Figure 5 is a three-dimensional structural schematic view of the sealing member of the present application;

[0031] Figure 6 is a front view of the sealing member of the present application;

[0032] Figure 7 is a method flow chart of the manufacturing method of the cast aluminum shell proposed by the present application.

[0033] Reference signs: 1, shell assembly; 2, shell body; 3, cooling water pipe; 4, water inlet joint; 5, water outlet joint; 6, water channel bulge; 7, sealing plate; 8, limiting tube; 9, limiting cylinder. DETAILED DESCRIPTION

[0034] In the present application, unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connecting", "fixing" and the like should be understood in a broad sense, for example, can be fixed connection, can also be detachable connection, or integral; can be mechanical connection, can also be electrical connection; can be directly connected, can also be indirectly connected through an intermediate medium, can be the internal communication of two elements or the interaction relationship between two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0035] The following will be further described in combination with the drawings and specific embodiments:

[0036] Embodiment 1

[0037] The present embodiment provides a cast aluminum shell with water cooling structure, as shown in Figure 1 , Figure 2 and Figure 3As shown, the shell assembly 1 is composed of a shell body 2 and a cooling water pipe 3. The shell body 2 is an aluminum shell, and the cooling water pipe 3 is made of a metal material whose melting point is higher than that of aluminum, such as iron, iron alloy, etc., so as to prevent the aluminum liquid from being melted during pouring. In this embodiment, the cooling water pipe 3 is made of a seamless steel pipe or a stainless steel pipe, and the wall thickness of the cooling water pipe 3 is between 1mm and 2mm. The cooling water pipe 3 cannot be too thin, otherwise it is easy to deform during casting, and cannot be too thick, otherwise it will affect heat dissipation and increase the weight of the shell assembly 1. The shell body 2 has a water channel bulge 6 matching the shape and size of the cooling water pipe 3, and the cooling water pipe 3 is located in the water channel bulge 6, and the outer wall of the cooling water pipe 3 is seamlessly connected with the inner wall of the water channel bulge 6. The water channel bulge 6 is provided with a water inlet connector 4 and a water outlet connector 5 at two ends respectively, and the water inlet connector 4 and the water outlet connector 5 are connected with the water inlet and the water outlet of the cooling water pipe 3 respectively.

[0038] As shown in Figure 2 , a structure of the cooling water pipe 3 is given, which is a multiple U-shaped arc-shaped pipe structure. Compared with a multiple U-shaped pipe, the multiple U-shaped arc-shaped pipe is an arc-shaped pipe obtained by bending two longitudinal parts of the multiple U-shaped pipe into a straight pipe, and the central angle of the arc-shaped pipe is between 150 degrees and 240 degrees, and is matched with the structure of the shell body 2.

[0039] As shown in Figure 4 , another structure of the cooling water pipe 3 is given, which is a spiral structure, and the size thereof is also matched with the structure of the shell body 2.

[0040] In this embodiment, the cooling water pipe 3 is provided with a water inlet pipe part at the water inlet thereof, and the water inlet pipe part is coaxial with the water inlet connector 4. The cooling water pipe 3 is provided with a water outlet pipe part at the water outlet thereof, and the water outlet pipe part is coaxial with the water outlet connector 5. The length of the water inlet pipe part and the water outlet pipe part is between 1mm and 3mm. In this way, the water inlet and the water outlet of the cooling water pipe 3 can be easily plugged to prevent the aluminum liquid from entering the cooling water pipe 3 during pouring.

[0041] Embodiment 2

[0042] The embodiment provides a manufacturing method of a cast aluminum shell with a water cooling structure, which is used for manufacturing the cast aluminum shell with the water cooling structure provided in the embodiment 1.

[0043] The manufacturing method needs to use a casting mold, and the casting mold includes two sealing members, and the structure of the sealing member is as shown in Figure 5 and Figure 6As shown, the sealing member includes a sealing plate 7, which is provided with a limiting tube 8 and a limiting cylinder 9 inside the limiting tube 8 and sharing a common central axis. The inner diameter of the limiting tube 8 is the same as the outer diameter of the water inlet joint 4 and the water outlet joint 5, and the diameter of the limiting cylinder 9 is the same as the inner diameter of the water inlet joint 4 and the water outlet joint 5 and the inner diameter of the cooling water pipe 3 at the water inlet and outlet, so that the limiting cylinder 9 can be inserted into the cooling water pipe 3 at the water inlet and outlet and block the water inlet and outlet. The casting mold is provided with a circular hole corresponding to the position of the water inlet joint 4 and the water outlet joint 5, and the diameter of the circular hole is the same as the outer diameter of the limiting tube 8. The outer cylindrical wall of the limiting tube 8 is provided with a rounded structure away from the sealing plate 7, so as to facilitate the insertion of the limiting tube 8 through the circular hole. The sealing plate 7 is provided with a plurality of mounting holes, and the outer wall of the casting mold is provided with threaded holes for mounting the sealing plate 7. The mounting holes and the threaded holes are one-to-one corresponding. The sealing plate 7 is bolted to the outer wall of the casting mold. At this time, the limiting tube 8 is inserted into the circular hole provided on the casting mold, and the two limiting cylinders 9 are inserted into and block the water inlet and outlet of the cooling water pipe 3. The end of the limiting cylinder 9 away from the sealing plate 7 is also provided with a rounded structure, which facilitates the insertion of the limiting cylinder into and blocks the water inlet and outlet of the cooling water pipe 3. During pouring, the water inlet joint 4 and the water outlet joint 5 are formed between the limiting tube 8 and the limiting cylinder 9.

[0044] As shown in Figure 7 the manufacturing method comprises the following steps:

[0045] S100, place the cooling water pipe 3 in the casting mold and fix it firmly to prevent displacement of the cooling water pipe 3 during pouring. Once the cooling water pipe 3 is displaced during pouring, the obtained shell assembly 1 can only be scrapped.

[0046] S200, mold pouring, obtain a shell assembly 1 containing a cooling water pipe 3. After pouring and bending, cooling water is introduced into the cooling water channel of the casting mold to accelerate the cooling of the shell assembly 1.

[0047] S300, after the temperature of the shell assembly 1 is reduced to a suitable process temperature, the mold is opened and the shell assembly 1 is taken out.

[0048] S400, machining the water inlet joint 4 and the water outlet joint 5 to obtain a joint structure with the required structure. The joint structure includes one or more of internal thread structure, external thread structure, and sealing ring installation groove structure.

[0049] S500, polishing the shell body 2 to remove burrs.

[0050] The working principle of the present application: the cast aluminum shell with water cooling structure provided by the present application is directly cast into shape by pre-embedding cooling water pipe 3 in the casting mold. The design and manufacturing process are relatively simple. The water channel body of the present application is the cooling water pipe 3, which can be made of seamless steel pipe and stainless steel pipe, and has the advantages of large structural strength and smooth water channel surface, and can ensure small flow resistance. Moreover, compared with the prior art, welding sealing is not required, and the problem of scrap due to poor sealing of the water channel is less likely to occur.

[0051] In addition, the casting mold used by the present application has two sealing members, which include sealing plate 7 provided with limiting pipe 8 and limiting cylinder 9, and the pouring of water inlet joint 4 and water outlet joint 5 can be realized through the sealing members, and the water inlet and outlet of cooling water pipe 3 can be effectively blocked by limiting cylinder 9, preventing the aluminum liquid from entering cooling water pipe 3 during pouring and causing cooling water pipe 3 to be blocked, and effectively reducing the problem of product scrap caused by the blocking of cooling water pipe 3.

[0052] The above is only the preferred embodiment of the present application and is not used to limit the present application. For those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A method of manufacturing an aluminum die casting case having a water cooling structure, characterized by, The cast aluminum shell with water cooling structure comprises a shell body (2) and a cooling water pipe (3) made of a metal material with a melting point higher than that of aluminum; the shell body (2) is provided with a water channel bulge (6) matching the shape and size of the cooling water pipe (3); the cooling water pipe (3) is located in the water channel bulge (6); the water channel bulge (6) is provided with a water inlet joint (4) and a water outlet joint (5) at two ends respectively; the water inlet joint (4) and the water outlet joint (5) are connected with the water inlet and the water outlet of the cooling water pipe (3) respectively; The manufacturing method comprises the following steps: S100, placing the cooling water pipe (3) in the casting mold and fixing it firmly; S200, closing and pouring to obtain a shell assembly (1) containing the cooling water pipe (3); S300, opening the mold to take out the shell assembly (1); The casting mold comprises two sealing members, each of which comprises a sealing plate (7) provided with a limiting tube (8) and a limiting cylinder (9); the limiting cylinder (9) is located inside the limiting tube (8) and has a common central axis; the inner diameter of the limiting tube (8) is the same as the outer diameter of the water inlet joint (4) and the water outlet joint (5); the diameter of the limiting cylinder (9) is the same as the inner diameter of the water inlet joint (4) and the water outlet joint (5) and the inner diameter of the pipe at the water inlet and the water outlet of the cooling water pipe (3); The casting mold is provided with a circular hole corresponding to the position of the water inlet joint (4) and the water outlet joint (5), and the diameter of the circular hole is the same as the outer diameter of the limiting tube (8); the sealing plate (7) is provided with a plurality of mounting holes, and the outer wall of the casting mold is provided with threaded holes for mounting the sealing plate (7); the mounting holes and the threaded holes are one-to-one corresponding; the sealing plate (7) is mounted on the outer wall of the casting mold by bolts; at this time, the limiting tube (8) is inserted into the circular hole provided on the casting mold, and the two limiting cylinders (9) are inserted into and block the water inlet and the water outlet of the cooling water pipe (3); The outer cylindrical wall of the limiting tube (8) is provided with a rounded structure at the end away from the sealing plate (7), and the end of the limiting cylinder (9) away from the sealing plate (7) is also provided with a rounded structure.

2. The method of manufacturing an aluminum die casting case having a water cooling structure according to claim 1, characterized by, The cooling water pipe (3) has a multiple U-shaped arc-shaped tubular structure; the water inlet pipe part at the water inlet of the cooling water pipe (3) has a common central axis with the water inlet joint (4); the water outlet pipe part at the water outlet of the cooling water pipe (3) has a common central axis with the water outlet joint (5).

3. The method of manufacturing an aluminum die casting case having a water cooling structure according to claim 1, characterized by, The cooling water pipe (3) has a spiral structure; the water inlet pipe part at the water inlet of the cooling water pipe (3) has a common central axis with the water inlet joint (4); the water outlet pipe part at the water outlet of the cooling water pipe (3) has a common central axis with the water outlet joint (5).

4. The method of manufacturing an aluminum die casting case having a water cooling structure according to claim 2 or 3, characterized in that, The length of the water inlet pipe part is between 1mm and 3mm, and the length of the water outlet pipe part is also between 1mm and 3mm.

5. The method of manufacturing an aluminum die casting case having a water cooling structure according to claim 1, characterized by, The wall thickness of the cooling water pipe (3) is between 1mm and 2mm.

6. The method of manufacturing an aluminum die casting case having a water cooling structure according to claim 1, characterized by, The manufacturing method further comprises the following steps: S400, machining the water inlet joint (4) and the water outlet joint (5) to obtain a joint structure with a required structure; the joint structure includes one or more of an internal thread structure, an external thread structure, and a sealing ring mounting groove structure; S500, polishing the shell body (2) to remove burrs.

Images